Heavy Duty Connectors - Inserts, Modules

Part Number	Description / PDF	Quantity
09320643001 HARTING	INSERT MALE 64POS+1GND CRIMP	6
09210644711 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	1
09700062616 HARTING	INSERT MALE 6POS SCREW	5
09100033300 HARTING	1A 3+PE FEMALE CRIMP INSERT WITH	0
09120043003 HARTING	INSERT MALE 4POS+2 FIBER CRIMP	0
09140062733 HARTING	MODULE FEMALE 6POS PUSH IN LOCK	8
09365102601 HARTING	HAN 10E EX MALE SCREW TERMINAL I	5
09338062704 HARTING	HAN HIGH TEMP 6E CRIMP FEMALE	0
09320323001 HARTING	INSERT MALE 32POS+1GND CRIMP	15
09320643101 HARTING	INSERT FEMALE 64POS+1GND CRIMP	5
09210404701 HARTING	INSERT FMALE 46P+1GND TERM BLOCK	4
09120033015 HARTING	HAN-BRID RJ45C-M-RJ INDUSTRIAL 1	0
09110013101 HARTING	MODULE FEMALE 1POS CRIMP	5
09330064626 HARTING	INSERT MALE 6POS+1GND TERM BLOCK	0
09210402601 HARTING	INSERT MALE 40POS+1GND WIRE WRAP	13
09340032602 HARTING	INSERT MALE 3+2POS+1GND CRIMP	0
09200162816 HARTING	HAN 32A - 16A FEMALE SCREW TERMI	96
09110012771 HARTING	MODULE FEMALE 1POS SCREW	0
09210642601 HARTING	INSERT MALE 64POS+1GND WIRE WRAP	1
09210644701 HARTING	INSERT FMALE 64P+1GND TERM BLOCK	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).