Heavy Duty Connectors - Inserts, Modules

Image	Part Number	Description / PDF	Quantity	Rfq
	1679498 Phoenix Contact	INSERT MALE 64POS CRIMP	0
	1647475 Phoenix Contact	INSERT MALE 24POS TENSION CLAMP	0
	1687914 Phoenix Contact	INSERT MALE 24POS TENSION CLAMP	0
	1775758 Phoenix Contact	INSERT MALE 8POS CRIMP	0
	1772324 Phoenix Contact	INSERT MALE 15POS CRIMP	0
	1678596 Phoenix Contact	INSERT FEMALE 4POS CRIMP	0
	1772515 Phoenix Contact	INSERT FEMALE 64POS CRIMP	0
	1663462 Phoenix Contact	MODULE FEMALE 6POS CRIMP	0
	1674697 Phoenix Contact	INSERT FEMALE 72POS CRIMP	0
	1687451 Phoenix Contact	INSERT FEMALE 18POS CRIMP	0
	1674561 Phoenix Contact	INSERT FEMALE 6POS SCREW	0
	1605005 Phoenix Contact	MODULE FEMALE 25POS CRIMP	0
	1773310 Phoenix Contact	INSERT MALE 3+2POS+1GND SCREW	0
	1772939 Phoenix Contact	INSERT FEMALE 10POS TERM BLOCK	0
	1687448 Phoenix Contact	INSERT MALE 10POS CRIMP	0
	1773051 Phoenix Contact	INSERT MALE 10POS SCREW	0
	1647721 Phoenix Contact	MODULE FEMALE 5POS TENSION CLAMP	0
	1772887 Phoenix Contact	INSERT MALE 6POS TERMINAL BLOCK	0
	1677021 Phoenix Contact	INSERT MALE 16POS SCREW	0
	1773093 Phoenix Contact	INSERT FEMALE 3POS SCREW	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).