Aerospace Cable Assemblies – What They Call For

When you talk about aerospace or aviation, you get multiple things boggling in your mind, such as the aircraft, the metal, the design, the engine, the control systems, the navigation systems, the communication systems, and everything else. But, how often do you think one thinks about cable assemblies when the words aerospace and aviation are considered or spoken about? Not too often, isn’t it? Yet, what an irony it is that these tiny often-so-overlooked components are so crucial to the success of communications and control systems used in both commercial and military aircrafts!

Over more than the past two decades, Miracle Electronics has become a primary source for such crucial cable assemblies used in both commercial and military avionics. Technological advances can make it difficult to know how to choose the right assembly for your needs. But, with the expertise and experience of the technicians and certified engineers at Miracle Electronics, one of the finest aircraft cable assembly manufacturers in India, there should be no trouble at all!

Requirements of aerospace applications

Technological advancements are creating new challenges for such cable manufacturers. Not only do they need to meet high-performance standards, they also need to come up with lighter and smaller designs more cost-effectively. Even though the devices are getting smaller, they still need to meet the same rugged requirements. They should be capable of operating in tough environmental conditions at extreme temperatures, accepting every kind of shock, vibration, and pressure that comes their way. Military component manufacturers are under pressure to accomplish all of this, while keeping costs down, and maintaining safety.

Two basic types of aerospace cable systems

Cables for aerospace applications range in high-speed data cables and RF assemblies to power distribution cables.

High-speed data cables

With tremendous amount of data being transmitted and received, aerospace cable assemblies are required to deliver high-speed connectivity for the demanding aerospace communications, in spite of the harsh environments they pass through on their way. The best options of cables that can serve this purpose are Cat 7 cables that support high-speed voice, video, and data traffic, and are completely compatible with Cat 6A couplers and adapters. Other high-temperature-rated Ethernet cables, specifically designed for aerospace environments are Cat 6A and Cat 5E. These cables meet all RoHS requirements, and are successfully used in cabin management systems, in-flight systems, backbone avionics, ground vehicle trunks, and general aerospace usage.

RF cable assemblies

Over time, the sheer amount and complexity of information to be transmitted in aerospace applications has substantially increased. The RF circuit building blocks have thus been through many changes to accommodate the latest advancements in the industry including miniaturization, increased reliability, and the ability to rapidly transmit even complex data. Spaces are becoming smaller, reducing the usage of bulky devices, bringing upon a challenge to fit more components into smaller device form factors, while ensuring optimal functionality. Aerospace cables are required to operate at higher frequencies, sending more information in a given amount of time, or sending the same things within a fraction of the time. All of this needs to be considered while building cable assemblies for aerospace applications, testing every cable thoroughly for all kinds of mechanical, electrical, and functional aspects. Lighter, smaller designs, that are critical for ever-growing space-constrained aerospace applications, coupled with compliance, stringent safety, and environmental requirements, will continue to drive the industry to make advances in designs and processes. You need to thus always be in touch with aircraft cable assembly manufacturers in India who know the ins-and-outs of the business, and are always up with the latest trends and technologies, so as to provide you with the most appropriate solutions for your particular application.

For more information, visit: https://www.miracle.net.in/

How To Customize A Toroidal Transformer?

While there are a number of high quality standard toroidal products available, many want to request customized designs for their specific applications. This is so because customized designs are specially tailored to meet the size, capacity, and performance required by the application, which means a perfect ideal fit.

When you’re looking for such customizable solutions, there are two ways you can work it out – first being where you provide with all the details and have the product only manufactured; the other being where you just convey your requirements and have the entire design-to-manufacture task taken care of by the manufacturer.

When you want to provide your own drawing

If you are the first sort, where you provide a specification or detailed drawing depicting all that you need within your transformer, it doesn’t mean that the drawing will be blindly followed. The manufacturer will first analyze the information, working on every detail, to see that the purpose of the transformer is served, without any chances of error. In case any such doubtful specification is seen, it will be brought to your notice, after which the required changes will be made. Only when both the manufacturer and the client are satisfied with the drawing, will the transformer be put into production.

When you want the entire process to be outsourced

If you’re not too sure about the specifications or drawings, you can have the entire process taken care of by a manufacturer. All you have to do is convey what your application is about, what purpose you want the transformer to serve, any specific environments the transformer will need to work in, any space constraints or other limitations, and the quantity and deadline. Once every such detail is conveyed by you, it becomes the duty of the manufacturer to design and manufacture the perfect toroidal product for you.

Do you want a prototype?

It’s absolutely alright if you want to see a prototype first, before putting the entire production into practice. Whether the design is made by you, or the manufacturer, you may be unsure of the outcome, and want to first look at a prototype. Manufacturers can use a software to create the plan for such a prototype, by inputting all the information on the drawing, and crafting a digital design of the product you need. This practice is a more accurate way of ensuring that the final product will be appropriate, and meet your specifications. Any adjustments required in the prototype are made, before moving on to manufacturing the complete project.

Where to get your toroidal transformers? Miracle Electronics’ highly-trained engineers oversee every step of the manufacturing process, right from designing to prototyping to production to testing. Only when the final product is proven to be effective, is it shipped to the client. With everything being done in-house, it saves on a lot of time that may otherwise be spent collaborating with different facilities. This not only avoids shipping delays, but also helps in carefully monitoring the entire manufacturing process. You’ll thus get toroidal transformers that enable the highest level of accuracy and reliability, meeting any regulatory requirements. So, when you need one-of-a-kind toroidal transformers for your applications, look no further than Miracle Electronics, where everything will be carried out within their ISO-certified facilities. Whether you’re in the manufacturing, medical, audio, energy, or any other industry, you can ensure that the final product is effective, efficient, reliable, and safe.

For more information, visit: https://www.miracle.net.in/

 

Making The Correct Toroidal Transformer Choice

When you’re looking to buy toroidal transformers for your application that can step up or step down a voltage, or for isolating an electronic equipment from a source of voltage, while allowing power to be transferred from the primary to the secondary coil, you need to make the right choice.

What is a toroidal transformer?

Constructed using a ring-shaped metal core, on which a wire is wound to form the primary input coil, overlaid with insulation, over which a secondary output wire is wound, toroidal transformers offer a neat and small variation of other kinds of transformers that require more space to be installed, and are also comparatively heavier.

Pros and cons of a toroidal transformers

Toroidal transformers have several advantages over other equivalent traditional devices, such as –

• Overlapped coils that allow for much smaller devices, unlike in the case where there are two separate coils
• Smaller number of turns required per coil, resulting in higher inductance relative to a similarly-sized traditional transformer.
• Magnetic flux limited to the toroidal core, having the transformer to shield itself from producing electromagnetic interference

Nevertheless, just like anything else, toroidal transformers also come with a disadvantage, which is that with each winding to be passed through the center hole, automated winding becomes difficult, or may require a dedicated winding machine specific to toroidal devices, resulting in cost additions when such toroids are manufactured.

Applications where toroidal transformers are the best choice

Because of the peculiar kind of construction and winding that a toroidal transformer is made with, as the size of the transformer increases, the advantages tend to diminish. For this reason, toroidal transformers are best suited for signal applications, like audio and radio frequency applications. They are also well suited for applications including security systems, LED lighting, inverter systems, industrial control equipment, power distribution equipment, isolation equipment, automotive electronics, and telecommunication systems.

Considerations to be made while making a toroidal transformer choice

Configuration

A transformer’s configuration refers to the number of input voltages it can accept, and the number of leads it must include. As the number of leads and required copper wiring increases, the manufacturing and product costs also increase. Toroidal transformers come in two basic types of configurations – single and dual.

• Single configuration transformers include only one primary coil winding, thus being able to accept only one input voltage.
• Dual configuration transformers include two windings in the primary coil winding, thus being able to accept two different input voltages. Here, in order to switch input voltages, a two-lead voltage selector must be used in conjunction with the transformer.
• Multiple configuration transformers can also be manufactured; however, they’re required to be used with a switching device.

Mounting

Toroidal transformers can be mounted using one of the below mentioned methods.

• Screwing onto an internal framework using in-built tabs
• Securing to a flat surface using a rubber washer and metal disk
• Securing to a flat surface using an H-shaped frame
• Soldering to a circuit board using through-hole or surface mount technology

Considering all of the above, you can select the perfect toroidal transformer type for your application. Whatever your toroidal transformer type, you can always rely on the products offered by Miracle Electronics. Other than standard products, you can also have your toroidal transformers customized perfectly here. Understanding the electrical needs of the customers, these expert toroidal transformer manufacturers in India are able to offer the most apt customized solution to every client!

Visit our website: https://www.miracle.net.in/

Why Choose Laser Marking Over Other Wire Marking Methods?

 “Why should I invest in a laser marking machine, when I can instead buy a less expensive alternative that can serve the same purpose?”

If this is the question that’s in your mind when you’re looking to buy a machine to mark your wires, we’re here to clear your doubts. Once you understand the advantages that laser marking has over other marking methods, you’d say for yourself that it is undoubtedly the best choice for your wires, regardless of your production requirements and the price. UV laser will have you to save money throughout its lifetime, while also proving to be more efficient than any other method.

Laser marking vs. hot stamping

Hot stamping has been a technique used to mark wires since World War II, but today, with the advancements in technologies, it seems to be impractical and dangerous. It is an out-dated method that takes far longer to mark a wire than it would with a UV laser marking machine.

• Hot stamping requires manual changing of characters, while UV laser marking uses a software to control the marking of characters, making the latter faster, requiring less operator time.
• With Teflon wires continuing to grow in popularity, using a hot stamping machine makes trouble marking on these wires. But, with laser markers, Teflon wires can be easy to mark.
• Hot stamping requires a certain width of the wire to be marked, as well as a thick insulation. Laser markers, on the other hand, can safely mark on even thin-insulated and small gauge wires, without any risk to the integrity of the cable.
• Hot stamping always keeps the wire at risk of getting burnt, which means the wire damaged even before being installed into the application. But, with laser marking, there is no such worry, as it simply tans the wire insulation, leaving a permanent mark, and maintaining the integrity of the wire.

Laser marking vs. heat shrinking

Heat shrinking is another popular method used to mark wires, but it is a long and labour-intensive process, which proves to be highly inefficient. It fails to address the needs of businesses looking to expand, as it is low on efficiency and speed, while being high on costs. Laser marking, on the other hand, eliminates the cost of applying more resources over the wire, also reducing the need for post mark treatment. This helps companies focus on cost savings, improved capacities, and long-term growth.

• In the process of heat shrinking, the user is required to manually carry out the entire process – marking the tubing, marking the wire, cutting the tubing and wire with precision, inserting it over the wire, heating both ends of the wire, and finally inserting the wire into the destination. Laser marking, on the other hand, is absolutely easy and automatic. It marks the wire directly, and then cuts it to the required length automatically, with no need for post mark treatment.
• In the case of heat shrinking, dirt or grime can get into the tube and be inserted over the wire, making the wire slippers and difficult to install, thus making it a difficult and time-consuming job, which is responsible for increasing labour hours. But, with laser marking, there is no such process. The wire that goes into the machine comes out itself, with no possibility of dirt and grime getting into the crevasses.

Laser marking vs. ink jet printing

Ink jet printers are very fast and mark at higher speeds than laser markers. However, they also pose multiple disadvantages to the wires.

• The markings made by ink jet printers are not permanent. Any liquids that touch the markings, such as gasoline or jet fuel, can remove or smear the mark on the wire. Laser markers, on the contrary, tan the wire insulation, creating a permanent mark that cannot fade or smear.
• Ink jet printers are high on maintenance. They require cleaning the ink applicator, checking for fading ink, and changing the cartridge. This not only results in high maintenance costs, but also increased down time and daily consumables, which add to the mounting operating costs. Laser markers, in opposition, require no ink, and have no daily consumables and maintenance.

After looking at all the above factors, it becomes clear that laser marking is the most efficient process that brings permanent results. It is a fast, safe, efficient, permanent, long-term solution, increasing marking capacity and reducing operator costs. Laser marking can thus save the business money in terms of time, cost, and maintenance. You can approach Miracle Electronics for laser marking for aircraft cables, no matter what your wire material, gauge size, character requirements, and spacing constraints.

Miracle Also , do subcontracting for Laser Marking on Cables with it’s spare capacity , You may send your requirements to us on sales@miracle.net.in

CALCULATING THE KVA RATING REQUIRED FOR A TRANSFORMER INSTALLATION

 Almost every industry, from basic manufacturing industries to critical healthcare facilities and testing laboratories, requires high-quality reliable transformers to keep their operations running safely and efficiently. Larger facilities require larger amounts of power, which means more dependable transformers to convert the energy coming from the power plant, into a form that can be used for the equipment.

But, in order to have the transformers do so effectively, businesses need to know how much power their particular transformers can give them. It is the transformer’s rating that provides this information. The rating, or size, is the transformer’s power level in kilovolt-amperes, denoted by kVA. You need to select a transformer with the correct kVA for your needs. If not, you may run the risk of damaging your valuable equipment. Seems difficult? But fortunately, it’s not as difficult as it sounds. In fact, sizing your transformer is relatively simple. You just need to use a simple straightforward formula to generate your kVA requirements, using the current and voltage of your electrical load. Let’s help you know how you can calculate the required kVA rating.

Calculating the kVA value

Transformers come in two basic ratings – volt-amperes (VA) and kilovolt-amperes (kVA). A transformer with a 100 VA rating can handle 100 volts at one ampere of current. Similarly, a transformer with a 1.0 kVA rating (1000 volt-amperes) can handle 100 volts at 10 amperes of current. To determine your appropriate kVA size, you need to make a few calculations, based on your electrical schematic.

There are two main measurements that you’ll need, that of the voltage (V) and of the current (I). Voltage is the electrical load that connects to the secondary winding, and current is the flow that the electrical load requires. Both these values can be determined simply by looking at the electrical schematic. Once these two values have been determined, you can then use them to figure out the load’s power requirements. To do that, you’ll need to multiple the voltage with the load, and then divide the number by 1000; hence, the formula being –

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Wire Harness – Different Industry Applications

Wire harnesses are widely used in almost every residential, commercial, and industrial application, to hold together the multitude of wires in a neat and organized manner, so as to avoid tangles, trips, and accidents. While the designs and materials can vary for every industry, finding a building, a machinery, a vehicle, or any other electric and electronic device without such wire harnesses is next to impossible! For instance, some applications may be able to do with regular materials and standard quality manufacturing, while others may require high quality materials and stringent engineering practices used to build their wire harnesses.

Depending upon your industry and application, you thus need to approach an industrial wire harness manufacturer in India that can cater to your requirements. Miracle Electronics is one such manufacturer who can manufacture simple as well complicated wire harnesses that require expert knowledge, expertise, and specialized materials and engineering skills. We pride ourselves on being able to manufacture wire harnesses for every industry, regardless of the requirements, expectations, and certifications required. Let’s take a look at all the various industries that different kinds of wire harnesses are capable of serving.

Automotives

We’re widely known for our automotive wire harnesses, which can fit and function well in different kinds of vehicles, for all sorts of different electric controls and devices that work together to transmit power and signals for the engine to work. Wire harnesses efficiently connect the vehicle’s different parts for effective usage and functioning.

Telecommunications

We all rely so highly upon telecommunications of all types today. May it be our smartphones, computer networks, internet, or the radio, they all play an essential role in our lives. But, do you know that all these wireless systems also require a large network of wires to help them work!? So, you can say that it takes a lot of wiring to help us work so wirelessly today. Bundling of different types of wires is required here, which is what wire harnesses serve so effectively.

Consumer electricals and electronics

Our everyday products, including electricals and electronics, also require multiple wire harnesses to make them work. Whether it is the lights, fans, and air conditioners, or other appliances like refrigerators, washing machines, microwave ovens, computers, etc., the wire assemblies that power and control them need to be effective for the job. Every application requires a different kind of wire harness, and must support performance and reliability.

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Wire Harness – The Nervous System Of Your Vehicle

We all have within our body a central nervous system structure, which is responsible for the functioning of the entire body. Consisting of the brain, spinal cord, and nerve cells, each part plays a vital role in working together to take in information and control how the body works. Just like the nervous system is critical for every human body, so is a wire harness for an automotive. It would be right to say that a wire harness is the central nervous system of any electrical system!

What is a wire harness?

A neatly organized compact bundle of wires and circuits, a wire harness is critical for a wide range of applications like industrial control panels, consumer appliances, commercial machineries, automotive, and every other equipment and machinery that transmits or relays electronic information or electrical power. Forming a reliable network of communication between all components and peripherals, it facilitates faster processing, maximum efficiency, and highest reliability.

How is a wire harness important to an automotive?

A wire harness consists of a central column of cables that branches off into secondary cables to connect to various components. From the battery to other vital components like spark plug, headlights, indicators, instrument console, sensors, and other controls, it serves as the backbone of every vehicle. It transfers electrical power and data to all the control units that help the vehicle to function. All the control units share this information amongst each other to work in a synchronized manner. How would it otherwise be possible for a vehicle to shift through the gears so smoothly, while managing the speed? How would otherwise a vehicle know how to fold in the side mirrors or switch off the headlights when you lock the vehicle with a remote FOB key? All this efficiency and precision comes with the reliable fast network of wire harnesses that is packed within the vehicle’s electrical system.

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Transformers From Miracle Electronics – An Investment In Quality

Replacing a transformer comes as an unwanted surprise with unexpected, yet unavoidable, expenses! You need the power back soon, but you aren’t really willing to pay that exaggerated bill you’re being asked to pay for an immediate replacement. So, you either opt for a low-cost transformer, which will only turn out to be an expensive mistake in the near future; or, you opt to pay unexpectedly high when you’re looking for quality replacement.

Remember, a power transformer is a priced asset that should offer vital services to an organization for decades. You haven’t paid such a hefty amount for your power transformer, only for it to break down within a few years! And, the price you have paid is not only for the transformer, but also for its installation and maintenance, so that you have a longer, efficient, and useful transformer life. And now, because you hadn’t made a right decision earlier, you are to pay an excess of all those charges again! But this time, don’t repeat the same mistake. Don’t just opt for any transformer that works fine just as of now, but instead, invest in power transformers in India that will prove to be long-life assets. We won’t say that you opt for a high-priced transformer because a high price means reliability. We also won’t say that transformers are any low-priced product. It certainly takes a good amount of money to manufacture a transformer, which is why the price. But, to be able to make the right choice, you need to invest in a transformer with the highest ROI.

Choosing the right transformer

An initial higher or lower cost does not actually help in making a decision. A product with a higher price is not always reliable, and a product with a lower price is not always low in terms of quality. What you need to investigate is whether the difference between two different initial purchase prices is an avoidable cost or a good investment opportunity. Two manufacturers may use the same materials, the same design, and the same manufacturing methods, yet have different selling prices. Why is that so? Well, the difference in costs is from the difference in business strategies and choices. While there is nothing that we can comment on for other manufacturers and suppliers, but we can certainly guarantee that the power transformers in India, manufactured at Miracle Electronics, are made with the best strategies and sold at the most reasonable prices. Here’s telling you why you should believe us.

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UNDERSTANDING CORES, CHOKES, AND LOSSES

Electric current, when flowing through a conductive material, generates a magnetic field, that which is strongest at the conductor’s surface, and weak farther from the conductor. Magnetizing a core material won’t stop it from having a magnetic charge when you stop magnetizing it. Instead, if you want to get it back to zero magnetization, you will have to reverse the magnetization. This is what is called the hysteresis loop, which occurs when alternating positive and negative magnetic fields are applied to the material.

Understanding the hysteresis loop

The magnetization force depicted by the symbol “H” is the magnetic field that is applied on the magnetic core material. And, the magnetic flux, depicted by the symbol “B”, is the total magnetic field flowing through an area, the intensity being referred to as flux density. The hysteresis loop is this B-H curve, analyzing which is very important when designing transformers, inductors, and chokes.

What elements alter the magnetic flux?

The area of the core, the number of turns, and the switching frequency are all important factors that alter the magnetic flux. If the core area, number of turns, and switching frequency are increased, the flux will decrease. Also, greater the core material’s permeability, greater is the flux density.

Designing a transformer, inductor, and choke

While designing an inductor or choke, you don’t want to cause saturation of the core by increasing the AC or DC current. The DC current is what generally saturates the core, as it’s constant and moves the core to a certain flux level. Yet, you need to always ensure that the maximum AC current is also well below the saturation point. Saturation can also be reached by increasing the flux density, normally by increasing the voltage. The core material’s permeability also impacts the saturation. High permeability saturates the core faster, and low permeability saturates the core at a higher flux density.

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CABLE ASSEMBLIES, WIRING HARNESSES, AND LOOMS – ARE THEY ALL THE SAME?

Cable assemblies, wire harnesses, and looms are all terms that are used interchangeably, but all the three are actually quite different from the other. The differences are in the way they are constructed and how they are used. While all the three are basically used to transfer electronic power or data signals between two points, when you get into the details, you’ll know how different they all actually are.

Cable assembly

Cable assemblies, following a predetermined layout, neatly hold a number of wires together, incorporating both individual wires as well as multicore cables within the design. The wiring system in a cable assembly is placed within an outer protective sheath made of rubber, polyurethane, vinyl, or heat-shrink plastic, in order to protect the wires and cables within from exposure to outer elements like extreme temperature, moisture, chemicals, and fire. Cable assemblies are a little expensive as compared to wire harnesses, thanks to the protection offered by the outer sheath.

Wire harness

Wire harnesses are the simplest form of wiring systems, which involve several wires of a required length bound together to save space, and also prevent damage during usage. The binding may involve heat shrinks, cable ties, or electrical tape. There may or may not be an outer covering in wire harnesses. Further, even if there is an outer covering, its basic function will be only to organize the wires, keeping them in a specific position, and minimizing the amount of movement that can take place. The outer covering may or may not offer any particular protection against environmental conditions. Also, the wire harnesses may or may not be terminated by connectors. Systems that have wires that go in multiple directions will have different termination components. The production of such wire harnesses is quite simple, which means they can be produced quickly and at reasonable costs. Moreover, this type of wiring system is cheapest and most effective when the same wiring setup is repeated multiple times, like in the case of mass-produced goods.

Read Full Article: CABLE ASSEMBLIES, WIRING HARNESSES, AND LOOMS – ARE THEY ALL THE SAME?

WIRE HARNESS TYPES – CONNECTORS AND TERMINALS

 With the rising usage of wire harnesses, thanks to their efficiencies and plethora of advantages, the demand for a variety of different harnesses is also on the rise. Every wire harness manufacturer in India works to fulfil these rising demands, thus coming up with a multitude of options to suit various applications where signal or power needs to be transmitted to electronic devices or machines. Some of the most popularly used wire harnesses are flat harnesses, ribbon harnesses, EMI shielded harnesses, RF harnesses, airborne looms, and military looms. You can choose to have a particular kind of wire harness, based on your application, and the required performance and stability.

Wire harness types based on the connectors used

The sole purpose of a connector type wire harness is to transmit electrical signals from the wire harness to the power source. Connectors comprise of different plugs and jacks, the design being based on the function and performance required. There are essentially two main types of wire harness connectors – male and female, which serve to provide the necessary junctions between the many different elements of the wire harness, to produce efficient transmission of data, power, or signal through the system. In simple terms, plugs are male connectors, and jacks are female connectors. The performance of a connector is also related to the material used, the ease of connection, and the insulation between the pins. Different applications call for different connector types, as the functions, designs, and working vary from one condition to another. It is thus best to let your wire harness manufacturer in India know about your particular requirements, based on which you can have your harnesses designed.

Read Full Article: WIRE HARNESS TYPES – CONNECTORS AND TERMINALS