Designing Flexible Printed Circuit Boards - Miracle Electronics

Flexible printed circuit boards  are PCBs that are flexible, and are made of insulating polymer film that provides an electronic interconnection. While there are many ways to achieve a good circuit design, even some smallest mistakes can cause a design failure. It is thus better to be aware of such mistakes, and learn from them so that any potential errors can be avoided.

The bend

The bending capabilities of the board will be decided upon by two factors – the number of times the board will be turning, and the bendability of the council. For proper functioning of a flexible PCB, it is important that the bending area is set right in the initial stages itself. Thus, understanding the required bendability early on in the design is important to help manufacture the right parts that can fit well into the board. The minimum and maximum bendable limits should be known in regards to the bend radius and the bending tolerance.

Conductor arrangement

Because flexible circuit boards can twist and bend, any incorrect conductor arrangements can lead to hazardous consequences. You need to thus be very cautious while designing conductor arrangement. Also, you must make sure that the conductors pass through curved areas, in order to minimize the stress on them during flexing.

Stacking of conductors

Stacking conductors onto a board can result in a thicker circuit that may lead to an “I beam” effect, which is observed when the line pairs are staggered, to minimize the impact from electromagnetic reduction. You must thus avoid stacking conductors when designing a flexible PCB.

Slots and gaps

You need to create the right bridging sections to place the slots. Every gap and curved area in a flexible PCB is critical. Preparing for a manageable arrangement with the right bridging sections can avoid any bottlenecks in the design, by helping to achieve better edges and making it easy to fit the deserved curved PCB.

Quality of cover material

The quality of material you choose for the cover of the circuit boards will also determine, on a huge scale, the overall performance and life of the board. You must thus choose only the most suitable material, never compromising on the quality.

Layer placements for multi-layer boards

When using multi-layer flexible circuit boards, you must take care of the layer placement. As these boards are used in high circuit density applications, one mistake can hamper the entire functionality of the board. You thus need to make accurate placements by avoiding circuit parts on the solder side of the circuit board.

Through-hole mounting method

When using the through-hole mounting method, you must make sure that the holes are well within a safe distance from areas that bend or flex, to avoid any possible risks. Also, pay attention to the surface finish on both sides of the board, as they need to be of the same quality, for the best performance. Another good suggestion is that you must avoid using holes near the bend areas.

With these 7 design elements kept in mind, you can design a quality PCB having the best performance. However, there are many other minute details that need to be worked on. This is why it is recommended that you have your PCBs designed and manufactured by professionals who have enough experience to know what they are doing, with every minute detail of the board taken care of in regards to the application they need to be installed in. Miracle Electronics  is one such PCB assembly manufacturer in India  you can rely upon to have the most perfect PCB designed, with attention paid to every detail like the circuit traces, hole sizes, landing patterns, and more.

Factors To Consider While Manufacturing A Switch Gear - Miracle Electronics

Electric power has become a basic necessity for each one of us today; and for electric power circuits to operate well, it is important that they are operated by the right switch gear controls, which can switch and protect individual components of the equipment. Composed of electrical disconnect switches, fuses, and circuit breakers to control, protect, and isolate electrical equipment, switch gears are used to de-energize equipment so hat work can be performed with zero faults down the line.

These equipment are thus directly linked to the reliability of the electric supply; and must be thus manufactured very cautiously. So, when you are looking to manufacture such important components for your application, it is crucial that you consider several factors so as to develop and implement these components properly.

The size of the switch gear

The first and foremost consideration is the size of your switch gear. What size of switch gear will be apt for your application? Especially, when maintenance is concerned, you need to have an appropriate switch gear, if you need to move it in and out of the enclosure at the base for repairs and upkeep.

The environmental factors it will encounter

Where are you planning to install your switch gear? What is the application? Where will your product be used or installed? What kind of environmental factors will the switch gear encounter? For example, if the environmental conditions are of extreme temperatures or humidity, you need to design your switch gear such that they can effectively perform under those circumstances.

The operation requirements

You also need to consider the general control action of the switch gear. Are there any special requirements you need your switch gear to perform? Whatever your requirements, you need to present the information to the manufacturer right at the beginning of the development phase. Depending upon all that you require from your switch gear, the design plans will be worked out; and based on the finalized plan, the manufacturing will be carried out. Hence, every tiny information should be communicated and clarified before moving into the manufacturing phase to ensure that every specification of the switch gear will complement your equipment operation requirements.

Typically, switch gear are located on both high and low voltage sides of large power transformers. The switch gear on the low voltage side of transformers may be located in a building, with medium voltage circuit breakers for distribution circuits, along with control, protection, and metering equipment. For industrial applications, transformers and switch gear are combined into one housing, known as a unitized substation. So, for any queries on switch gear and transformers, and their components, or to place an order, you can always get in touch with Miracle Electronics, the best transformer manufacturer in India , where you can communicate all your information with skilled technicians, and have only the best electronic components manufactured for you. You can have almost every kind of electronics manufacturing services offered here, right from product and system designing to manufacturing the best quality products.

Receiving A Transformer And Installing It Correctly - Miracle Electronics

A transformer’s performance and success depends highly upon how it is designed and how it is installed. The design should be prepared well in advance keeping every aspect in mind by experts; the best quality materials should be used; and every care should be taken to install the transformer properly. Every transformer comes with a manufacturer’s guide that thoroughly describes the installation and testing procedure, and it is crucial to follow these guidelines to ensure safety to both the equipment and the personnel.

Acceptance testing

Before the transformer is shipped to you, it is important that you contact the transformer manufacturer in India to know about the acceptance tests that need to be followed. Every test comes with a specific objective that describes the transformer’s applicability for various uses.

Packaging inspection

Once you have received your transformer, the very first step is to check the packaging first, before even taking it out of the truck or any other vehicle that it is delivered to you in. If the packaging itself is damaged, you must return it immediately, or speak to the manufacturer as to what should be done about it.

Unloading and handling the transformer

Every transformer has a different weight, size, and mechanical configuration; and these aspects decide upon how the transformer should be handled – how it should be removed from the vehicle, how it should be lifted, and how it should be moved. Make sure your unloading people are well aware of all these things, and are capable of handling the transformer with care.

Deciding upon the location of installation

Before you plan on opening up your package and installing your transformer, it is essential that you choose a proper location that is apt for the installation, one that fulfills all the safety codes without affecting the normal movement of the equipment, material, or personnel. The location you choose must keep the transformer prevented as much as possible from harsh environmental factors like rain, wind, and heat; and also exposure to any kind of damage from trucks, cranes, or moving equipment.

Inspecting the transformer

Now that you have unloaded your parcel, and have also decided upon the location where your transformer should be installed, you are all set to go. But, hold on! Before you blindly install the transformer, it is absolutely crucial that you inspect your transformer thoroughly. Any flaws, defects, or errors in the transformer can be repaired or replaced there and then by speaking to the manufacturer. Once you install the transformer, this option may have lesser chances. However, if you have partnered with Miracle Electronics, there would be zero worries about any damages or errors, as they are the most reputed and experienced transformer manufacturer in India, who has been successfully manufacturing and delivering a variety of transformers to clients across the globe.

Installing the transformer

So, everything’s right, and you’re all set to install the transformer. It is absolutely important to carefully abide by the guidelines mentioned on the nameplate or on the connection diagram. Other than this, be very careful while considering the grounding of your transformer, as it is extremely important to eliminate the static charges that may accumulate. You must also safeguard the transformer windings so that it does not accidently get in touch with the core or enclosure. Also, after installing the transformer, do a final inspection to check for every assembling and connection.

Simplifying The Printed Circuit Board Design Process - Miracle Electronics

Designing Printed Circuit Boards is a challenging task that requires complete understanding of more than just circuit functionality, such as how the board will fit within the application, how heat will be dispersed within the board, and much more. With all of this to be considered, designing a Printed Circuit Board can become really complicated, which is why you’ll need to get your circuit boards from a professional PrintedCircuit Board manufacturer in India, who has complete knowledge and understanding of every aspect of the PCB as well as its designing procedure. 

One such manufacturer is Miracle Electronics, who has been manufacturing a wide range of PCBs and supplying them successfully to clients across the globe since more than a decade now. However, this blog also lets you know a few tips to simplify thePCB design process, bringing ease to the oh-so-very complicated process.

Spacing between components

One may want to stuff as many components onto the board as possible. However, there must be ample space left between the components. Putting up components too close to one another can create a number of problems. Also, cramping up the components together may leave very little room for wiring; thus creating additional problems. Thus, there must always be enough space left between components to avoid any such problems, while also making it simpler to solder the components in place, and making auto-routing easier.

Orientation of components

The components must be placed within the same orientation. Keeping a single orientation throughout the entire circuit board can lead to fewer errors during the soldering process, while also making inspecting the circuit boards simpler.

A small loop size

Keeping the loops small in size ensures avoiding certain issues. Smaller loops themselves possess lower inductance; however, keeping the loops over a ground plane can reduce inductance even more. Smaller loops also reduce high-frequency voltage spikes and the number of signals in the node.

Appropriate trace size

Copper plays an important role in a circuit board design; and equally important is the amount of resistance within the copper wires. It is thus important to size the traces appropriately to account for things like voltage drop, power dissipation, and temperature increase. And for this, the length, width, and thickness must be factored in to control resistance. Because the physical properties of the metal cannot be controlled, the size of the metal can be decided upon to combat resistance and other challenged that can affect the performance of the circuit board.

Correct placing of decoupling capacitors

Decoupling capacitors play a significant role in a circuit board design, but only if they are placed appropriately. They must be placed as close as possible to the power and ground pins of the integrated circuits to improve their efficiency and reduce inductance.

Avoiding 90 degree trace angles

Creating a 90 degree trace angle can prove to be problematic; for example, the outside corner becomes narrower than the standard trace width, or multiple angles can only be partially traced, leading to shorting and other problems. Thus, instead of 90 degree angles, 45 degree angles must be chosen, to ensure that etching can be fully accomplished, while avoiding shorting.

Important Considerations While Manufacturing A PCB Assembly - Miracle Electronics

PCBs are the integral part of almost every electronic device that we use on a day to day basis, which tells electricity where to head to, so that our electronics are brought to life. But, have you ever thought about how these tiny boards are made to function so effectively at such high levels?

Direct plating

Plating is an electrochemical process that involves depositing metal onto the surface of the PCB, and inside the plated through holes. Direct plating is an environment-friendly low-cost process, which eliminates the use of heavy metals, against the alternative electrochemical plating.

Etching

When a copper layer is applied onto the board, etching out the unwanted copper from the prefabricated laminate is an important step, which is done using various kinds of materials, the two most common ones being Ferric Chloride and Ammonium Persulphate.

Photographic processing

Photographic processing is another important process, which involves covering the copper on the bare board with a thin lining of photo-resist, after which it is exposed to light through a photographic film, which details all the relevant tracks that will now be on the new board.

Screen printing

Screen printing is where a silkscreen layer is added onto a PCB, in order to identify all the components of a board, along with the logos, warning symbols, test points, and other marks. Silkscreen can be applied using a variety of ways, like manual screen printing, direct legend printing, and liquid photo imaging.

Reflow Soldering Technology

Reflow soldering technology is the process of applying solder paste as a means of temporarily attaching thousands of small electrical parts to the contact pads, which is then subjected to controlled heat for reliable soldering.

Selection of PCB assembly equipment

You need the right PCB equipment suitable for every job. Using substandard tools and equipment might bring to you faulty products. Some of the best equipment that you must use include –

•    Solder paste printing machine for screen printing of solder paste to the PCB
•     Dispenser for dispensing adhesives on the PCB
•     Pick and place machine for picking and placing components onto the PCB
•     Reflow soldering machine and wave soldering machine for soldering
•     Functional Verification Test device for verifying the device under test functions
•     In-Circuit Test fixture for checking shorts, opens, resistance, and capacitance
•    Solder Paste Inspection machine for quickly and efficiently inspecting the         accuracy of the solder paste on the PCB

Selection of photographic tools

PCB assembling is a very long process that involves a number of steps like fabrication, material inspection, solder paste printing, reflow soldering, X-ray inspection, wave soldering, manual soldering, and more. All these steps require the use of the right photographic tools such as milling machines, paper slitting cutting machines, and post-press equipment.

PCB testing procedures

PCB testing is absolutely essential to prevent any errors or mishaps in the future, and ensure that the manufactured products won’t fail or experience a shortened shelf life. While the selection of a test depends upon what the designer wants to achieve, some example of functional tests include X-ray inspection, micro-sectioning analysis, PCB solderability test, solder float test, peel test, and PCB contamination test.

With all such processes in place, a reliable PCB assembly manufacturer from India like Miracle Electronics can bring up PCB assemblies that are of the best quality, meeting the highest benchmarks, following RoHS and REACH compliance, and meeting standard ISO certification criteria.

Cyber Risk In Electronics Manufacturing – How To Combat It - Miracle Electronics

Technology is always evolving; and with the rising technologies comes a risk of cyber security. For example, digital connectivity, sensor technologies, and iCloud infrastructure bring a lot many advantages like higher product quality, reduced downtime, better production, improved maintenance, and much more.

But, at the same time, these advancements bring an increased risk of cyber attacks, especially for the electronics manufacturing industry, which has been one of the top eight industries to report data breaches the most. Hence, it is very crucial to stringently control such cyber security to ward off any potential risks that may arise because of it. Below mentioned, in this blog, are some of the important steps that electronic manufacturing services providers, like Miracle Electronics, should be taking to protect their productivity and processes.

The current scenario

Before diving into the ways of combating cyber threats in the electronics manufacturing industry, let us first understand the current scenario of the trade.

• As a result of the rapid advancement of the Fourth Industrial Revolution, there is increasing cyber threat that manufacturers are experiencing. This makes cyber security a critical pillar of Industry 4.0.
• 85% of electronics manufacturers in India claim that cyber security is a key element of their digital transformation blueprint. And, 82% of them have a clearly defined cyber security strategy.
• Coming to maintaining a consistent level of cyber security across the breadth of their information technology (IT) and operational technology (OT) environments, 71% of electronics manufacturers in India are bringing together IT and OT to digitize their business.
• Majority of manufacturers express confidence in their own cyber security defences, but they are always less certain for the same about their supply chain partners. Only 11% of manufacturers today claim that they insist on their suppliers to provide evidence of their cyber security defences.

Strategies to combat cyber threats

As part of the digital transformation processes that electronics manufacturers adopt in their industries, there are five very important strategies that they should be putting in place.

1. First and foremost, every electronics manufacturing company should ensure that their information technology (IT) and operational technology (OT) environments are unified. Then, there must also be a company-wide commitment to shared responsibility in protecting against cyber threats.
2. There must be vigilance in protecting intellectual property and valuable intellectual intelligence.
3. Business continuity and the availability of manufacturing operations should be maintained.
4. The integrity, confidentiality, and availability of the entire supply chain must be thoroughly verified, insisting that the suppliers provide evidence of their robust cyber security defences.
5. The best possible practices must be followed in order to secure new routes to market and increase customer engagement.

In short, there must be cohesiveness maintained across the entire IT landscape, right from the programmable logic controllers used on the factory floor to the integration of cloud-based machine learning. With these five stringent policies, every electronic manufacturing services provider can lead the industry; and following such critical measures can have the electronic manufacturing industry be completely free of any potential cyber threats.

Identifying The Right Cable Assembly Manufacturer - Miracle Electronics

There are tremendous amounts of choices available for almost every product and service today, no matter what the industry or application. Customers have a difficult time picking out the right product and service, sorting from the varied choices available. They need to be able to see what sets a particular manufacturer apart from the others, which makes their products and services beneficial, thus making them the best choice for partnering up with.