How Are Copper Wire Cables Tested - Miracle Electronics

Copper wire cables are a very small part of any electronic application, but that doesn’t mean they are insignificant. In fact, they are one of the most important parts of a circuit that connects different parts and sends power or signals to them for an effective functioning. And, this is why it is highly crucial that these wires and cables are of the best quality. For this, one, you need reliable and experienced wire harness manufacturers from India, who make only genuine high-quality wires with no compromise; and two, you need thoroughly tested wire cables that ensure zero faults. Although a genuine manufacturer will himself test every product before delivering it to you, yet we put it up as a different point to bring to your notice the importance of testing.

Tests done by the manufacturer

There are a variety of different tests that are done on copper wire cables to ensure best quality and perfect functionality.

Continuity test – This test allows to check for solid wire connections within the cable. Multimeters are used to check this by measuring the current, voltage, and resistance of the circuit.

Resistance test – This test helps measure the voltage and current resistance within a cable, which can then be compared to the expected cable performance to reveal how well the cable is performing. An ohmmeter is used for this purpose, where it passes a small current through the cable and measures the voltage drop.

Isolation test – This test uses low voltage power to help see how well isolated the wires within the cable are. A megohmmeter is used to measure current leakage with a low voltage.

Shorts test – This test uses high voltage power to help find any shorts within the cable, which is not revealed when low voltage is used.

Miracle Electronics tops the list of wire harness manufacturers from India, who makes sure to conduct all the above tests and more to ensure high quality and high-performance wires and cables before delivering the same to clients.

Three tests after purchase

While your manufacturer should have done all the above-mentioned tests already, there are three other critical tests that should be done after the purchase. One is to be done during the installation, second during having it to perform the first time, and third is during frequent maintenance procedures.

During installation – You must check for any damage during transit, and ensure that the cables are working, upon installation.

When functioning first time – Once you install the cables, turn on your application and thoroughly check for any interference or problems. The cables must be compatible, and must seamlessly interact with the software and other elements involved with the application.

Frequent maintenance procedures – You must carry out maintenance procedures periodically to check if the integrity of the cables have been compromised after a set period of time, or following peak load times.

With all the above tests, you can ensure quality performance and safe procedures within the space where the application has been installed.

 

Cables And Wires For Medical Applications - Miracle Electronics

When looking to satisfy medical applications, you need a perfect manufacturer  that has a great experience of manufacturing cables and wires for such sensitive products. They must have a thorough understanding of the particularly rigorous standards and regulations that apply to the medical industry. After all, you’ll need only the highest quality cables and wires in the market, suitable for all kinds of medical applications like diagnostic equipment, laboratory equipment, treatment equipment, lighting systems, automation devices, and more.

Diagnostic equipment

Medical diagnostic equipment and imaging equipment like MRIs, PET scans, CT scans, X-rays, and ultrasounds are critical for the diagnosis and treatment of patient injuries and ailments. And, all such critical equipment requires high-performance and reliable wiring connections so that information can be transferred accurately and in a secured manner.

Laboratory equipment

Laboratory equipment like life support equipment, dialysis machines, ventilators, anesthetic dispensers, and more require cables that can ensure accurate measurement, monitoring, and analysis of patient health. These equipment are highly sensitive and critical, used to help medical professionals examine body fluids for signs of disease or infection.

Treatment equipment

There are a variety of tools that are used in the medical industry for treating a variety of health problems; for instance, surgical lasers, medical infusion pumps, and LASIK equipment, to name a few. All these equipment, as well as the operating tables must be equipped with reliable cables and wires to ensure appropriate positioning of the patient during sensitive procedures.

Lighting systems

When any kind of treatment is being executed, may it be a simple LASIK operation, or a significant heart operation, nothing can be executed successfully without the use of extremely bright lighting. And, for such bright lighting, it is important that extremely reliable and durable wires and cables are used that can withstand high power levels, and also extreme temperature fluctuations.

Automation devices

Automation is becoming more common in medical practice today to provide medical practitioners with accurate, quick, and efficient procedures. But, to be able to make the automation precise and reliable, data cables that receive and transmit instructions, and also sensor cables that transmit critical information to the operating system in real time, need to be efficient as well as have the ability to withstand all kinds of bends, turns, and other motions.

These are just some of the medical applications that use wires and cables of various types. There is so much more than the healthcare industry calls for. But, no matter what the application or requirement, every medical equipment and process requires efficient, high-performing, durable, and reliable connections. You thus need high quality cables and wires; and for that to be possible, you need experienced and trustworthy wire and cable manufacturers. Miracle Electronics is one of the best cable and wire harnessmanufacturers from India, where you can get not only all of the above, but also customized engineered solutions, tailored to meet your particular needs at the premises that is designed to create cable and wire products that meet the most stringent industry standards.

 

Copper Wires _ Benefits & Applications - Miracle Electronics

 Copper is a very common metal used in all kinds of electrical applications, because it is considered as one of the best materials for conducting electricity. Today, the material is used in electrical wiring for both domestic and industrial use in a variety of applications like electronic circuitry, home appliances, telecommunications, etc. In fact, half of all the copper that is mined today is used to produce wires and cable conductors! Copper is thus a versatile metal of the future.

What makes copper so popular and admired?

Copper possesses excellent electrical and thermal conductivity

Copper has the best know electrical and thermal conductivity, better than any other conducting metal. It has the least resistance to conduction, hence it can be used in even the highest conductivity applications like lightning rods for safety measures in buildings and skyscrapers.

Copper has great tensile strength

Copper has excellent tensile strength and can also resist a number of mechanical failures like stretching, breaking, necking, etc; thus achieving so much of admiration.

Copper is highly malleable and ductile

Copper is a very highly malleable and ductile metal, which makes it very easy to draw it into wires, strips, and strands. This is why copper finds so much admiration in the applications of wiring.

Copper can be easily soldered

Copper wires can be easily soldered to form connections, making connections easy for transmission and termination points. Moreover, the excellent strength that copper possesses makes it possible to pull it through different areas, and even tiny tight spaces to lay conduits.

Copper has good corrosion resistance

Copper’s great corrosion resistance makes it one of the best metals to be used for electrical transmission. Its low reactivity series does not let it corrode, thus making it an excellent choice to be used in wires.

Copper has excellent creep resistance

When a metal expands and contracts under certain cyclic load conditions, the deformation that results is known as creep. When there’s higher creep, a screw can deform a conductor and reduce contact pressure, which leads to resistance in joints, loose connections, oxidation, and overheating. But, copper has an almost negligible creep, making it the best metal to be used in a wire.

Types of copper wires

With the amazing properties that copper possesses, it now becomes clear why the metal is so popularly used in wires and cables. But, did you know that there are a variety of different copper wires available for you to choose from?

Solid copper wire – This is a single copper wire, bare or sheathed , in an insulating cover, used to transfer electricity.

Stranded copper wire – This is when numerous thin copper wires are wound together to form a single wire.

Copper cable – When copper wires are twisted, braided, twisted, or woven into a single assembly, a copper cable is produced.

We’ve learnt all about copper wires and cables, and how they are such a great choice. But, it is essential that you rely on a genuine copper wire manufacturer to ensure that you get good quality and unadulterated copper wires that are proven and certified. And, MiracleElectronics tops the list of the most reliable and trustworthy wire harness manufacturers from India, where you can get all kinds of wires and wire harness, customized to your specific needs, each being high on quality and certified for production processes.

Choosing Heavy Duty Connectors For Cable Assemblies - Miracle Electronics

 Designing cable assemblies for use in harsh environments poses a number of challenges, especially those that need to be used in industrial equipment that may be subjected to conditions like high temperatures, high humidity, water, chemicals, electromagnetic interference, vibration, impact, or particulate ingress from close proximity to moving factory components. Over time, exposure to such components starts to hamper conductivity, requiring repairs or replacements.

To avoid all such hassles and inconvenience, it is advisable that you choose to install heavy duty connectors for the cable assemblies that are to be used in applications that need to withstand one or more of the conditions and environments mentioned above. So, here’s a guide that can help you choose the best quality heavy duty connectors for your application.

The housing material

A die-cast aluminum housing should be the best choice as these are light weight yet highly impact resistant. However, if your application is to be used in wet environments, plastic connectors should be a better alternative as they won't rust or corrode. And, if your application is too small with tiny spaces, you can choose materials that provide EMI shielding instead.

The insert types

Heavy duty connectors with pluggable inserts that carry power, data, or signal to and from factory equipment have been traditionally used. But today, modular inserts that support an integrated hybrid cable assembly are more popularly used. Heavy duty connector systems need to meet the demands of the hybridization trend, which is why more and more customized cable assemblies are being preferred. And, with such customizations, modular connectors are more popularly used as they provide an integrated hybrid assembly that creates new considerations for power and signal wiring beyond the fundamentals of approval ratings, clamping type, and wire guage. The various insert types that you can choose from include fiber optic, pneumatic, D-sub, USB, M12, and RJ45.

The ratings and standards

IP ratings depict the level of protection that an electrical enclosure provides against solids and liquids, and NEMA ratings describe the environments where the enclosure can be used. You need to choose from such ratings, or buy standardized connectors to ensure their quality and performance.

The manufacturer

You need to choose the right cable assembly and connector manufacturer too; one that has experience, knowledge, skill, and expertise in the field. One such cable assembly manufacturer in India is Miracle Electronics, a contract manufacturer that is tooled for majority of industries such as electronics, aerospace, audio, and medical. You can have all kinds of cable assemblies manufactured here, some of them being EMI shielded assemblies, flat assemblies, ribbon assemblies, RF assemblies, airborne looms, military looms, and power cable assemblies. You can also have circular, D-sub, military specific, and many other kinds of connectors built here too. And, whatever kind of cables, assemblies, and connectors you have customized with Miracle Electronics, you can rest assured about the quality you’ll receive because every production process executed here is certified for quality to ISO 9001, AS9100C. Also, every product manufactured here is certified and approved by DGAQA and MSQAA for platform specific applications, after undergoing all kinds of tests for dimension, weight, continuity, Hi-Pot, Pull, and environment compliance.

Why Should Industrial Bus Cables Be Standardized - Miracle Electronics

The two main sectors for series data cables are computer bus and industrial bus; the former being a communication system that transfers data between components inside or between computers; and the latter being a communication system that transfers data between components or devices at different levels in a manufacturing plant. But, it is the computer industry that has had greater success in achieving unbiased industry-wide standards, while the industrial sector is more independent, and can produce cables specifically for their brand names.

In the industrial world, there are a number of variations due to different speed and impedance requirements, ranging from 100 to 150 ohms. Moreover, manufacturers may design a hybrid cable for automotive manufacturing plants with components using PROFINET, INTERBUS, and Industrial Ethernet protocols, all in one cable; allowing them to connect their PLC logic to whatever control line happens to come on the next machine.

Protocol standardization

Industries are looking for open architecture interface as the need for plant-wide system compatibility increases. Ethernet protocol of 100 ohms seems to be a good choice in this case. Higher information speed requirements, diagnostic feedback of controls, and interest in motor feedback make Ethernet a great choice to offer the performance required. However, these requirements are still driven from the controls manufacturers’ system trademark, some of them being PROFINET, CC-Link IE, Industrial Ethernet, and Foundation Fieldbus HP. Yet, many independent special interest groups have started to come up and work for system compatibility of conventional Ethernet. One such example is Ethernet POWERLINK Standardization Group that has developed a formidable product offering with data transmission speeds of 100 Mbit/sec; and is waiting for component manufacturers to adopt their standard Ethernet protocol into their systems.

Connector standardization

The standardization of connectors is also being accepted as major device dealers are settling for metric-type connectors like M-8, M-10, and M-12. RJ45 is also used, but it is modified to provide larger gauge compatibility, harsh environment resistance, and shielding capabilities.

To conclude

As you can see, Ethernet-based architecture is becoming an accepted choice for serial bus networks, since the compatibility and standardization of Ethernet from the computer side, found in front office, drives the manufacturing side to generic products. However, the marketing side of the controls industry still continues to manufacture proprietary products, developing cable requirements that are exclusive to the brand. Having such a diversity of protocols allows cable manufacturers to offer a lot many different cable systems. Also, each architecture has a unique conductor configuration and electrical requirements.

From past to present

The goal of various bus protocols and designs developed over the last 50 years was to find a cable capable of fast computer speeds that could withstand electrical noise and harsh environments. To accomplish this goal, technology is advancing to produce fiber optic cables, which is more suited to these requirements.

Whatever kind of cables you’re looking for – basic or fiber optic – Miracle Electronics is where you should be. These are the most dependable and versatile wire harness manufacturers from India, manufacturing a variety of different types of cables and harnesses for a myriad of applications and industries. You can also get in touch to design the perfect customized cable harness for your requirements.

HDI PCBs _ Why And Where To Use Them - Miracle Electronics

As we’re all shifting more and more to studying, working, browsing, and shopping online, after the pandemic has struck us, our world is becoming even more dependent on digital technologies. Moreover, the digital world today is becoming even more complex; but the hardware associated with it is becoming smaller. For instance, PCBs are becoming smaller with more interconnections. This makes the applications they are used in sleek and lean. And, if they are portable, it becomes really convenient to carry the devices around.

The PCB industry plays a significant role in the development of all electronic gadgets that our lives revolve around today. And, to make it simpler and easier, PCB manufacturers are always coming up with newer trends; one such innovation being the HDI PCB, which is a smaller PCB assembly from India that is dense with high component count.

What is HDI PCB?

HDI PCBs are smaller PCBs with a high density component count, and thus more number of interconnections, but those that occupy lesser space. Although the components are placed very close to one another to reduce the size of the board, the functionality isn't compromised. The general HDI PCB is one that has an average of 120 to 160 pins per square inch, and a dense circuitry that is implemented through microvias, buried vias, and blind vias.

What are the advantages of HDI PCBs?

HDI PCBs offer many advantages over regular PCBs, some of them being a compact design, lighter weight, and great performance. In addition, the signal path length is reduced as the components are placed very close to one another, and the reflections of signal are reduced, which results in remarkably improved signal quality. Also, the implementation of stacked vias makes these boards a super shield against extreme environmental conditions. All in all, with so many advantages offered, HDI PCBs are extremely cost-effective.

What are the applications of HDI PCBs?

HDI PCBs, because of the benefits they offer, are used in a variety of industries, such as those listed below.

Smartphone industry – With smartphones becoming more of a necessity than a luxury, manufacturers are using HDI PCBs to make these phones even smaller, and thus, conveniently portable.

Automotive industry – Car manufacturers are using more of HDI PCBs to save significant space in the vehicles. Moreover, the integration of smaller and smarter electronic devices provides a better driving experience.

Medical industry – Medical devices manufactured today use more of HDI PCBs when they want to fit into small compact devices like implants, lab equipment, and imaging equipment. In diagnostic devices, miniaturized cameras using HDI PCBs can help get better and intricate picture quality.

Aerospace and military industries – Aerospace and military equipment like planes, missiles, and defense systems use HDI PCBs that can function better in extreme environments and hazardous conditions.

Wearable technology industry – Wearable devices like VR headsets, watches, and many others use HDI PCBs to make the devices sleek, while offering exceptional functionality.

You can see how HDI PCBs have revolutionized almost every industry today with usage in a variety of devices and applications. This has increased the demand for such PCBs. You may also opt for such advanced and improved PCBs to fit into your smaller and smarter products. You can choose from readily available PCBs or have your PCB assembly from India especially customized as per your requirements at Miracle Electronics, the leader in manufacturing a variety of PCB assemblies since more than a decade now.

  

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

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

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

Advantages and disadvantages of using SMPS transformers

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

Types of SMPS transformers

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

Materials used

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

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

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

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