Why Approach A PCB Manufacturer For Box Build Manufacturing - Miracle Electronics

The PCB is a very tiny, yet most important piece of equipment, that makes every electronic device on the earth function as expected. And, to make this very tiny piece, it takes a lot of time and effort. The board has to be manufactured, the cables and harnesses built, and different sub-assemblies connected together to make one complete system. It may take hundreds, at times thousands, of tiny components to bring together one single board, which may make it very overwhelming for designers to form the perfect picture. But, there are some experts who can do the job just right; someone like Miracle Electronics, who has a skilled engineering team and facilities equipped with the latest technologies to ensure optimal and cost-effective production of even the most complicated and dense PCB assembly from India.

At Miracle Electronics, you can have the best quality PCB assemblies built using standardized procedures that translate unique customer requirements into production, every piece thoroughly tested for consistent quality performance; no matter what the size of the project, whether low, medium, high-mix, or high. Furthermore, they are also skilled at offering box builds, a complete package for innovative products, offering designs and finishing services for surface mount, through hole assemblies, cable manufacturing, panel wiring, and complete cabinet assemblies, with the help of dedicated lean manufacturing techniques in every operation. Why we say this is because outsourcing a box build assembly  to a PCB manufacturer can definitely help you in many ways, three most advantageous benefits mentioned below.

Hassles are reduced

Building a box build requires a lot of equipment like PCBs, cable assemblies, power supplies, control panels, and more. This means, if you want to take up the task on your own, you need to be associated with multiple vendors who can provide you with such different stuff. But, working with multiple vendors is a lot of hassle. It requires strong coordination and effective communication to manage everything, because one wrong vendor can result in an unlikely outcome. On the other hand, if you put the task on the shoulders of a reputed PCB and box build assembly manufacturer, they’ll make sure that the final circuit board fits in all the interconnecting wires and cables, working together with the other components.

Unnecessary overheads are eliminated

Having multiple vendors not only adds hassles and errors to the process, but it also increases the overhead costs. Passing on the equipment from one vendor to another, procuring the same at every step, and delivering it to another involves lots of time wastage, as well as additional expenses. Working with a single specialist can eliminate the expenses involved with operating and procuring the equipment from each vendor; thus making it easier and cost-effective, with no time delay.

Performance is guaranteed

The performance of a box build depends upon how well the components fit and work together. There are a variety of different components that needs to be designed and assembled in a box build to work together. And, a plan in place is very essential for the same. Different vendors handling different aspects of the process could cause hindrance in the plan. One wrong connection or component could result in an ineffective or faulty performance. The best way to eliminate such errors is by having one professional handle the entire task, from the beginning till the end. There will be no planning and communication issues if one specialist handles the task.

To conclude, teaming up with a professional PCB manufacturer who knows the A-Z of box build manufacturing is a wise decision. You could have your PCB assembly from India, cable assemblies, and every other component manufactured and connected effectively with one single specialist; and get the anticipated outcomes!

What Causes PCB Warpage & How To Avoid It - Miracle Electronics

Imagine, you receive a PCB package, but when you place it onto your application device, you realize that it doesn’t fit into the flat space available! Can you envisage how annoying and bothersome that may be! The reason behind such a scenario is board warping, the unintended change in the geometry of a PCB. A warped PCB is thus an altered PCB, regardless of the shape it forms into, such as bow, twist, etc. In short, a warped PCB is one that does not sit accurately on a flat surface.

What causes PCB warpage?

There are several reasons that could cause PCB warpage, but there are two specific causes – one of them could be layout-related, while the other could be process-related. If the PCB is warped before the beginning of the assembly process, the problem lies between the layout and fabrication. But, if the PCB was flat earlier, and warped after assembly, then the problem lies between the fabrication and assembly.

Design issues causing the warpage – There could be certain design issues that may contribute to PCB warpage, which need to be first and foremost eliminated, before moving onto the fabrication or assembly process. And, in order to eliminate them, you first need to know the main design contributors; some of them being odd shapes, large cut-outs, a thin board, grouping together of heavy components, and uneven copper pour.

Assembly issues causing the warpage – If polyimide or FR-4 is used to build a PCB, and a stack of such bare boards are stored for some time before assembling, they may absorb moisture from the environment, to eliminate which it is customary to bake them for at least 3 hours at 80-150°C first, and then cool them to room temperature before assembling.

Another reason for warpage in large boards may be related to the orientation as the boards enter the reflow oven. In order to prevent uneven heating between the edge of the PCB and the middle, the larger dimension must be placed parallel to the conveyor of the oven.

Small PCBs are generally grouped together to form panels for more efficient assembling, after which they are separated manually into individual PCBs. The separation takes place by either breaking them away or through V-scoring. In the process of breaking away, most of the material between the smaller PCBs is cut away, leaving them joined by only small lands; and if the panelization is large, the cut-outs could lead to warping. On the other hand, V-scoring is where a V-shaped groove forms the separation line, instead of removing a part of the PCB, which prevents warping of the panel during assembly, while making it easier to separate the boards.

How to prevent PCB warpage?

• Storing the PCBs properly before the assembly process is crucial in preventing warpage. Standing them on their edge cannot guarantee that they will be vertical all the while. Moreover, the combined weight of the PCBs will ultimately cause a camber. It is thus important that the PCBs are stored properly, and horizontally on a flat surface.
• PCBs should be stored in an area where the temperature and humidity is under control, because it is usual for PCBs to absorb moisture from the surroundings. And, where it is impractical to control the environment, desiccants can be used to control the moisture.
• Just like PCB fabricators use heat to form multi-layered boards , re-application of heat to warped bare boards can help straighten them as well. But, this may require heavy-pressing the boards between heated smooth steel plates for 3-6 hours and baking the PCBs 2-3 times.

In order to prevent such warpage in your PCBs, you need to ensure that you get your PCB assembly from India from an experienced manufacture, who knows how to take care of every process involved in storing and manufacturing the PCBs well, such that every PCB is built successfully and effectively.

What Makes Custom Wire Harnesses Easier And Better - Miracle Electronics

When there’s an application that involves a range of electronically operated features and functions, there is certainly some or many wires and cable involved too. And, to make it easier and safer to work with, it’s certainly better to have a few wire harnesses in place, rather than having innumerous wires getting entangled amongst themselves, creating a mess and possible hazards. But, even better is using customized wire harnesses, as compared to readily available off-the-shelf ones. Why? Let’s help you know.

Quality and safety are guaranteed

You never know what kind of quality is used to make regular wire harnesses. But, when it’s customized wire harnesses, you know the kind of quality that is being used. This means there is complete guarantee here. Low quality materials, otherwise, can cause harm to either the application or operator, or both; and this risk you cannot take! With customized wire harnesses, high quality materials are used, thus increasing quality assurance and safety, while reducing risks.

There’s enhanced durability

When you opt to use customized wire harnesses, standard materials are used with better insulation, which means the quality is enhanced, thus increasing the life expectancy. This is one big difference between regular wire harnesses and customized ones. And, this is one reason that has increased the demand for such customized wire harnesses.

Product specifications are met

Customized wire harnesses are tailored to every kind of required specification, such as the length, width, weight, and every other aspect tailored to your requirements. In addition, you could also have your cables jacketed, colour-coded, labelled, or any other feature added as required, for easy identification and better performance or protection. Such added features will certainly add some costs to the final product, but the performance and durability is definitely going to be worth it!

Reliable wire harness manufacturers are guaranteed

Not every wire harness manufacturer can work on customized products. Generally, wire harness manufacturers will be well-versed with working with regular standard wires and cables. It is only experienced and professional manufacturers who will be able to work on specially customized requirements that the products need to be tailored for. Thus, if the manufacturer is accepting your proposal for building customized wire harnesses, you know that he is an experienced one. One such manufacturer is Miracle Electronics who you can completely rely on. This is the manufacturer who is skilled at manufacturing any and every kind of customized EMI shielded harnesses, flat harnesses, ribbon harnesses, RF harnesses, power harnesses, airborne harnesses, military harnesses, and more. Each of these types can be customized based on the requirement of the client, with each product being certified and approved by DGAQA and MSQAA for platform specific applications, and every production process being certified for quality to ISO 9001 and AS9100C. Furthermore, every wire harness is tested for dimension, continuity, weight, pull test, compliance to environmental requirements, and every other test for verifying production processes.

Hence, whenever you are looking for a customized wire harness  of any type, but with no compromise on quality, you can always rely on Miracle Electronics, one of the most dependable and consistent wire harness manufacturers in India.

 

Are Your Cable Harnesses Over-Engineered - Miracle Electronics

When you want your project to be a success, you’re looking for cable harness manufacturers in India, who can provide you with robust cable harness designs and the best quality components that can meet, or even exceed, your requirements. But, what if you don’t have the amount of time that the manufacturers are asking you to give them? Then, you ask them to take up your special case, willing to pay even a little more. 

We have all been there at least one time in our lives, haven’t we? But, when it’s about having your cables manufactured, the budget could go a little higher than expected, when you opt for an urgent delivery. That’s because cable manufacturers will certainly charge a little higher as compared to your other manufacturers like tailors, bakers, or other artisans. So, what do you do in such a situation then? Worry not. Despite of the situation you are in, there are still certain things you can do to bring down the costs into line with your goals.

Work on the design

Design is the first step towards manufacturing. You may have designed an awesome cable harness that can perform well in every kind of situation, but it is this exceptionality that has added even more to your spiked-up costs in case of emergency. So, look again, and see if you really need such an exceptional cable. Obviously, having a well-performing cable harness is a good thing, but you may work it over if its not really needed. For instance, if your cable harness will not need to work in conditions that are exposed to extreme temperatures or abrasions, you need not include the same aspects into your design; you could instead opt for simpler harnesses to lower the costs. So, scale back your “excellent” design to a “good” one to fit closer to the needs of your particular application, not only to reduce costs, but also the lead times. Having the right manufacturer by your side can help analyze your design to look for opportunities that can help achieve your goals without going overboard.

Substitute components

Just like the design aspects, you can work over the quality of your components too. You may have included exceptional high-quality components into your design, which may be either a little more expensive, or difficult to obtain, resulting in either costly or delayed deliveries. For instance, using military-specific connectors in applications that have nothing to do with military or defense work isn’t bad, but certainly adds to the cost for nothing. When you want things to fall within your budget, you could opt out of these rugged and high-performing connectors, and choose good quality regular connectors instead that provide essential functioning, while being readily available at lower costs.

Look out for a flexible manufacturer

Whether during crisis or not, you must always work with a manufacturer that is flexible. What we mean by flexible is that the manufacturer should be skilled at working in every way. There are certain manufacturers who work only with certain brands, certain components, and certain tools, in their own certain ways. This is a good procedure to follow, but in times of crisis, when you either want to alter the design or substitute components, or make any other such changes, such manufacturers could only make it difficult. But, if you have a flexible manufacturer, they will be willing to work as per your requirements, to serve you better and in time, even if that means compromising on their comfort zone a little. Miracle Electronics is one such manufacturer you can rely on. They are the best cable harness manufacturers in India who work keeping in mind the requirements of their customers at all times, while also providing them with the right advice and feedback on their designs and thoughts, to make them better cost-effective customized cable harnesses fortheir applications .

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.