Why Choose To Install Custom Wire Harness Assemblies - Miracle Electronics

Aren’t you surrounded with wires wherever you go? Just think about it. Whether you’re at home, at work, or elsewhere, you can’t do anything without power and signal transmission. It may be your household appliances, computers, vehicles, or even the simple electricity you use to power up your applications, wires are all around you! Moreover, when you’re looking to set up your own application or premises, you’re even more concerned about the wires to be installed. This is when you think about approaching a wire harnessmanufacturer in India, like Miracle Electronics.

Every electrical application, whether big or small, requires wires – some lesser, some more. Manageable number of wires are convenient to handle, but when there are too many wires to install, it’s always wise to bundle them up into harnesses before installing. Even better is when you choose to install specially tailored wire harnesses for your application. Many manufacturers offer the chance to have your wire harnesses completely customized to your specifications, ranging in sizes, colours, labelling, shielding, jacketing, insulation materials, etc. From the design to the appearance to the functioning, the options are endless!

We don’t deny the fact that customized wire harnesses are costlier than regular standard assemblies available, but when you jot down the multiple number of benefits you can achieve from such customized products, you’ll realize how cost-effective your assemblies can prove to be! Let’s help you understand.

Customization helps use superior materials

Isn’t it obvious that standard off-the-shelf wire harnesses are cheaper because of the regular materials used to manufacture them? We don’t say that store-bought harnesses are any low in quality, but they don’t even exceed your expectations. They are just as standard as helping the wires to perform appropriately. But, with custom-made wire harnesses, you can choose to have better quality raw materials put in that can boost up the performance as well as life of the end product. With superior materials, you’ll certainly receive the highest levels of signal and power transmission.

Customization improves product quality

Optimum product quality is one very important aspect of proper management of a wire harness production line. With superior materials used, and the design chosen to best suit your application requirements, you’re certain to end up with improved quality wire harnesses. You can have your wires specially sourced, bundled, labelled, and packed with easy-to-install connectors. This makes installation as well as performance easier and better.

Customization eliminates time wastage

Time is of utmost importance today, and you wouldn’t want any of it wasted unnecessarily, would you? Customized wire harnesses make it easier and quicker to install the product, improve the performance of the application, and eliminate all possible errors associated with the product/functioning. This way, all possible time wastage is eliminated, and the performance is quicker and better.

Customization serves a myriad of purposes

Customization can help you design your product as per your application. You can thus have the flexibility to fit in sturdy wires for tough applications, and space-saving designs for difficult project schemes. Further, you can have your harnesses laser stripped, marked and labelled for easy identification, and choose your own special jacketing and insulation materials . All in all, you end up with a product that can’t be compared to any standard regular store-bought wire harnesses.

Choosing from a wide variety of materials and other options, and designing thatperfect setup for your application , can all eb a tedious task. But, this problem can be taken care of by working with a professional and experienced wire harness manufacturer in India, especially one like Miracle Electronics, who can serve as the one-stop destination for all your wiring and cabling requirements.

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.

 

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 .

 

Basic Terms You Need To Know About A Wire Harness - Miracle Electronics

Looking to order a custom wire harness? That’s a very wise decision, because a customized wire harness is certainly a better choice that a standard available one. But, if you think customizing is an easy task, hold on. Until and unless you consider certain aspects, you won’t be able to make the right decision. Certain terms, in the field of wire harnesses, are used interchangeably by a layman, but essentially, every term is different, and you must be able to understand what you want exactly, and what that particular feature is known as, so that you can convey the same to the manufacturer and get what you precisely want.

Wires and cables

People generally use the terms wires and cables interchangeably, but in reality, both these terms are different. Wires are made of a single conductor, while cables are a group of conductors. Wires are bare and twisted, while cables have the wires running parallelly and twisted together to form a single case, with an outer insulation covering to protect it from abrasion, moisture, and wear and tear. The basic materials used to make such wires and cables are copper and aluminium.

Wire harness and cable assembly

These are two other terms that are often confused with each other, but there is a difference. Wire harnesses are a basic exterior coating, covering smaller wires within. The basic materials used to make a wire harness include thermoplastic and thermoset materials, which mildly protect the wires from certain weather conditions. Cables assemblies, on the other hand, are a group of cables wrapped in an outer layer, to keep the cables together and organized. These assemblies are made from heavy-duty materials like thermoplastic rubber, vinyl, or shrink-wrapped thermoplastic. Thus, cable assemblies serve a similar function to wire harnesses, being more durable so as to withstand tougher environments like heat, moisture, friction, etc.

Braided wires and coaxial cables

Basically, you’ll use solid stranded wires in your harness. But, if you want a stronger option, braided wires are a better choice. In a braided wire, many small strands of wire are formed into a braid; thus making it difficult to break or tear the wires easily. This is why critical industries like aerospace and mining use braided wires. Coaxial cables are also a type of braided wires, with an inner copper core, and a braided copper shield on top of the dielectric insulator, covered with another protective insulation or sheathing. These cables are ideal for transmission of audio, video, and radio frequencies, which is why they are often found in cable TV connections, home audio systems, DVD players, and the like.

Conductors

Conductors are wires made of copper, stainless steel, or copper alloys, responsible for carrying electrical signals. A wire has only one conductor, while a cable can have multiple conductors. It is the conductors that decide on the electrical properties of a wire or cable, such as operating temperature, solderability, weight, and corrosion resistance.

Connectors and terminals

Connectors and terminals join two circuits or wires, in a way that information and electric signals can pass. Connectors can complete an electric circuit by connecting two points, and terminals can form a connection between two conductors or wires. The most common types of connectors include power connectors, computer connectors, and audio connectors; the that of terminals include crimp terminals, turret terminals, and screw terminals.

Insulation

Insulation is the protective covering over a core or strands of wires or cables, which protects the wires and cables from external damage, breakage, and wear and tear.

With knowledge about the most basic terms associated with wires and cables, you should now be in a better position to understand as well as convey what you want. Even better, you can partner with a reliable and genuine cable assembly or wire harness manufacturer in India to help you. One such manufacturer is Miracle Electronics, where you can get only the best quality harnesses and assemblies that are made with the finest materials, and great craftsmanship, yet being delivered to you at the most reasonable prices!