When Choosing A Wire Harness Manufacturer - Miracle Electronics

A critical part of every electronic and electrical application is the wiring used. And, when hundreds and thousands of wires are to be used in a single application, it is always wise to group them up into wire harnesses, for which you need to consult and partner with a professional wire harness manufacturer in India. 

You need a manufacturer who can provide you with the best products that are high on quality and reliable in performance, because any kind of compromise in the quality or performance of the harness means issues in the application. Whether the issue is as small as a short, or as big as application failure, the results aren’t what you would want to experience. You thus need to be very careful when you’re choosing your wire harness manufacturer. While there is a lot you need to know about the manufacturer you are choosing, we’ve come up with only the most essential considerations that you need to make.

Consideration 1 – Experience

There may be wire harness manufacturers that specialize in only one or a few industries. Then, there may be those who work for almost every kind of industry. If you choose the former, you need to check if your industry is on their list, while if you choose the latter, you need to ensure that the manufacturer has a good amount of knowledge and experience about your particular industry. In any case, partner with the manufacturer who is knowledgeable about your industry and the requirements so that they provide you with reliable end products.

Consideration 2 – Customization

When you choose a manufacturer, you should likely choose one who offers customization services. If the manufacturer is good at customizing, you can always have your products specifically tailored to suit your application and requirements. Even though the cost will be a little higher than readily available harnesses, the results of customized wire harnesses  will certainly be worth-it.

Consideration 3 – Production capacity

You must always check for the production capacity of the manufacturer. Is he capable of fulfilling the kind of quantity you are looking for? If you are a small business, you may need only a handful of harnesses for your limited applications. But, if you are a large commercial trade, you may need larger volumes. Then, at times, it’s possible that you may need to place a different kind of one-time order volume than the regular kind of production you require. This is why it is advisable that you choose a manufacturer who produces both big and small volumes, so that you can rely on them for any and every kind of production type.

With these three considerations, you should be handing over your manufacturing processes into the hands of a reliable professional. MiracleElectronics is one such professional wire harness manufacturer in India who has great expertise in almost every kind of industry like electronics, aerospace, medical, and audio. Moreover, here you’ll get quality assurance because of the ISO 9001 and AS9100C certified production processes and DGAQA and MSQAA certified products. Last but not the least, every wire harness is tested and verified for perfection before being delivered to the clients.

 

Printed Circuit Boards _ What & Why - Miracle Electronics

Printed Circuit Boards (or PCBs) are seen in almost every electronic device – that small green board with tiny black and golden components and connections. These tiny boards are capable of supplying electrical signals by connecting all the mounted electronic components together. 

There are a variety of PCBs available in the market, which can be selected depending upon the application it needs to be used in, and the purpose it needs to serve. Some of the most common PCBs seen are single-sided, double-sided , through-hole, and surface-mount. Let’s take a look at the types of PCBs and their applications below.

Types of PCBs

Single-sided PCBs

A single-sided PCB is the most basic type, which consists of a flat sheet of insulating material and a layer of copper foil laminated to the substrate. The copper is etched to divide it into separate conducting lines called traces. Then, there are all sorts of connections and electromagnetic shielding made possible with the help of insulated wires. The copper layer is finally coated to reduce the chances of shorts and prevent it from corrosion.

Double-sided PCBs

These PCBs are just like single-sided boards, but with copper layers and componentson both sides of the substrate layer , which allows the traces to cross over each other. This results in high-density complex circuits that are more difficult to produce. Double-sided PCBs can have their components connected using two technologies – through hole and surface mount. But, both these technologies come with their own benefits and limitations.

Through-hole PCBs

This is the most basic technology that has been used since initial times to produce PCBs, wherein the electronic components are mounted by leads inserted through holes on one side of the board, and soldered onto the copper traces on the other side. The leads are bent at 90 degrees to horizontally install the through-hole parts with two axial leads, inserted into the board, soldered, and trimmed off at the ends. The through-hole technology requires many holes to be drilled, limiting the available routing area for signal traces.

Surface-mount PCBs

Surface-mount technology  came after the through-hole technology to enable mounting of very small-sized components on the board, with small metal tabs or end caps that can be soldered directly onto the PCB surface, instead of wire leads passing through holes. With this technology, it became possible to mount components on both sides of the board easily; thus allowing very small PCB assemblies with much higher circuit densities. The technology is also automated, which reduces time and costs related to manual labour, thus increasing production rates.

Applications of PCBs

Electronic devices – PCBs are highly used in electronic devices, providing channels and pathways for electricity and signals to follow, thus allowing functioning of the device.

Computers – PCBs are very popularly seen in motherboards of computers, which makes complex functions possible too.

Medical devices – PCBs can help in the medical industry by performing a variety of functions like diagnosing, monitoring, and treatment. For instance, PCBs are used in the medical field in equipment like medical imaging systems, monitors, and infusion pumps. However, the PCBs to be used in medical devices should strictly comply to stringent standards for sanitation and functionality.

Automotive components – Automotive components need to withstand extreme temperatures and vibrations; and with the advancement of technologies, PCBs are not limited to windshield wipers and headlight switches only; rather they are also used in many other automotive components like control systems, stereo systems, navigation systems, and sensors.

Aerospace and military components – PCBs are also used in the most critical applications like aerospace and military. In the aerospace industry, PCBs are used in planes, satellites, space shuttles, and radio communication systems. And, in the military industry, PCBs are used in communication equipment, control systems in military vehicles, firearms, and more.

No matter what the application, you can always get the most appropriate PCB assembly for your equipment. And, when you’re looking for perfect products, you can always opt for Miracle Electronics’ customized solutions to get seamless PCB assembly manufacturing from India.

 

Field Vs. Moulded Wire Harness _ Which One To Choose - Miracle Electronics

You’ll always want only the best type of wiring and harnesses for your application, but which one is it for you – field wire harness or moulded wire harness? This is a question that is always stirring up a debate in the minds of those planning on choosing a harness for their system. Considering how confusing and puzzling it may be, we’ve come up with a blog to shed a light on the subject. We’ll discuss, in this blog, the basics of both types of wire harnesses, and the key factors that can help you decide between the two.

Field wire harness

A field wire harness consists of a housing that is screwed in or clipped on, requiring a comparatively lesser setup, thus reducing the time of production. However, building a field wire harness is normally assembled by hand, which makes it a lesser suitable option for high-volume applications. But, for low-volume applications, field wire harnesses can prove to be an ideal choice, especially when you’re looking for a faster development time or prototyping.

Moulded wire harness

A moulded wire harness is made by melting down a large amount of plastic, after which a mould is created into which the high-pressure plastic is inserted. This gives more durability and greater seal strength to the harness. Because this is a fully automated process, moulded wire harnesses can be ideal for high-volume production. But, it isn’t suitable for low-volume applications as it can prove to be very expensive for smaller amounts of products. In the case of high-volume applications, it can prove to be economical and efficient, even though there is more setup involved, because the final products are worth it.

Which one is better?

As mentioned above, you can see that we cannot consider one to be better over the other. Depending upon the application, you can decide as to which one you should choose. A field wire harness is better when you have a small production run, while a moulded wire harness is better when you want a larger volume. But, the decision making process isn’t as simple. There are many other factors that you want to consider too when deciding as to which wire harness to consider.

Budget – A higher budget in hand can make it painless to opt for a moulded wire harness production. But, if you are on a tight budget, it may be difficult. However, you also need to understand that a field wire harness production run is also labour-intensive, which requires a good sum of money too. So, it is a choice between the cost of labour versus the cost of machinery.

Materials – The material you wish to choose decides on which kind of wire harness would be suitable. For instance, a field wire harness generally comprises of metal and plastic components, while a moulded harness is crafted from more durable parts with higher IP ratings.

Durability – When durability is a big concern, a moulded wire harness tends to be comparatively much stronger than a field harness. Obviously, field wire harnesses can be improved to enhance durability, but there are limitations to it.

Repairs – When you need repairs in the future, you must understand that field wire harnesses can be repaired and modified if any issues arise, but a moulded wire harness cannot be fixed.

Consider all the above factors when deciding upon the kind of wire harness you need for your application, after which you can approach an apt wire harness manufacturer. However, when you approach Miracle Electronics, you can rest assured that you’re with the most versatile wire harnessmanufacturer in India, meaning that you can get almost any and every kind of wire harness manufactured here. Just communicate your requirements, and you’ll have the most reliable and genuine products delivered to you, especially customized to suit yourapplication .