Every Possible Issue Related To Wire Harness – The Problems & Solutions – Miracle Electronics

Wire harnesses are engineered for different applications, but they play a critical role mainly in electrical and electronic devices and systems. Their rugged construction helps them to withstand almost all kinds of impacts and environments such as extreme temperature, humidity, compression, friction, vibration, etc.

 However, these harnesses can experience certain issues that can stop them from working as expected. Below, we’ve highlighted some of the most common problems that occur, along with some ways to either avoid the issues or resolve them.

Common issues

While there could be multiple kinds of problems seen within a wire harness, the most common issues include –

•         Poor performance
•         Shorter lifespan
•         Incorrectly placed components
•         Missing components or wires
•         Oxidation
•         Corrosion
•        Circuit issues

The causes

Inappropriate material selection – If the material chosen to build the harness is not one that can withstand the environmental forces in which it is to be installed, it can lead to poor quality and deteriorated performance.

Incorrect wire preparation – Not only is selecting the material important; it’s also vital that the wire is cut tothe right length, stripped right , and connected correctly. Failing to do so can lead to incorrectly prepared components.

Incorrect installation – Any imperfections in installing the wires can result in imbalanced pressure, circuit issues, and deterioration in the quality and performance over time.

Inadequate/flawed testing – If the harnesses are not tested properly, it may lead to missed issues that may cause bigger problems in the future.

Incomplete protection – Oxidation and corrosion are quite common to occur when certain metals come in contact with air and moisture.

The solution

It is very important to test the harnesses in order to eliminate all the above issues. Testing them after completion of every manufacturing stage, as well as after completion of the entire process, is essential. This brings forward any issues immediately so that the problem can be resolved at the earliest before moving on to the next stage. This results in reduced wastage of time, material, and labour. There are five different ways in which the harnesses can be tested.

Visual testing – This involves visually analyzing if every component is placed correctly or not; for instance, the dimensions, the gauge, the placement, the connectors/terminals , and the labelling.

Mechanical testing – This involves testing the mechanical properties such as flexibility, tensile strength, elongation, impact resistance, and crush resistance.

Electrical testing – This involves assessing the electrical performance; whether or not the configuration and performance are proper or not. Open wires, incorrect wiring, and shorts are tested for, by connecting the harness to an electrical fixture.

Environmental testing – This involves testing whether the harness can withstand the environmental conditions it is installed in, such as humidity, temperature, pressure, and vibration.

Signal integrity testing – This involves assessing the strength of the signals that can be carried, which include signal error and crosstalk. Whether or not the signal strength can be maintained with the integration of connectors, filters, or splices is also checked for.

Partnering with Miracle Electronics

You can see how it is important that you partner with a professional wire harness manufacturer like Miracle Electronics, where the harnesses are not only manufactured, but also tested at every stage to identify for potential errors at the earliest, so as to reduce wastage of time and labour, and bring to the client a thoroughly tested end product.

 

Importance Of RoHS For Medical Isolation Transformers – Miracle Electronics

The term “medical” in itself indicates safety and caution. Medical transformers thus also need to be very carefully designed so as to keep both the operators and patients safe while they’re around the device. 

And, this is the reason why the transformers used in medical applications are always isolation transformers – those that isolate the patient and operator from electric shock, and protect the equipment from power surges and other faults. Such medical grade isolation transformers  thus need to maintain strict adherence to certain crucial standards; one of them being RoHS.

What is RoHS?

RoHS, or the Restriction on the use of Hazardous Substances, in itself states that no kind of hazardous substances are permitted to be used while manufacturing the particular device. The main goal of RoHS is to reduce the environmental effect and health impact of electronic equipment, by making electronics manufacturing safe at every stage of the electronic device’s life cycle.

When was RoHS introduced?

The RoHS restriction originated in the European Union in 2002, restricting the use of 6 particular hazardous substances found in electrical and electronic equipment. It was then officially adopted in February 2003. In 2005, on the 21^st of October, the European Commission decided to exempt the use of Cadmium and its compounds in electrical contacts. The next year, the European community established July 1 as the phase-out date for hazardous material in electronic products.

Why was RoHS introduced?

A wide range of materials were used to manufacture electrical and electronic equipment, such as radium, lead-tin allow, etc. But these materials, despite of the fact that the had many useful properties, were also discovered to be hazardous to both humans and the environment. It was thus a must to stop the usage of such harmful materials. For strict adherence, the RoHS was introduced, in order to improve the welfare of consumers, manufacturers, distributors, and the environment.

Which materials are restricted for use under the RoHS restriction?

As per the RoHS, products compliant with the derivative must not exceed the allowable amounts of the restricted materials (with some limited exemptions). The 6 restricted materials include lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls, and polybrominated diphenyl ethers. This derivative applied to manufacturers, importers, distributors, and authorized representatives of a wide array of products. Some of the most common products that need to adhere to the RoHS standard include small and large household appliances, consumer electronics, lighting, computing equipment, communication equipment, power tools, and not to forget – medial transformers.

Why is it a must to adhere to the RoHS standard?

The 6 materials that fall under the RoHS derivative are hazardous to the environment, and also dangerous in terms of occupational exposure during manufacturing and recycling. Complying to RoHS reduces the amount of hazardous chemicals used in manufacturing electronics. This is why whenever you’re planning to purchase a medical isolation transformer in India, or any other electronic equipment for that matter, you should always approach a manufacturer whose products are all compliant to the RoHS certification. One such trusted manufacturer is Miracle Electronics, where every medical isolation transformer is not only RoHS compliant, but REACH compliant too!

 

Choosing The Right Power Supply For Your LED Application - Miracle Electronics

Discovering the right kind of power source for your LED lights and fixtures is absolutely important, may it be to build a new fixture, or retrofitting an existing one. What you’ll need is a constant current LED driver or a constant voltage power supply, or a combination of both, in order to make your LEDs work properly. Let’s help you know the different factors you need to consider when choosing a power supply for your LED lighting.

Most LEDs require a current-limiting device to prevent them from being over-driven. Such devices are used to regulate the current coming in to the LEDs, keeping them running safe, and maximizing their lifespan. If the current is not regulated, the LEDs may get heated up, thus changing their electrical characteristics to draw too much current, thus resulting in fluctuations or even failure. If your lighting fixture doesn’t have a current-limiting device, your first step should be to find a driver. But, if your LED product already has the current under control, you can move ahead to find a constant voltage power supply.

When the LED products already have current-limiting devices within the system, they call for a constant DC voltage, which is generally not available, and then you’ll need to find a power supply to convert your power to a safe DC voltage. But, in order to be able to effectively convert your AC voltage down to a safe DC voltage, there are many factors you need to consider, some of the most important ones being mentioned below.

Wattage and voltage

Identify the total amount of watts that all your lights combined will consume, and add to it a 20% cushion, or multiply the total wattage by 1.2. You’ll need to find a power supply rated for this calculated amount of wattage. Also, identify the output voltage that is compatible with the voltage of the LEDs. You also need to ensure that the power supply you select should be capable of handling the input power you have.

Temperature and environment

The area and the environment that you need the power supply in is also an important consideration. Power supplies operate efficiently only when they’re used within their temperature parameters. Installing a power system within a tiny enclosure, or where there is no ventilation system, is a bad idea. Rather, you should choose an area where it’s neither to warm, nor too cold, and where the heat produced cannot build up to damaging levels.

IP rating

Every power supply has an ingress protection rating, which is more popularly known as IP rating, consisting of a two-digit code that respectively indicates the size of solids and pressure of liquids that a power supply can resist. You need to ensure a power supply with an IP rating that will protect your source from the environment.

Size

The space that you have for installing the power supply should be well identified, and the right size of power supply device should be chosen. If the power supply is to be installed outside of the application, there should be a mounting possibility.

Using the above considerations, you should be on the right road to choosing the right power supply for your LED lights. There are a multitude of options to choose from, which is why you should take your time to consider every little aspect, so as to find the one that best fits your application, and is highly efficient in regards to how and where it needs to perform. And, when you’re done with all your contemplations, you’ll look for a place to begin your product search. This is where we suggest to you Miracle Electronics, a reputed brand where you can get standard as well as customized programmable power supply for LED light panel in India, each manufactured in dedicated work cells, using lean manufacturing techniques, to maximize efficiency.

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.