Choosing Heavy Duty Connectors For Cable Assemblies - Miracle Electronics

 Designing cable assemblies for use in harsh environments poses a number of challenges, especially those that need to be used in industrial equipment that may be subjected to conditions like high temperatures, high humidity, water, chemicals, electromagnetic interference, vibration, impact, or particulate ingress from close proximity to moving factory components. Over time, exposure to such components starts to hamper conductivity, requiring repairs or replacements.

To avoid all such hassles and inconvenience, it is advisable that you choose to install heavy duty connectors for the cable assemblies that are to be used in applications that need to withstand one or more of the conditions and environments mentioned above. So, here’s a guide that can help you choose the best quality heavy duty connectors for your application.

The housing material

A die-cast aluminum housing should be the best choice as these are light weight yet highly impact resistant. However, if your application is to be used in wet environments, plastic connectors should be a better alternative as they won't rust or corrode. And, if your application is too small with tiny spaces, you can choose materials that provide EMI shielding instead.

The insert types

Heavy duty connectors with pluggable inserts that carry power, data, or signal to and from factory equipment have been traditionally used. But today, modular inserts that support an integrated hybrid cable assembly are more popularly used. Heavy duty connector systems need to meet the demands of the hybridization trend, which is why more and more customized cable assemblies are being preferred. And, with such customizations, modular connectors are more popularly used as they provide an integrated hybrid assembly that creates new considerations for power and signal wiring beyond the fundamentals of approval ratings, clamping type, and wire guage. The various insert types that you can choose from include fiber optic, pneumatic, D-sub, USB, M12, and RJ45.

The ratings and standards

IP ratings depict the level of protection that an electrical enclosure provides against solids and liquids, and NEMA ratings describe the environments where the enclosure can be used. You need to choose from such ratings, or buy standardized connectors to ensure their quality and performance.

The manufacturer

You need to choose the right cable assembly and connector manufacturer too; one that has experience, knowledge, skill, and expertise in the field. One such cable assembly manufacturer in India is Miracle Electronics, a contract manufacturer that is tooled for majority of industries such as electronics, aerospace, audio, and medical. You can have all kinds of cable assemblies manufactured here, some of them being EMI shielded assemblies, flat assemblies, ribbon assemblies, RF assemblies, airborne looms, military looms, and power cable assemblies. You can also have circular, D-sub, military specific, and many other kinds of connectors built here too. And, whatever kind of cables, assemblies, and connectors you have customized with Miracle Electronics, you can rest assured about the quality you’ll receive because every production process executed here is certified for quality to ISO 9001, AS9100C. Also, every product manufactured here is certified and approved by DGAQA and MSQAA for platform specific applications, after undergoing all kinds of tests for dimension, weight, continuity, Hi-Pot, Pull, and environment compliance.

Balanced Audio Cables Vs. Unbalanced Audio Cables - Miracle Electronics

When you buy an audio system, you expect it to work at an unmatched quality; and the quality of sound produced by a system is highly dependent on the kind of audio cables used. This is specifically important during a live event recording, or live streaming. If the right kinds of cables are not used, it will produce a lot of noise and distortion. It is thus very important that you know which cables you need to use. There are two typical kinds of cables that you can use – balanced and unbalanced. But, in order to know which one of the two cables you should be using for your application, you need to understand what these are where each one is applicable. So, let’s take a look.

What are unbalanced cables?

Unbalanced cables are those that consist of two wires inside a plastic casing – a ground wire and a signal wire. The signal wire lies in the center of the cable, passing the audio signal through. And, the ground wire surrounds the signal wire, shielding the main signal wire from external electronic interference coming from lights, televisions, radios, transformers, and other devices. The unbalanced cables take the audio signal from the equipment used, passing it to a mixer or another receiving device without any manipulation. This, although a simple process, makes the audio distorted and noisy. Unbalanced cables generally use two kinds of connectors – one is the standard tip sleeve ¼” connector, and the other is the FCA connector.

What are balanced cables?

Balanced cables are those that consist of three wires inside a plastic casing – one ground wire and two signal wires. While the ground wire performs the same function as in an unbalanced cable, the difference lies in the working of the signal wires. In balanced cables, the signal wires pass an identical audio signal through each wire. This results in balanced cables being used such that the equipment sending and receiving the signals each have a converter, which allows them to make use of both the signal wires. Sending two signals simultaneously results in putting them out of phase, this means that while the signals are identical, one of them is the inverted mirror opposite of the other. When such out-of-phase signals reach the receiving equipment, they are then put back in phase, reverting the mirrored signal back to its original form. Finally, the two matched signals are passed to the mixer. This results in any distortion produced going out of phase, canceling itself out, thus culminating into a much clearer audio without distortion. Balanced cables also use two kinds of connectors – tip ring sleeve connectors and XLR connectors.

Which cable is right for you?

After understanding the construction, working, and performance of balanced and unbalanced cables, you can conclude that balanced cables reduce the distortion in the audio, while unbalanced cables do not. Then, you would assume that one must always use balanced cables because of the better sound quality that they produce. But, you would be surprised to know that this is not always the case! Each cable has its own pros and cons, which is why you need to learn about the specific cable that can prove beneficial to you. So, here are some points to help.

The length of the cable – When you need to use cables that are long, probably more than 20 feet in length, unbalanced cables can pick up noise from any nearby audio system, bringing to you a distorted sound at the receiver’s end. Balanced cables do not pick up such surrounding noise; thus making them apt to be used for longer lengths.

The strength of the signal – The above point is again another proof that clearly says why you must use balanced cables for your system. But, hold on! You would like to know that balanced cables have a weaker signal than unbalanced cables. Yes, unbalanced cables have a very strong signal. Thus, it is better to use unbalanced cables to get an uninterrupted sound.

The price – Unbalanced cables are way cheaper than balanced cables – one because of their simple construction, and two because they aren’t distortion-free like balanced cables. Thus, unbalanced cables are generally 30-60% cheaper than their balanced counterparts. And, to add to that, even after you pay a good price for balanced cables, you will also need to invest in special balanced mixed equipment, which can add to your costs. So, you need to keep that in mind while planning to opt for balanced cables.

To sum up:

After reading all that is written above, we can simply come down to two points –

• If you need cables that are to be within 10 feet of length, there should be no issue in buying unbalanced cables, because these cables when used at such short lengths can bring stronger signals, uninterrupted sound, and are less likely to pick up any surrounding hum. Thus, you can get good sound quality at a cheaper price.
• If the cables you need to use are longer in length, and if you don’t mind investing a little extra for that amazing sound quality at the receiving end, then you must opt for a balanced cable. Then, you’ll get professional sound quality with no noise distortion, considering you are paying a good price!

So now, you are ready to make your choice . And, after taking up an informed decision, you can always buy a balanced power transformer to convert any unbalanced power to balanced power. For this, you can get highly efficient balanced studio power supply in India from Miracle Electronics, to bring an audible improvement in frequency response and stereo imaging.

Fiber Optic Cables _ The Types And Benefits - Miracle Electronics

The data transmission industry is in full swing with all sorts of data being transferred from one point to another for various applications to run. Cable assemblies are one important element of this industry, which are required to send a signal from one device to another. The copper wire within these assemblies is mainly responsible for transmitting data through electrical signals or pulses. But, with advancements in technology, this copper wire is being slowly replaced with fiber optic cables.

What are fiber optic cables?

Fiber optic cables use a completely different method to transmit data, as compared to copper wires. With these cables, the data is sent using light pulses that travel through the fibers of the cable, which are made up particularly of plastic or glass, so that light can penetrate them. The light signals transmitted are then shot through the cable, hitting the cable walls. Because light travels very fast, the fiber optic cables have a much higher speed than the traditional copper wire.

Types of fiber optic cables

There are various types of fiber optic cables available, the choice depending upon the end connector and application in which they are to be used. The three main types of fiber optic cables include single-mode fiber cables, multi-mode fiber cables, and plastic optical fiber cables. Let us look at each one of them in detail.

Single mode fiber cables These cables are those that have only one strand of glass fiber running through them, with a thickness ranging from 8.3 to 10 microns in diameter. These cables can transmit data in only one direction. In spite of this, these cables have a higher bandwidth, and thus cost more.

Multi mode fibers These cables have multiple strands of glass fibers running through them, with larger diameters that range from 50 to 100 microns. Because of the multiple strands within, these cables can follow a linear and a non-linear path. The thickness can bring to these cables a higher bandwidth, but restricts the length. Longer cables result in a distorted signal.

Plastic optical fiber cables As the name itself suggests, these cables have plastic fibers instead of glass fibers, making it a cheaper option for short-distance applications. However, plastic optic fibers can lose their signal over long distances.

Connectors used in fiber optic cables

The connectors used at the ends of the cable assemblies are equally important to make sure that the cable is secured and connected properly to the application. Let’s now also take a look at the various kinds of connectors used.

Fixed connectors – These connectors are fixed on an application via a screw and threaded end housing, serving the purpose of securing the cable assembly to the application with movement.

Lucent connectors – These connectors contain small ferrules and a push-pull latching mechanism, being most popularly used with single mode fibers. Subscriber connectors – These connectors have ceramic ferrules, and are used for push-pull applications with dual mode fibers.

Straight tip connectors – These connectors contain a unique design where a half-twist bayonet locking mechanism is used. They come equipped with a longer ferrule, primarily used with multi mode fiber assemblies.

Whatever your cable assembly requirements, you can get in touch with Miracle Electronics, the most versatile cable assembly manufacturer in India. Here, you’ll get all kinds of cable assemblies, along with a variety of connectors to suit your application.

Cable Faults - The Best Troubleshooting Tips - Miracle Electronics

How far can you go without electricity? Doesn’t seem like for more than a few minutes, does it? You can't live without your fans and air conditioners; and if your mobile battery is down, you can't stand the power cut-off for even a minute. It’s almost like you life is leaving you, now that you are so very dependent on your electronics, and have such less capacity to fight the heat. Imagine if you have to stay off electricity for hours together, or maybe an entire day!

This can easily happen in the case of a cable fault. If a cable fault is not identified, you won't be able to fix the problem, no matter how long it takes. It is thus important to understand a cable and its possible faults well. Locating the fault area can help fix the issue quicker, thus bringing your electricity, electrical appliances, and electronic appliances back to life. Understanding this, we have brought forward to you some of the best troubleshooting tips for cabling faults.

Visual inspection

Visual inspection can help identify any external damage. Any damaged cable should be replaced. If not, there could be problems in the connector, as this is where most of the issues originate from.

Damaged cable replacement

As soon as a faulty cable wire is detected, it is wise to throw it away. Install a new cord set in its place. One of the quickest ways is to route a new spare cable, or swap cables to make the machine get back to work faster.

In the case of multiple cables

If several cables are joined together, and the specific reason of the fault cannot be diagnosed, it is better to replace the entire cable system, so as to not waste time.

Connector issues

If the fault is one that is linked to the connector, it could be difficult to detect. This is when having an extra set of cables can be of great help.

Cable extenders

Cable extenders and repeaters are different technologies aimed at addressing longer USB cable runs. Improperly installed, inadequately powered, defective extenders can cause significant problems. A signal delay may mean problem in the cable extenders. You must thus use multiple active USB repeaters or a single active USB extender. At the same time, avoid cascading multiple active USB extenders.

Other issues

Other issues that may not be with the cable could mean issues with the wall plates or adapters. Wall plates may bring the possibility of poor or loose connections; so you need to check all the front and back of the wall plate to ensure that they are screwed in well. Adapters may also be an issue if the right ones are not selected. There are a variety of formats and sizes of adapters available. If the wrong one is used, it may result in jostling or snapping off of the adapters.

As we can see, cables are one of the most challenging elements of any system. Using cables for your application other than those supplied by the manufacturer can ass yet another level of complexity. This is why it is always suggested that you have your cables particularly customized for your precise application by an experienced and expert cable assembly manufacturer in India, one like Miracle Electronics. Using such specifically designed cables and assemblies from reputed manufacturers will have your cables last longer, and your applications function better for longer too.

Mistakes To Avoid When Designing A Flexible PCB - Miracle Electronics

When designing flexible PCBs, a lot of extra attention needs to be paid to every detail in the design and manufacturing process. Overlooking some basic stuff may cause design failure, and thus lots of loss and damage. There are a lot of common mistakes that are committed while designing and manufacturing a flexible PCB. Let’s take a look at some of them, and learn from them what we are not supposed to do.

Mistake 1 – Incorrect conductor arrangement

Unlike solid PCBs, flexible PCBs can twist and bend. This is why if there is any incorrect conductor arrangement, it may lead to hazardous consequences, especially during board flexing. One way to minimize the stress is to make sure that the conductors pass through curved areas. This will help during flexing.

Mistake 2 – Wrong setup of bends

Flexible PCBs are mainly made as they are required to bend at some point or another during usage. To make the PCBs capable of handling the bend, it is important to check two main factors – the bendability of the council, and the number of times the board will be turning. For a flexible PCB to work perfectly, it is very important to consider these two factors and set the right bending area in the initial stages itself, so that the right parts can be manufactured that can fit perfectly for the flexible circuit board. Also, the minimum and maximum bendable limits should be ascertained beforehand. 

Mistake 3 – Inappropriate bridging sections

The curved areas and gaps within a flexible board are critical design elements. It is important to have perfect understanding of the right bridging sections to place the slots. Generally, the bridges should be designed around the narrowest regions so that there can be extra room for the slots, and better edges can be achieved, making it easy to fit the deserved curved PCBs.

Mistake 4 – Incorrect wire routing

Constructing the wire routing on the path of a flexible circuit board can be quite tricky, and is extremely important too as it is the base of placing the active elements on the board. It is important to avoid any kinds of beans and minimize the ability of copper circuits to thin. If not, there’ll be discontinuities experienced when the course is bent or stretched.

Mistake 5 – Thoughtless hole placements

When using the through-hole method of circuit designing, it is important to carefully plan the placement of holes. The holes must never be near the bend areas. They must be at a very safe distance from areas that bend or flex.

Mistake 6 – Wrong layer and component placements in multilayered boards

In the case of building multilayered boards, it is important to place the layers absolutely correctly. One mistake can jeopardize the entire functionality of the board. Thus, enough time should be taken to make accurate placements. Also, the conductors should never be stacked one over the other, as this will only result in a thicker circuit board, which can impact electromagnetic interference to a great extent.

To avoid these and many other such disastrous mistakes, it is important that you hire a professional PCB manufacturer for the job, who has enough experience of designing both rigid and flexible PCBs. Miracle Electronics is one such manufacturer who not only specializes in PCBs, but also many other such electronic components, which is why it has earned a reputation as the best PCB and cable assembly manufacturer in India.