What is heavy duty connector and Application ?

CAZN Electrics 2022-03-12

A heavy-duty connector is an assembled connector that farexceeds the traditional connector in terms of electrical performance in termsof structural design, material use, module combination, and functions.  

Heavy-dutyconnectors are specially designed to meet the requirements of harshenvironmental conditions. The main fields of application are industrial automation, plant construction and industrial systems buildings as well as information and control technology. Its housing protects the instrument from rain, freezing and dust.  

cazn heavy duty connector various modules

Compared with the traditional connection method, the use ofheavy-duty connectors can save 20-30% of the installation cost for themachining center; increase the production efficiency and reduce the error rateof wiring. 

With the in-depth development of industrial automation, there are more innovations in mechanical products. For example, many products have been modularly designed to continuously expand functions according to the needs of applications. Using heavy-duty connectors including pneumatic modules and high-current modules not only achieves barrier-free and fast connection between modular devices, but also ensures the transmission of signals and power supplies.

For machinery and equipment manufacturers, it can save installation time, secure and reliable connections, and reduce overall production costs. For terminal users, they can freely install and operate equipment without any professional guidance. It also becomes easier to maintain. This not only increases the effectiveness and availability of machinery, but also reduces downtime and reduces equipment maintenance time. The efficiency has been effectively improved. Greatly meet the needs of customers. 

Structure of heavy duty connectors 



  • Male and female inserts And Contacts 

The inserts have different sizes to fit different metal hood , and support different quantity pins , contains a variety of modules for signal, power, data transmission and pneumatic applications

The connection forms of the male plug pin are: screw crimping, cold pressing needle connection, shrapnel crimping form,coiled contact, axial bolt crimp, quick crimp . 

The contact pins have different size , which can support different current and voltage 

  • U

pper protective cover – Metal hood


Formsare: low or high construction, side or top entry, 2 or 4 lugs, single or doublebuckle

  • Base – Bulk head mounting housing

Forms are: open-hole mounting base, with or without protective cover, single or double buckle form. 

Surface mount base: low or high structure, with or without protective cover, 2 or 4 lugs,

Single or double button, 1 or 2 outlet holes 

  • Cable entry protection

     Flush fittings with single or multiple seals

     Metal or plastic cable glands

     Special cable protection 

  • Accessories and modules

Various types of protective covers, coding pins, rail mounting frames, Crimping tool, Removal tool,etc. 

The basic performance of heavy-dutyconnectors can be divided into three categories: 

  • Mechanical performance 

Mechanical Properties Insertion force isan important mechanical property in terms of connection function. The insertionforce is divided into the insertion force and the extraction force (the extraction force is also called the separation force), and the requirements of the two are different. In the relevant standards, there are provisions for the maximum insertion force and the minimum separation force, which means that from the point of view of use, the insertion force should be small (thereby a structure with low insertion force LIF and no insertion force ZIF), and if the separation force is too small, will affect the reliability of the contact. 

Another important mechanical property is the mechanical life of the connector. Mechanical life is actually a durabilityindex, which is called mechanical operation in the national standard GB5095. Ittakes one insertion and one extraction as a cycle, and judges whether the connector can normally complete its connection function (such as contact resistance value) after the specified insertion and extraction cycle. 

The insertion force and mechanical life ofthe connector are related to the contact structure (positive pressure), thecoating quality (sliding friction coefficient) of the contact part, and thedimensional accuracy (alignment) of the contact arrangement. 

  • Electrical performance

The main electrical properties of connectors include contact resistance,insulation resistance and electric strength. 

① Contact resistance High-qualityelectrical connectors should have low and stable contact resistance. Thecontact resistance of connectors varies from a few milliohms to tens of milliohms. 

Insulation resistance It is an indexthat measures the insulation performance between the contacts of the electricalconnector and between the contacts and the shell, and its magnitude ranges from hundreds of megohms to several gigaohms. 

 Dielectric strength, or withstandvoltage, dielectric withstand voltage, is to characterize the ability of theconnector to withstand the rated test voltage between the contacts or betweenthe contacts and the shell. 

Other electrical properties Theelectromagnetic interference leakage attenuation is to evaluate theelectromagnetic interference shielding effect of the connector, and theelectromagnetic interference leakage attenuation is to evaluate theelectromagnetic interference shielding effect of the connector, which isgenerally tested in the frequency range of 100MHz~10GHz. For RF coaxialconnectors, there are also electrical indicators such as characteristicimpedance, insertion loss, reflection coefficient, and voltage standing waveratio (VSWR). 

Due to the development of digitaltechnology, in order to connect and transmit high-speed digital pulse signals,a new type of connector, namely high-speed signal connector, has appeared.Correspondingly, in terms of electrical performance, in addition tocharacteristic impedance, some new electrical indicators have also appeared. ,such as crosstalk, delay, skew, etc.  

Environmental performance 

Common environmental properties includetemperature, humidity, salt spray, vibration and shock.

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① Temperature resistance At present, themaximum working temperature of the connector is 200°C (except for a fewhigh-temperature special connectors), and the minimum temperature is -65°C. Since the current generates heat at the contact point when the connector is working, resulting in a temperature rise, it is generally believed that the operating temperature should be equal to the sum of the ambient temperature and the temperature rise of the contact point. In some specifications, the maximum temperature rise allowed by the connector at the rated operating current isclearly specified. 

Moisture resistance the intrusion ofmoisture will affect the insulation performance of the connection and corrodemetal parts. The constant damp heat test conditions are relative humidity90%~95% (according to product specifications, up to 98%), temperature +40±20℃, and the test time is at least 96 hours according to productregulations. The alternating damp heat test is more severe. 

 Salt spray resistance when the connectorworks in an environment containing moisture and salt, the surface treatmentlayer of its metal structural parts and contact parts may cause galvaniccorrosion, which will affect the physical and electrical properties of the connector. 

To evaluate the ability of electricalconnectors to withstand this environment, the salt spray test is specified. Itis to hang the connector in a temperature-controlled test box, and spray it with compressed air with a specified concentration of sodium chloride solution to form a salt fog atmosphere, the exposure time of which is specified by the product specification, at least 48 hours .

Advantages of heavy duty connectors 

①The heavy-duty connector can integrate connector modules of various functions together, which is conducive to the installation, maintenance, transportation and repair of equipment. It is a very suitable connector in the field of power transmission and distribution.

② Heavy-duty connectors can reach the waterproof level of IP68. General waterproof connectors cannot adapt to such a harsh environment. Even in harsh environments such as sand, rain, cold, ice and snow, and oil pollution, they can work normally and achieve perfection. protection standards.

③The heavy-duty connectors integrating various functions can be installed in the equipment in advance to avoid production accidents caused by wrong wiring and improve work efficiency.

④The heavy-duty connector integrates multiple functions in one connector, reducing the installation space. 

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Major Manufacturers of Heavy Duty Connectors 

The main brands of heavy-duty connectors are Wieland, Amphenol, Phoenix, HARTING, Weidmüller, Xiamen Weien, Xiamen Xibas, CAZN, etc. 

HARTING Heavy Duty Connector

HARTING hasalways focused on modularity and miniaturization in the direction of HDCheavy-duty connectors. The compactness brought by the miniaturized design and the flexibility brought by the modular design are extremely applicable in the industrial field. 

HARTING heavy-duty industrial connectors is to be compact and more flexible. On thepremise of ensuring the best transmission density, the installation space is saved as much as possible and the transmission of EMC shielding signals is enhanced. Heavy-duty connectors based on this standard, called Han, gain greater flexibility in industrial applications. 

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The Han L32 Bcan replace two 16B interfaces, saving more than 40% of the installation space.The same signal and data transmission requirements require fewer interfaces and components than before under this heavy-duty connector. In the industrial application direction of robots, the reduced space and weight can bring more value. The Han L32 B enclosure contains a Han-Modular hinged frame that can accommodate up to eight modules. This form factor allows more space for hinged frames with the most module slots, and also maximizes the density of modular connectors. 

Two X- orD-coded connectors can be installed inside each module, which allows 10Gbit/sEthernet to be integrated into the modular interface in a particularly space-saving way. Compared with the traditional RJ45 solution, this solution will be more reliable and adaptable.  

TE Heavy Duty Connector 

TE's heavy-duty connectors have always been known to adapt to harshenvironments, ensuring that their HDC heavy-duty connectors can still providestable data signal connections in environments with vibration , dust, temperature challenges and mechanical shocks. 

TE's heavy-duty connector Dynamic series focuses on high-power, modular and hybrid transmission, and has a good reputation in the field of industrial applications where connectors are increasingly demanding. The HDC Dynamic series combined with Dynamic terminals provide extremely high reliability. First of all, the three-sided contact terminal design can provide extremely high shock resistance and can be suitable for automatic crimping. In addition, the Dynamic series considers the density limit in the design. The high-density design of this series can reach up to 288 bits (6 modules x 48 signal pins/module), and is compatible with up to 6 modules. It gives full play to flexibility while maintaining performance. 

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With the HMNmodular system, the Dynamic series can support more than 30 standardizedmodules to save space and combine various power, signal and data transmission technologies in a single connector, including but not limited to RJ45, D-Sub and fiber optics. Each connector housing has an IP65-IP67 double locking or single locking lever system with EMC protection. Reliability is alsounquestionable. 

This is theembodiment of reliable high power and flexible modularity. How about hybrid transmission? The same is the Dynamic series, a connector can complete the transmission of power, data and signals at the same time. This connector series in a one-piece frame design is rated up to 1000V and up to 200A. Space-saving hybrid connectors support the transfer of power, signal and data hybrid data in a single connection. 

Amphenol Heavy Duty Connector 

Amphenol's heavy duty connector is also a series with good reputation in industrialconnectors. The heavymate series is also modularized, consisting of shells and shells, plug-ins and contacts, and is specially designed for harsh industrial environment applications.

The heavy duty connector enables extremely cost-effective processing by using stamped crimpcontacts in a consistently high quality connection, followed by individual bespoke arrangements for signal, power, pneumatic, coax and ethernet connections. The heavy duty connector A series is rated at 16 A and voltages up to 400 V and can be engaged or disconnected at voltage but not current. So the A series is suitable for 10-pole and 16-pole inserts in low profile and high profile housings. 

amphenol heavy duty connector

The C serieshas a current carrying capacity of up to 350A, coupled with the low insertionforce brought by the RADSOK contacts to the connector, the C series is suitable for cables up to 120mm2 and used in combination with enclosures up to IP68 / IP69K. In the field of motor applications, this series is an ideal choice. 

There are manysubdivided models in the heavy duty connector series, each of which is suitable for acertain type of professional industrial scene. 

CAZN heavy duty connector

CAZN is ISO9001 manufacture in China , we have various metal hoods , inserts , crimp screw pins , multy modules , different type of bulkhead mounting housing , quality reliable , reasonable price .

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