Choosing The Ideal Core For Your SMPS Transformer – Miracle Electronics

 When you’re looking to transfer electrical power effectively while also providing galvanic isolation, an SMPS transformer proves to be the best choice that provides a clear barrier against dangerous high voltages from passing to the output. This is thus a safe and space-saving option, unlike other traditional linear kinds of transformers.

But when planning on having SMPS transformers manufactured for your application, you also need to be capable of making the right core choice. This choice is generally based on your power requirements, the frequency required, and the switching topology. Let’s help you know some basic considerations to make the right material, shape, and size selection.

Core material

It’s basically ferrite that is used for making the core of an SMPS transformer; the reason being that its frequency spectrum ranges between 20 kHz to 2 MHz, thanks to its reduce expense and minimal losses. But, ferrites should be employed in the saturating approach for low power and low frequency functioning. In the case of high power functionality, a tape-wrapped core used as the saturating core, with a ferrite core used as the output transformer, proves to be a better choice.

Core type

There are a variety of different core types you can choose from, some of the most popular ones stated below. Each core type has its own size and shape advantages. Let’s check them out.

EFD cores – EFD cores are economical flat design cores that offer excellent space utilization for transformers or inductors. They’re thus ideal for compact transformer and inductor applications.

EP cores – EP cores are circular center-post cubical designs that surround the coil thoroughly, with the exception of PCB terminals. This eliminates the influence of air flow crevices established at mating walls in the magnetic track, giving a more significant volume ratio to the absolute area used.

ETD and EER cores – ETD and EER cores are those with a round center-post and broad winding areas which offer the advantage of a short winding path length, and thus minimum winding resistance. They are absolutely good for high power designs and multiple output designs.

PQ cores – PQ cores have a maximum ratio of bulk to winding region and surface area. This results in comparatively fewer turns with a maximum winding area, lesser space consumed, and maximum inductance.

A perfect transformer is one that promises minimal core decline, while demanding the very least volume of room. The core loss is affected by the flux denseness and frequency. Having all of this considered is of utmost importance when selecting both the transformer and the core. This is why, when making your core choice, it is always advisable to work with an expert SPMS transformer manufacturer in India, one like MiracleElectronics. That’s because the expert engineers available here can help choose the most suitable material and dimensions for your particular project, so that your expenses are minimized, and profits maximized. Moreover, Miracle Electronics’ SMPS transformers are all RoHS and REACH compliant, thus assuring quality performance and minimal power wastage.

 

How Important Is Aftermarket Service For Aerospace Components? – Miracle Electronics

Ever thought of how essential parts of commercial or military aircrafts are manufactured? Have you wondered what happens to them over the course of time? If you live in a fantasy world, you would believe that once such crucial parts are manufactured, they’d last a lifetime, because of the immense caution put in and the high-grade materials used for manufacturing them.

There’s no doubt in the fact that aircraft parts manufacturers use only the best quality materials and put in utmost care and caution while manufacturing such parts, but considering the parts to last an era is not agreeable. Whether it is auxiliary power unit mufflers, nozzles, engine exhaust plugs, pneumatic ducts, or any other component, it isn’t necessary that they all last the lifetime of the airplane they are installed in. That’s because a myriad of things happen during the daily operation of an aircraft. Environmental conditions and other impacts may result in damages and premature wear and tear. So, what can you do about it?

Importance of aftermarket services

Even if you approach the best aircraft parts manufacturer, you can be certain about getting A-grade components, but you can’t assure that you won’t have to keep a check on them again. There will be required regular checks, and repairs or replacements as required. This is where aftermarket services are critical to get the aircrafts back in the air. Every day brings new adventures and issues in the life of an airplane; and it is important that regular assessments are done.

Who to approach?

You must approach an establishment that considers itself a service business rather than a company that only manufactures a product. Customers consider a company only as good as the last order fulfilled, which is why businesses must strive to focus on building customer relationships. Customers always return to a store, restaurant, salon, or service provider only if they have had a good experience, and are satisfied with their products/services. But, once they receive a terrible experience, they’ll never return again. Same is the case for aircraft services businesses as well. One bad experience can cost a customer relationship forever!

Why choose Miracle Electronics?

One manufacturer you can trust for both products and service is MiracleElectronics. If you’re in the aircraft industry, you can approach Miracle Electronics for the best quality aerospace cables, transformers, inductors, and box build assemblies.

Aircraft cables – Every kind of aircraft cable and harness can be manufactured here with machineries for wire cutting, wire stripping, terminal and lugs crimping, and more. Laser marking for aircraft cables is also available here, to help with easy identification.

Aircraft transformers – Efficient, small-sized, lower weight transformers are manufactured here that possess lower exterior magnetic field, make less mechanical hum, and generate very low off-load losses.

Aircraft inductors – Whether it is commonmodes chokes  for infiltering supply and return conductors with in-phase signals of equal amplitude, or differential mode inductors for filtering out-of-phase uneven amplitude signals, you can get them all here.

Aircraft box build assemblies – Complete turnkey box-build and system level integration services, with the capability of producing all major sub-assembly components for an aircraft, with offerings including BTO, CTO, custom tooling and fixtures, custom production process design, and more, is all available under one roof.

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 .