Circular connectors: small components playing a big role in Australian industry

From food and beverage production lines to robotics, renewable energy, and advanced manufacturing, circular connectors are a quiet but critical enabler of Australia’s industrial automation landscape.

Designed to transmit power, signals, and data reliably in compact, often harsh environments, circular connectors are increasingly specified where space, vibration resistance and long-term reliability are non-negotiable.

“Circular connectors might be small, but their role in keeping industrial systems running safely and efficiently is significant,” said Simon Pullinger, Managing Director, LAPP Australia. “As Australian manufacturers push for higher automation, smaller machine footprints, and greater uptime, these connectors are becoming a default choice.”

Built for industrial conditions

Unlike household connectors, industrial circular connectors are developed and tested to meet demanding international standards such as IEC 61984, addressing higher electrical loads, mechanical stress, and environmental exposure.

“In industrial environments you’re dealing with vibration, temperature extremes, moisture, oils, and electromagnetic interference,” Pullinger said. “Connectors need to perform consistently through millions of cycles — even under harsh conditions.”

This robustness explains their widespread use in servo motors, automated production equipment and motion control systems, where compact design and secure locking mechanisms are essential.

Where circular connectors are used in Australia

Across Australia, circular connectors are commonly specified in:

• general- and special-purpose machinery
• automotive and advanced manufacturing
• conveyor and materials handling systems
• food and beverage processing
• industrial robotics
• energy and infrastructure projects.
   

In automated bottling or packaging plants for example, servo motors rely on circular connectors to transmit power, feedback and control signals with millimetre-level precision — cycle after cycle.

“These systems can’t afford signal interruptions or power loss,” Pullinger explained. “Circular connectors provide a stable, vibration-resistant interface that supports consistent output, even in high-speed applications.”

Power, signal and high-current applications

Modern circular connector portfolios typically cover three key application areas:

• Signal transmission: Signal connectors are designed to reliably transmit feedback and control signals, even at low voltages and currents. High-quality contact systems and effective EMC shielding help prevent interference in electrically noisy environments.
• Power transmission: Power connectors focus on delivering high electrical performance within minimal installation space — making them ideal for servo motors, robotics, and compact machinery. Integrated strain relief, protective earth connections and robust contact materials are standard features.
• High-current power distribution: Single-pin circular connectors are increasingly used for very high-current applications such as mobile generators, temporary power installations and industrial energy infrastructure. Colour and geometric coding help prevent incorrect connections in safety-critical environments.

Why circular connectors are gaining ground

Several characteristics continue to drive the uptake of circular connectors in Australian industry, including:

• compact, space-saving design
• high resistance to vibration and mechanical stress
• effective protection against dust, moisture and chemicals
• strong EMC performance with metallic housings
• secure locking for long-term reliability.
   

“In many applications, circular connectors provide optimum sealing and handle mechanical stress more effectively than larger or rectangular types,” said Pullinger. “That’s particularly relevant in food processing, mining-adjacent industries and outdoor installations.”

Inside the connector: what matters

While the external form factor gets most attention, internal design plays a major role in performance and safety. Industrial circular connectors typically consist of:

• a housing, providing mechanical protection and environmental sealing
• an insulating contact insert, holding contacts securely and preventing leakage currents
• male and female contacts, designed to minimise insertion force while ensuring consistent conductivity.
   

Pole configuration is another key consideration. The number, size, and type of contacts determine voltage ratings, current capacity and whether power, signal and protective earth conductors can be combined within a single connector.

“As systems become more compact, engineers are looking for connectors that can handle mixed power and signal requirements without compromise,” Pullinger added. “That’s where careful pole configuration and contact design become critical.”

A small component with growing importance

As Australian industry continues to invest in automation, electrification and smarter manufacturing, circular connectors are set to play an increasingly visible role behind the scenes.

“They’re not the most glamorous component on a machine,” Pullinger concluded, “but when connectors fail, production stops. Choosing the right connector upfront is a simple decision that can deliver long-term reliability and peace of mind.”

LAPP’s EPIC circular connector product group offers an extensive product portfolio so that industrial specifiers can find the perfect circular connector for every application. View LAPP Australia’s range of locally-stocked EPIC circular connectors.