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.

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