Crimping fifty pins just cost your shift an extra hour – modular connectors give it back.
In the high-paced manufacturing world of Southeast Asia, every minute spent on termination impacts your profitability and time-to-market. This guide is a practical look at how switching to modular rectangular connectors is a strategic choice to reduce assembly bottlenecks, simplify your design, and cut on-site labour.
The Core Difference: Geometry & Mix-and-Match
At a glance, the choice seems simple, but the design philosophy is fundamentally different.
Circular Connectors (e.g., M8, M12, M23): These use standardized shell sizes and codings with fixed contact layouts per insert. You can choose variants (power, signal, some hybrid options), but you can’t freely mix media inside one shell the way a modular rectangular frame allows.
Modular Rectangular Connectors: Think building blocks. Start with a rectangular frame, then add modules for power, signal, data, or pneumatics. The result is a customizable, all-in-one connector that reduces wiring complexity and footprint in complex machines. Confirm the exact part’s certifications with the manufacturer.
Where Modular Wins: The Time-Ladder Breakdown
The real advantage becomes clear when you look at the entire connector assembly time. In an internal bench build wiring a control box with EPIC® MH, end‑to‑end assembly time dropped by ≈65% versus three M23 + two M12 circulars (61 min → 21 min). Results vary by connector variants, tooling, and operator skill.
Illustrative scenario:
| Task | Circular (3 × M23 + 2 × M12) | EPIC® MH or MC (1 frame, 4 modules) |
| Panel Cut-outs | 5 holes – 12 min | 1 hole – 3 min |
| Pin Crimp/Termination | 5 × 12 pins – 45 min | 1 multi‑pole power, 1 signal, 1 RJ45, 1 pneumatics – 18 min |
| Final Mating | 5 threaded couplings – 4 min | 1 lever latch – 30 sec |
| Total | ≈ 61 min | ≈ 21 min (‑65%) |
Pro‑Tip: The biggest time saving comes from parallel pre‑assembly. Modular inserts can be wired offline by multiple technicians simultaneously and then snapped into the housing on the main assembly line. Circular connectors can also be pre‑terminated, but typically as whole connectors, which limits parallelization.
The LAPP EPIC® Advantage in Action
Mix Your Media with EPIC® MH and MC System
The power of modularity is combining different functions. The EPIC® MH System and EPIC® MC System lets you snap modules for high power (up to 250 A on the dedicated 250 A module) and high voltage (up to 1000 V on specific power modules), alongside shielded data/Ethernet (Cat.5e–Cat.6A) and pneumatic modules, into a single connector housing. Ratings are module‑dependent—confirm per part number.
Save Space with EPIC® H‑BE
Panel space is always at a premium. EPIC® H‑BE 24 is a 24‑contact insert designed for 24B housings. A typical 24B panel cut‑out is about 35 × 112.2 mm, consolidating up to 24 control wires at one interface and simplifying your panel layout.
When Circular Still Makes Sense
To be clear, circular connectors still have their place. For applications requiring:
- IP68 wash‑down ratings common in food & beverage lines (e.g., many M12 variants).
- Micro‑space connections (≤ M8) on a robot’s end‑of‑arm tooling (EOAT) where space is extremely limited.
…a dedicated circular connector is often the right tool for the job. But for the majority of modern industrial machinery, the speed and flexibility of modular rectangular connectors offer a clear advantage.
Quick‑Start Resources
- EPIC® Connector Configurator: https://www.lapp.com/en_US/us/products/product-configuration/connector-configurator/e/031031
- CAD data (EPLAN/CADENAS): available from individual module product pages (see “CAD data” links on EPIC® MH modules)
- How‑To video: https://www.youtube.com/playlist?list=PLo6Qw32-W1xbbg4sWPiyAKYZuaMR05SrB
The Bottom Line: Build Faster and Smarter
In a competitive market, reducing your assembly time is a direct path to higher profitability. Modular rectangular connectors offer a trifecta of benefits: faster installation, simplified design and procurement, and fewer potential points of failure.
Ready to streamline your next build? Explore the LAPP EPIC® Modular Connector system or book a free 15‑minute build‑time audit with a JJ‑LAPP connectivity expert to calculate your potential time savings.
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