Copper Clad Cables Or Solid Copper Cables – Which Are Better - Miracle Electronics

Cables are a very tiny, yet very important parts of any electrical application. We often neglect the cables we use, but we fail to understand that it is the quality and type of cables that we use that decides on the performance of the entire application. While the quality of cables can be obtained by partnering with genuine and reliable cable harness manufacturers in India, the type of cables you need is for you to decide upon.

There are two basic types of cables you could use – copper clad and solid copper cables. So, which one of the two is better suited for your particular application? Both these kinds of cables are different from each other, and you must know what you must choose in order to maintain data integrity and have a reliable performance.

Copper clad cables – What they are

Copper clad cables are available as either copper clad aluminium or copper clad steel. This means that the conductor is made either of aluminium or steel, with a coating of copper wrapped around. So, these are not 100% copper cables.

Advantages of copper clad cables – One reason why such copper clad cables are used instead of solid copper cables is their light weight. With copper conductors being replaced with aluminium or steel, the weight of the cable reduces, which makes it apt for lightweight applications. Another benefit is that copper clad cables are less expensive because of the inner copper portion being replaced with aluminium or steel.

Disadvantages of copper clad cables – There is one drawback with copper clad cables. These cables are effective over short distances and for sending lesser amounts of data, unlike their counterparts, where data can be sent through longer distances without any kind of signal problems. When the distances are longer in the case of copper clad cables, there are issues with signal integrity, which then requires multiple signals to be sent to reach the end point.

Solid copper cables – What they are

Solid copper cables are 100% copper, with the conductor being made of copper, as well as the coating being of copper.

Advantages of solid copper cables – The two biggest benefits of using solid copper cables are durability and flexibility. Such cables easily bend back and forth, thus making it easy to shape and form them. In addition, copper conductors perform undoubtedly well. Another benefit with solid copper cables is that they are ideal for transmitting signals over long distances, with no issues in signal integrity. They excel in transmitting high levels of data over longer distances, with minimal current required to push the signals all the way through to the end.

Disadvantages of solid copper cables – There is just one drawback with solid copper cables, and that is their heavy weight. But, the performance and durability covers up for that.

So, what’s your choice?

You can determine the pros and cons of each cable to identify which one is more suited for your application. Consider the weight, cost, distance, durability, and data load of both, and decide as to which aspects you can compromise on, and which not. Accordingly, you can decide on purchasing the copper cable that you require from Miracle Electronics, the most reliable cable harness manufacturers in India, where you can have any and all kinds of cables manufactured. Whether you choose off-the-shelf products, or have your cables customized , you can rest assured to have products that are certified and approved by DGAQA and MSQAA for platform specific applications.

EAF Transformers – Why & Where Are They Used - Miracle Electronics

EAF transformers – The name may make you think about them to be complex transformers with a complicated functioning. But, they aren’t so complex. EAF transformers are Electric Arc Furnace transformers that are generally used with electric arc furnaces or ladle metallurgy stations to transform high-voltage low-current electrical power to low-voltage high-current electric arcs inside an EAF furnace to melt scrap steel. The scrap steel is exposed directly to the electric arc produced by the EAF transformers inside an electrical arc furnace to temperatures up to 1800°C. 

These transformers help in maintaining a perfect balance in the electric circuit, as a lot of charge accumulation in one portion of the circuit can lead to load shedding or wearing down of the device. This advantage and functioning of an EAF transformer is what helps it to be used in a number of applications, such as in gas factories, steel plants, and in industries manufacturing calcium carbide.

Benefits of using an EAF transformer

There are a lot many benefits of using an EAF transformer, some of the advantages being mentioned below.

ü EAF transformers are industrially manufactured devices, each unit being sold by registered dealers, who procure complete details of the customer before making the sale. This is because these EAF transformers are highly expensive, which is why you must always purchase from a leading transformer manufacturer in India, to ensure safety and the guarantee of making a right purchase.

ü The details of EAF transformer manufacturers are always available online, which makes it easy to track them down. This means there is no possibility of any unscrupulous practices, which is why these industrial devices are rarely mishandled, thus saving you from any such problems, as you can be sure you’ve made a legitimate purchase.

ü An EAF transformer is manufactured with the help of machines, and each component is made by expert manpower, which means you can expect a strong-built device at your service. This means there is completely durability. And, if you purchase from a genuine transformer manufacturer in India, one like Miracle Electronics, you can rest assured of having the best after sales service too.

Applications of EAF transformers

Gas factories – Electricity is used in gas factories to perform the process of catalysis, that is, combining or breaking down the components of a gaseous mixture, which cannot be achieved by normal processes of applying heat and pressure. EAF transformers are useful to carry out such specific reactions.

Steel plants – Steel plants require melting of iron at high temperatures, and a sturdy furnace that can help them achieve a large amount of heat, which can liquefy the iron, so that the various components can be formed from it. This is where EAF transformers can help.

So, whether your application is that in a gas factory or steel plant, or even in an industry that manufactures calcium carbide, you can rely on EAF transformers to easily and effectively carry out your power transformations from high-voltage low-current electrical power to low-voltage high-current electric arcs inside an EAF furnace.

 

Where And Why Are Isolation Transformers Used - Miracle Electronics

Isolation transformers are one of the most unique types of transformers  used in the industrial sector in machineries. These are transformers that transfer electrical power from a source of AC power to an equipment or device, while isolating the powered device from the power source for safety reasons. They provide galvanic isolation with no conductive path present between the source and load; the isolation used to protect against electric shock, and to suppress electrical noise in sensitive devices.

Applications of isolation transformers

Sensitive equipment – Isolation transformers block the transmission of the DC component in signals from one circuit to the other, while allowing AC components in signals to pass. And, there is special insulation between the primary and secondary windings, specified to withstand a high voltage between them. These characteristics make isolation transformers ideal for use in sensitive equipment like medical devices, laboratory instruments, and computers.

Pulse circuits – Certain small isolation transformers are used for isolation in pulse circuits.

Electronics testing – Isolation transformers are used in electronics testing equipment to avoid exposing live metal in a device under test, which may otherwise prove hazardous because of the high voltage. When isolation transformers are used, there is no conductive connection between the primary and secondary windings, which results in a very small leakage current flow if the exposed live metal is connected to the earth.

Equipment at elevated potentials – Isolation transformers are used for the power supply of devices that are not at ground potential; for example, radio antenna masts. Without the isolation transformers on such masts, the lighting circuits would conduct radio-frequency energy to the ground through the power supply.

Benefits of using isolation transformers

Voltage control – Isolation transformers have their primary and secondary windings isolated from each other; thus reducing the electrical noise between them.

Impedance matching – The low voltage side of a transformer has low impedance, while the high voltage side has high impedance. Isolation transformers can generate superior impedance matching of a critical load to an electrical circuit. And, internal low impedance isolation transformers can create complete isolation from the input AC line.

Other benefits – There are many other benefits that an isolation transformer can provide, such as continuous filtering of power line noise, reduction of electrical surges, removal of neutral-to-ground voltage and noise, improved reliability, and lowered costs.

With all these benefits, you can have isolation transformers installed in a variety of different critical applications, may it be laboratory equipment, hospital equipment, sensitive equipment, electronics testing equipment, diagnostic testing equipment, telecom, and equipment related to transactions. No matter what your application, you can get the best quality isolation transformers by partnering with Miracle Electronics, the most reliable and genuine isolation transformer manufacturer in India. Here, you’ll get only RoHS and REACH compliant transformers that adhere to UL 60601-1 standards, in terms of minimum enclosure leakage current, limited maximum earth leakage current, minimum temperature rise at load, maximum high voltage test between windings, excellent creepage distance, and excellent air distance.

Designing Reliable & Cost-Effective Cable Assemblies – The Golden Tips - Miracle Electronics

Reliability is of utmost importance when it comes to any electrical device, because such devices may experience electrical surges, and may be highly sensitive too. This brings to us the importance of reliable cable assemblies too. It is only the cable assemblies that can help in keeping the devices protected against such surges or any other environmental issues. Moreover, reliable cable assemblies can help transfer signals effectively from one point to another. It is thus absolutely important to have reliable cable assemblies for your application.

But, the facet of reliability may also bring a surge in the costs, isn’t it? That certainly goes without saying. However, you “NEED TO” find a way to have reliability and cost-effectiveness clubbed together. And for this, you need a genuine and reliable manufacturer. Miracle Electronics is one of the most reliable cable assembly manufacturersin India you can trust to help you with genuine reliable products, without being too heavy on your pocket. Let’s help you know what makes Miracle Electronics’ products so reliable, yet cost-effective.

The factors to consider

It is important to understand that minute attention needs to paid to every facet like the type of wire, the type of connector, the type of jacketing, the placement of cable ties, the overall tolerance, etc. All these aspects play an important role in determining the material costs, manufacturing costs, and long-term reliability of a cable assembly. Below are a few things, which need to be carefully considered, or else they may add unnecessary costs and complexities to a cable assembly.

The type of insulation

PVC insulation is less expensive and also easier to work with in the manufacturing process, as compared to other materials like Teflon. Hence, whenever possible, PVC insulation should be chosen to save on costs.

The type of external protection

You may either jacket or shield your wires. Both these types provide excellent external protection, but shielding proves to be more expensive as it requires additional labour to install terminals and connectors, thus adding to the costs.

The type of contacts

Soldering contacts require a very high degree of trained operations and labour time, which makes them more expensive as compare to crimped contacts. Crimped contacts should thus be chosen when you want to save on costs.

The type of tie wrap

The type of tie wrap, and the number of tie wraps required, determine the costs involved. Tie wrap prices vary from manufacturer to manufacturer, and the labour involved; so choose your tie wrap and manufacturer wisely.

The tolerances

Designers generally take the safe path of using tight tolerances on cable assemblies. But, tight tolerances are actually unnecessary. The tighter the tolerances are, the more difficult it becomes to manufacture the assembly; thus making the end product more expensive.

These are just a few things, which when considered, can significantly impact the overall cost of an assembly. But, you must make it a point to partner with genuine cable assembly manufacturers inIndia, who can help you not only save costs , but can at the same time also provide you with the right kind of product.

Toroidal Transformers – The Making, The Working, And The Advantages - Miracle Electronics

Toroidal transformers that are so widely used in a variety of applications like home appliances, automatic control equipment, audio equipment, telecommunications, medical equipment, and more, have so many benefits over other transformers because of their construction and working. Let’s take a look at the making and working of a toroidal transformer that brings with it so many advantages.

The construction of a toroidal transformer

ü The core of a toroidal transformer is made of high quality cold-rolled silicon steel sheet with a thickness generally below 0.35 mm, which is seamlessly rolled to have the core perform better than other traditional laminated cores.

ü Then, the coil is wound around the core. The primary is first wound; a high quality high strength enameled wire with a diameter similar to the original wire is taken and double-wound on the I-shaped wire shuttle. The double thread head is then adhered to the outer circumference of the ring shaped core with double-sided tape, and the thread shuttle is wound in the inner circumference of the core. This first layer is insulated, after which a second layer is then wound over it.

ü After winding, the heads and tails of the two coils are connected to make them in series; and the other two wires are soldered out with a soft wire and insulated. After all the windings and insulation are done, the transformer is let to dry well.

The working of a toroidal transformer

With the primary and secondary coils wound around the toroidal core, the current that flows through the primary induces an electromotive force and a current in the secondary, thus transferring power from the primary coil to the secondary coil. The coil wound around the core produces a magnetic field whose direction is almost completely coincident with the core magnetic circuit. It is the unique shape of the transformer that  allows for shorter coils, reducing resistive losses or winding losses, and improving overall efficiency.

The benefits of a toroidal transformer

ü Compact and lightweight – The construction of a toroidal transformer makes it compact, and also lighter in weight. A toroidal transformer is in fact almost half the weight of other traditional type transformers.

ü High efficiency – The electrical efficiency of a toroidal transformer can be as high as 95%, or even more, with the no-load current being only 10% of other laminated-core type transformers.

ü Less magnetic interference – With no air gap in the core of a toroidal transformer, and the windings evenly wound around the core, the magnetic leakage is absolutely small, thus resulting in a very low electromagnetic radiation too. This particular property makes toroidal transformers ideal for usage in high sensitive electronic and medical equipment.

ü Lesser noise – Toroidal transformers produce very less noise with a wider frequency response, thus improving the sound quality of a power amplifier.

With all these performance and benefits, don’t you want to install a toroidal transformer into your premises or application? Then, hurry up and get in touch with experts like Miracle Electronics, one of the most experienced and reliable  toroidal transformer manufacturers in India, who have the understanding and skill of manufacturing transformers for almost every industry and requirement. You can also have customized transformers made depending upon your industry, application, input voltage, output power required, installation method, size, and any other special requirements.

Which Transformers Are Best For Electrical Isolation In Medical Devices - Miracle Electronics

 With a multitude of transformer options available, identifying the best one out of the lot becomes difficult, for every individual application. And, the application that we are going to speak about in this blog is a critical one – medical devices. No kind of fault can be afforded in the case of medical applications. This is why only the most ideal kind of transformer that can offer safety and protection against electrical surges should be used. So, which one is it?

Toroidal transformers is the answer. Toroidal transformers are ideal for electrical isolation in medical equipment as they are compact, have low stray fields, and can be encapsulated when required. Hence, these transformers are less likely to cause electromagnetic disturbances. Isolation is when two parts of a circuit are physically and electrically separated, which is achieved by using electromagnetic field coupling between the two circuits. Isolation provides several safety advantages like breaking ground loops, improving common-mode voltage rejection, and permitting the two parts of the circuit to be at different voltage levels. For an isolation method to be safe enough for use in medical equipment, it needs high-integrity isolation components and a safe insulator barrier. The three most commonly used isolation methods include transformers, capacitive couplers, and optocouplers. But, in this blog, we will focus on the use of transformers to electrically isolate medical equipment.

A transformer transfers energy between two or more circuits through electromagnetic induction. They increase or decrease the voltages of alternating current in electric power applications, by passing a varying current through the primary winding to generate a magnetic flux in the transformer’s core, which in turn induces a voltage in the transformer’s secondary winding.

Toroidal cores are made form a continuous strip of silicone steel wound like a tight clock spring, with the ends tacked into place with small spot welds to prevent the coiled steel from unwinding. The core is insulated with an epoxy coating or a set of caps or multiple wraps of insulating film. The transformer’s windings wound around the core require additional insulation to be isolated. However, the construction of a toroidal transformer is very labour-intensive. But yet, these transformers are preferred more than any other transformer because of its performance. With the continuous strip of steel used in the core, the transformer becomes smaller, lighter, more efficient, and quieter than other kinds of transformers. These qualities are the most apt for sensitive medical electrical equipment; and clearly justify the additional expense.

Thus, to conclude, toroidal transformers are ideal for electrical isolation in medical equipment. So, if you are looking for the perfect transformer for your application, just get in touch with Miracle Electronics, a reliable and reputed medicaltransformer manufacturer in India, who can provide you with the most ideal toroidal medical isolation transformer . And, you can rest assured about the quality of transformers you will get here because every medical isolation toroidal transformer you’ll get will be RoHS and REACH compliant, adhering to the regulations under UL 60601-1 standards.

Preventing Water Ingress On Electrical Assemblies - Miracle Electronics

What happens when water and electricity come together? Obviously, it’s a very dangerous combination! Water is an excellent conductor of electricity, so if you’re probably in touch with water, and electricity comes in contact, you’ll probably be electrocuted!

But, you may have also seen heavy equipment used in environments where water is present. How is it that such equipment is protected against water then? What about the electrical cables and harnesses present within? Is it not affected in the case of water ingress? Obviously, when water comes in touch with the cables and harnesses, the consequences can be deadly! There could be electrical shorts, malfunctioning of the equipment, shock hazards, fire, or even death, in case of a high voltage application!

No matter what the outcomes of water ingress into the harnesses, it is absolutely important that the water ingress is prevented. But, how is this possible? Let’s take a look.

Understanding the working environment

The first step to preventing water ingress is to understand the type of working environment the equipment is to be used in. Will the equipment be completely submerged into water while in operation, or will it be rained upon? This information will help you use appropriately rated components in the design. That’s because different environments require varied levels of protection. This is where IP codes come into play, which are two-digit numbers that indicate how resistant components are to intrusion by solid particles and liquids. It is important that appropriate IP-rated components are used that meet or exceed the requirements of the working environment.

Other tools and tips

Other tools and tips that can help prevent water ingress are stated below.

ü Overmoulding can help protect small electrical components like resistors, capacitors, diodes, and PCBs.

ü Gaskets can seal the junction where multiple surfaces meet, used typically to help make something that wasn’t designed to be watertight.

ü Sealed connectors and cord grips can protect electrical enclosures from water ingress.

ü Installing hinges outside the gasket of an enclosure can prevent compromising the gasket’s integrity.

ü Leaving a small gap between the conduit and connectors can help liquid/water to escape.

ü Using braided looms on wire harnesses can help liquids flow through, instead of getting trapped inside the conduit.

ü RTV silicone can be used as a seal for small volumes.

Preventing water ingress on wire harnesses is important to protect the equipment from failure, and humans against shock or other serious consequences. Getting in touch with professional wire harness manufacturers in India, like Miracle Electronics, can help take care of all of the above, thus bringing to you protected and safe wire harnesses for all your equipment and environments. Every wire harness manufactured here is certified for quality to ISO 9001, AS9100C; and the quality of the cable looms and harnesses are certified and approved by DGAQA and MSQAA for platform specific applications. Moreover, ever wire harness manufactured here is tested for dimension, weight, continuity, pull test, and many other verifying processes that ensure compliance to environmental requirements.