When Choosing A Wire Harness Manufacturer - Miracle Electronics

A critical part of every electronic and electrical application is the wiring used. And, when hundreds and thousands of wires are to be used in a single application, it is always wise to group them up into wire harnesses, for which you need to consult and partner with a professional wire harness manufacturer in India. 

You need a manufacturer who can provide you with the best products that are high on quality and reliable in performance, because any kind of compromise in the quality or performance of the harness means issues in the application. Whether the issue is as small as a short, or as big as application failure, the results aren’t what you would want to experience. You thus need to be very careful when you’re choosing your wire harness manufacturer. While there is a lot you need to know about the manufacturer you are choosing, we’ve come up with only the most essential considerations that you need to make.

Consideration 1 – Experience

There may be wire harness manufacturers that specialize in only one or a few industries. Then, there may be those who work for almost every kind of industry. If you choose the former, you need to check if your industry is on their list, while if you choose the latter, you need to ensure that the manufacturer has a good amount of knowledge and experience about your particular industry. In any case, partner with the manufacturer who is knowledgeable about your industry and the requirements so that they provide you with reliable end products.

Consideration 2 – Customization

When you choose a manufacturer, you should likely choose one who offers customization services. If the manufacturer is good at customizing, you can always have your products specifically tailored to suit your application and requirements. Even though the cost will be a little higher than readily available harnesses, the results of customized wire harnesses  will certainly be worth-it.

Consideration 3 – Production capacity

You must always check for the production capacity of the manufacturer. Is he capable of fulfilling the kind of quantity you are looking for? If you are a small business, you may need only a handful of harnesses for your limited applications. But, if you are a large commercial trade, you may need larger volumes. Then, at times, it’s possible that you may need to place a different kind of one-time order volume than the regular kind of production you require. This is why it is advisable that you choose a manufacturer who produces both big and small volumes, so that you can rely on them for any and every kind of production type.

With these three considerations, you should be handing over your manufacturing processes into the hands of a reliable professional. MiracleElectronics is one such professional wire harness manufacturer in India who has great expertise in almost every kind of industry like electronics, aerospace, medical, and audio. Moreover, here you’ll get quality assurance because of the ISO 9001 and AS9100C certified production processes and DGAQA and MSQAA certified products. Last but not the least, every wire harness is tested and verified for perfection before being delivered to the clients.

 

Printed Circuit Boards _ What & Why - Miracle Electronics

Printed Circuit Boards (or PCBs) are seen in almost every electronic device – that small green board with tiny black and golden components and connections. These tiny boards are capable of supplying electrical signals by connecting all the mounted electronic components together. 

There are a variety of PCBs available in the market, which can be selected depending upon the application it needs to be used in, and the purpose it needs to serve. Some of the most common PCBs seen are single-sided, double-sided , through-hole, and surface-mount. Let’s take a look at the types of PCBs and their applications below.

Types of PCBs

Single-sided PCBs

A single-sided PCB is the most basic type, which consists of a flat sheet of insulating material and a layer of copper foil laminated to the substrate. The copper is etched to divide it into separate conducting lines called traces. Then, there are all sorts of connections and electromagnetic shielding made possible with the help of insulated wires. The copper layer is finally coated to reduce the chances of shorts and prevent it from corrosion.

Double-sided PCBs

These PCBs are just like single-sided boards, but with copper layers and componentson both sides of the substrate layer , which allows the traces to cross over each other. This results in high-density complex circuits that are more difficult to produce. Double-sided PCBs can have their components connected using two technologies – through hole and surface mount. But, both these technologies come with their own benefits and limitations.

Through-hole PCBs

This is the most basic technology that has been used since initial times to produce PCBs, wherein the electronic components are mounted by leads inserted through holes on one side of the board, and soldered onto the copper traces on the other side. The leads are bent at 90 degrees to horizontally install the through-hole parts with two axial leads, inserted into the board, soldered, and trimmed off at the ends. The through-hole technology requires many holes to be drilled, limiting the available routing area for signal traces.

Surface-mount PCBs

Surface-mount technology  came after the through-hole technology to enable mounting of very small-sized components on the board, with small metal tabs or end caps that can be soldered directly onto the PCB surface, instead of wire leads passing through holes. With this technology, it became possible to mount components on both sides of the board easily; thus allowing very small PCB assemblies with much higher circuit densities. The technology is also automated, which reduces time and costs related to manual labour, thus increasing production rates.

Applications of PCBs

Electronic devices – PCBs are highly used in electronic devices, providing channels and pathways for electricity and signals to follow, thus allowing functioning of the device.

Computers – PCBs are very popularly seen in motherboards of computers, which makes complex functions possible too.

Medical devices – PCBs can help in the medical industry by performing a variety of functions like diagnosing, monitoring, and treatment. For instance, PCBs are used in the medical field in equipment like medical imaging systems, monitors, and infusion pumps. However, the PCBs to be used in medical devices should strictly comply to stringent standards for sanitation and functionality.

Automotive components – Automotive components need to withstand extreme temperatures and vibrations; and with the advancement of technologies, PCBs are not limited to windshield wipers and headlight switches only; rather they are also used in many other automotive components like control systems, stereo systems, navigation systems, and sensors.

Aerospace and military components – PCBs are also used in the most critical applications like aerospace and military. In the aerospace industry, PCBs are used in planes, satellites, space shuttles, and radio communication systems. And, in the military industry, PCBs are used in communication equipment, control systems in military vehicles, firearms, and more.

No matter what the application, you can always get the most appropriate PCB assembly for your equipment. And, when you’re looking for perfect products, you can always opt for Miracle Electronics’ customized solutions to get seamless PCB assembly manufacturing from India.

 

Field Vs. Moulded Wire Harness _ Which One To Choose - Miracle Electronics

You’ll always want only the best type of wiring and harnesses for your application, but which one is it for you – field wire harness or moulded wire harness? This is a question that is always stirring up a debate in the minds of those planning on choosing a harness for their system. Considering how confusing and puzzling it may be, we’ve come up with a blog to shed a light on the subject. We’ll discuss, in this blog, the basics of both types of wire harnesses, and the key factors that can help you decide between the two.

Field wire harness

A field wire harness consists of a housing that is screwed in or clipped on, requiring a comparatively lesser setup, thus reducing the time of production. However, building a field wire harness is normally assembled by hand, which makes it a lesser suitable option for high-volume applications. But, for low-volume applications, field wire harnesses can prove to be an ideal choice, especially when you’re looking for a faster development time or prototyping.

Moulded wire harness

A moulded wire harness is made by melting down a large amount of plastic, after which a mould is created into which the high-pressure plastic is inserted. This gives more durability and greater seal strength to the harness. Because this is a fully automated process, moulded wire harnesses can be ideal for high-volume production. But, it isn’t suitable for low-volume applications as it can prove to be very expensive for smaller amounts of products. In the case of high-volume applications, it can prove to be economical and efficient, even though there is more setup involved, because the final products are worth it.

Which one is better?

As mentioned above, you can see that we cannot consider one to be better over the other. Depending upon the application, you can decide as to which one you should choose. A field wire harness is better when you have a small production run, while a moulded wire harness is better when you want a larger volume. But, the decision making process isn’t as simple. There are many other factors that you want to consider too when deciding as to which wire harness to consider.

Budget – A higher budget in hand can make it painless to opt for a moulded wire harness production. But, if you are on a tight budget, it may be difficult. However, you also need to understand that a field wire harness production run is also labour-intensive, which requires a good sum of money too. So, it is a choice between the cost of labour versus the cost of machinery.

Materials – The material you wish to choose decides on which kind of wire harness would be suitable. For instance, a field wire harness generally comprises of metal and plastic components, while a moulded harness is crafted from more durable parts with higher IP ratings.

Durability – When durability is a big concern, a moulded wire harness tends to be comparatively much stronger than a field harness. Obviously, field wire harnesses can be improved to enhance durability, but there are limitations to it.

Repairs – When you need repairs in the future, you must understand that field wire harnesses can be repaired and modified if any issues arise, but a moulded wire harness cannot be fixed.

Consider all the above factors when deciding upon the kind of wire harness you need for your application, after which you can approach an apt wire harness manufacturer. However, when you approach Miracle Electronics, you can rest assured that you’re with the most versatile wire harnessmanufacturer in India, meaning that you can get almost any and every kind of wire harness manufactured here. Just communicate your requirements, and you’ll have the most reliable and genuine products delivered to you, especially customized to suit yourapplication .

 

Should You Use Filled Or Untreated Vias For Your PCB - Miracle Electronics

Most manufacturers are opting for the surface mount technology for building PCBs, rather than the through hole technology, so as to allocate lesser space on the board, making them smaller and easier to install. But, with the rising use of surface mount technology components, more vias are being used too. Vias are holes for electrically connecting stacked pads on different circuit layers. 

While all vias essentially perform this same function, there can be different types of vias, depending upon their appearance on the PCB surface, namely through vias, blind vias, and buried vias.

Treating the vias

In order to improve the thermal performance of the PCB, there can also be done some additional treatments on the vias, such as filling, covering, capping, plugging, or tenting. Such treatments can help eliminate several assembly issues like shorting between component pads, or wicking down of the solder through the hole of a via. It can also eliminate expensive troubleshooting and reworking.

Filling – This treatment fills a regular or encroached via with non-conductive epoxy paste. These filles vias have the solder mask stopping short of the pad by a few mils, making it a good compromise for medium-density PCBs, as the presence of the solder mask reduces the likelihood of the solder bridging between the via and neighbouring pad.

Plugging – This treatment plugs one or both ends of the via with a non-conductive epoxy paste to prevent solder flow-through or wicking during soldering. But, in order to allow the epoxy to plug the hole effectively, the diameter of the via should be limited to a maximum of 20 mils.

Tenting – This treatment covers both pads at the end of the hole with a non-conductive solder mask, effectively sealing the openings. A dry film with a 4-mil thickness is adequate for covering even large holes effectively, without breaking down much. But today, manufacturers are opting out of the traditional dry film, and choosing modern LPI solder mask instead, which is only one-tenth the thickness of dry films.

Advantages of filled vias

Filling the vias can have several advantages over untreated ones, some of the benefits being high routing density, better conductivity (both thermal and electrical), and EMI reduction. Being very small in size, micro-vias allow high routing density on the PCB, allowing substantial reduction in the overall PCB size, and lowering the number of layers. All of this ultimately reduces the cost of the PCB. With a smaller size, there is also reduction in the distance between the components, which in turn reduces the overall resistance of the tracks, resulting in better electrical conductivity. This high conductivity in turn helps to lower the EMI reduction. Hence, filled micro-vias are particularly helpful for conducting a large amount of heat away from a hot component. The metallic nature of the filling wicks heat naturally away from the chip to the other side of the board for further dissipation by a heat sink.

If you want to take advantage of such filled micro-vias, you can always get in touch with Miracle Electronics to get your preferred customized PCB assembly from India. Get in touch and explain all your requirements and purposes, and you’ll get the most apt PCB assembly for your application, reliable and safe.

 

Should You Use Branded Or Non-Branded Connectors - Miracle Electronics

We see lots of products from brand names that we know about, and then, we also see imitations of such products that look just the same, also feel/taste/function the same, but are available at much lower costs, only because they aren’t a well-known brand yet. This applies to almost every product category like eatables, cosmetics, accessories, and electronics. In the case of electronics, we’ll speak about connectors in this blog.

Which connectors to use – branded or non-branded?

Connectors are specified on customer drawings. But, which connectors should one use – branded or non-branded ones? Well, the form, fit, and function can be the same for both branded and non-branded connectors. The non-branded connectors are referred to as substitute or equivalent components, having several benefits like local availability and cost reduction. However, not every electrical component can be substituted, which makes it very important to review the product application and design details before opting for such substitutes.

What all to consider?

Before deciding on using a substitute connector, it is important that the application, industry, and qualification requirements are assessed. For instance, critical industries like military, aerospace, and medical cannot afford to use downgraded quality products. Moreover, such industries can encounter challenges in using equivalent connectors. When deciding for less critical industries like industrial applications and consumer products, the decision to allow substitute connectors generally falls on the end customer or the individual with design authority. And, if you’re unable to decide, you may always consider consulting your cable assembly manufacturer to review the impacts and constraints of employing an equivalent connector.

Considerations while opting for an equivalent connector

When you decide on using an equivalent connector, again there are quite some considerations you ought to make. Some of the considerations are pin length, pin diameter, pin count, pin pitch, material compatibility, interface tolerances, footprint, polarization, electrical rating, flammability rating, and planned obsolescence.

Benefits of using local component sourcing

It is generally advised to choose local component sourcing for electrical manufacturing. Doing so can help reduce supply chain risk, as well as lower the effective product cost. Other than cost advantages, it can also impact the lead time. It’s always best to plan for samples and mechanical fit checks, so as to have a proper verification of all interconnects and mates. Although it isn’t always advisable to opt for suitable equivalent connectors for every project, but the benefits that they provide can offer tremendous value, when used in the right applications.

Where can you get what you’re looking for?

Miracle Electronics is one of the best cable harnessmanufacturers in India where you can get almost any and every kind of cable harness, both standard as well as customized, along with connectors of all types, such as circular connectors, D-Sub connectors, military specific connectors, and D-38999 circular connectors. With more than two decades of experience in the field, Miracle Electronics knows what it is providing, which is why every product is certified and approved by DGAQA and MSQAA for platform specific applications, and each product is tested well before being delivered to the clients.

 

Wire Harnesses & Cable Assemblies – The Manufacturing - Miracle Electronics

When you want to build an electrical system, you’ll need lots of wires and cables, which makes it better to replace them with fewer harnesses or assemblies. Wire harnesses or cable assemblies will hold multiple wires together, optimizing space, as well as protecting the wires against climatic and environmental conditions like heat, moisture, vibration, etc. Thus, errors and faults are eliminated, helping the functioning of the system to run smoothly.

Are wire harnesses and cable assemblies the same?

So, when we speak of having wire harnesses or cable assemblies, do you realize the difference between the two? Generally, as a layman, you may consider both of them to be the same, but when you get down into the details, you’ll notice that they are actually two different things. Let’s help you with understanding the differences.

•         Wire harnesses involve wires that are individually sealed, and then wrapped in another casing. But, these are not as durable, and are thus used in small electronic applications and internal systems.
•         Cable assemblies, on the other hand, are bundles of wires or cables in a single heavy casing. This equipment can be easily used in harsh environments because of the heavy-duty thermoplastic rubber or vinyl used for the casing, which helps hold up against outside elements like extreme temperatures, moisture, friction, abrasion, and compression/expansion.

How are harnesses and assemblies made?

•         Planning – The first and foremost step is planning, both the design and construction. Without a pre-plan, no product can be successfully made. In the case of harnesses or assemblies, the type and size of wire needs to be determined, to be used between each connection.
•        Prototyping – A test version is first created depending upon the plan. It helps engineers know how the final product will look like, while identifying any errors or gaps that need to be rectified before building the actual product.
•     Wire cutting – Once the prototype is approved, it’s time to move on to the actual product making, which involves first cutting the wires to the required length. Wire-cutting machines can be used here to automatically cut the required wires in bulk.
•       Wire stripping – After cutting, the casing is stripped back to reveal the core, which is then fed into the necessary connectors. Crimping and soldering the wires into their proper connections can be automated with the help of machines.
•        Assembling – The prepared wire-connector devices are gathered up and crafted into a harness, which is done majorly with the help of manual labour. This is because each wire needs to be fed through the harness, taped off, and measured to make sure that the distances match the design specifications.

Partnering with the right manufacturer

Manufacturing harnesses and assemblies is a time-consuming task, especially because of the intensive manual labour required in the last stage of assembling the equipment together. And, in order to not waste any more time, you need to get hold of a manufacturer who knows the job well so that there is no time wasted in making errors and rectifying them. Moreover, the manufacturer you should must have the right machines to make the process as automated as possible, and the right tools to use to speed up the processes that require manual labour invested. Some of the most basic tools that a good manufacturer must have are an injection mould machine, wire cutter, wire stripper, crimper, positioners, die sets, insertion and extraction tools, and all sorts of testers for testing the assemblies before delivering them to the customers.

Miracle Electronics is one of the best cableharness manufacturers in India you can approach to have your harnesses and assemblies made, as they have the right tools and machineries, skilled engineers, and the best testing facilities to build and test your products. Moreover, they are also skilled at manufacturing customized wire harnesses and cable assemblies  if you wish, each product being certified and approved by DGAQA and MSQAA for platform specific applications.

 

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!