Switch Mode Power Supply Transformers _ What They Are - Miracle Electronics

 Switched mode power supply (SMPS) is an electronic power supply that incorporates a switching regulator to convert electrical power efficiently, by transferring power from a DC or AC source to DC loads. The pass transistor of an SMPS continually switches between low dissipation, full on, and full off states, spending very little time in the high dissipation transitions, which minimizes wasted energy. Also, by varying the ratio of on to off time, voltage regulation is achieved. This high power conversion efficiency with no energy wastage is an important advantage of an SMPS.

Unlike linear power supply transformers, SMPS are small and light due to the smaller size and weight of the transformers installed, which is why they are effectively used as replacements for linear regulators when high efficiency is required with lighter weight and smaller size. The transformers that are mainly composed of magnetic core and winding, are used for conversion, energy storage, and isolation. But, the materials used will affect the performance of the transformer, which will in turn affect the heat dissipation and working efficiency of the equipment. Thus, you need to be very sure about the materials that you are having installed in your SMPS transformer. This is why when planning on getting an SMPS transformer for your application, you need to approach only an expert transformer manufacturer in India, one like Miracle Electronics, who has immense knowledge about, and enough experience of manufacturing and working with SMPS transformers.

Advantages and disadvantages of using SMPS transformers

• One of the main advantages of using SMPS transformers is that you can have efficiency up to 96% because the switching transistor dissipates very little power when acting like a switch. Other advantages include small size, light weight, and low noise. Also, the standby power loss is very low.
• One disadvantage is that they are very complicated and they can cause electrical noise problems if not carefully suppressed; thus causing harmonic distortion.

Types of SMPS transformers

SMPS transformers are divided into two types – unipolar and bipolar. Unipolar transformers are characterized by a unipolar pulse as input voltage, and are divided into positive flyback voltage output. Bipolar transformers are characterized by a bipolar pulse as input voltage, with the output generally being bipolar pulse voltage. 

Materials used

As mentioned above, it is very important to choose the right materials for the SMPS transformer. There are three main components of an SMPS transformer – magnetic materials, wire materials, and bobbin materials.

Magnetic materials – These are soft ferrite which are divided into two categories according to their composition and application frequenct – MnZm and NiZn.

Wire materials – Polyurethane and polyester enameled wires are generally used to wind small electronic transformers, divided into thin paint and thick paint types, depending upon the thickness of the paint layer.

Bobbin materials – Bobbins of SMPS transformers are different from general transformers, as they play a dual role of mounting and positioning of the entire transformer, along with insulating and supporting the coil. Thus, the bobbin material needs to meet insulation requirements, as well as possess tensile strength and heat resistance.

Why Should You Opt For Core Cap Transformers - Miracle Electronics

The typical method of manufacturing a transformer involves creating a core, insulating it, winding a magnet wire around to create a primary winding, insulating it, winding a magnet wire over the insulation to create a secondary winding, and finally insulating it too, to complete the transformer.

What are core caps?

To support the primary and secondary windings, and to reduce leakage current, segmented core caps are used in alternate sectors. Several modular electrically insulating segments snap or join together to form core caps for covering the transformer core. These core cap modules insulate the windings from the core over the full range of windings, allowing double-wall insulation between adjacent windings, significantly reducing leakage current. They also help in direct cooling of the core by ambient or forced air, without interfering with the insulation. The segments of each module include a pair of spaced insulating walls between which a core-covering panel portion is connected. The walls are inclined at a predetermined angle to each other, typically 30, 45, or 60 degrees, which is what determines the number of segments required to complete one core cap.

Benefits of using core caps

Reduced time invested – With the installation of core caps, there is no need for ground and inter-winding insulation and outer wrap. Also, both the primary and secondary windings can be wound on one machine only. In addition, providing the core cap includes mounting holes, which means that the time to fill the center of the transformer with epoxy is not required. All of this results in lesser time invested to manufacture and handle the transformers.

Reduced weight of the transformer – As mentioned above, there is no epoxy required to fill the center of the transformers if core caps are installed. Besides, no mounting washer will also be necessary. Hence, the weight of the transformer is also considerably reduced.

Reduced costs – Assembling core caps requires lesser skill levels that other core insulation techniques. Also, the cost to tool a smaller part for injection moulding is lesser than the cost of tooling a larger part. Thus, the cost to tool and assemble the core caps is way lesser. This means that the overall manufacturing costs of the transformer will be lesser too.

Reduced temperature rise – With core caps, there is a direct path for heat to escape into the environment. There is also no inter-winding insulation and outer wrap that traps heat. Thus, with all windings having a direct path for heat to transfer to the environment, then the temperature rise of the transformer is also reduced.

As you can see, core cap transformers help with reducing the time, weight, and costs of the transformer to a considerable extent, while also reducing the heat buildup. So, it can be clearly seen why core cap transformers are much better than standard transformers. You now know which kind of transformers to opt for, for your next application.

No matter what industry you are working in, and what kind of transformers you need, Miracle Electronics is your one stop destination to design all your transformer requirements. You can get all kinds of bundles of massive energy from this power, toroidal, EI, UI, SMPS, audio, and medical transformer manufacturer in India. And, every transformer you receive will always be RoHS and REACH compliant, having you to worry less about its quality and performance.

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.

Challenges In Medical Equipment Manufacturing Amidst The Pandemic - Miracle Electronics

Medical equipment electronics always require stringent measures to be taken while manufacturing them, as we always want to make sure that there is no chance of failure during any kind of critical procedures. The components used in such electronics also should be able to be easily traced back to their origin in case any problems are discovered, so as to find where the fault lies, and ensure that care is taken on manufacturing those particular components to avoid any issues in future components.

Now, with the COVID-19 pandemic that has struck so hard on us, there is even more pressure to hasten medical equipment development. There is also the need to satisfy the testing, documentation, and regulatory requirements of manufacturing medical electronics. Amidst all of this, let us take a look at some of the challenges that PCB manufacturers are facing to get the products to the market sooner. We want to see this because a PCB is one very crucial component of almost every electronic device today.

Why is precision important in medical equipment development?

Manufacturing of medical equipment is a tightly controlled process to ensure that the products built are of the highest quality. The best quality can be achieved by keeping a few goals in mind, some of which include –

• The product may have to work in the most critical applications, which is why it must have a more robust design than any other consumer product.
• The product should be designed as per applicable industry standards like ISO, by a manufacturer that holds applicable licenses to build medical devices.
• The product has to be safe to operate in even the most unexpected conditions, without any worry of shock or failure in any environment.

The challenges faced by the manufacturing industry due to the pandemic

Adding to all of the standard requirements above, medical equipment have an all new sense of urgency today with the threat of the worldwide spread COVID-19 pandemic. Certain medical equipment that are required for testing and treating the virus are facing even more challenges.

• The pandemic had brought a shut down on majority of manufacturing facilities since the past two months, slowly reopening across certain states since the past few days. All this hassle, and the way manufacturers are yet coping up on their lost time, has affected lead times for medical equipment and their components.
• Another issue was that of shipment. With all flights and trains cancelled, there was huge damage done to the lead time of getting timely shipments of devices and components.

What solutions can be helpful?

With so much of crisis around, and so many stringent measures required, what can be the solution? When you want quick response to your medical equipment requirements, there is no one that can help better than local PCB manufacturers amidst the lockdowns and restrictions. Here’s how.

• To cover up for all the loss made, many manufacturers have implemented dedicated shifts to make sure that the work gets done quicker, while ensuring safety of their staff.
• Every manufacturer has their own network of suppliers and distributors to satisfy their immediate requirements. Identifying such a local manufacturer can have them respond quickly to your urgent medical equipment assembly requests.
• Local manufacturers may help with not only PCB assemblies, but also box builds and cable assemblies so that you have to go nowhere else in these times of challenges. This can help respond quickly to requests of specialized fixtures for unique assemblies.

So, get in touch with a local manufacturer for your electronic device requirements, and we’re sure you’ll find a quick response. If you are in Bangalore, you can get in touch with Miracle Electronics  to take advantage of the best-in-class PCB assembly services from India  that can help you get your medical devices built as quickly as possible amidst these difficult times, without compromising on the quality of components. The engineering staff, the manufacturing teams, and the supply chain network here work together to achieve optimal manufacturing results to built products that are ready to be used in response to the current crises.