The Basic Fundamentals About Defense Offset Guidelines – Miracle Electronics

A defense offset policy is drafted to leverage capital acquisitions in order to develop the Indian defense industry by fostering the development of internationally competitive enterprises, augmenting capacity for R&D, and encouraging the development of synergistic sectors like civil aerospace and internal security.

But, so as to achieve such a partnership, there is a list of defense offset guidelines that need to be followed. While the number of guidelines are umpteen, let’s help you get a brief in this blog below.

Application of provisions

The provisions apply to every capital acquisition, may it be outright purchase from a vendor, or purchase from a vendor that is followed by Licensed Production, where the estimated cost of the acquisition proposal is 300 crores or more. Generally, 30% each of both these costs of acquisition will be the required value of the offset obligations. However, the Defence Acquisition Council may prescribe varying offset obligations in special cases if required. Nevertheless, these provisions will not apply to procurements under the Fast Track procedure, and those under the “Option” clause, where an offset obligation was not stipulated in the original contract.

Discharge of offset obligations

The offset obligations may be discharged by one or more of the following methods –

ü Direct purchase or export orders for eligible products manufactured or serviced by Indian enterprises

ü Foreign direct investment in joint ventures with Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services

ü Investment in ‘kind’ in terms of transfer of TOT (Transfer OF Technology) to Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services

ü Investment in ‘kind’ in Indian enterprises in terms of provision of equipment through the non-equity route for the manufacture and/or maintenance of eligible products and provision of eligible services, excluding TOT, civil infrastructure and second-hand equipment.

ü Provision of equipment and/or TOT to government institutions and establishments engaged in the manufacture and/or maintenance of eligible products and provision of eligible services.

ü Technology Acquisition by the DRDO in areas of high technology

Then, there are a multitude of other offset obligation discharge policies that are divided into different sectors, such as vendor responsibility, performance bond, offset credits, offset banking, value addition, Buy Global procurements, offset valuation, and more.

Submission of offset proposals

Vendors are required to submit a written undertaking to the effect that every offset obligation will be met. Any failure on the part of the vendor to comply with the guidelines may result in disqualification of the vendor from any further participation in the contract. The proposals should be submitted by a specified date, failure of which may render the bid non-responsive, and liable to be rejected.

Evaluation of offset proposals

The Acquisition Wing in the Department of Defence is responsible for technical and commercial evaluation of offset proposals received in response to RFPs, and the conclusion of offset contracts. The Defence Offsets Management Wing in the Department of Defence Production is responsible for the formulation of the offset guidelines, auditing and reviewing or progress reports, and post contract management. And, both these wings work in close collaboration for the smooth implementation of the guidelines.

Processing of offset proposals

Technology acquisition – The Technology Acquisition Committee is responsible for assessing the offset proposals, covering both technical and financial parameters, including valuation of technology, and the timeframe and strategy for utilizing the technology.

Technical evaluation – The Technical Offset Evaluation Committee (TOEC), constituting of representatives of the Service Headquarters, Defence Finance, DRDO, DOMW, and other experts, is responsible for scrutinizing the technical offset proposals to ensure conformity with the offset guidelines. The TOEC report is then forwarded to the Technical Manager, who will then process the report for acceptance.

Approval authority – After the offset proposals are processed by the Acquisition Manager, they will be approved by the Raksha Mantri.

Penalties – If a vendor fails to fulfil the obligations as agreed to, a penalty equivalent to 5% of the unfulfilled offset obligation will be levied, after which the unfulfilled offset value will be re-phased over the remaining period of the contract. The vendor may also be liable for debarment from participation in future defence contracts for a period of up to 5 years, the decision that will depend upon the Director General of Acquisition.

Re-phasing requests – A vendor has the advantage of requesting re-phasing of the offset obligations within the period of the offset contract, providing valid reasons. If justified, the request may be granted.

Annual reporting – An annual report is submitted to the Defence Acquisition Council in June every year, regarding the details of the contracts signed, and the status of implementation of all on-going contracts.

Indian enterprises, institutions, and establishments engaged in the manufacture of eligible products and/or provision of eligible services are referred to as Indian Offset Partners, who are required to comply with all the above guidelines/licensing requirements and many more. Vendors are free to select such a partner. If you’re looking for the same too, Miracle Electronics can prove to the best Offset Partner For Indian Defense, thanks to their complete adherence to the obligations, proven industry capabilities, consistent R&D, and every necessary quality certification in place!

Choosing The Right SMPS Transformer – Miracle Electronics

A multitude of electrical and electronic personal daily-use products, such as computers, mobile phone chargers, automobiles, telecommunications, and security systems, involve the usage of SMPS transformers, making it one of the most in-demand transformers across the globe.

These transformers are used to provide galvanic isolation at the input, meaning a clear barrier that prevents dangerous high voltages from passing to the output, thus providing safety from electrical shock. However, one disadvantage of such isolated power supply is low efficiency, which can range between only 70 to 90%.

What causes low efficiency?

As the power supply is run at high voltage/current, strong magnetic fields are passed into the core of the SMPS transformer, which causes hysteresis in the magnetic core as the input AC signal oscillates. Further, because of such high input current, the core can saturate during operation, leading to even severe hysteresis and heat dissipation. Due to this, almost every SMPS transformer manufacturer in India supplies hysteresis curves with their components, allowing the designer to determine the limits on the input current.

What problem can low efficiency cause? How can it be resolved?

Lower efficiency of the SMPS units can cause heat up to higher temperatures when run at high voltage/current. This is why thermal management strategies are required to remove the heat. Heat sinks can help here, as they provide sufficient cooling when used with chassis-mounted fans.

How to place an SMPS transformer effectively?

SMPS transformers can be placed in one or more locations in a regulator circuit, in any of the multiple power conversion and regulation stages. But, one very common location for the transformer is between the output regulation stage and the switching stage. However, the exact location for the SMPS will depend on the power supply topology – two common topologies being flyback converter and forward converter.

How to choose your SMPS transformer?

There are a variety of SMPS transformers that use different core materials, coil numbers, and winding directions. For instance, different core materials saturate at different magnetic field strengths, which determines the highest voltage that can be used with the transformer. Generally, 2 coil transformers are the most common, while 3 coil transformers are used to provide multiple output power levels from a single SMPS circuit. In this way, you must be able to determine the exact specifications that you require. You must be able to choose the ideal SMPS transformer for your application. It must be one that operates within the linear hysteresis range for your supply, in order to minimize heating and power loss.

Partnering with a professional SMPS transformer manufacturer in India, one like Miracle Electronics, can ensure that every minute detail about designing the transformer is taken care of. That’s because they are skilled and capable of designing unique customized SMPS transformers for your particular application, delivering RoHS and REACH compliant solutions that guarantee minimal power wastage and highest possible efficiency. Miracle Electronics’ SMPS transformers have a high power-to-size ratio, with each segment topology having a unique V-in to V-out transfer function, leading to absolute efficiency. Hence, with a reliable transformer manufacturer  like Miracle Electronics, your transformers produce the desired output voltage, ensuring that the ripple is within your tolerances.

 

 

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

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

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

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

Insulator types

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

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

Connector types

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

Terminal types

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

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

Is An EI Transformer A Good Choice For You? – Miracle Electronics

With every transformer performing the same task of trading voltage for current in a circuit, without affecting the total electrical power, different types of transformers work differently to achieving the same goal. Also, different types in regards to the shape, size, material, etc. also affects the quality of performance. In this blog today, we’ll speak about one particular kind of transformer – the EI transformer.

What is EI transformer?

As the name itself suggests, EI transformer is one whose core is combined by laminations shaped “E” and “I”. A traditional and economical transformer, the EI transformer is widely used in a variety of electronic equipment and audio applications. The air gap between the E and I laminations can be easily adjusted by filling it with a suitable medium, making it suitable for building output transformers and chokes. This is the reason why many audio output transformers and chokes are designed with the EI transformer.

Why should you opt for an EI transformer?

EI transformers have a very simple structure, making it absolutely easy to manufacture, which is why most transformer factories are able to manufacture these transformers.

It is very easy to find the components required to build an EI transformer in the market, making it an easy-make as well as economical solution. With everything being available easily, the prices automatically go down.

EI cores are flat stampings with no need of any kind of bending or forming, which makes it very economical to manufacture.

The laminations can be removed from a single rectangular sheet without substantial wastage.

The mounting method of the EI transformer is simple.

EI transformer cores are more preferred than other U, C, and L core types, mainly because more surface space is protected by the winding in these cores.

The make of an IE transformer is such that the whole thing can be held together conveniently with simple corner fixings, or just vacuum impregnation with lacquer.

There is very good magnetic coupling between the two ends of the core.

Are there any disadvantages of using an EI transformer?

Just like anything else, EI transformers, in spite of having so many good qualities, also have drawbacks. One major drawback is that these cores don’t have self-shielding quality in them.

After going through the blog, it’s time you decide as to whether you would want to use an EI transformer for your application or not. Despite the fact that an EI transformer doesn’t have self-shielding, there are so many other benefits associated with it. So, whether it is for differential, power, or telecom inductors, converters, or inverter transformers, if EI seems to be the right choice for you, you could approach Miracle Electronics for the same. They’re the most reliable EI transformer manufacturer in India, where you can get durable and highly efficient transformers that come with superior wiring, varnishing, and connection terminators, all of which provide excellent regulation with minimal temperature rise. You can thus make the most of your electrical devices by buying such RoHS and REACH compliant EI transformers that can lower the voltage exactly to a value that is required by your appliance, while keeping it running right and safe.

 

When Building Electronic Box Assemblies – Miracle Electronics

An electronic box assembly is an electromechanical assembly process that includes enclosure fabrication, installation of sub-assemblies and components, and routing of wires and harnesses. It could mean anything from a PCB assembly in a cabinet fill or wires, or a complex fully integrated electromechanical system with pneumatics and electronics. 

Whatever it may be, you need to have your components placed in a project box that protects, as well as makes your product truly useful and accessible.

Designing electronic box assemblies in India presents its own challenges, which is why you need a manufacturer who goes ahead with the right approach. You need one who specializes in the capability you want to build, and has experience in building the particular product and components you’re looking for. Outsourcing your electronic box assembly is an easy task when you have such a reliable manufacture partnered with. But, while you outsource, you also need to consider a few basics to help the build process go smoothly. There are certain instructions you need to send to the manufacturer for building the box appropriately. These include –

Bill of Materials (BOM)

The Bill of Materials gives the manufacturer an idea of all the key components, with a clear mention about the materials that you will be providing, and those to be sourced by the manufacturer. You may also define every tiny detail like the adhesives, tie wraps, nuts and bolts, washers, heat shrink, etc. if you wish to avoid even the smallest confusion or misconceptions in the future. You should also clearly specify the tolerances and finish of each component if you want anything particular to be considered. All in all, it is best to specify every minute detail just exactly how you need it. If you’re too confused as to what materials or specifications should be used for your particular requirement, you can also communicate all your ideas and purposes to the manufacturer, and help him decide the best solution for you.

Assembling

Once all the materials and components are decided and discussed upon, along with all the specifications and details mentioned, it’s now time to move on to the process of assembling them. if possible, you can provide a 3D CAD model to help the manufacturer visualize the final product like you want it to be. Or, at the least, you must provide the assembly drawings with every detail clearly mentioned. However, if you’re not too sure, you can always define the purpose and requirement, and leave the job of designing and prototyping to the manufacturer. This can also help when there are large amounts of space, labour, and specialist tools required for the build.

Testing

Testing is always an integral part for any product, especially when it is an electronic or electrical device. The basic electrical safety testing, such as earth bond and flash tests, need to be conducted, thus specified well in advance. Other tests may include visual inspection, functional testing, factory acceptance testing, etc., depending upon your specific product. If you’re not too sure again, your manufacturer can help decide as to what kind of testing is important, as they will have the proper knowledge and experience of what will work best for your particular product.

Outsourcing and electronic box assembly inevitable requires close cooperation between the client and manufacturer. By providing all the above information, and every other detail possible, there would be lesser confusion, lesser misunderstandings, and lesser wastage of time and money. Whether you require a simple box build assembly, or complex electronic box assemblies in India, you can get in touch with Miracle Electronics to ensure that your product is protected and looks good with the final assemble that proves to be a true reflection of your encased product. Dedicated to lean manufacturing techniques, Miracle Electronics will always offer maximized efficiency and a complete package, no matter what the product may be.

 

Connecting The World With Cords – Miracle Electronics

A few decades ago, travelling overseas or across the country was not part of everyday life. But today, with countries and communities around the world becoming more connected, travel is more accessible and affordable. Businesses are operating on a global scale, and people are frequently travelling overseas for vacation. 

Technology and new transport options are the two main contributions to these ease and accessibility, which are helping our world become smaller. What took us days to reach another city or country, now takes only a few hours to be there. But, all this technology is becoming only possible with the help of the variety of wires and cables being used within the systems of all kinds of transport. Whether you’re travelling by road, rail, or air, every transportation vehicle holds a multitude of wires and cables within its system to be able to run.

Different purposes solved by transportation

• Scooters, autorickshaws, cars, jeeps, and buses are the most common vehicles used to travel by road for everyday chores.
• Metros and trains are used to travel from one city zone to another, or from one city to the other.
• Trucks, lorries, and cargo trains are used to import export freight within cities or countries.
• Ships are used to transport both people as well as cargo from one country to the other.
• Flights have become an easy way to travel from one country to another, may it be for vacation, occasion, or business trips; or for transporting cargo faster.
• Each of these modes of transportation depends highly on wires and cables to operate , as well as communicate to systems on the land.

How are wires and cables important for these vehicles?

• Cars, trucks, buses, and lorries require wires and cables to have their electrical and electronic  systems, like dashboard controls and radio systems, function and perform.
• Communication and GPS systems also require the use of wires and cables within these vehicles,  to be bale to safely convey important information between users, and navigate the roads to and from different destinations.
•  Electric vehicles that are highly being adopted today rely even more heavily on wires and cables. In addition to the standard electrical and electronic functioning, such vehicles also require them to run their battery systems and charging ports.
•  Boats and ships rely highly on communication and GPS devices, which require innumerous wires and cables to run. Proper networking of such wires ensures the operators safely navigate the waters, without the fear of getting lost or travelling into unsafe weather and water conditions.
• Ships that carry passengers also need to install entertainment devices like televisions, radios, and music systems, to provide recreational activities to the travellers, which again require a number of wires and cables.
• Cargo ships require wires and cables for electronic inventory tracking systems, to streamline loading and unloading operations.

Where to get your wires and cables?

At Miracle Electronics, you can have all kinds of wires, cables, and harnesses to make travel possible. From cables for communication devices to wire harnesses for operational systems, you can get it all. Miracle Electronics is the leading automotive wire harness manufacturerin India that provides solutions for all standard and customized requirements, each being certified and approved by DGAQA and MSQAA for platform specific applications.

Why Are Toroidal Transformers A Better Choice? – Miracle Electronics

Like every transformer type, a toroidal transformer is designed to change the AC current, without the need for any type of movement or action, on the part of the component. But, what makes it different is that its doughnut shaped core is made of cold-rolled silicon steel, which boosts the performance of the core, as compared to any other traditional laminated core. 

The core is wrapped with a coil that generates magnetic field lines, which are completely coincident with the magnetic circuit of the core. This results in a reduced excitation energy and core loss. A toroidal transformer thus benefits the application by offering high electrical efficiency and less magnetic interference, packed in a small size, which also makes it absolutely light in weight.

Distinguishing the outcomes produced by a toroidal transformer

By using an efficient toroidal transformer, large amounts of energy can be saved. Let us take an example. You can take two different types of transformers for the same application; for instance, one being an EI-core transformer 2 x 24V 50 VA, and the second being a toroidal transformer 2 x 9V 50 VA. Loading both these transformers with several load resistors, and the loading power ranging from 5 to 40 Watts, the energy losses can be measured to find the remarkable difference between the two outcomes. The difference between the input and output powers is the energy loss that is converted into heat within the transformer. Moreover, dividing the output power by the input power can also bring to you the transformer’s efficiency. Calculating with different numbers of load resistors, you’ll be able to clearly see the significant differences in the outcomes. The toroidal transformer will result in much less losses than an EI transformer.

Where can you use a toroidal transformer?

Toroidal transformers are used widely in home appliances and other electronic equipment with high technical requirements, such as computers, lighting, telecommunications, audio equipment, medical equipment, and automatic control equipment. You can choose to use the same for your equipment too. And, to bring about even better results, you can opt for a customized toroidal transformer, manufactured by professional and expert toroidal transformer manufacturers in India.

Designing a customized toroidal transformer

Before designing a customized toroidal transformer, there are certain parameters that need to be considered; some of them being –

• The industry – With every industry having different requirements, the industry and equipment in which the toroidal transformer needs to be used should be thoroughly considered and understood.
• Input voltage – Generally, the toroidal transformer is designed according to 220V, but it can also be customized as per any special requirements regarding the input voltage.
• Output voltage and current – Whether the toroidal transformer is single or multi-wound, the output voltage and current of each winding needs to be considered well.
• Output power – The wattage obtained by multiplying the output voltage and the output current also needs to be contemplated.
• The installation method – The kind of installation method needs to be carefully decided upon, such as bracket installing, middle hole potting, full potting, etc.
• Any other special requirements – Any other special requirements such as the lead length, or whether the lead needs to be added with a terminal plug, and other such considerations, need to be reflected upon.

Whether standard or customized, whatever your choice may be, Miracle Electronics are the toroidal transformer manufacturers in India you can rely upon to satisfy all your requirements!