Driving Manufacturing Innovation with HARTING’s Modular Connectors

Manufacturing engineers can appreciate the frustration of a production line being halted because one motor controller fails, yet accessing it requires dismantling dozens of wire connections. What should take minutes stretches into hours while technicians trace circuits through cable bundles, hoping they can pinpoint the correct wires among hundreds of similar-looking conductors. This scenario highlights a challenge with electrical connectivity in industrial environments. Hardwired systems, while initially appearing cost-effective, can create hidden inefficiencies that compound over equipment lifecycles, and the problem lies in the rigid nature of the hardwired connections. Fortunately, there are now modular connector solutions (Figure 1) that can adapt to changing requirements while maintaining industrial-grade reliability.

Figure 1: Han-Modular® Connector System. (Image source: HARTING)

Origins of standardized industrial connection technology

Wilhelm HARTING’s vision in 1945 recognized that post-war industrial growth required connection solutions fundamentally different from existing designs. Starting with a small repair operation in Minden, Germany, HARTING developed what became known as Heavy Duty Connectors (HDCs), establishing principles that continue to influence industrial connectivity design today.

The breakthrough came from creating rectangular connectors in contrast to the circular designs that initially dominated military and aerospace applications. Rectangular architectures provided superior space utilization in industrial control panels and achieved higher contact density within standardized footprints. The Han Connector Series, launched before the 1960s industrial boom, demonstrated how standardized, robust connections could handle multiple types of media while withstanding harsh factory environments.

This historical foundation matters because Han-Modular technology builds directly upon proven principles. Rather than reinventing basic concepts, it merges time-tested designs with the latest materials, manufacturing techniques, and integration capabilities.

Deconstructing modular connection system design

Han-Modular technology from HARTING employs a building-block approach where engineers can select individual modules based on specific media (power, signal, data, air, etc.,) requirements and combine these elements within protective housings designed for particular environments.

Han-Modular modules handle specific media types within the connector assembly, e.g., power modules to accommodate currents from 16 to 200 A for heavy-duty applications, signal modules to support low-voltage control circuits, as well as communication modules for Ethernet, fieldbus, or fiber optic connections. Engineers can combine these different module types within the same assembly framework, eliminating the need for separate connectors for each media. Protective housings provide mechanical support and environmental sealing for module combinations, with standardized enclosures ranging from compact Han 6B configurations to Han 48B (Figure 2) suitable for and heavy-duty/multi-media requirements.

Figure 2: An example of a Han 48B Bulkhead mounted housing. (Image source: HARTING)

Environmental protection utilizes graduated sealing constructions based on application severity. Basic IP65 ratings protect against dust infiltration and water ingress, which is common in most manufacturing facilities. On the other hand, the enhanced IP69K specifications for Han-Modular connectors to withstand high-pressure washdown procedures required in food processing and pharmaceutical production.

Han-Modular connectors incorporate multiple security features that eliminate connection errors. The mechanical keying system utilizes uniquely shaped guide elements that allow only properly matched male and female connector halves to connect together. This physical design prevents technicians from connecting incompatible connectors, a wiring mistake that frequently occurs in hardwired connections. Rather than relying on wiring labels or circuit diagrams that can become unclear over time, the keying system makes incorrect connections physically impossible.

HARTING’s partnership with DigiKey: the Han Configurator

Connector specifications create challenges in engineering workflows. Engineers must manually cross-reference component specs across multiple datasheets, verify environmental ratings, and validate the compatibility requirements for each connector type. This is a time-intensive process that introduces selection errors while impacting project timelines.

DigiKey’s collaboration with HARTING addresses these problems with integrated design tools that automate validation and component selection. The Han Configurator® allows engineers to input system requirements, e.g., media types, current ratings, and environmental specifications and receive real-time feedback on component compatibility and availability. The configurator utilizes a rule-based selection logic that prevents incompatible combinations and suggests alternatives when their choices create conflicts. It also displays configured assemblies from multiple angles, allowing engineers to verify mechanical fit and cable routing requirements before purchasing.

The Han Configurator also generates complete documentation like bills of materials with current pricing and availability status. Direct integration with DigiKey’s procurement systems can help to eliminate manual parts list creation and ordering. Engineers can use the post comparison tools to evaluate modular vs. hardwiring alternatives or pre-configured libraries as starting points for common applications across multiple industries.

Practical benefits for manufacturing teams

HARTING’s Han-Modular connectors deliver measurable installation time improvements compared to hardwiring methods. Pre-assembled connector sets eliminate the time-consuming process of individual wire termination in the field, and mechanical keying systems avoid connection errors that often plague wiring installations. The standardized housing designs, ranging from compact Han 6B (Figure 3) configurations through Han 48B assemblies for complex applications, enable consistent installation across various system requirements.

Figure 3: An example of a Han 6B Bulkhead mounted housing. (Image source: HARTING)

The modular design simplifies maintenance procedures by replacing complicated circuit tracing and rewiring operations with simple connector disconnection/reconnections. When components require replacement or technicians need to troubleshoot, they can identify and isolate problems easily. The lever-actuated locking mechanism also allows maintenance workers to perform the operations quickly without using specialized equipment.

Another key benefit is having the ability to test complete connector assemblies under controlled conditions. Doing this eliminates any variables that create reliability issues with field-terminated connections. Manufacturing facilities can control conductor preparation quality, contact insertion force, and sealing integrity in ways that are not possible during field installation. Environmental testing also ensures that assemblies meet their specified IP65 or IP69K ratings before delivery.

All in all, modifications are much simpler with the modular design. The standard interfaces allow engineers to upgrade power handling capabilities, add more communication channels, or even integrate new components by swapping out individual modules.

Validation across critical manufacturing sectors

Automotive assembly lines (Figure 4) are some of the most demanding applications for connectivity. For example, robotic welding cells require simultaneous transmission of high-current welding power (typically exceeding 600 A), servo control signals for robot positioning, and high-speed Ethernet communication for real-time motion coordination. This means connection failures can halt entire production lines, making reliability essential. Han-Modular connectors are designed to withstand continuous mechanical stress from robotic motion, maintaining electrical integrity and long-term reliability under extreme ambient conditions.

Figure 4: A typical automotive assembly line. (Image source: Adobe Stock)

Similarly, remote generator installations must operate reliably in temperature extremes ranging from Arctic conditions through desert environments, often with minimal maintenance access for extended periods. These applications require connectors to simultaneously handle high-current primary power distribution and sensitive control circuits within single assemblies. Han-Modular connectors in generator facilities remain operational for years without maintenance intervention, validating the design approach under the most challenging conditions.

Mining and construction equipment also operate in aggressive environments with extreme dust exposure, hydraulic fluid contamination, and heavy mechanical impact. While they exceed most industrial specifications, Han-Modular connectors help maintain sealed protection and electrical continuity under conditions that rapidly degrade conventional connectivity solutions.

Chemical facilities are probably the most challenging validation environments where connectors must resist chemical exposure with explosion-proof requirements. Han-Modular design enables assembly testing under controlled laboratory conditions before deployment to hazardous areas to prevent failures that could extend beyond production disruption to safety concerns.

Conclusion

Modular connectivity fundamentally changed in how engineers approach system design. Rather than optimizing individual components, it focuses on designing robust connectivity infrastructure that supports both requirements and future technological innovation. For engineers optimizing for longer-term system performance, modular connectivity delivers the adaptability essential for technological change management and maintains high operational reliability for a wide range of industrial applications. Engineering decisions should evaluate connectivity as infrastructure that can either enable or constrain future system modifications.