Heavy Duty Connectors - Inserts, Modules

Image	Part Number	Description / PDF	Quantity	Rfq
	09100022605 HARTING	1A 2+PE MALE SCREW INSERT FOR LO	0
	09100022600 HARTING	1A 2+PE MALE SCREW INSERT WITH S	0
	09338062601 HARTING	HAN HIGH TEMP 6E SCREW MALE	0
	09100033105 HARTING	1A 3+PE FEMALE SHIELDED CRIMP IN	0
	09338102701 HARTING	HAN HIGH TEMP 10E-S FEMALE	0
	09100032705 HARTING	1A 3+PE FEMALE SCREW INSERT FOR	0
	09100033005 HARTING	1A 3+PE MALE SHIELDED CRIMP INSE	0
	09100032700 HARTING	1A 3+PE FEMALE SCREW INSERT WITH	0
	09100053000 HARTING	1A 5+PE MALE CRIMP INSERT WITH S	0
	09338162701 HARTING	HAN HIGH TEMP 16E-S FEMALE	0
	09100022700 HARTING	1A 2+PE FEMALE SCREW INSERT WITH	0
	09100032600 HARTING	1A 3+PE MALE SCREW INSERT WITH S	0
	09338162601 HARTING	HAN HIGH TEMP 16E-S MALE	0
	09330242716XL HARTING	HAN 24 ES-F (PU 40)	0
	09100053101 HARTING	1A 5+PE FEM CRIMP INSERT SLATCH	0
	09338062602 HARTING	HAN HIGH TEMP 6E CRIMP MALE	0
	09100043105 HARTING	CRIMP INSERT 4PIN	0
	09100083100 HARTING	CRIMP INSERT 8PIN	0
	09340032603 HARTING	HAN HVE 3 POS. M INSERT SCREW	0
	09120063001XL HARTING	HAN BRID-STI-C CU BUS-STI-C BIGP	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).