Making The Correct Toroidal Transformer Choice

When you’re looking to buy toroidal transformers for your application that can step up or step down a voltage, or for isolating an electronic equipment from a source of voltage, while allowing power to be transferred from the primary to the secondary coil, you need to make the right choice.

What is a toroidal transformer?

Constructed using a ring-shaped metal core, on which a wire is wound to form the primary input coil, overlaid with insulation, over which a secondary output wire is wound, toroidal transformers offer a neat and small variation of other kinds of transformers that require more space to be installed, and are also comparatively heavier.

Pros and cons of a toroidal transformers

Toroidal transformers have several advantages over other equivalent traditional devices, such as –

• Overlapped coils that allow for much smaller devices, unlike in the case where there are two separate coils
• Smaller number of turns required per coil, resulting in higher inductance relative to a similarly-sized traditional transformer.
• Magnetic flux limited to the toroidal core, having the transformer to shield itself from producing electromagnetic interference

Nevertheless, just like anything else, toroidal transformers also come with a disadvantage, which is that with each winding to be passed through the center hole, automated winding becomes difficult, or may require a dedicated winding machine specific to toroidal devices, resulting in cost additions when such toroids are manufactured.

Applications where toroidal transformers are the best choice

Because of the peculiar kind of construction and winding that a toroidal transformer is made with, as the size of the transformer increases, the advantages tend to diminish. For this reason, toroidal transformers are best suited for signal applications, like audio and radio frequency applications. They are also well suited for applications including security systems, LED lighting, inverter systems, industrial control equipment, power distribution equipment, isolation equipment, automotive electronics, and telecommunication systems.

Considerations to be made while making a toroidal transformer choice

Configuration

A transformer’s configuration refers to the number of input voltages it can accept, and the number of leads it must include. As the number of leads and required copper wiring increases, the manufacturing and product costs also increase. Toroidal transformers come in two basic types of configurations – single and dual.

• Single configuration transformers include only one primary coil winding, thus being able to accept only one input voltage.
• Dual configuration transformers include two windings in the primary coil winding, thus being able to accept two different input voltages. Here, in order to switch input voltages, a two-lead voltage selector must be used in conjunction with the transformer.
• Multiple configuration transformers can also be manufactured; however, they’re required to be used with a switching device.

Mounting

Toroidal transformers can be mounted using one of the below mentioned methods.

• Screwing onto an internal framework using in-built tabs
• Securing to a flat surface using a rubber washer and metal disk
• Securing to a flat surface using an H-shaped frame
• Soldering to a circuit board using through-hole or surface mount technology

Considering all of the above, you can select the perfect toroidal transformer type for your application. Whatever your toroidal transformer type, you can always rely on the products offered by Miracle Electronics. Other than standard products, you can also have your toroidal transformers customized perfectly here. Understanding the electrical needs of the customers, these expert toroidal transformer manufacturers in India are able to offer the most apt customized solution to every client!

Visit our website: https://www.miracle.net.in/

Why Choose Laser Marking Over Other Wire Marking Methods?

 “Why should I invest in a laser marking machine, when I can instead buy a less expensive alternative that can serve the same purpose?”

If this is the question that’s in your mind when you’re looking to buy a machine to mark your wires, we’re here to clear your doubts. Once you understand the advantages that laser marking has over other marking methods, you’d say for yourself that it is undoubtedly the best choice for your wires, regardless of your production requirements and the price. UV laser will have you to save money throughout its lifetime, while also proving to be more efficient than any other method.

Laser marking vs. hot stamping

Hot stamping has been a technique used to mark wires since World War II, but today, with the advancements in technologies, it seems to be impractical and dangerous. It is an out-dated method that takes far longer to mark a wire than it would with a UV laser marking machine.

• Hot stamping requires manual changing of characters, while UV laser marking uses a software to control the marking of characters, making the latter faster, requiring less operator time.
• With Teflon wires continuing to grow in popularity, using a hot stamping machine makes trouble marking on these wires. But, with laser markers, Teflon wires can be easy to mark.
• Hot stamping requires a certain width of the wire to be marked, as well as a thick insulation. Laser markers, on the other hand, can safely mark on even thin-insulated and small gauge wires, without any risk to the integrity of the cable.
• Hot stamping always keeps the wire at risk of getting burnt, which means the wire damaged even before being installed into the application. But, with laser marking, there is no such worry, as it simply tans the wire insulation, leaving a permanent mark, and maintaining the integrity of the wire.

Laser marking vs. heat shrinking

Heat shrinking is another popular method used to mark wires, but it is a long and labour-intensive process, which proves to be highly inefficient. It fails to address the needs of businesses looking to expand, as it is low on efficiency and speed, while being high on costs. Laser marking, on the other hand, eliminates the cost of applying more resources over the wire, also reducing the need for post mark treatment. This helps companies focus on cost savings, improved capacities, and long-term growth.

• In the process of heat shrinking, the user is required to manually carry out the entire process – marking the tubing, marking the wire, cutting the tubing and wire with precision, inserting it over the wire, heating both ends of the wire, and finally inserting the wire into the destination. Laser marking, on the other hand, is absolutely easy and automatic. It marks the wire directly, and then cuts it to the required length automatically, with no need for post mark treatment.
• In the case of heat shrinking, dirt or grime can get into the tube and be inserted over the wire, making the wire slippers and difficult to install, thus making it a difficult and time-consuming job, which is responsible for increasing labour hours. But, with laser marking, there is no such process. The wire that goes into the machine comes out itself, with no possibility of dirt and grime getting into the crevasses.

Laser marking vs. ink jet printing

Ink jet printers are very fast and mark at higher speeds than laser markers. However, they also pose multiple disadvantages to the wires.

• The markings made by ink jet printers are not permanent. Any liquids that touch the markings, such as gasoline or jet fuel, can remove or smear the mark on the wire. Laser markers, on the contrary, tan the wire insulation, creating a permanent mark that cannot fade or smear.
• Ink jet printers are high on maintenance. They require cleaning the ink applicator, checking for fading ink, and changing the cartridge. This not only results in high maintenance costs, but also increased down time and daily consumables, which add to the mounting operating costs. Laser markers, in opposition, require no ink, and have no daily consumables and maintenance.

After looking at all the above factors, it becomes clear that laser marking is the most efficient process that brings permanent results. It is a fast, safe, efficient, permanent, long-term solution, increasing marking capacity and reducing operator costs. Laser marking can thus save the business money in terms of time, cost, and maintenance. You can approach Miracle Electronics for laser marking for aircraft cables, no matter what your wire material, gauge size, character requirements, and spacing constraints.

Miracle Also , do subcontracting for Laser Marking on Cables with it’s spare capacity , You may send your requirements to us on sales@miracle.net.in

CALCULATING THE KVA RATING REQUIRED FOR A TRANSFORMER INSTALLATION

 Almost every industry, from basic manufacturing industries to critical healthcare facilities and testing laboratories, requires high-quality reliable transformers to keep their operations running safely and efficiently. Larger facilities require larger amounts of power, which means more dependable transformers to convert the energy coming from the power plant, into a form that can be used for the equipment.

But, in order to have the transformers do so effectively, businesses need to know how much power their particular transformers can give them. It is the transformer’s rating that provides this information. The rating, or size, is the transformer’s power level in kilovolt-amperes, denoted by kVA. You need to select a transformer with the correct kVA for your needs. If not, you may run the risk of damaging your valuable equipment. Seems difficult? But fortunately, it’s not as difficult as it sounds. In fact, sizing your transformer is relatively simple. You just need to use a simple straightforward formula to generate your kVA requirements, using the current and voltage of your electrical load. Let’s help you know how you can calculate the required kVA rating.

Calculating the kVA value

Transformers come in two basic ratings – volt-amperes (VA) and kilovolt-amperes (kVA). A transformer with a 100 VA rating can handle 100 volts at one ampere of current. Similarly, a transformer with a 1.0 kVA rating (1000 volt-amperes) can handle 100 volts at 10 amperes of current. To determine your appropriate kVA size, you need to make a few calculations, based on your electrical schematic.

There are two main measurements that you’ll need, that of the voltage (V) and of the current (I). Voltage is the electrical load that connects to the secondary winding, and current is the flow that the electrical load requires. Both these values can be determined simply by looking at the electrical schematic. Once these two values have been determined, you can then use them to figure out the load’s power requirements. To do that, you’ll need to multiple the voltage with the load, and then divide the number by 1000; hence, the formula being –

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Wire Harness – Different Industry Applications

Wire harnesses are widely used in almost every residential, commercial, and industrial application, to hold together the multitude of wires in a neat and organized manner, so as to avoid tangles, trips, and accidents. While the designs and materials can vary for every industry, finding a building, a machinery, a vehicle, or any other electric and electronic device without such wire harnesses is next to impossible! For instance, some applications may be able to do with regular materials and standard quality manufacturing, while others may require high quality materials and stringent engineering practices used to build their wire harnesses.

Depending upon your industry and application, you thus need to approach an industrial wire harness manufacturer in India that can cater to your requirements. Miracle Electronics is one such manufacturer who can manufacture simple as well complicated wire harnesses that require expert knowledge, expertise, and specialized materials and engineering skills. We pride ourselves on being able to manufacture wire harnesses for every industry, regardless of the requirements, expectations, and certifications required. Let’s take a look at all the various industries that different kinds of wire harnesses are capable of serving.

Automotives

We’re widely known for our automotive wire harnesses, which can fit and function well in different kinds of vehicles, for all sorts of different electric controls and devices that work together to transmit power and signals for the engine to work. Wire harnesses efficiently connect the vehicle’s different parts for effective usage and functioning.

Telecommunications

We all rely so highly upon telecommunications of all types today. May it be our smartphones, computer networks, internet, or the radio, they all play an essential role in our lives. But, do you know that all these wireless systems also require a large network of wires to help them work!? So, you can say that it takes a lot of wiring to help us work so wirelessly today. Bundling of different types of wires is required here, which is what wire harnesses serve so effectively.

Consumer electricals and electronics

Our everyday products, including electricals and electronics, also require multiple wire harnesses to make them work. Whether it is the lights, fans, and air conditioners, or other appliances like refrigerators, washing machines, microwave ovens, computers, etc., the wire assemblies that power and control them need to be effective for the job. Every application requires a different kind of wire harness, and must support performance and reliability.

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Wire Harness – The Nervous System Of Your Vehicle

We all have within our body a central nervous system structure, which is responsible for the functioning of the entire body. Consisting of the brain, spinal cord, and nerve cells, each part plays a vital role in working together to take in information and control how the body works. Just like the nervous system is critical for every human body, so is a wire harness for an automotive. It would be right to say that a wire harness is the central nervous system of any electrical system!

What is a wire harness?

A neatly organized compact bundle of wires and circuits, a wire harness is critical for a wide range of applications like industrial control panels, consumer appliances, commercial machineries, automotive, and every other equipment and machinery that transmits or relays electronic information or electrical power. Forming a reliable network of communication between all components and peripherals, it facilitates faster processing, maximum efficiency, and highest reliability.

How is a wire harness important to an automotive?

A wire harness consists of a central column of cables that branches off into secondary cables to connect to various components. From the battery to other vital components like spark plug, headlights, indicators, instrument console, sensors, and other controls, it serves as the backbone of every vehicle. It transfers electrical power and data to all the control units that help the vehicle to function. All the control units share this information amongst each other to work in a synchronized manner. How would it otherwise be possible for a vehicle to shift through the gears so smoothly, while managing the speed? How would otherwise a vehicle know how to fold in the side mirrors or switch off the headlights when you lock the vehicle with a remote FOB key? All this efficiency and precision comes with the reliable fast network of wire harnesses that is packed within the vehicle’s electrical system.

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Transformers From Miracle Electronics – An Investment In Quality

Replacing a transformer comes as an unwanted surprise with unexpected, yet unavoidable, expenses! You need the power back soon, but you aren’t really willing to pay that exaggerated bill you’re being asked to pay for an immediate replacement. So, you either opt for a low-cost transformer, which will only turn out to be an expensive mistake in the near future; or, you opt to pay unexpectedly high when you’re looking for quality replacement.

Remember, a power transformer is a priced asset that should offer vital services to an organization for decades. You haven’t paid such a hefty amount for your power transformer, only for it to break down within a few years! And, the price you have paid is not only for the transformer, but also for its installation and maintenance, so that you have a longer, efficient, and useful transformer life. And now, because you hadn’t made a right decision earlier, you are to pay an excess of all those charges again! But this time, don’t repeat the same mistake. Don’t just opt for any transformer that works fine just as of now, but instead, invest in power transformers in India that will prove to be long-life assets. We won’t say that you opt for a high-priced transformer because a high price means reliability. We also won’t say that transformers are any low-priced product. It certainly takes a good amount of money to manufacture a transformer, which is why the price. But, to be able to make the right choice, you need to invest in a transformer with the highest ROI.

Choosing the right transformer

An initial higher or lower cost does not actually help in making a decision. A product with a higher price is not always reliable, and a product with a lower price is not always low in terms of quality. What you need to investigate is whether the difference between two different initial purchase prices is an avoidable cost or a good investment opportunity. Two manufacturers may use the same materials, the same design, and the same manufacturing methods, yet have different selling prices. Why is that so? Well, the difference in costs is from the difference in business strategies and choices. While there is nothing that we can comment on for other manufacturers and suppliers, but we can certainly guarantee that the power transformers in India, manufactured at Miracle Electronics, are made with the best strategies and sold at the most reasonable prices. Here’s telling you why you should believe us.

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UNDERSTANDING CORES, CHOKES, AND LOSSES

Electric current, when flowing through a conductive material, generates a magnetic field, that which is strongest at the conductor’s surface, and weak farther from the conductor. Magnetizing a core material won’t stop it from having a magnetic charge when you stop magnetizing it. Instead, if you want to get it back to zero magnetization, you will have to reverse the magnetization. This is what is called the hysteresis loop, which occurs when alternating positive and negative magnetic fields are applied to the material.

Understanding the hysteresis loop

The magnetization force depicted by the symbol “H” is the magnetic field that is applied on the magnetic core material. And, the magnetic flux, depicted by the symbol “B”, is the total magnetic field flowing through an area, the intensity being referred to as flux density. The hysteresis loop is this B-H curve, analyzing which is very important when designing transformers, inductors, and chokes.

What elements alter the magnetic flux?

The area of the core, the number of turns, and the switching frequency are all important factors that alter the magnetic flux. If the core area, number of turns, and switching frequency are increased, the flux will decrease. Also, greater the core material’s permeability, greater is the flux density.

Designing a transformer, inductor, and choke

While designing an inductor or choke, you don’t want to cause saturation of the core by increasing the AC or DC current. The DC current is what generally saturates the core, as it’s constant and moves the core to a certain flux level. Yet, you need to always ensure that the maximum AC current is also well below the saturation point. Saturation can also be reached by increasing the flux density, normally by increasing the voltage. The core material’s permeability also impacts the saturation. High permeability saturates the core faster, and low permeability saturates the core at a higher flux density.

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