Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09330242621 HARTING	INSERT MALE 24POS SCREW	0
09330162656 HARTING	INSERT MALE 16POS+1GND PUSH IN	0
09320465751 HARTING	INSERT FEMALE 46POS+1GND CRIMP	0
09100083001 HARTING	CRIMP INSERT 8PIN MALE	0
09140043042 HARTING	MODULE HAN CC PROTECTED	0
09200103003 HARTING	INSERT MALE 10POS CRIMP	0
09330164639 HARTING	INSERT MALE 16P+1GND TERM BLOCK	0
09700062817 HARTING	INSERT FEMALE 6POS SCREW	0
09380122653 HARTING	INSERT MALE 6+6POS+1GND CRIMP	0
09140012671 HARTING	HAN 1MOD-M-C 200A PE 16QMM	0
09140122735 HARTING	MODULE FEMALE PUSH IN WITH LOCK	0
09110013111 HARTING	MODULE FEMALE 1POS CRIMP	0
09330162652 HARTING	INSERT MALE 16POS CRIMP	4
09140082635 HARTING	HAN EE 8PIN MODULE MALE QUICKLOC	0
09330162725 HARTING	HAN ES 16 POS. F INSERT CAGE CLA	0
09100033206 HARTING	1A 3+PE MALE CRIMP INSERT LLEVER	0
09360242602 HARTING	HAN 24EX-M-C	0
09210153106 HARTING	INSERT FEMALE 15POS CRIMP	0
09330102656 HARTING	INSERT MALE 10POS PUSH IN	0
09330164739 HARTING	INSERT FMALE 16P+1GND TERM BLOCK	0

Heavy Duty Connectors - Inserts, Modules

1. Overview

Heavy duty connectors inserts and modules are specialized electromechanical components designed to establish robust electrical connections in demanding environments. These systems provide modular solutions for power transmission, signal routing, and data communication in industrial and infrastructure applications. Their importance lies in enabling reliable connectivity in harsh conditions involving high currents, extreme temperatures, vibration, and contamination.

2. Major Types & Functional Classification

Type	Functional Features	Application Examples
Modular Insert Systems	Customizable contact arrangements, hot-swappable design	Industrial control cabinets, automated machinery
High-Power Modules	Rated for >100A currents, integrated cooling channels	Electric vehicle charging stations, factory automation
Signal Transmission Inserts	Shielded contacts for <10Gbps data rates	Smart grid monitoring systems, robotics
Hybrid Power-Signal Modules	Combined power and fiber optic transmission	Wind turbine pitch control, mining equipment

3. Structural Composition

Typical construction includes:

Durable thermoplastic or metal housing (IP65-IP69K rating)
Copper alloy contact elements with gold/silver plating
Integrated locking mechanisms (screw, bayonet, or push-pull)
Modular frame supporting mixed contact types
Environmental seals (EPDM or silicone rubber)

4. Key Technical Specifications

Parameter	Importance
Current Rating (10-2000A)	Determines power transmission capacity
Voltage Range (24V-10kV)	Defines insulation requirements
Contact Resistance (<1m )	Impacts energy efficiency and heat generation
Operating Temperature (-40 C to +125 C)	Dictates environmental suitability
Mating Cycles (500-10,000)	Determines service life and reliability

5. Application Fields

Primary industries include:

Industrial Automation: PLC systems, CNC machines
Energy: Wind turbines, solar inverters
Transportation: Rail traction systems, e-mobility charging
Heavy Machinery: Excavators, mining equipment
Marine: Offshore platform systems, shipboard power

6. Leading Manufacturers & Products

Manufacturer	Representative Product
TE Connectivity	DEUTSCH HC Series High-Current Connectors
Amphenol Industrial	MAXdur Hybrid Power/Sig nal Modules
Phoenix Contact	Heavycon Modular Insert Systems
Weidm ller	HA-Modular Hybrid Connection Technology

7. Selection Guidelines

Key considerations:

Calculate maximum current/voltage requirements with safety margins
Assess environmental factors (temperature, vibration, chemicals)
Verify IP rating for ingress protection
Evaluate mating cycle requirements
Check industry-specific certifications (UL, CSA, IEC standards)
Consider modular expandability for future upgrades

8. Industry Trends

Current development trends include:

Miniaturization while maintaining high current capacity
Integration of smart sensing capabilities
Adoption of fiber-optic hybrid transmission
Increased use of corrosion-resistant composite materials
Development of quick-connect systems for reduced downtime

Market growth is driven by electrification in industrial sectors and the rise of renewable energy systems, with a projected CAGR of 6.2% through 2028 (Source: MarketsandMarkets).