Thursday 23 September 2021

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.

Wednesday 22 September 2021

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!


Tuesday 21 September 2021

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.

 

Friday 17 September 2021

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 21st 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!

 

Monday 6 September 2021

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.