Heavy Duty Connectors - Inserts, Modules

Image	Part Number	Description / PDF	Quantity	Rfq
	09330162616XL HARTING	HAN 16 ES-M (PU 50)	0
	09140013134 HARTING	HAN 150A SINGLE MODULE AXIAL,FEM	0
	09200042711XL HARTING	HAN A 04 POS. F INSERT SCREW	0
	09140022653XL HARTING	HAN 100A AXIAL MODULE, M 10-25MM	0
	09330242607 HARTING	HAN 24E-M-S WITH RIVETS	0
	09150043113XL HARTING	HAN-QUINTAX CONTACT FEMALE, 3-9.	0
	09338162702 HARTING	HAN HIGH TEMP 16E CRIMP FEMALE	0
	09100022601 HARTING	1A 2+PE MALE SCREW INSERT SLATCH	0
	09100033001 HARTING	1A 3+PE MALE SHIELD CRIMP SLATCH	0
	09338162602 HARTING	HAN HIGH TEMP 16E CRIMP MALE	0
	0910003100 HARTING	CRIMP INSERT 3PIN	0
	09100083000 HARTING	CRIMP INSERT 8PIN	0
	09120053001XL HARTING	HAN Q 5/0 MALE INSERT CRIMP	0
	09320463144XL HARTING	HAN EE 46 FEMALE CRIMP WITHOUT F	0
	09100033306 HARTING	1A 3+PE FEM CRIMP INSERT LLEVER	0
	09140023141XL HARTING	HAN 70A CRIMP MODULE, FEMALE	0
	09140033002XL HARTING	HAN C MODULE, CRIMP MALE, 7.5MM	0
	09320183144 HARTING	HAN 18EE-F-C WITHOUT FIXING SCRE	0
	09160243002 HARTING	HAN 24DD-M-C W/O FIXING SCREWS	0
	09210643120 HARTING	HAN D 64POS F INSERT CRIMP	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).