Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09140044513 HARTING	MODULE FEMALE 4POS CRIMP/SOLDER	5
09365062701 HARTING	HAN 6E EX FEMALE SCREW TERMINAL	5
09140124512 HARTING	MODULE FEMALE 12POS CRIMP	26
09120042601 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	30
09120022653 HARTING	INSERT MALE 2POS SCREW	16
09330064739 HARTING	INSERT FEMALE 6P+1GND TERM BLOCK	1
09110013001 HARTING	MODULE MALE 1POS CRIMP	5
09360162701 HARTING	HAN 16EX-F-S	0
09210073001 HARTING	INSERT MALE 7POS CRIMP	10
09330102601 HARTING	INSERT MALE 10POS+1GND SCREW	39
09340102601 HARTING	INSERT MALE 10+2POS+1GND SCREW	2
09160423001 HARTING	INSERT MALE 42POS+1GND CRIMP	203
09120053001 HARTING	INSERT MALE 5POS CRIMP	155
09360463101 HARTING	HAN 46EX-F-C	0
09338102603 HARTING	HAN HIGH TEMP 10E SCREW MALE	0
09330162626 HARTING	INSERT MALE 16POS+1GND PUSH IN	5
09200042611 HARTING	INSERT MALE 4POS+1GND SCREW	230
09140033052 HARTING	HAN-ECO MODULAR GUIDING PE MODUL	37
09140022751 HARTING	MODULE FEMALE 2POS SCREW	40
09140084720 HARTING	HAN-MOD RJ45 PRELINK SET 8P	3

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).