Choosing Heavy Duty Connectors For Cable Assemblies - Miracle Electronics

 Designing cable assemblies for use in harsh environments poses a number of challenges, especially those that need to be used in industrial equipment that may be subjected to conditions like high temperatures, high humidity, water, chemicals, electromagnetic interference, vibration, impact, or particulate ingress from close proximity to moving factory components. Over time, exposure to such components starts to hamper conductivity, requiring repairs or replacements.

To avoid all such hassles and inconvenience, it is advisable that you choose to install heavy duty connectors for the cable assemblies that are to be used in applications that need to withstand one or more of the conditions and environments mentioned above. So, here’s a guide that can help you choose the best quality heavy duty connectors for your application.

The housing material

A die-cast aluminum housing should be the best choice as these are light weight yet highly impact resistant. However, if your application is to be used in wet environments, plastic connectors should be a better alternative as they won't rust or corrode. And, if your application is too small with tiny spaces, you can choose materials that provide EMI shielding instead.

The insert types

Heavy duty connectors with pluggable inserts that carry power, data, or signal to and from factory equipment have been traditionally used. But today, modular inserts that support an integrated hybrid cable assembly are more popularly used. Heavy duty connector systems need to meet the demands of the hybridization trend, which is why more and more customized cable assemblies are being preferred. And, with such customizations, modular connectors are more popularly used as they provide an integrated hybrid assembly that creates new considerations for power and signal wiring beyond the fundamentals of approval ratings, clamping type, and wire guage. The various insert types that you can choose from include fiber optic, pneumatic, D-sub, USB, M12, and RJ45.

The ratings and standards

IP ratings depict the level of protection that an electrical enclosure provides against solids and liquids, and NEMA ratings describe the environments where the enclosure can be used. You need to choose from such ratings, or buy standardized connectors to ensure their quality and performance.

The manufacturer

You need to choose the right cable assembly and connector manufacturer too; one that has experience, knowledge, skill, and expertise in the field. One such cable assembly manufacturer in India is Miracle Electronics, a contract manufacturer that is tooled for majority of industries such as electronics, aerospace, audio, and medical. You can have all kinds of cable assemblies manufactured here, some of them being EMI shielded assemblies, flat assemblies, ribbon assemblies, RF assemblies, airborne looms, military looms, and power cable assemblies. You can also have circular, D-sub, military specific, and many other kinds of connectors built here too. And, whatever kind of cables, assemblies, and connectors you have customized with Miracle Electronics, you can rest assured about the quality you’ll receive because every production process executed here is certified for quality to ISO 9001, AS9100C. Also, every product manufactured here is certified and approved by DGAQA and MSQAA for platform specific applications, after undergoing all kinds of tests for dimension, weight, continuity, Hi-Pot, Pull, and environment compliance.

Why Should Industrial Bus Cables Be Standardized - Miracle Electronics

The two main sectors for series data cables are computer bus and industrial bus; the former being a communication system that transfers data between components inside or between computers; and the latter being a communication system that transfers data between components or devices at different levels in a manufacturing plant. But, it is the computer industry that has had greater success in achieving unbiased industry-wide standards, while the industrial sector is more independent, and can produce cables specifically for their brand names.

In the industrial world, there are a number of variations due to different speed and impedance requirements, ranging from 100 to 150 ohms. Moreover, manufacturers may design a hybrid cable for automotive manufacturing plants with components using PROFINET, INTERBUS, and Industrial Ethernet protocols, all in one cable; allowing them to connect their PLC logic to whatever control line happens to come on the next machine.

Protocol standardization

Industries are looking for open architecture interface as the need for plant-wide system compatibility increases. Ethernet protocol of 100 ohms seems to be a good choice in this case. Higher information speed requirements, diagnostic feedback of controls, and interest in motor feedback make Ethernet a great choice to offer the performance required. However, these requirements are still driven from the controls manufacturers’ system trademark, some of them being PROFINET, CC-Link IE, Industrial Ethernet, and Foundation Fieldbus HP. Yet, many independent special interest groups have started to come up and work for system compatibility of conventional Ethernet. One such example is Ethernet POWERLINK Standardization Group that has developed a formidable product offering with data transmission speeds of 100 Mbit/sec; and is waiting for component manufacturers to adopt their standard Ethernet protocol into their systems.

Connector standardization

The standardization of connectors is also being accepted as major device dealers are settling for metric-type connectors like M-8, M-10, and M-12. RJ45 is also used, but it is modified to provide larger gauge compatibility, harsh environment resistance, and shielding capabilities.

To conclude

As you can see, Ethernet-based architecture is becoming an accepted choice for serial bus networks, since the compatibility and standardization of Ethernet from the computer side, found in front office, drives the manufacturing side to generic products. However, the marketing side of the controls industry still continues to manufacture proprietary products, developing cable requirements that are exclusive to the brand. Having such a diversity of protocols allows cable manufacturers to offer a lot many different cable systems. Also, each architecture has a unique conductor configuration and electrical requirements.

From past to present

The goal of various bus protocols and designs developed over the last 50 years was to find a cable capable of fast computer speeds that could withstand electrical noise and harsh environments. To accomplish this goal, technology is advancing to produce fiber optic cables, which is more suited to these requirements.

Whatever kind of cables you’re looking for – basic or fiber optic – Miracle Electronics is where you should be. These are the most dependable and versatile wire harness manufacturers from India, manufacturing a variety of different types of cables and harnesses for a myriad of applications and industries. You can also get in touch to design the perfect customized cable harness for your requirements.

HDI PCBs _ Why And Where To Use Them - Miracle Electronics

As we’re all shifting more and more to studying, working, browsing, and shopping online, after the pandemic has struck us, our world is becoming even more dependent on digital technologies. Moreover, the digital world today is becoming even more complex; but the hardware associated with it is becoming smaller. For instance, PCBs are becoming smaller with more interconnections. This makes the applications they are used in sleek and lean. And, if they are portable, it becomes really convenient to carry the devices around.

The PCB industry plays a significant role in the development of all electronic gadgets that our lives revolve around today. And, to make it simpler and easier, PCB manufacturers are always coming up with newer trends; one such innovation being the HDI PCB, which is a smaller PCB assembly from India that is dense with high component count.

What is HDI PCB?

HDI PCBs are smaller PCBs with a high density component count, and thus more number of interconnections, but those that occupy lesser space. Although the components are placed very close to one another to reduce the size of the board, the functionality isn't compromised. The general HDI PCB is one that has an average of 120 to 160 pins per square inch, and a dense circuitry that is implemented through microvias, buried vias, and blind vias.

What are the advantages of HDI PCBs?

HDI PCBs offer many advantages over regular PCBs, some of them being a compact design, lighter weight, and great performance. In addition, the signal path length is reduced as the components are placed very close to one another, and the reflections of signal are reduced, which results in remarkably improved signal quality. Also, the implementation of stacked vias makes these boards a super shield against extreme environmental conditions. All in all, with so many advantages offered, HDI PCBs are extremely cost-effective.

What are the applications of HDI PCBs?

HDI PCBs, because of the benefits they offer, are used in a variety of industries, such as those listed below.

Smartphone industry – With smartphones becoming more of a necessity than a luxury, manufacturers are using HDI PCBs to make these phones even smaller, and thus, conveniently portable.

Automotive industry – Car manufacturers are using more of HDI PCBs to save significant space in the vehicles. Moreover, the integration of smaller and smarter electronic devices provides a better driving experience.

Medical industry – Medical devices manufactured today use more of HDI PCBs when they want to fit into small compact devices like implants, lab equipment, and imaging equipment. In diagnostic devices, miniaturized cameras using HDI PCBs can help get better and intricate picture quality.

Aerospace and military industries – Aerospace and military equipment like planes, missiles, and defense systems use HDI PCBs that can function better in extreme environments and hazardous conditions.

Wearable technology industry – Wearable devices like VR headsets, watches, and many others use HDI PCBs to make the devices sleek, while offering exceptional functionality.

You can see how HDI PCBs have revolutionized almost every industry today with usage in a variety of devices and applications. This has increased the demand for such PCBs. You may also opt for such advanced and improved PCBs to fit into your smaller and smarter products. You can choose from readily available PCBs or have your PCB assembly from India especially customized as per your requirements at Miracle Electronics, the leader in manufacturing a variety of PCB assemblies since more than a decade now.