Audio Output Transformers – What & Why? – Miracle Electronics

An audio transformer  is one that works in the audio range, with a working frequency range being generally between 10 to 20,000 Hz, and the impedance often used to transform the voltage or change the load. These transformer types are generally used in radios, televisions, voltage amplifiers, and other such applications.

Construction of an audio transformer

The core of the audio transformer is superimposed by a high magnetic material, with the primary and secondary windings tightly coupled, so that the flux across the original winding almost all has a phase chain with the secondary winding, and the coupling coefficient is close to 1.

Working of an audio transformer

The lowest frequency of the passband is determined by the inductance of the original winding, while the highest frequency is determined by the leakage inductance of the transformer. The original winding inductance is large, and the leakage inductance is small, in order to ensure that the transformer has sufficient passband. The saturation of the magnetic circuit and the hysteresis loss of the core can cause signal distortion. To counteract this, there should be proper load distribution and increased load current. Also, the core section should be increased, and an air gap left to reduce the saturation of the magnetic circuit. Doing so can significantly reduce the distortion of the signal.

Audio output transformer

With multiple types of audio transformers available, what we’ll focus on in this blog is the audio output transformer, which is one that is intended to isolate an input circuit from an output circuit, while providing filtering to a signal that passes through it. It is designed to operate on signals with a frequency spectrum in the audible band. Output transformers basically perform two functions – completing the matching of output impedance, and completing the conversion of voltage to current, so that higher voltage signal can be converted to an electrical signal with lower output current.

Note: Close attention should be paid to the matching of the front and back impedance, in order to avoid signal distortion caused by the reflection. Also, the impedance of the load must be consistent with the impedance required by the power amplifier stage, through the impedance of the output transformer, in order to maximize the load.

Designing an audio output transformer

When you’re deciding on the kind of audio output transformer you want for your application, the choice of the core material and its size depends upon the frequency response, power levels, and harmonic distortion. Audio output transformers are generally preferred to use both high-permeability cores and the largest number of coil turns to create high primary inductance. Remember, by changing the number of wire turns in each winding, transformers can be manufactured to have various impedance ratios. You can choose to have your specific customized audio output transformer India to suit your particular application requirements at Miracle Electronics, where every transformer manufactured is of the highest quality, which is proved by their RoHS and REACH compliance certificates. So, get in touch whenever you are looking for the finest quality audio transformers!

Building A Box Build Assembly – Miracle Electronics

When you want a box build assembly made, you’ll try to search for the best and least expensive vendors. Obviously, who doesn’t want to save money! So, you’ll begin by sourcing components from one company, then send them to a manufacturer to sub-assemble the elements, and then forward the parts to another manufacturer who finally tackles the final assembly.

But, doing so can waste valuable time and money, while also compromising on the quality of your product, if any of the vendors are not up to the mark. Instead, why not send your project to only one manufacturer, who is dedicated to your project from start to finish, rather than opting for multiple sub-assemblers? Find a box build electronics manufacturer who can take care of everything, right from component sourcing to the final end product. A box build is a systems integration; a complete electronic assembly placed inside an enclosure, which is why it is advisable to get your project into the hands of an apt integrated service provider  who can handle it all effectively and successfully.

Designing

The designing phase involves the material and component selection, layout, concepts, and tooling. Combining all of this into one complete project is a task, which needs the skills of an expert manufacturer.

Assembling

Assembling involves combining all the components appropriately as per the design layout. In addition, the manufacturer will also help determine the input/output of the power, power sources, mounting options, and environmental constraints.

Cables and wire harnesses

No box build can be complete without the use of a combination of wires and cables. High or low voltage cables and wire harnesses will be incorporated into your box build. This could include standard or customized options, fabricated to meet your specifications, which again is the responsibility of the manufacturer.

Enclosure

The enclosure may require unique dimensions, special spacing, specific routing, or distinct mounting. Your manufacturer must look at all these factors, and determine the best shape and size that can hold every component easily in place, while also checking for the access of sensors and power.

Testing

Testing is a very important task within the manufacturing process of any and every electronic product. Testing ensures the quality and performance of the equipment, thus also ensuring reliability for the product to stand up to everyday use. Testing should be done after every phase of the manufacturing process, as well as after the final assembling of the box build.

Every box build is unique. It can range from a simple PCB in an enclosure to a large cabinet full of wires, complete with electronics and pneumatics. Whether your application requires a simple box build or a complex one, Miracle Electronics has the experience and expertise to meet your requirements. They are apt for surface mount and through hole assembly to cable manufacturing and complete electronic box assemblies in India; all in all a complete package, built with dedication to lean manufacturing techniques. 

The Basic Fundamentals About Defense Offset Guidelines – Miracle Electronics

A defense offset policy is drafted to leverage capital acquisitions in order to develop the Indian defense industry by fostering the development of internationally competitive enterprises, augmenting capacity for R&D, and encouraging the development of synergistic sectors like civil aerospace and internal security.

But, so as to achieve such a partnership, there is a list of defense offset guidelines that need to be followed. While the number of guidelines are umpteen, let’s help you get a brief in this blog below.

Application of provisions

The provisions apply to every capital acquisition, may it be outright purchase from a vendor, or purchase from a vendor that is followed by Licensed Production, where the estimated cost of the acquisition proposal is 300 crores or more. Generally, 30% each of both these costs of acquisition will be the required value of the offset obligations. However, the Defence Acquisition Council may prescribe varying offset obligations in special cases if required. Nevertheless, these provisions will not apply to procurements under the Fast Track procedure, and those under the “Option” clause, where an offset obligation was not stipulated in the original contract.

Discharge of offset obligations

The offset obligations may be discharged by one or more of the following methods –

ü Direct purchase or export orders for eligible products manufactured or serviced by Indian enterprises

ü Foreign direct investment in joint ventures with Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services

ü Investment in ‘kind’ in terms of transfer of TOT (Transfer OF Technology) to Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services

ü Investment in ‘kind’ in Indian enterprises in terms of provision of equipment through the non-equity route for the manufacture and/or maintenance of eligible products and provision of eligible services, excluding TOT, civil infrastructure and second-hand equipment.

ü Provision of equipment and/or TOT to government institutions and establishments engaged in the manufacture and/or maintenance of eligible products and provision of eligible services.

ü Technology Acquisition by the DRDO in areas of high technology

Then, there are a multitude of other offset obligation discharge policies that are divided into different sectors, such as vendor responsibility, performance bond, offset credits, offset banking, value addition, Buy Global procurements, offset valuation, and more.

Submission of offset proposals

Vendors are required to submit a written undertaking to the effect that every offset obligation will be met. Any failure on the part of the vendor to comply with the guidelines may result in disqualification of the vendor from any further participation in the contract. The proposals should be submitted by a specified date, failure of which may render the bid non-responsive, and liable to be rejected.

Evaluation of offset proposals

The Acquisition Wing in the Department of Defence is responsible for technical and commercial evaluation of offset proposals received in response to RFPs, and the conclusion of offset contracts. The Defence Offsets Management Wing in the Department of Defence Production is responsible for the formulation of the offset guidelines, auditing and reviewing or progress reports, and post contract management. And, both these wings work in close collaboration for the smooth implementation of the guidelines.

Processing of offset proposals

Technology acquisition – The Technology Acquisition Committee is responsible for assessing the offset proposals, covering both technical and financial parameters, including valuation of technology, and the timeframe and strategy for utilizing the technology.

Technical evaluation – The Technical Offset Evaluation Committee (TOEC), constituting of representatives of the Service Headquarters, Defence Finance, DRDO, DOMW, and other experts, is responsible for scrutinizing the technical offset proposals to ensure conformity with the offset guidelines. The TOEC report is then forwarded to the Technical Manager, who will then process the report for acceptance.

Approval authority – After the offset proposals are processed by the Acquisition Manager, they will be approved by the Raksha Mantri.

Penalties – If a vendor fails to fulfil the obligations as agreed to, a penalty equivalent to 5% of the unfulfilled offset obligation will be levied, after which the unfulfilled offset value will be re-phased over the remaining period of the contract. The vendor may also be liable for debarment from participation in future defence contracts for a period of up to 5 years, the decision that will depend upon the Director General of Acquisition.

Re-phasing requests – A vendor has the advantage of requesting re-phasing of the offset obligations within the period of the offset contract, providing valid reasons. If justified, the request may be granted.

Annual reporting – An annual report is submitted to the Defence Acquisition Council in June every year, regarding the details of the contracts signed, and the status of implementation of all on-going contracts.

Indian enterprises, institutions, and establishments engaged in the manufacture of eligible products and/or provision of eligible services are referred to as Indian Offset Partners, who are required to comply with all the above guidelines/licensing requirements and many more. Vendors are free to select such a partner. If you’re looking for the same too, Miracle Electronics can prove to the best Offset Partner For Indian Defense, thanks to their complete adherence to the obligations, proven industry capabilities, consistent R&D, and every necessary quality certification in place!

Choosing The Right SMPS Transformer – Miracle Electronics

A multitude of electrical and electronic personal daily-use products, such as computers, mobile phone chargers, automobiles, telecommunications, and security systems, involve the usage of SMPS transformers, making it one of the most in-demand transformers across the globe.

These transformers are used to provide galvanic isolation at the input, meaning a clear barrier that prevents dangerous high voltages from passing to the output, thus providing safety from electrical shock. However, one disadvantage of such isolated power supply is low efficiency, which can range between only 70 to 90%.

What causes low efficiency?

As the power supply is run at high voltage/current, strong magnetic fields are passed into the core of the SMPS transformer, which causes hysteresis in the magnetic core as the input AC signal oscillates. Further, because of such high input current, the core can saturate during operation, leading to even severe hysteresis and heat dissipation. Due to this, almost every SMPS transformer manufacturer in India supplies hysteresis curves with their components, allowing the designer to determine the limits on the input current.

What problem can low efficiency cause? How can it be resolved?

Lower efficiency of the SMPS units can cause heat up to higher temperatures when run at high voltage/current. This is why thermal management strategies are required to remove the heat. Heat sinks can help here, as they provide sufficient cooling when used with chassis-mounted fans.

How to place an SMPS transformer effectively?

SMPS transformers can be placed in one or more locations in a regulator circuit, in any of the multiple power conversion and regulation stages. But, one very common location for the transformer is between the output regulation stage and the switching stage. However, the exact location for the SMPS will depend on the power supply topology – two common topologies being flyback converter and forward converter.

How to choose your SMPS transformer?

There are a variety of SMPS transformers that use different core materials, coil numbers, and winding directions. For instance, different core materials saturate at different magnetic field strengths, which determines the highest voltage that can be used with the transformer. Generally, 2 coil transformers are the most common, while 3 coil transformers are used to provide multiple output power levels from a single SMPS circuit. In this way, you must be able to determine the exact specifications that you require. You must be able to choose the ideal SMPS transformer for your application. It must be one that operates within the linear hysteresis range for your supply, in order to minimize heating and power loss.

Partnering with a professional SMPS transformer manufacturer in India, one like Miracle Electronics, can ensure that every minute detail about designing the transformer is taken care of. That’s because they are skilled and capable of designing unique customized SMPS transformers for your particular application, delivering RoHS and REACH compliant solutions that guarantee minimal power wastage and highest possible efficiency. Miracle Electronics’ SMPS transformers have a high power-to-size ratio, with each segment topology having a unique V-in to V-out transfer function, leading to absolute efficiency. Hence, with a reliable transformer manufacturer  like Miracle Electronics, your transformers produce the desired output voltage, ensuring that the ripple is within your tolerances.

 

 

Cable Harnesses – Insulators, Connectors, And Terminals – Miracle Electronics

When you’re looking to protect your wires and cables against environmental conditions like moisture, temperature, and friction, you’ll need to install cable harnesses in your application. Depending upon the intended environment, there are multiple types of cable harnesses available to choose from. 

You may opt for standard readily available harnesses, or have your harnesses customized by proficient cable harness manufacturers in India.

When you’re planning to have your cable harnesses customized, you may either tell the manufacturer all about your requirements, or sit with them to design your specialized assemblies. If you choose the latter, you need to first have a basic understanding about the product, before you can sit down to decide on what you want. Considering this, we’ll let you know about the three main components that comprise a cable harness, which are insulators, connectors, and terminals.

Insulator types

The cables or the insulation that covers the wires can be of two types, depending upon the kind of environment or application the harnesses are to be used in. they could either be thermoplastics or thermosets.

•     Thermoplastics are the materials that soften or melt when exposed to a sufficiently high temperature, but also easily harden when cooled. They can be repeatedly softened and hardened by heating and cooling, without affecting the performance of the material. This quality enables recycling of the components, which also proves to be economical. Some common thermoplastic insulations include PE, PVC, PVDF, ECTFE, and nylon.
•          Thermosets are the materials that don’t soften even at high temperatures, but they’re rubbery and retain their properties at all times. However, once moulded or cast, these materials cannot be reshaped, because the moulding results in a permanent chemical change within the material’s structure. Some common thermoset insulations include CPE, EPR, and XLPE.

Connector types

Connectors are the electromechanical devices used to form a continuous electrical signal between the cable harness and power source. Basically, connectors consist of male plugs and female jacks that are joint together to relay an electronic signal. Such connectors broadly differ in materials, sizes, shapes, and dimensions, which can be chosen from or customized as per the intended application. The mating type, the insulation requirement, the power contacts, and the signal contacts are all the different factors that determine the kind of connector required by the application. When selecting a connector, it is also very crucial to know the wire size, circuit size, circuit density, operating voltage, current rating, and other such important numbers.

Terminal types

Terminals are the electromechanical devices that terminates a conductor to a fixed post, stud, chassis, etc. in order to establish a connection. Available in a variety of designs, shapes, and sizes, terminals may be crimped, soldered, press-fitted, or wire-wrapped. They are available in ring, spade, hook, bullet, butt, and flagged forms. The type of terminals to be used can depend on the requirements of the intended application. The terminals could be insulated or non-insulated. Insulated terminals are better used in harsh environmental conditions to protect the device and components from moisture and temperature extremes. If no such protection is required, non-insulated terminals are an economical choice.

Determining the type of insulator, connector, and terminal is of prime importance to come up with the best performing cable harness. They harness should be very carefully designed while keeping the specific application needs and environmental conditions in mind. The correct materials, sizes, and shapes are vital to ensure that the harnesses are properly placed and appropriately routed, while being completely protected. Professional cable harness manufacturers in India like Miracle Electronics can take care of every such aspect that affects the quality of the end product , so as to come up with a harness that’ll extend the life of the wires, without requiring early replacements or repairs. It’s thus always better to partner with a professional for even the smallest electrical or electronic build.

Is An EI Transformer A Good Choice For You? – Miracle Electronics

With every transformer performing the same task of trading voltage for current in a circuit, without affecting the total electrical power, different types of transformers work differently to achieving the same goal. Also, different types in regards to the shape, size, material, etc. also affects the quality of performance. In this blog today, we’ll speak about one particular kind of transformer – the EI transformer.

What is EI transformer?

As the name itself suggests, EI transformer is one whose core is combined by laminations shaped “E” and “I”. A traditional and economical transformer, the EI transformer is widely used in a variety of electronic equipment and audio applications. The air gap between the E and I laminations can be easily adjusted by filling it with a suitable medium, making it suitable for building output transformers and chokes. This is the reason why many audio output transformers and chokes are designed with the EI transformer.

Why should you opt for an EI transformer?

EI transformers have a very simple structure, making it absolutely easy to manufacture, which is why most transformer factories are able to manufacture these transformers.

It is very easy to find the components required to build an EI transformer in the market, making it an easy-make as well as economical solution. With everything being available easily, the prices automatically go down.

EI cores are flat stampings with no need of any kind of bending or forming, which makes it very economical to manufacture.

The laminations can be removed from a single rectangular sheet without substantial wastage.

The mounting method of the EI transformer is simple.

EI transformer cores are more preferred than other U, C, and L core types, mainly because more surface space is protected by the winding in these cores.

The make of an IE transformer is such that the whole thing can be held together conveniently with simple corner fixings, or just vacuum impregnation with lacquer.

There is very good magnetic coupling between the two ends of the core.

Are there any disadvantages of using an EI transformer?

Just like anything else, EI transformers, in spite of having so many good qualities, also have drawbacks. One major drawback is that these cores don’t have self-shielding quality in them.

After going through the blog, it’s time you decide as to whether you would want to use an EI transformer for your application or not. Despite the fact that an EI transformer doesn’t have self-shielding, there are so many other benefits associated with it. So, whether it is for differential, power, or telecom inductors, converters, or inverter transformers, if EI seems to be the right choice for you, you could approach Miracle Electronics for the same. They’re the most reliable EI transformer manufacturer in India, where you can get durable and highly efficient transformers that come with superior wiring, varnishing, and connection terminators, all of which provide excellent regulation with minimal temperature rise. You can thus make the most of your electrical devices by buying such RoHS and REACH compliant EI transformers that can lower the voltage exactly to a value that is required by your appliance, while keeping it running right and safe.

 

When Building Electronic Box Assemblies – Miracle Electronics

An electronic box assembly is an electromechanical assembly process that includes enclosure fabrication, installation of sub-assemblies and components, and routing of wires and harnesses. It could mean anything from a PCB assembly in a cabinet fill or wires, or a complex fully integrated electromechanical system with pneumatics and electronics. 

Whatever it may be, you need to have your components placed in a project box that protects, as well as makes your product truly useful and accessible.

Designing electronic box assemblies in India presents its own challenges, which is why you need a manufacturer who goes ahead with the right approach. You need one who specializes in the capability you want to build, and has experience in building the particular product and components you’re looking for. Outsourcing your electronic box assembly is an easy task when you have such a reliable manufacture partnered with. But, while you outsource, you also need to consider a few basics to help the build process go smoothly. There are certain instructions you need to send to the manufacturer for building the box appropriately. These include –

Bill of Materials (BOM)

The Bill of Materials gives the manufacturer an idea of all the key components, with a clear mention about the materials that you will be providing, and those to be sourced by the manufacturer. You may also define every tiny detail like the adhesives, tie wraps, nuts and bolts, washers, heat shrink, etc. if you wish to avoid even the smallest confusion or misconceptions in the future. You should also clearly specify the tolerances and finish of each component if you want anything particular to be considered. All in all, it is best to specify every minute detail just exactly how you need it. If you’re too confused as to what materials or specifications should be used for your particular requirement, you can also communicate all your ideas and purposes to the manufacturer, and help him decide the best solution for you.

Assembling

Once all the materials and components are decided and discussed upon, along with all the specifications and details mentioned, it’s now time to move on to the process of assembling them. if possible, you can provide a 3D CAD model to help the manufacturer visualize the final product like you want it to be. Or, at the least, you must provide the assembly drawings with every detail clearly mentioned. However, if you’re not too sure, you can always define the purpose and requirement, and leave the job of designing and prototyping to the manufacturer. This can also help when there are large amounts of space, labour, and specialist tools required for the build.

Testing

Testing is always an integral part for any product, especially when it is an electronic or electrical device. The basic electrical safety testing, such as earth bond and flash tests, need to be conducted, thus specified well in advance. Other tests may include visual inspection, functional testing, factory acceptance testing, etc., depending upon your specific product. If you’re not too sure again, your manufacturer can help decide as to what kind of testing is important, as they will have the proper knowledge and experience of what will work best for your particular product.

Outsourcing and electronic box assembly inevitable requires close cooperation between the client and manufacturer. By providing all the above information, and every other detail possible, there would be lesser confusion, lesser misunderstandings, and lesser wastage of time and money. Whether you require a simple box build assembly, or complex electronic box assemblies in India, you can get in touch with Miracle Electronics to ensure that your product is protected and looks good with the final assemble that proves to be a true reflection of your encased product. Dedicated to lean manufacturing techniques, Miracle Electronics will always offer maximized efficiency and a complete package, no matter what the product may be.

 

Connecting The World With Cords – Miracle Electronics

A few decades ago, travelling overseas or across the country was not part of everyday life. But today, with countries and communities around the world becoming more connected, travel is more accessible and affordable. Businesses are operating on a global scale, and people are frequently travelling overseas for vacation. 

Technology and new transport options are the two main contributions to these ease and accessibility, which are helping our world become smaller. What took us days to reach another city or country, now takes only a few hours to be there. But, all this technology is becoming only possible with the help of the variety of wires and cables being used within the systems of all kinds of transport. Whether you’re travelling by road, rail, or air, every transportation vehicle holds a multitude of wires and cables within its system to be able to run.

Different purposes solved by transportation

• Scooters, autorickshaws, cars, jeeps, and buses are the most common vehicles used to travel by road for everyday chores.
• Metros and trains are used to travel from one city zone to another, or from one city to the other.
• Trucks, lorries, and cargo trains are used to import export freight within cities or countries.
• Ships are used to transport both people as well as cargo from one country to the other.
• Flights have become an easy way to travel from one country to another, may it be for vacation, occasion, or business trips; or for transporting cargo faster.
• Each of these modes of transportation depends highly on wires and cables to operate , as well as communicate to systems on the land.

How are wires and cables important for these vehicles?

• Cars, trucks, buses, and lorries require wires and cables to have their electrical and electronic  systems, like dashboard controls and radio systems, function and perform.
• Communication and GPS systems also require the use of wires and cables within these vehicles,  to be bale to safely convey important information between users, and navigate the roads to and from different destinations.
•  Electric vehicles that are highly being adopted today rely even more heavily on wires and cables. In addition to the standard electrical and electronic functioning, such vehicles also require them to run their battery systems and charging ports.
•  Boats and ships rely highly on communication and GPS devices, which require innumerous wires and cables to run. Proper networking of such wires ensures the operators safely navigate the waters, without the fear of getting lost or travelling into unsafe weather and water conditions.
• Ships that carry passengers also need to install entertainment devices like televisions, radios, and music systems, to provide recreational activities to the travellers, which again require a number of wires and cables.
• Cargo ships require wires and cables for electronic inventory tracking systems, to streamline loading and unloading operations.

Where to get your wires and cables?

At Miracle Electronics, you can have all kinds of wires, cables, and harnesses to make travel possible. From cables for communication devices to wire harnesses for operational systems, you can get it all. Miracle Electronics is the leading automotive wire harness manufacturerin India that provides solutions for all standard and customized requirements, each being certified and approved by DGAQA and MSQAA for platform specific applications.

Why Are Toroidal Transformers A Better Choice? – Miracle Electronics

Like every transformer type, a toroidal transformer is designed to change the AC current, without the need for any type of movement or action, on the part of the component. But, what makes it different is that its doughnut shaped core is made of cold-rolled silicon steel, which boosts the performance of the core, as compared to any other traditional laminated core. 

The core is wrapped with a coil that generates magnetic field lines, which are completely coincident with the magnetic circuit of the core. This results in a reduced excitation energy and core loss. A toroidal transformer thus benefits the application by offering high electrical efficiency and less magnetic interference, packed in a small size, which also makes it absolutely light in weight.

Distinguishing the outcomes produced by a toroidal transformer

By using an efficient toroidal transformer, large amounts of energy can be saved. Let us take an example. You can take two different types of transformers for the same application; for instance, one being an EI-core transformer 2 x 24V 50 VA, and the second being a toroidal transformer 2 x 9V 50 VA. Loading both these transformers with several load resistors, and the loading power ranging from 5 to 40 Watts, the energy losses can be measured to find the remarkable difference between the two outcomes. The difference between the input and output powers is the energy loss that is converted into heat within the transformer. Moreover, dividing the output power by the input power can also bring to you the transformer’s efficiency. Calculating with different numbers of load resistors, you’ll be able to clearly see the significant differences in the outcomes. The toroidal transformer will result in much less losses than an EI transformer.

Where can you use a toroidal transformer?

Toroidal transformers are used widely in home appliances and other electronic equipment with high technical requirements, such as computers, lighting, telecommunications, audio equipment, medical equipment, and automatic control equipment. You can choose to use the same for your equipment too. And, to bring about even better results, you can opt for a customized toroidal transformer, manufactured by professional and expert toroidal transformer manufacturers in India.

Designing a customized toroidal transformer

Before designing a customized toroidal transformer, there are certain parameters that need to be considered; some of them being –

• The industry – With every industry having different requirements, the industry and equipment in which the toroidal transformer needs to be used should be thoroughly considered and understood.
• Input voltage – Generally, the toroidal transformer is designed according to 220V, but it can also be customized as per any special requirements regarding the input voltage.
• Output voltage and current – Whether the toroidal transformer is single or multi-wound, the output voltage and current of each winding needs to be considered well.
• Output power – The wattage obtained by multiplying the output voltage and the output current also needs to be contemplated.
• The installation method – The kind of installation method needs to be carefully decided upon, such as bracket installing, middle hole potting, full potting, etc.
• Any other special requirements – Any other special requirements such as the lead length, or whether the lead needs to be added with a terminal plug, and other such considerations, need to be reflected upon.

Whether standard or customized, whatever your choice may be, Miracle Electronics are the toroidal transformer manufacturers in India you can rely upon to satisfy all your requirements!

Every Possible Issue Related To Wire Harness – The Problems & Solutions – Miracle Electronics

Wire harnesses are engineered for different applications, but they play a critical role mainly in electrical and electronic devices and systems. Their rugged construction helps them to withstand almost all kinds of impacts and environments such as extreme temperature, humidity, compression, friction, vibration, etc.

 However, these harnesses can experience certain issues that can stop them from working as expected. Below, we’ve highlighted some of the most common problems that occur, along with some ways to either avoid the issues or resolve them.

Common issues

While there could be multiple kinds of problems seen within a wire harness, the most common issues include –

•         Poor performance
•         Shorter lifespan
•         Incorrectly placed components
•         Missing components or wires
•         Oxidation
•         Corrosion
•        Circuit issues

The causes

Inappropriate material selection – If the material chosen to build the harness is not one that can withstand the environmental forces in which it is to be installed, it can lead to poor quality and deteriorated performance.

Incorrect wire preparation – Not only is selecting the material important; it’s also vital that the wire is cut tothe right length, stripped right , and connected correctly. Failing to do so can lead to incorrectly prepared components.

Incorrect installation – Any imperfections in installing the wires can result in imbalanced pressure, circuit issues, and deterioration in the quality and performance over time.

Inadequate/flawed testing – If the harnesses are not tested properly, it may lead to missed issues that may cause bigger problems in the future.

Incomplete protection – Oxidation and corrosion are quite common to occur when certain metals come in contact with air and moisture.

The solution

It is very important to test the harnesses in order to eliminate all the above issues. Testing them after completion of every manufacturing stage, as well as after completion of the entire process, is essential. This brings forward any issues immediately so that the problem can be resolved at the earliest before moving on to the next stage. This results in reduced wastage of time, material, and labour. There are five different ways in which the harnesses can be tested.

Visual testing – This involves visually analyzing if every component is placed correctly or not; for instance, the dimensions, the gauge, the placement, the connectors/terminals , and the labelling.

Mechanical testing – This involves testing the mechanical properties such as flexibility, tensile strength, elongation, impact resistance, and crush resistance.

Electrical testing – This involves assessing the electrical performance; whether or not the configuration and performance are proper or not. Open wires, incorrect wiring, and shorts are tested for, by connecting the harness to an electrical fixture.

Environmental testing – This involves testing whether the harness can withstand the environmental conditions it is installed in, such as humidity, temperature, pressure, and vibration.

Signal integrity testing – This involves assessing the strength of the signals that can be carried, which include signal error and crosstalk. Whether or not the signal strength can be maintained with the integration of connectors, filters, or splices is also checked for.

Partnering with Miracle Electronics

You can see how it is important that you partner with a professional wire harness manufacturer like Miracle Electronics, where the harnesses are not only manufactured, but also tested at every stage to identify for potential errors at the earliest, so as to reduce wastage of time and labour, and bring to the client a thoroughly tested end product.

 

Importance Of RoHS For Medical Isolation Transformers – Miracle Electronics

The term “medical” in itself indicates safety and caution. Medical transformers thus also need to be very carefully designed so as to keep both the operators and patients safe while they’re around the device. 

And, this is the reason why the transformers used in medical applications are always isolation transformers – those that isolate the patient and operator from electric shock, and protect the equipment from power surges and other faults. Such medical grade isolation transformers  thus need to maintain strict adherence to certain crucial standards; one of them being RoHS.

What is RoHS?

RoHS, or the Restriction on the use of Hazardous Substances, in itself states that no kind of hazardous substances are permitted to be used while manufacturing the particular device. The main goal of RoHS is to reduce the environmental effect and health impact of electronic equipment, by making electronics manufacturing safe at every stage of the electronic device’s life cycle.

When was RoHS introduced?

The RoHS restriction originated in the European Union in 2002, restricting the use of 6 particular hazardous substances found in electrical and electronic equipment. It was then officially adopted in February 2003. In 2005, on the 21^st of October, the European Commission decided to exempt the use of Cadmium and its compounds in electrical contacts. The next year, the European community established July 1 as the phase-out date for hazardous material in electronic products.

Why was RoHS introduced?

A wide range of materials were used to manufacture electrical and electronic equipment, such as radium, lead-tin allow, etc. But these materials, despite of the fact that the had many useful properties, were also discovered to be hazardous to both humans and the environment. It was thus a must to stop the usage of such harmful materials. For strict adherence, the RoHS was introduced, in order to improve the welfare of consumers, manufacturers, distributors, and the environment.

Which materials are restricted for use under the RoHS restriction?

As per the RoHS, products compliant with the derivative must not exceed the allowable amounts of the restricted materials (with some limited exemptions). The 6 restricted materials include lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls, and polybrominated diphenyl ethers. This derivative applied to manufacturers, importers, distributors, and authorized representatives of a wide array of products. Some of the most common products that need to adhere to the RoHS standard include small and large household appliances, consumer electronics, lighting, computing equipment, communication equipment, power tools, and not to forget – medial transformers.

Why is it a must to adhere to the RoHS standard?

The 6 materials that fall under the RoHS derivative are hazardous to the environment, and also dangerous in terms of occupational exposure during manufacturing and recycling. Complying to RoHS reduces the amount of hazardous chemicals used in manufacturing electronics. This is why whenever you’re planning to purchase a medical isolation transformer in India, or any other electronic equipment for that matter, you should always approach a manufacturer whose products are all compliant to the RoHS certification. One such trusted manufacturer is Miracle Electronics, where every medical isolation transformer is not only RoHS compliant, but REACH compliant too!

 

Choosing The Right Power Supply For Your LED Application - Miracle Electronics

Discovering the right kind of power source for your LED lights and fixtures is absolutely important, may it be to build a new fixture, or retrofitting an existing one. What you’ll need is a constant current LED driver or a constant voltage power supply, or a combination of both, in order to make your LEDs work properly. Let’s help you know the different factors you need to consider when choosing a power supply for your LED lighting.

Most LEDs require a current-limiting device to prevent them from being over-driven. Such devices are used to regulate the current coming in to the LEDs, keeping them running safe, and maximizing their lifespan. If the current is not regulated, the LEDs may get heated up, thus changing their electrical characteristics to draw too much current, thus resulting in fluctuations or even failure. If your lighting fixture doesn’t have a current-limiting device, your first step should be to find a driver. But, if your LED product already has the current under control, you can move ahead to find a constant voltage power supply.

When the LED products already have current-limiting devices within the system, they call for a constant DC voltage, which is generally not available, and then you’ll need to find a power supply to convert your power to a safe DC voltage. But, in order to be able to effectively convert your AC voltage down to a safe DC voltage, there are many factors you need to consider, some of the most important ones being mentioned below.

Wattage and voltage

Identify the total amount of watts that all your lights combined will consume, and add to it a 20% cushion, or multiply the total wattage by 1.2. You’ll need to find a power supply rated for this calculated amount of wattage. Also, identify the output voltage that is compatible with the voltage of the LEDs. You also need to ensure that the power supply you select should be capable of handling the input power you have.

Temperature and environment

The area and the environment that you need the power supply in is also an important consideration. Power supplies operate efficiently only when they’re used within their temperature parameters. Installing a power system within a tiny enclosure, or where there is no ventilation system, is a bad idea. Rather, you should choose an area where it’s neither to warm, nor too cold, and where the heat produced cannot build up to damaging levels.

IP rating

Every power supply has an ingress protection rating, which is more popularly known as IP rating, consisting of a two-digit code that respectively indicates the size of solids and pressure of liquids that a power supply can resist. You need to ensure a power supply with an IP rating that will protect your source from the environment.

Size

The space that you have for installing the power supply should be well identified, and the right size of power supply device should be chosen. If the power supply is to be installed outside of the application, there should be a mounting possibility.

Using the above considerations, you should be on the right road to choosing the right power supply for your LED lights. There are a multitude of options to choose from, which is why you should take your time to consider every little aspect, so as to find the one that best fits your application, and is highly efficient in regards to how and where it needs to perform. And, when you’re done with all your contemplations, you’ll look for a place to begin your product search. This is where we suggest to you Miracle Electronics, a reputed brand where you can get standard as well as customized programmable power supply for LED light panel in India, each manufactured in dedicated work cells, using lean manufacturing techniques, to maximize efficiency.

Choosing The Ideal Core For Your SMPS Transformer – Miracle Electronics

 When you’re looking to transfer electrical power effectively while also providing galvanic isolation, an SMPS transformer proves to be the best choice that provides a clear barrier against dangerous high voltages from passing to the output. This is thus a safe and space-saving option, unlike other traditional linear kinds of transformers.

But when planning on having SMPS transformers manufactured for your application, you also need to be capable of making the right core choice. This choice is generally based on your power requirements, the frequency required, and the switching topology. Let’s help you know some basic considerations to make the right material, shape, and size selection.

Core material

It’s basically ferrite that is used for making the core of an SMPS transformer; the reason being that its frequency spectrum ranges between 20 kHz to 2 MHz, thanks to its reduce expense and minimal losses. But, ferrites should be employed in the saturating approach for low power and low frequency functioning. In the case of high power functionality, a tape-wrapped core used as the saturating core, with a ferrite core used as the output transformer, proves to be a better choice.

Core type

There are a variety of different core types you can choose from, some of the most popular ones stated below. Each core type has its own size and shape advantages. Let’s check them out.

EFD cores – EFD cores are economical flat design cores that offer excellent space utilization for transformers or inductors. They’re thus ideal for compact transformer and inductor applications.

EP cores – EP cores are circular center-post cubical designs that surround the coil thoroughly, with the exception of PCB terminals. This eliminates the influence of air flow crevices established at mating walls in the magnetic track, giving a more significant volume ratio to the absolute area used.

ETD and EER cores – ETD and EER cores are those with a round center-post and broad winding areas which offer the advantage of a short winding path length, and thus minimum winding resistance. They are absolutely good for high power designs and multiple output designs.

PQ cores – PQ cores have a maximum ratio of bulk to winding region and surface area. This results in comparatively fewer turns with a maximum winding area, lesser space consumed, and maximum inductance.

A perfect transformer is one that promises minimal core decline, while demanding the very least volume of room. The core loss is affected by the flux denseness and frequency. Having all of this considered is of utmost importance when selecting both the transformer and the core. This is why, when making your core choice, it is always advisable to work with an expert SPMS transformer manufacturer in India, one like MiracleElectronics. That’s because the expert engineers available here can help choose the most suitable material and dimensions for your particular project, so that your expenses are minimized, and profits maximized. Moreover, Miracle Electronics’ SMPS transformers are all RoHS and REACH compliant, thus assuring quality performance and minimal power wastage.

 

How Important Is Aftermarket Service For Aerospace Components? – Miracle Electronics

Ever thought of how essential parts of commercial or military aircrafts are manufactured? Have you wondered what happens to them over the course of time? If you live in a fantasy world, you would believe that once such crucial parts are manufactured, they’d last a lifetime, because of the immense caution put in and the high-grade materials used for manufacturing them.

There’s no doubt in the fact that aircraft parts manufacturers use only the best quality materials and put in utmost care and caution while manufacturing such parts, but considering the parts to last an era is not agreeable. Whether it is auxiliary power unit mufflers, nozzles, engine exhaust plugs, pneumatic ducts, or any other component, it isn’t necessary that they all last the lifetime of the airplane they are installed in. That’s because a myriad of things happen during the daily operation of an aircraft. Environmental conditions and other impacts may result in damages and premature wear and tear. So, what can you do about it?

Importance of aftermarket services

Even if you approach the best aircraft parts manufacturer, you can be certain about getting A-grade components, but you can’t assure that you won’t have to keep a check on them again. There will be required regular checks, and repairs or replacements as required. This is where aftermarket services are critical to get the aircrafts back in the air. Every day brings new adventures and issues in the life of an airplane; and it is important that regular assessments are done.

Who to approach?

You must approach an establishment that considers itself a service business rather than a company that only manufactures a product. Customers consider a company only as good as the last order fulfilled, which is why businesses must strive to focus on building customer relationships. Customers always return to a store, restaurant, salon, or service provider only if they have had a good experience, and are satisfied with their products/services. But, once they receive a terrible experience, they’ll never return again. Same is the case for aircraft services businesses as well. One bad experience can cost a customer relationship forever!

Why choose Miracle Electronics?

One manufacturer you can trust for both products and service is MiracleElectronics. If you’re in the aircraft industry, you can approach Miracle Electronics for the best quality aerospace cables, transformers, inductors, and box build assemblies.

Aircraft cables – Every kind of aircraft cable and harness can be manufactured here with machineries for wire cutting, wire stripping, terminal and lugs crimping, and more. Laser marking for aircraft cables is also available here, to help with easy identification.

Aircraft transformers – Efficient, small-sized, lower weight transformers are manufactured here that possess lower exterior magnetic field, make less mechanical hum, and generate very low off-load losses.

Aircraft inductors – Whether it is commonmodes chokes  for infiltering supply and return conductors with in-phase signals of equal amplitude, or differential mode inductors for filtering out-of-phase uneven amplitude signals, you can get them all here.

Aircraft box build assemblies – Complete turnkey box-build and system level integration services, with the capability of producing all major sub-assembly components for an aircraft, with offerings including BTO, CTO, custom tooling and fixtures, custom production process design, and more, is all available under one roof.