Circular Connector

Company Introduction

CIXI WANJIE ELECTRONIC CO., LTD was founded in 1992, we are a professional manufacturer that specializing in R&D, design, processing, production, sales and service of terminal blocks. The products include PCB screw and spring, pluggable, MCS, feed through and barrier terminal block, which are widely used in electric power control, automation control, elevator, instrumentation, communications, power supply, security, lighting, rail transportation and other related fields. The products are sold all over the world and have received the unanimous praise from customers.

WANJIE has passed ISO9001, ISO14001, OHSAS18001, the products are UL, CUL, VDE, CQC, CE, CB, ROHS, REACH approved. Besides, with the excellent management, R&D and QC team, advanced testing equipment and production device, comprehensive quality inspection system and UL witness laboratory, we try our best to ensure the quality could reach the relevant standard as well as meet the requirement of customers.

Why Choose Us?

Excellent Product Quality
With the excellent management, R&D and QC team, advanced testing equipment and production device, comprehensive quality inspection system and UL witness laboratory, we try our best to ensure the quality could reach the relevant standard as well as meet the requirement of customers.

Rich Experience In Production
The products include PCB screw and spring, pluggable, MCS, feed through and barrier terminal block, which are widely used in electric power control, automation control, elevator, instrumentation, communications, power supply, security, lighting, rail transportation and other related fields.

After-sales Service
WANJIE not only develop standard product but also provide ODM/OEM service, in order to establish a long-term cooperative relationship with customers and provide them the best solution.

Global Shipping
Our products support global shipping and the logistics system is complete, so our customers are all over the world.

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What is Circular Connector

A circular connector is a cylindrical, multi-pin electrical connector that contains contacts that power electrical devices, transmit data, or transmit electrical signals. A circular connector is designed to withstand harsh environments and reliably deliver data.

Benefits of Circular Connector

From the field of application, because the circular connector has excellent stability, and therefore is widely used in aerospace, transport and industrial applications such as the connector stability requirements of the stringent areas of application.　

From the connector reliability, circular connectors have a compact and tight, reliable contact, good sealing performance and stable connection performance and other characteristics.　

From the strength-to-weight ratio, the circular connector of this value is higher, that is to say, in the case of resisting the same external forces, the circular connector shell can be made smaller and lighter, which is very consistent with the connector miniaturisation, lightweight development trend.　　

From the advantages of the connection scheme, due to the uniqueness of the circular connector itself, currently in the components and cables, cables and cables between the interconnection of application scenarios, the circular connector is still the preferred option.　

From the connection mode characteristics, circular connectors more bayonet, straight, threaded and other connection methods, the connection is more reliable and fast, should not be loose.　

From the processing technology, circular connectors have a very mature processing and production routes, easy to protect the quality of the product and the accessibility of the process.　

From the application of environmental attributes, if the aviation plug level circular connectors, its performance advantages will be even stronger. It has a waterproof and dustproof, oil and corrosion resistance, vibration and impact resistance, high and low temperature resistance, etc., can be applied to complex and harsh industrial, outdoor and other scenes.　

From the mechanical point of view, because the circular connector in shape largely into a cylindrical or cylindrical deformation, such a shape and structure can withstand greater external impact and stress.

Application of Circular Connector

Healthcare
One of the most common applications of these connectors is in the healthcare industry. In this industry, these connectors help create reliable connections in a hospital's backend systems. Additionally, this help brings modularity to machinery as these connectors can connect multiple sensors and testing equipment to the main healthcare supercomputers.

With the number of wires going through one of these connectors and the reliability they bring, no other connector can match the peace of mind and experience.

Aerospace
The aerospace industry has varying requirements for the equipment used. The electronics in this industry have to face sudden impacts and temperature changes, high pressure and G force, humidity, and multiple other environmental factors. So, a much more reliable connection type that can deal with all these conditions is the circular connector.

These connectors are screwed in together, and both sides come with a strain protector, or at least one side of the other is screwed into the body. Thus, a durable connection is achieved.

Military
Military equipment and aerospace equipment have similar requirements for electrical connections. Here equipment needs to be disconnected easily and bear pressure and extreme environmental conditions. These connectors come with a screw-on connection method, and in a small size, multiple wires for all-electric, data, and internet connections can pass signals.

Some connectors also provide a water resistance rating for connections which makes these withstand humid and submerged conditions.

Industry
Equipment and tools are usually not fixed with the backend computers to ensure modularity and stable connections. That’s where the circular connectors make a great choice since these can handle a huge number of wires in a small size.

In addition to the number of wires and modularity, these offer durable connections that can withstand dust, humidity, and strain to a certain level.

Automobile
Automobiles go through every condition. Cars go off-road and on all other types of terrains. So, it is essential to have a stable type of connection between the ECU and electrical components. For automobiles that often need tuning, these connectors make a good choice.

Additionally, some trucks have attachments at their back, and these connectors make a good choice for supplying power and signals for brake lights and turn indicators.

Four Connection Methods of Circular Connector

Thread connection method of circular connector

A connection form that is often used by circular connectors that have larger-sized contacts and work in a strong vibration environment. This type of connection can be installed with a fuse to prevent loosening after the connection is completed. This connection form is reliable to use, but the connection and disassembly speed is slow.

The plug-in connection method of the circular connector

Is a versatile form of connection. When the plug and socket of the circular connector are connected and separated, the moving direction is usually a reciprocating linear motion, without twisting and rotating, and only a small working space is required to complete the connection and disassembly.
Common plug-in connections have two structures: balls or pins. Because there is no mechanically labor-saving mechanism in this connection form, once it is mis-inserted, the mechanical resistance will increase significantly, and it can be found in time.

M12 Female Straight UnShield A-Coding 8PIN PVC Cable 2.0M M12X1.0

The bayonet connection method of the circular connector

It is a reliable and rapid connection and separation form. Most card 121 connection style circular connectors have a visual indication of proper connection and locking, which can be viewed from the small hole on the side of the circular connector connection nut.

Cabinet connection method of circular connector

It is suitable for circular connectors on some equipment that is close to the frame and needs to be connected blindly, which can make electrical equipment lighter and smaller, easier to maintain and more reliable.
This type of connection makes the operator unable to feel the connection, and an accurate positioning device must be designed to avoid forcing the misinserted circular connectors together, making misinsertion impossible. Cabinet circular connectors usually adopt floating or elastic contact design structure to ensure their correct connection.

Components of Circular Connector

Contacts

The internal pins and sockets housed in the connector used to form the electrical connection. A mated pair consists of male contacts and female sockets.

Insulator

This component encapsulates the contacts and insulates them from each other and the connector shell. It also provides proper spacing of the contacts and holds them in the correct position.

Shell

As the outer cover of the connector, the shell protects the contacts and insulator while providing the alignment and connection mechanism for pairing two connector halves.

Accessories

These can include pins, keys, rings, clamps, gaskets, and additional components utilized to guide, secure, position, and seal parts of the connector.

How to maintain Circular Connector

Always perform a routine inspection

No matter how good your circular connectors are, continuous use will cause some wear and tear. This is why you need to perform a routine inspection on your connectors. And hey, don't rely on your memory; create a schedule for a routine inspection.
You should regularly inspect your connectors for any visible damage signs, and see if they have any cracks, breaks, or corrosion so that you can nip the evil in the bud. You also want to check your connectors’ pins and sockets. If they are bent, misaligned, or damaged, it’s time to replace them.

Try to avoid over-mating

If you are repeatedly connecting and disconnecting your connectors more than what is necessary, heads up, you’re over-mating your connectors. This will cause premature damage to your circular connectors and, in return, reduce their performance. Don’t get it? Let us explain.
Whenever you mate and unmate a connector, a small amount of mechanical stress and friction is placed on the connector's contacts. This will reduce your connector’s lifecycle in the long run, so follow the manufacturer's guidelines on how to mate and unmate safely.

Avoid going over current

Like every other thing, your connector has a maximum tolerance for current. This is called the current rating, which represents the highest electric current level it can safely handle.
If your connectors are subjected to currents higher than this rating, you risk overheating, contact damage, and sometimes even connector failure. Here are a few ways how you can avoid these issues:

Before choosing a connector, check with your manufacturer and select the one that fits your application.
Regularly monitor current levels to ensure they don't exceed your connector’s maximum limit.
Use fuses or circuit breakers to prevent excessive current from reaching your connectors.

Regularly remove dirt and debris

Now you might think what harm can a few dust particles do, but, in the long run, these can interfere with the electrical connection of your circular connectors. If you’re experiencing signal degradation, these tiny friends could be the reason. So, regularly inspect your connectors for dirt and debris and remove it using a suitable tool.
Ready to clean your connectors? Follow these steps:

You can use compressed air to blow away loose dirt and debris particles by holding the connector at an angle.
Use a soft brush to dislodge stubborn contaminants.
Allow your circular connectors to air dry completely before putting them to use again.

Adjust according to your environment

Is your application in an industrial setting or outdoor installation? If yes, they need extra care because these areas face extreme environmental conditions. You wouldn’t even notice that various environmental factors, like temperature, humidity, etc., will wear out your connectors slowly.
If you’re still confused, these benefits will help you make a choice:
Humidity: By monitoring humidity levels, you can maintain optimal moisture levels for your connectors to protect them from corrosion and ensure reliable electrical connections.
Temperature: By monitoring temperature, you can identify if your connectors are overheating, face thermal stress, or are undergoing cold-induced brittleness.
Vibrations: If you keep an eye on the vibration levels of your circular connectors, you can easily detect if mechanical stress is affecting their performance in any way.

Keep labels and documents handy

If you have a huge industrial setup, keeping track of maintenance would be a nightmare for you. You have no idea how easy your maintenance and inspection will become once you start labelling all of your connectors. These 3 labelling and documentation points are any manufacturer’s holy grail; have a look!
Labelling: Each of your circular connectors should be clearly labelled with relevant information such as its type, model number, serial number, and other important details.
Documentation: Start maintaining detailed documentation of each circular connector you own. This will include information such as its installation date, application or system it's used in, maintenance schedule, and any modifications or repairs performed.
Usage tracking: Additionally, you can record the usage pattern of your connectors, such as the number of mating and unmating cycles, duration of operation, and so on.

Selection Criteria for Circular Connectors

Gender (male/female)
The male part incorporates the contact pins that plug into the sockets in the receptacle, or female portion. Most plugs and receptacles are designed to mate within their own brand, or manufactured product line. Typically, connectors from different manufacturers do not interconnect. You will typically be sourcing connectors as a mated pair, but not always.

Number Of Contacts
The number of conductive pins or contacts that your design requires in the connector to carry the signals, data, or power you need to move.

Termination
This is how your wire or cable will mate with the conductive contacts in the connector. Some options include solder, wire wrap, lugs, or crimping.

Contact Size
The diameter of the individual contacts, or the gauge of the wire that can mate with each contact.

Voltage & Current Rating
The maximum voltage or current that the connector is designed to carry. Current rating is the flow of electricity, expressed as amps (A). Voltage rating is the amount of voltage that can be safely carried, expressed as volts (V).

Insertion Frequency
The regularity of connection and disconnection of the connector (also known as mating cycles). Frequent mating cycles may require a more robust connector or cable protection accessory.

Mounting Type
How the connector will be mounted, including cable mount, panel mount or circuit board mount. Different mounting hardware applies to each type.

Coupling Or Locking Style
How the connector will be securely mated. Locking styles include bayonet, latch, push-pull, threaded, and quick-disconnect.

Type Of Backshell
The connector backshell is threaded onto the cable side of a circular connector to provide secure cable support. Many different types of backshells are available, including straight, right angle, braid tail, spring, strain relief, sealed and crimped.

Environmental Factors
Will the connector be exposed to liquids, gasses, or subject to immersion? Does the connector require protection from EMI or RFI signals? Will the connector come in contact with caustic chemicals, excessive vibration or frequent impacts? The answers to each of these will help determine the quality, features, and accessories you may need.

Materials Used
Connector bodies can be stainless steel, aluminum, plastic, composite, or brass, depending on your requirements and budget.

Accessories
Connector manufacturers offer many different types of accessories that add to the functionality of their products. The list of these is quite long, but some examples include seals, boots, and caps to lock out liquids and gasses, strain reliefs and cable clamps to protect cable disconnect, backshells to protect connections, flanges, gaskets, and grommets for installation, and cable grips for easier insertion/removal.

Plugs & Sockets
While there are variations in industry standards, typically sockets and jacks are associated with panel mounted connectors while plugs are connectors that are part of cable assemblies. Again, there is no standard convention for this naming so different manufacturers may use alternate terms.

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FAQ

Q: What is the round connector called?

A: They may be known as "coaxial power connectors", "barrel connectors", "concentric barrel connectors" or "tip connectors".

Q: How to connect circular connectors?

A: Circular connectors are most often (but not always) connected by threaded areas on the shells. This screw-in connection allows them to be easily and securely locked into position and remain in place despite vibration or impact. Other types of connection systems include bayonet locking, push/pull locking, and snap lock.

Q: What is the difference between circular and rectangular connectors?

A: Circular is ideal for single-use low-power connection points, while rectangular connectors are perfect for high-power or multi-use connection. For some applications, each connection point needs to be separate.

Q: What is the shell size of a circular connector?

A: The shell of a circular connector is a cylinder available in incremental sizes starting as small as . 375 diameter up to 3.25 diameter and larger. The most common shell sizes are available in . 0625 increments starting at shell size 8.

Q: What are the parts of circular connector?

A: The main components of the basic structure of the push pull self-locking circular connector are shell, contact pin, insulator, and accessories.

Q: How do I choose a circular connector?

A: Choosing the right circular connector involves considering several factors based on your specific application requirements. Electrical Requirements: Determine the electrical characteristics needed for your application, such as voltage rating, current capacity, and signal requirements.

Q: What is the purpose of circular connector?

A: In industrial machinery, circular connectors provide robust housings and strain relief to help withstand impact, shock and vibration, to help prevent damage to connection points.

Q: What size are circular connectors?

A: Also our extensive range of IP-protected circular connectors in sizes M8, M12, M16, M23, and 7/8" ensures the reliable cabling of your system. During development, we always concentrate on efficient and cost-effective assembly and installation concepts.

Q: How are circular connectors made?

A: Circular connectors as judged by their name consist of two circular parts, a multi-pin male plug and a multi-socket female receptacle. In the male plug a circular shell made from plastic or metal encases an insulating insert which in turn orientates electrical contacts or pins.

Q: What are the different types of circular connectors?

A: Coupling Types: Circular connectors are available with bayonet, threaded, push-pull, quick-disconnect, snap-on, and screw-in coupling types.

Q: How to identify circular connectors?

A: Circular connectors are cylindrical electrical devices of varying size with circular mating surfaces. They contain multiple pins, or contacts that connect with applicable parts to transfer electrical power, signals, or data. They may also be referred to as circular interconnects.

Q: What is a circular mil spec connector?

A: MIL-SPEC connectors are specially designed to comply with military specifications. MIL-C-5015: is a general use connector standard that specifies the most popular type of circular connector, used in commercial applications as well as military.

Q: Where are circular connectors used?

A: Circular connectors, due to their high performance in extremes of vibration, shock, temperature, pressure, and interference (EMI & RFI) are finding increased use in many industrial applications requiring electric power transmission, signal transmission, data transfer, and mixed signal transmission.

Q: What is the significance of circular connectors in aircraft electrical systems?

A: Circular connectors are an ideal choice for applications that require an electrical connector with a more rugged terminal. Their cylindrical shape makes them especially resistant to mechanical turbulence and impact damage.

Q: How do circular connectors work?

Q: What are the properties of connectors?

A: The basic properties of connectors can be divided into three categories: mechanical properties, electrical properties and environmental properties. Mechanical Properties Insertion force is an important mechanical property in terms of connection function.

Q: What is a circular connection?

A: A circular connector is a cylindrical, multi-pin electrical connector that contains contacts that power electrical devices, transmit data, or transmit electrical signals. A circular connector is designed to withstand harsh environments and reliably deliver data.

Q: How do you remove oxidation from connectors?

A: On the mild side, a mild acid like vinegar can be used, and other agents are offered for battery terminal cleaning, such as baking soda. Regardless of the cleaning material, care should be taken to rinse it off. A cleaner strong enough to remove rust could continue to work on unintended metal surfaces.

Q: How do you keep electrical connectors from corroding?

A: “Every six months, or more frequently in highly corrosive environments, use a plug and socket brush with electrical cleaner to clean 7-way connectors,” advises Phillips. “After every cleaning, re-apply dielectric grease on plug and socket pins to keep corrosion at bay.

Q: How do you protect electrical connectors?

A: Connector grease is a cost-effective solution to protect the contact surface from moisture and environmental corrosion. A common misconception surrounding connector grease is that it is absorbs water. Connector grease repels water from the connector surface.

We're professional circular connector manufacturers in China for 30 years, specialized in providing high quality products and service. We warmly welcome you to buy bulk high-grade circular connector for sale here from our factory.

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