Guide To Crimp Quality In Cable Harnesses

 

Cable harnesses are essential for connecting electrical and electronic components to guarantee effective and dependable performance in a variety of industries. These harnesses’ performance and longevity are directly influenced by the crimp quality used in them. This makes crimping among the most crucial steps when assembling cable harnesses. The process of crimping involves joining wires within a harness by attaching connectors to the ends of cables with a crimping tool. Many crimping steps, including stripping, cutting, and crimping the terminals on either side of the wires, can be automated. The correct crimping of wires, whether manual or automatic, is crucial because it creates a safe electrical connection and guards against problems like signal loss, voltage drop, and potential breakdowns.

The procedure

In a nutshell, the crimping procedure starts with the connector being placed in the crimping tool, followed by the exposed wire being inserted into the connector at the end of the cable, and then completed by installers squeezing the crimping tool’s handle to firmly link the connector to the cable. To begin, the wire is first properly put into the terminal’s barrel by first positioning the terminal in the crimp tool’s jaws. The crimp is then formed uniformly, without gaps or over-crimping, by applying pressure to the handles of the crimp tool. The final step is to confirm that the insulation crimp or the wings of the terminal have fully compressed around the wire insulation. When properly carried out, these steps result in effective crimping.

Advantages of crimping

Crimping is a quick and easy operation that can be automated using a crimping machine or done manually with crimping tools. It forms an airtight connection between the cable and connector to produce a union that is consistently dependable. Crimping is also consistent in comparison to other procedures like soldering, making it the best choice for applications that demand consistent durability even under the most trying circumstances. Crimping does have one possible drawback, though, namely the need for connector-specific tooling, which could result in high prices.

Why is it important to have good crimp quality?

When electrical components, such as cables and wires, are compressed with specially created splice bands or crimp terminations, gas-tight joints are created. A wire’s strands are reshaped by the resulting terminal to provide a solderless, low resistance electrical connection. To stop the corrosion of metals from oxygen and moisture, joints must be gas-tight. Additionally, they need to be sturdy, with a single joint that is free of splits or pieces. The crimping procedure makes all of this possible, while also making tiny connections in the wires that permit the passage of electrical current. Crimps of high quality can last for ten years or more.

How to ensure good crimp quality?

There are specific procedures that must be followed and certain criteria to be taken into account in order to guarantee a good crimp quality that has them lasting for up to a decade or longer.

Choosing the right crimp tool

The first step in assuring perfect crimps is choosing the right crimp tool. The wire gauge and termination size should be compatible with the tool. Purchasing a high-calibre, accurately calibrated crimp tool will enhance precision and uniformity throughout the assembly process.

Proper terminal selection

For a reliable crimp, choosing the appropriate terminal for the wire size and application is crucial. Terminals are made of a variety of materials, including copper, aluminium, and stainless steel. It is essential to make sure the insulation and conductor of the wire are compatible with the terminal.

Accurate wire stripping

For correct crimps to be achieved, wire stripping must be accurate and constant. To remove the proper length of insulation, a high-quality wire stripper that is compatible with the wire gauge needs to be used. Poor crimp quality might result from excessive or insufficient stripping.

Regular calibration and maintenance

To achieve accurate and consistent crimps, calibrating and maintaining crimp tools is required. By preventing under- or over-crimping, calibration guarantees that all crimps adhere to the necessary standards. The tool’s lifespan is extended by routine maintenance, which also lowers the possibility of subpar crimps.

Rigorous quality control and inspection

Implementing a stringent quality control procedure that involves checking crimps mechanically and visually is crucial. Compression, strain relief, and appropriate orientation all need to be checked visually. The integrity of the crimp is guaranteed through mechanical testing, such as pull force testing. Also, cutting and inspecting a crimped sample to determine its quality aids in identifying problems like inadequate compression or structural flaws in the crimp.

Training and certification

Operators who have received proper training are more likely to produce reliable, high-quality crimps, which lowers the possibility of errors like using the wrong wire ratio, overtightening, or not tightening the clamp enough. This is why you should always approach trained and certified personnel for having your cables crimped. One such trusted and certified cable harness manufacturers in India is Miracle Electronics, where there is a team of IPC certified engineers taking care of the entire manufacturing process, and automated machines used for cutting, stripping, and crimping processes. Only UL-approved and military grade materials are used here to manufacture cables and harnesses using lean manufacturing processes, followed by mistake proofing and testing procedures  to guarantee the best quality cable harness for every industry and application.

Cable Harnesses – Insulators, Connectors, And Terminals – Miracle Electronics

When you’re looking to protect your wires and cables against environmental conditions like moisture, temperature, and friction, you’ll need to install cable harnesses in your application. Depending upon the intended environment, there are multiple types of cable harnesses available to choose from. 

You may opt for standard readily available harnesses, or have your harnesses customized by proficient cable harness manufacturers in India.

When you’re planning to have your cable harnesses customized, you may either tell the manufacturer all about your requirements, or sit with them to design your specialized assemblies. If you choose the latter, you need to first have a basic understanding about the product, before you can sit down to decide on what you want. Considering this, we’ll let you know about the three main components that comprise a cable harness, which are insulators, connectors, and terminals.

Insulator types

The cables or the insulation that covers the wires can be of two types, depending upon the kind of environment or application the harnesses are to be used in. they could either be thermoplastics or thermosets.

•     Thermoplastics are the materials that soften or melt when exposed to a sufficiently high temperature, but also easily harden when cooled. They can be repeatedly softened and hardened by heating and cooling, without affecting the performance of the material. This quality enables recycling of the components, which also proves to be economical. Some common thermoplastic insulations include PE, PVC, PVDF, ECTFE, and nylon.
•          Thermosets are the materials that don’t soften even at high temperatures, but they’re rubbery and retain their properties at all times. However, once moulded or cast, these materials cannot be reshaped, because the moulding results in a permanent chemical change within the material’s structure. Some common thermoset insulations include CPE, EPR, and XLPE.

Connector types

Connectors are the electromechanical devices used to form a continuous electrical signal between the cable harness and power source. Basically, connectors consist of male plugs and female jacks that are joint together to relay an electronic signal. Such connectors broadly differ in materials, sizes, shapes, and dimensions, which can be chosen from or customized as per the intended application. The mating type, the insulation requirement, the power contacts, and the signal contacts are all the different factors that determine the kind of connector required by the application. When selecting a connector, it is also very crucial to know the wire size, circuit size, circuit density, operating voltage, current rating, and other such important numbers.

Terminal types

Terminals are the electromechanical devices that terminates a conductor to a fixed post, stud, chassis, etc. in order to establish a connection. Available in a variety of designs, shapes, and sizes, terminals may be crimped, soldered, press-fitted, or wire-wrapped. They are available in ring, spade, hook, bullet, butt, and flagged forms. The type of terminals to be used can depend on the requirements of the intended application. The terminals could be insulated or non-insulated. Insulated terminals are better used in harsh environmental conditions to protect the device and components from moisture and temperature extremes. If no such protection is required, non-insulated terminals are an economical choice.

Determining the type of insulator, connector, and terminal is of prime importance to come up with the best performing cable harness. They harness should be very carefully designed while keeping the specific application needs and environmental conditions in mind. The correct materials, sizes, and shapes are vital to ensure that the harnesses are properly placed and appropriately routed, while being completely protected. Professional cable harness manufacturers in India like Miracle Electronics can take care of every such aspect that affects the quality of the end product , so as to come up with a harness that’ll extend the life of the wires, without requiring early replacements or repairs. It’s thus always better to partner with a professional for even the smallest electrical or electronic build.

Choosing Segmented Cap Transformers Over Conventional Ones - Miracle Electronics

When you’re operating a critical application, something involved with medical, aerospace, or military, you’re always trying to settle down on a few crucial decisions. One such decision may be determining the kind of transformers you want to use, upon which lots of electrical and signal-based outcomes will depend. 

For instance, if you are into the medical industry, deciding upon the kind of medical isolation transformer in India you want to use for your applications, you may be unable to decide whether you should opt for a simple conventional one, or go in for a more radical one installed with segmented cap technology. If this is what you are unable to decide upon, you’re at the right place! We’ll help you know how a basic transformer is different from a segmented capped one, and how the latter can prove to be beneficial.

The basic construction of a toroidal transformer

A toroidal transformer has a basic method of construction which involves the following steps.

Creating a steel core – insulating the core – winding a magnetic wire around the core to create a primary winding – insulating the primary – winding a magnetic wire over the insulation to create a secondary winding – and finallyinsulating the secondary to complete the transformer.

Mounting the transformer

Once the transformer is manufactured, it is mounted either using a mounting washer and bolt, or by filling the center of the transformer with an epoxy, with a hole for a bolt.

The role of segmented core caps

Toroidal transformers are generally plain, but there are certain applications where additional segmented core caps are used. These core caps are mainly used to support the primary and secondary windings in alternate sectors to reduce leakage current. The insulating segments insulate the windings from the core over the full range of windings, allowing for double-wall insulation between adjacent windings, thus reducing leakage current to a great extent, as compared to conventional toroidal transformers. They also help to directly cool the core through ambient or forced air, without interfering with the insulation.

The construction of core caps

Several modular electrically insulating segments are snapped or joined together to form an annular or semi-annular core cap design to fully or partially cover the transformer core. The number of such segments that are required to complete a core cap is predetermined, based on the angle at which the adjacent walls are placed to each other. This is because the walls, which include male and female connector portions, are all disposed at a predetermined angle relative to each other, typically 30, 45, or 60 degrees. Typically, there are identical core cap segments in a single core, but there may also be groups of different segments spanning different arcs. The latter is basically seen in customized core cap designs that require certain particular properties and characteristics.

The benefits of a core cap design

Reduced costs – When a core cap design involves snapped segments, the cost to assemble the caps is reduced because the process of snapping requires lesser skill level than other techniques. Also, the cost to tool a smaller part for injection-moulding is lesser than the cost of tooling a larger part.

Reduced time – When a core cap design meets safety specifications for creepage and clearance, the manufacturing time is reduced because of no requirement for ground and inter-winding insulation and outer wrap. Moreover, the windings can be wound on one single machine, thus reducing the handling time.

Reduced temperature rise – When a core cap design allows airflow around the core and windings, while keeping creepage and clearance specifications safe, the temperature rise is reduced because there will be a direct path for the heat to escape from the un-insulated core into the environment, without having the windings and insulation to trap the heat within.

Reduced weight – When a core cap design includes mounting holes, the weight of the transformer is significantly reduced because there will be no center epoxy or mounting washer required.

As you can see, segmented cap transformers can offer significant reduction in leakage current, heat rise, costs, and time invested, in comparison to standard toroidal transformers. All of this combined, segmented cap transformers are lighter, faster, less expensive, and are rated for extended power for the same volume. This makes segmented cap transformers the ideal choice for critical applications like medical isolation transformers. So, whenever you are looking for an advantageous medical isolation transformer in India, you know what you have to choose. But, if you want a transformer that complies with applicable requirements, you need a manufacturer who you’re sure will provide you with only genuine standard transformers. One such reliable manufacturer  is Miracle Electronics, where every transformer is RoHS and REACH compliant, and also adhered to the regulations under UL 60601-1 standards.

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.

 

Printed Circuit Boards _ What & Why - Miracle Electronics

Printed Circuit Boards (or PCBs) are seen in almost every electronic device – that small green board with tiny black and golden components and connections. These tiny boards are capable of supplying electrical signals by connecting all the mounted electronic components together. 

There are a variety of PCBs available in the market, which can be selected depending upon the application it needs to be used in, and the purpose it needs to serve. Some of the most common PCBs seen are single-sided, double-sided , through-hole, and surface-mount. Let’s take a look at the types of PCBs and their applications below.

Types of PCBs

Single-sided PCBs

A single-sided PCB is the most basic type, which consists of a flat sheet of insulating material and a layer of copper foil laminated to the substrate. The copper is etched to divide it into separate conducting lines called traces. Then, there are all sorts of connections and electromagnetic shielding made possible with the help of insulated wires. The copper layer is finally coated to reduce the chances of shorts and prevent it from corrosion.

Double-sided PCBs

These PCBs are just like single-sided boards, but with copper layers and componentson both sides of the substrate layer , which allows the traces to cross over each other. This results in high-density complex circuits that are more difficult to produce. Double-sided PCBs can have their components connected using two technologies – through hole and surface mount. But, both these technologies come with their own benefits and limitations.

Through-hole PCBs

This is the most basic technology that has been used since initial times to produce PCBs, wherein the electronic components are mounted by leads inserted through holes on one side of the board, and soldered onto the copper traces on the other side. The leads are bent at 90 degrees to horizontally install the through-hole parts with two axial leads, inserted into the board, soldered, and trimmed off at the ends. The through-hole technology requires many holes to be drilled, limiting the available routing area for signal traces.

Surface-mount PCBs

Surface-mount technology  came after the through-hole technology to enable mounting of very small-sized components on the board, with small metal tabs or end caps that can be soldered directly onto the PCB surface, instead of wire leads passing through holes. With this technology, it became possible to mount components on both sides of the board easily; thus allowing very small PCB assemblies with much higher circuit densities. The technology is also automated, which reduces time and costs related to manual labour, thus increasing production rates.

Applications of PCBs

Electronic devices – PCBs are highly used in electronic devices, providing channels and pathways for electricity and signals to follow, thus allowing functioning of the device.

Computers – PCBs are very popularly seen in motherboards of computers, which makes complex functions possible too.

Medical devices – PCBs can help in the medical industry by performing a variety of functions like diagnosing, monitoring, and treatment. For instance, PCBs are used in the medical field in equipment like medical imaging systems, monitors, and infusion pumps. However, the PCBs to be used in medical devices should strictly comply to stringent standards for sanitation and functionality.

Automotive components – Automotive components need to withstand extreme temperatures and vibrations; and with the advancement of technologies, PCBs are not limited to windshield wipers and headlight switches only; rather they are also used in many other automotive components like control systems, stereo systems, navigation systems, and sensors.

Aerospace and military components – PCBs are also used in the most critical applications like aerospace and military. In the aerospace industry, PCBs are used in planes, satellites, space shuttles, and radio communication systems. And, in the military industry, PCBs are used in communication equipment, control systems in military vehicles, firearms, and more.

No matter what the application, you can always get the most appropriate PCB assembly for your equipment. And, when you’re looking for perfect products, you can always opt for Miracle Electronics’ customized solutions to get seamless PCB assembly manufacturing from India.

 

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 .

 

Should You Use Filled Or Untreated Vias For Your PCB - Miracle Electronics

Most manufacturers are opting for the surface mount technology for building PCBs, rather than the through hole technology, so as to allocate lesser space on the board, making them smaller and easier to install. But, with the rising use of surface mount technology components, more vias are being used too. Vias are holes for electrically connecting stacked pads on different circuit layers. 

While all vias essentially perform this same function, there can be different types of vias, depending upon their appearance on the PCB surface, namely through vias, blind vias, and buried vias.

Treating the vias

In order to improve the thermal performance of the PCB, there can also be done some additional treatments on the vias, such as filling, covering, capping, plugging, or tenting. Such treatments can help eliminate several assembly issues like shorting between component pads, or wicking down of the solder through the hole of a via. It can also eliminate expensive troubleshooting and reworking.

Filling – This treatment fills a regular or encroached via with non-conductive epoxy paste. These filles vias have the solder mask stopping short of the pad by a few mils, making it a good compromise for medium-density PCBs, as the presence of the solder mask reduces the likelihood of the solder bridging between the via and neighbouring pad.

Plugging – This treatment plugs one or both ends of the via with a non-conductive epoxy paste to prevent solder flow-through or wicking during soldering. But, in order to allow the epoxy to plug the hole effectively, the diameter of the via should be limited to a maximum of 20 mils.

Tenting – This treatment covers both pads at the end of the hole with a non-conductive solder mask, effectively sealing the openings. A dry film with a 4-mil thickness is adequate for covering even large holes effectively, without breaking down much. But today, manufacturers are opting out of the traditional dry film, and choosing modern LPI solder mask instead, which is only one-tenth the thickness of dry films.

Advantages of filled vias

Filling the vias can have several advantages over untreated ones, some of the benefits being high routing density, better conductivity (both thermal and electrical), and EMI reduction. Being very small in size, micro-vias allow high routing density on the PCB, allowing substantial reduction in the overall PCB size, and lowering the number of layers. All of this ultimately reduces the cost of the PCB. With a smaller size, there is also reduction in the distance between the components, which in turn reduces the overall resistance of the tracks, resulting in better electrical conductivity. This high conductivity in turn helps to lower the EMI reduction. Hence, filled micro-vias are particularly helpful for conducting a large amount of heat away from a hot component. The metallic nature of the filling wicks heat naturally away from the chip to the other side of the board for further dissipation by a heat sink.

If you want to take advantage of such filled micro-vias, you can always get in touch with Miracle Electronics to get your preferred customized PCB assembly from India. Get in touch and explain all your requirements and purposes, and you’ll get the most apt PCB assembly for your application, reliable and safe.

 

Should You Use Branded Or Non-Branded Connectors - Miracle Electronics

We see lots of products from brand names that we know about, and then, we also see imitations of such products that look just the same, also feel/taste/function the same, but are available at much lower costs, only because they aren’t a well-known brand yet. This applies to almost every product category like eatables, cosmetics, accessories, and electronics. In the case of electronics, we’ll speak about connectors in this blog.

Which connectors to use – branded or non-branded?

Connectors are specified on customer drawings. But, which connectors should one use – branded or non-branded ones? Well, the form, fit, and function can be the same for both branded and non-branded connectors. The non-branded connectors are referred to as substitute or equivalent components, having several benefits like local availability and cost reduction. However, not every electrical component can be substituted, which makes it very important to review the product application and design details before opting for such substitutes.

What all to consider?

Before deciding on using a substitute connector, it is important that the application, industry, and qualification requirements are assessed. For instance, critical industries like military, aerospace, and medical cannot afford to use downgraded quality products. Moreover, such industries can encounter challenges in using equivalent connectors. When deciding for less critical industries like industrial applications and consumer products, the decision to allow substitute connectors generally falls on the end customer or the individual with design authority. And, if you’re unable to decide, you may always consider consulting your cable assembly manufacturer to review the impacts and constraints of employing an equivalent connector.

Considerations while opting for an equivalent connector

When you decide on using an equivalent connector, again there are quite some considerations you ought to make. Some of the considerations are pin length, pin diameter, pin count, pin pitch, material compatibility, interface tolerances, footprint, polarization, electrical rating, flammability rating, and planned obsolescence.

Benefits of using local component sourcing

It is generally advised to choose local component sourcing for electrical manufacturing. Doing so can help reduce supply chain risk, as well as lower the effective product cost. Other than cost advantages, it can also impact the lead time. It’s always best to plan for samples and mechanical fit checks, so as to have a proper verification of all interconnects and mates. Although it isn’t always advisable to opt for suitable equivalent connectors for every project, but the benefits that they provide can offer tremendous value, when used in the right applications.

Where can you get what you’re looking for?

Miracle Electronics is one of the best cable harnessmanufacturers in India where you can get almost any and every kind of cable harness, both standard as well as customized, along with connectors of all types, such as circular connectors, D-Sub connectors, military specific connectors, and D-38999 circular connectors. With more than two decades of experience in the field, Miracle Electronics knows what it is providing, which is why every product is certified and approved by DGAQA and MSQAA for platform specific applications, and each product is tested well before being delivered to the clients.

 

Wire Harnesses & Cable Assemblies – The Manufacturing - Miracle Electronics

When you want to build an electrical system, you’ll need lots of wires and cables, which makes it better to replace them with fewer harnesses or assemblies. Wire harnesses or cable assemblies will hold multiple wires together, optimizing space, as well as protecting the wires against climatic and environmental conditions like heat, moisture, vibration, etc. Thus, errors and faults are eliminated, helping the functioning of the system to run smoothly.

Are wire harnesses and cable assemblies the same?

So, when we speak of having wire harnesses or cable assemblies, do you realize the difference between the two? Generally, as a layman, you may consider both of them to be the same, but when you get down into the details, you’ll notice that they are actually two different things. Let’s help you with understanding the differences.

•         Wire harnesses involve wires that are individually sealed, and then wrapped in another casing. But, these are not as durable, and are thus used in small electronic applications and internal systems.
•         Cable assemblies, on the other hand, are bundles of wires or cables in a single heavy casing. This equipment can be easily used in harsh environments because of the heavy-duty thermoplastic rubber or vinyl used for the casing, which helps hold up against outside elements like extreme temperatures, moisture, friction, abrasion, and compression/expansion.

How are harnesses and assemblies made?

•         Planning – The first and foremost step is planning, both the design and construction. Without a pre-plan, no product can be successfully made. In the case of harnesses or assemblies, the type and size of wire needs to be determined, to be used between each connection.
•        Prototyping – A test version is first created depending upon the plan. It helps engineers know how the final product will look like, while identifying any errors or gaps that need to be rectified before building the actual product.
•     Wire cutting – Once the prototype is approved, it’s time to move on to the actual product making, which involves first cutting the wires to the required length. Wire-cutting machines can be used here to automatically cut the required wires in bulk.
•       Wire stripping – After cutting, the casing is stripped back to reveal the core, which is then fed into the necessary connectors. Crimping and soldering the wires into their proper connections can be automated with the help of machines.
•        Assembling – The prepared wire-connector devices are gathered up and crafted into a harness, which is done majorly with the help of manual labour. This is because each wire needs to be fed through the harness, taped off, and measured to make sure that the distances match the design specifications.

Partnering with the right manufacturer

Manufacturing harnesses and assemblies is a time-consuming task, especially because of the intensive manual labour required in the last stage of assembling the equipment together. And, in order to not waste any more time, you need to get hold of a manufacturer who knows the job well so that there is no time wasted in making errors and rectifying them. Moreover, the manufacturer you should must have the right machines to make the process as automated as possible, and the right tools to use to speed up the processes that require manual labour invested. Some of the most basic tools that a good manufacturer must have are an injection mould machine, wire cutter, wire stripper, crimper, positioners, die sets, insertion and extraction tools, and all sorts of testers for testing the assemblies before delivering them to the customers.

Miracle Electronics is one of the best cableharness manufacturers in India you can approach to have your harnesses and assemblies made, as they have the right tools and machineries, skilled engineers, and the best testing facilities to build and test your products. Moreover, they are also skilled at manufacturing customized wire harnesses and cable assemblies  if you wish, each product being certified and approved by DGAQA and MSQAA for platform specific applications.

 

What Makes Custom Wire Harnesses Easier And Better - Miracle Electronics

When there’s an application that involves a range of electronically operated features and functions, there is certainly some or many wires and cable involved too. And, to make it easier and safer to work with, it’s certainly better to have a few wire harnesses in place, rather than having innumerous wires getting entangled amongst themselves, creating a mess and possible hazards. But, even better is using customized wire harnesses, as compared to readily available off-the-shelf ones. Why? Let’s help you know.

Quality and safety are guaranteed

You never know what kind of quality is used to make regular wire harnesses. But, when it’s customized wire harnesses, you know the kind of quality that is being used. This means there is complete guarantee here. Low quality materials, otherwise, can cause harm to either the application or operator, or both; and this risk you cannot take! With customized wire harnesses, high quality materials are used, thus increasing quality assurance and safety, while reducing risks.

There’s enhanced durability

When you opt to use customized wire harnesses, standard materials are used with better insulation, which means the quality is enhanced, thus increasing the life expectancy. This is one big difference between regular wire harnesses and customized ones. And, this is one reason that has increased the demand for such customized wire harnesses.

Product specifications are met

Customized wire harnesses are tailored to every kind of required specification, such as the length, width, weight, and every other aspect tailored to your requirements. In addition, you could also have your cables jacketed, colour-coded, labelled, or any other feature added as required, for easy identification and better performance or protection. Such added features will certainly add some costs to the final product, but the performance and durability is definitely going to be worth it!

Reliable wire harness manufacturers are guaranteed

Not every wire harness manufacturer can work on customized products. Generally, wire harness manufacturers will be well-versed with working with regular standard wires and cables. It is only experienced and professional manufacturers who will be able to work on specially customized requirements that the products need to be tailored for. Thus, if the manufacturer is accepting your proposal for building customized wire harnesses, you know that he is an experienced one. One such manufacturer is Miracle Electronics who you can completely rely on. This is the manufacturer who is skilled at manufacturing any and every kind of customized EMI shielded harnesses, flat harnesses, ribbon harnesses, RF harnesses, power harnesses, airborne harnesses, military harnesses, and more. Each of these types can be customized based on the requirement of the client, with each product being certified and approved by DGAQA and MSQAA for platform specific applications, and every production process being certified for quality to ISO 9001 and AS9100C. Furthermore, every wire harness is tested for dimension, continuity, weight, pull test, compliance to environmental requirements, and every other test for verifying production processes.

Hence, whenever you are looking for a customized wire harness  of any type, but with no compromise on quality, you can always rely on Miracle Electronics, one of the most dependable and consistent wire harness manufacturers in India.

 

Are Your Cable Harnesses Over-Engineered - Miracle Electronics

When you want your project to be a success, you’re looking for cable harness manufacturers in India, who can provide you with robust cable harness designs and the best quality components that can meet, or even exceed, your requirements. But, what if you don’t have the amount of time that the manufacturers are asking you to give them? Then, you ask them to take up your special case, willing to pay even a little more. 

We have all been there at least one time in our lives, haven’t we? But, when it’s about having your cables manufactured, the budget could go a little higher than expected, when you opt for an urgent delivery. That’s because cable manufacturers will certainly charge a little higher as compared to your other manufacturers like tailors, bakers, or other artisans. So, what do you do in such a situation then? Worry not. Despite of the situation you are in, there are still certain things you can do to bring down the costs into line with your goals.

Work on the design

Design is the first step towards manufacturing. You may have designed an awesome cable harness that can perform well in every kind of situation, but it is this exceptionality that has added even more to your spiked-up costs in case of emergency. So, look again, and see if you really need such an exceptional cable. Obviously, having a well-performing cable harness is a good thing, but you may work it over if its not really needed. For instance, if your cable harness will not need to work in conditions that are exposed to extreme temperatures or abrasions, you need not include the same aspects into your design; you could instead opt for simpler harnesses to lower the costs. So, scale back your “excellent” design to a “good” one to fit closer to the needs of your particular application, not only to reduce costs, but also the lead times. Having the right manufacturer by your side can help analyze your design to look for opportunities that can help achieve your goals without going overboard.

Substitute components

Just like the design aspects, you can work over the quality of your components too. You may have included exceptional high-quality components into your design, which may be either a little more expensive, or difficult to obtain, resulting in either costly or delayed deliveries. For instance, using military-specific connectors in applications that have nothing to do with military or defense work isn’t bad, but certainly adds to the cost for nothing. When you want things to fall within your budget, you could opt out of these rugged and high-performing connectors, and choose good quality regular connectors instead that provide essential functioning, while being readily available at lower costs.

Look out for a flexible manufacturer

Whether during crisis or not, you must always work with a manufacturer that is flexible. What we mean by flexible is that the manufacturer should be skilled at working in every way. There are certain manufacturers who work only with certain brands, certain components, and certain tools, in their own certain ways. This is a good procedure to follow, but in times of crisis, when you either want to alter the design or substitute components, or make any other such changes, such manufacturers could only make it difficult. But, if you have a flexible manufacturer, they will be willing to work as per your requirements, to serve you better and in time, even if that means compromising on their comfort zone a little. Miracle Electronics is one such manufacturer you can rely on. They are the best cable harness manufacturers in India who work keeping in mind the requirements of their customers at all times, while also providing them with the right advice and feedback on their designs and thoughts, to make them better cost-effective customized cable harnesses fortheir applications .

Copper Clad Cables Or Solid Copper Cables – Which Are Better - Miracle Electronics

Cables are a very tiny, yet very important parts of any electrical application. We often neglect the cables we use, but we fail to understand that it is the quality and type of cables that we use that decides on the performance of the entire application. While the quality of cables can be obtained by partnering with genuine and reliable cable harness manufacturers in India, the type of cables you need is for you to decide upon.

There are two basic types of cables you could use – copper clad and solid copper cables. So, which one of the two is better suited for your particular application? Both these kinds of cables are different from each other, and you must know what you must choose in order to maintain data integrity and have a reliable performance.

Copper clad cables – What they are

Copper clad cables are available as either copper clad aluminium or copper clad steel. This means that the conductor is made either of aluminium or steel, with a coating of copper wrapped around. So, these are not 100% copper cables.

Advantages of copper clad cables – One reason why such copper clad cables are used instead of solid copper cables is their light weight. With copper conductors being replaced with aluminium or steel, the weight of the cable reduces, which makes it apt for lightweight applications. Another benefit is that copper clad cables are less expensive because of the inner copper portion being replaced with aluminium or steel.

Disadvantages of copper clad cables – There is one drawback with copper clad cables. These cables are effective over short distances and for sending lesser amounts of data, unlike their counterparts, where data can be sent through longer distances without any kind of signal problems. When the distances are longer in the case of copper clad cables, there are issues with signal integrity, which then requires multiple signals to be sent to reach the end point.

Solid copper cables – What they are

Solid copper cables are 100% copper, with the conductor being made of copper, as well as the coating being of copper.

Advantages of solid copper cables – The two biggest benefits of using solid copper cables are durability and flexibility. Such cables easily bend back and forth, thus making it easy to shape and form them. In addition, copper conductors perform undoubtedly well. Another benefit with solid copper cables is that they are ideal for transmitting signals over long distances, with no issues in signal integrity. They excel in transmitting high levels of data over longer distances, with minimal current required to push the signals all the way through to the end.

Disadvantages of solid copper cables – There is just one drawback with solid copper cables, and that is their heavy weight. But, the performance and durability covers up for that.

So, what’s your choice?

You can determine the pros and cons of each cable to identify which one is more suited for your application. Consider the weight, cost, distance, durability, and data load of both, and decide as to which aspects you can compromise on, and which not. Accordingly, you can decide on purchasing the copper cable that you require from Miracle Electronics, the most reliable cable harness manufacturers in India, where you can have any and all kinds of cables manufactured. Whether you choose off-the-shelf products, or have your cables customized , you can rest assured to have products that are certified and approved by DGAQA and MSQAA for platform specific applications.

What Makes PCB Manufacturing So Precise - Miracle Electronics

PCB assemblies are so dense, so complicated, filled with so many tiny elements connected together, yet so precise! Have you ever wondered how something so tiny and complicated can be so precise? One of the major reasons for the precision is the latest technology used in manufacturing PCBs today. While earlier, PCB making was a manual process, over the years, the PCB manufacturing process has significantly changed, thanks to the latest technological innovations that have allowed PCB manufacturers to innovate accurately and skilfully. Here’s how a prototype PCB assembly from India is made  with such skill and accuracy.

Pre-manufacturing – Planning

Before a PCB prototype is begun for manufacturing, there is a lot of planning done, considering countless aspects. First and foremost, the PCB manufacturer will look over the design and Gerber files. Then, step-by-step instructions will be laid out for fabrication, which will be reviewed by an engineer, who will then convert these plans into a data format that will help engineer the board. Any issues will also be checked for with formatting or cleaning up. Based on this data, the final board will be created.

Manufacturing

Step 1 – Plotting

Once inspected and finalized, a panel array is then chosen for the best fit, after which photo plotting begins. This is the first step of the production process. A laser is used to plot the patterns, silk screens, and other primary images that are required on the PCB.

Step 2 – Lamination

In the case of multi-layered PCBs, the multiple layers need to be fused together, which can be attained with the help of lamination, that is done using heat and pressure.

Step 3 – Drilling

Once heat and pressure laminates the layers together, expert drilling systems are used, programmed to drill holes into the board, accurately and precisely. This drilling program ensures that there is no human error while manufacturing the PCB.

Step 4 – Copper Deposition and Plating

The copper layer of the PCB, which is deposited through electrolysis, is an important part of the PCB, the conductive property essential to the functionality of the PCB prototype. PCBs generally become conductive after electroplating, which is where the copper is plated via a plating bath. These copper tracks prove to be conductive tracks that connect two points within the circuit board.

Post-manufacturing – Testing

After the prototype is built, it is thoroughly tested in every way to identify any mistakes or flaws that may lead to errors or unexpected end results. Identifying these mistakes in the prototype can help correct them right there so that the rest of the manufactured products are not flawed, thus saving on costs and time. Once the prototype is confirmed to be perfect, the remaining lot is manufactured.

You can see how the latest technologies used bring such precision to PCBs. For such a precise and accurate PCB assembly from India, you can get in touch with Miracle Electronics, the leading PCB assembly manufacturer in the country, who is an expert in building PCBs of all kinds and sizes in world-class manufacturing environments to provide scalable, high-quality, and low-cost PCB assemblies to totally satisfy customers!