Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09100032606 HARTING	1A 3+PE MALE SCREW INSERT LLEVER	0
09160243031 HARTING	INSERT MALE 24POS HAN DD-PCI-C	0
09100053106 HARTING	1A 5+PE FEM CRIMP INSERT LLEVER	0
09161083018 HARTING	INSERT 108POS HAN DD-PCI-C SO	0
09330242782 HARTING	INSERT FEMALE 24POS CRIMP	0
09100083006 HARTING	CRIMP INSERT 8PIN MALE	0
09200102622 HARTING	INSERT MALE 10POS SCREW	0
20751081101 HARTING	HAN MODUL ELISA IN 0...100 C M	0
09330242788 HARTING	HAN 48ES - 24ES PRESS FEMALE INS	0
09100043101 HARTING	CRIMP INSERT 4PIN FEMALE	0
09150043112 HARTING	INSERT FEMALE HAN-QUINTAX 6-95	0
09320463181 HARTING	INSERT FEMALE 46POS CRIMP	0
09140012775 HARTING	MODULE M8 SCREW BOLT	0
20751052201 HARTING	MODUL OUT 0...10V F	2
09330242608 HARTING	INSERT MALE 24POS SCREW	0
09330102752 HARTING	INSERT FEMALE 10POS CRIMP	0
09128053104 HARTING	HAN Q 5/0 FEMALE CRIMP INSERT (1	8
09330242652 HARTING	INSERT MALE 24POS CRIMP	0
09140273022 HARTING	HAN SHIELDED MODULE 27PIN MALE C	25
09330242758 HARTING	HAN 24ESS FEMALE CAGE CLAMP WITH	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).