Guide To Crimp Quality In Cable Harnesses

 

Cable harnesses are essential for connecting electrical and electronic components to guarantee effective and dependable performance in a variety of industries. These harnesses’ performance and longevity are directly influenced by the crimp quality used in them. This makes crimping among the most crucial steps when assembling cable harnesses. The process of crimping involves joining wires within a harness by attaching connectors to the ends of cables with a crimping tool. Many crimping steps, including stripping, cutting, and crimping the terminals on either side of the wires, can be automated. The correct crimping of wires, whether manual or automatic, is crucial because it creates a safe electrical connection and guards against problems like signal loss, voltage drop, and potential breakdowns.

The procedure

In a nutshell, the crimping procedure starts with the connector being placed in the crimping tool, followed by the exposed wire being inserted into the connector at the end of the cable, and then completed by installers squeezing the crimping tool’s handle to firmly link the connector to the cable. To begin, the wire is first properly put into the terminal’s barrel by first positioning the terminal in the crimp tool’s jaws. The crimp is then formed uniformly, without gaps or over-crimping, by applying pressure to the handles of the crimp tool. The final step is to confirm that the insulation crimp or the wings of the terminal have fully compressed around the wire insulation. When properly carried out, these steps result in effective crimping.

Advantages of crimping

Crimping is a quick and easy operation that can be automated using a crimping machine or done manually with crimping tools. It forms an airtight connection between the cable and connector to produce a union that is consistently dependable. Crimping is also consistent in comparison to other procedures like soldering, making it the best choice for applications that demand consistent durability even under the most trying circumstances. Crimping does have one possible drawback, though, namely the need for connector-specific tooling, which could result in high prices.

Why is it important to have good crimp quality?

When electrical components, such as cables and wires, are compressed with specially created splice bands or crimp terminations, gas-tight joints are created. A wire’s strands are reshaped by the resulting terminal to provide a solderless, low resistance electrical connection. To stop the corrosion of metals from oxygen and moisture, joints must be gas-tight. Additionally, they need to be sturdy, with a single joint that is free of splits or pieces. The crimping procedure makes all of this possible, while also making tiny connections in the wires that permit the passage of electrical current. Crimps of high quality can last for ten years or more.

How to ensure good crimp quality?

There are specific procedures that must be followed and certain criteria to be taken into account in order to guarantee a good crimp quality that has them lasting for up to a decade or longer.

Choosing the right crimp tool

The first step in assuring perfect crimps is choosing the right crimp tool. The wire gauge and termination size should be compatible with the tool. Purchasing a high-calibre, accurately calibrated crimp tool will enhance precision and uniformity throughout the assembly process.

Proper terminal selection

For a reliable crimp, choosing the appropriate terminal for the wire size and application is crucial. Terminals are made of a variety of materials, including copper, aluminium, and stainless steel. It is essential to make sure the insulation and conductor of the wire are compatible with the terminal.

Accurate wire stripping

For correct crimps to be achieved, wire stripping must be accurate and constant. To remove the proper length of insulation, a high-quality wire stripper that is compatible with the wire gauge needs to be used. Poor crimp quality might result from excessive or insufficient stripping.

Regular calibration and maintenance

To achieve accurate and consistent crimps, calibrating and maintaining crimp tools is required. By preventing under- or over-crimping, calibration guarantees that all crimps adhere to the necessary standards. The tool’s lifespan is extended by routine maintenance, which also lowers the possibility of subpar crimps.

Rigorous quality control and inspection

Implementing a stringent quality control procedure that involves checking crimps mechanically and visually is crucial. Compression, strain relief, and appropriate orientation all need to be checked visually. The integrity of the crimp is guaranteed through mechanical testing, such as pull force testing. Also, cutting and inspecting a crimped sample to determine its quality aids in identifying problems like inadequate compression or structural flaws in the crimp.

Training and certification

Operators who have received proper training are more likely to produce reliable, high-quality crimps, which lowers the possibility of errors like using the wrong wire ratio, overtightening, or not tightening the clamp enough. This is why you should always approach trained and certified personnel for having your cables crimped. One such trusted and certified cable harness manufacturers in India is Miracle Electronics, where there is a team of IPC certified engineers taking care of the entire manufacturing process, and automated machines used for cutting, stripping, and crimping processes. Only UL-approved and military grade materials are used here to manufacture cables and harnesses using lean manufacturing processes, followed by mistake proofing and testing procedures  to guarantee the best quality cable harness for every industry and application.

Transformers: The Unsung Heroes Of The Electrical Power Industry

The transformer is an essential component in supplying electrical power for everyday needs. These amazing machines support the entire electrical power sector by facilitating the effective transmission and distribution of electricity to buildings, commercial buildings, and industrial facilities. Yet, these heroes frequently go unseen! But here, in this blog, we’ll shed some light on these amazing equipment, giving them the respect they ought to receive!

Transformers facilitate power generation

Transformers are crucial for integrating power plants with the electrical grid, and converting generated electricity to appropriate voltage levels for distribution. They also integrate renewable energy sources like solar and wind power into the grid, and enable the generation of sustainable energy.

Transformers provide for effective power distribution

Transformers make it easier to change electrical voltage levels, enabling electricity to be delivered across great distances with little loss. They also enable dependable power supply by stepping up the voltage for effective long-distance transmission, and stepping it down for safe distribution to end consumers.

Transformers enhance energy efficiency

By working at high voltage levels, transformers reduce power losses during transmission, thus increasing the total energy efficiency. Furthermore, distribution transformers ensure that power is delivered at the proper voltage levels, reducing waste and maximizing energy efficiency. This ultimately optimizes power utilization.

Transformers ensure reliable power supply

Transformers maintain a constant voltage level, compensating for fluctuations in the power grid and guaranteeing a steady supply of electricity to consumers. They also assist in reducing problems like voltage sags, harmonics, and power surges, which improves the quality and dependability of the electrical supply.

Transformers support industrial and commercial applications

Transformers supply the necessary energy for heavy machinery and equipment used in a variety of industries. In addition, they also help the efficient operation of commercial applications by supplying dependable electricity for lighting, heating, cooling, and other operational requirements.

Transformers promote safety and protection

Transformers provide electrical isolation, preventing humans and equipment from electric shocks and short circuits. Also, transformers integrate protection devices including fuses, circuit breakers, and surge arresters, to guard against damage from electrical faults and guarantee safety.

As you can see, transformers quietly deliver electricity to homes, offices, and industries in a safe and effective manner. It is impossible to emphasize their critical importance in voltage transformation, power generation, energy efficiency, dependability, and safety. With such an extraordinary role that transformers have played in sustaining the convenience of electricity in our daily life, they are yet often neglected. This clearly shows why we say that transformers are the unsung heroes of the electrical power industry.

To get your hands on these silent heroes, you can get in touch with Miracle Electronics, the leading transformer manufacturer in India, who has been offering a number of different types of transformers to clients across the globe since almost three decades now! Power, toroidal, EI, three phase, SMPS, encapsulated, UI, and planar are only some of the finest transformers on the list. Choosing any of these transformers will ensure an investment in quality.

For more information, visit: https://www.miracle.net.in/

Cable Assembly, Wire Harness, Or Wire Loom – What Do I Need?

Wire looms, wire harnesses, and cable assemblies are all phrases that are frequently used interchangeably. However, they actually differ greatly, and it is because of these distinctions that their respective uses are determined. While it is true that all three share the ability to transmit data or electronic power between two points, as you will see below, each option has certain features and advantages of its own.

Why choose these options?

Cable assemblies, wire harnesses, and wire looms are all phrases that are used to refer to a grouping of various cables or wires that are connected or bonded together into a single unit. The advantage of this design is that each wire or cable can be created to precisely the appropriate length and size, and they are all grouped together in a precise fashion to avoid wasting space or adding more wiring and to make installation quicker and simpler.

Manufacturers who need to make hundreds or thousands of similar pieces of equipment frequently employ such assemblies. As a result of the constant vibration created by the automotive sector, single wires and cables were initially made popular in the 1920s and 1930s.  The wires were more protected and secured, according to the engineers, when they were tied together. Today, the majority of equipment uses a harness, assembly, or loom to organize its internal wiring.

Wire harness

These wiring systems are the most basic. A wiring harness is used to organize numerous wires as per a predetermined arrangement. A wire harness is simply a wrapper or sheath that keeps numerous wires or cables in place neatly, which is typically constructed of thermoset or thermoplastic material. To conserve space and shield them from harm while in operation, many wires of the necessary length are tied together. They might or might not have one or more connectors to terminate them. A more complicated harness might include wires running in several different directions and have a wide variety of termination components. Simple and complex harnesses both use materials like heat shrink, cable ties, or electrical tape to bind the wires together. These harnesses can typically be constructed relatively simply, which allows for speedy production at an affordable price.

The main purpose of a wire harness is to retain the cables and wires in the predetermined arrangement, minimizing movement and maximizing the use of available space while relying on the cable or wires' own sheath for protection. As a result, wire harnesses are typically a low-cost alternative. A wiring harness has the advantages of keeping the wires neatly in place, making them visible for easy fault tracing, and strengthening the assembly by binding the wires.

When the same wiring arrangement is used repeatedly, like during the mass production of items, this kind of wiring system is especially useful. The automotive industry popularized wire harnesses in the 1920s and 1930s to solve the issue of individual wires coming undone and getting damaged from the vibration of the car.

Cable assembly

A cable assembly is comparable to a wire harness, but its protective wrapping is more robust, and can be composed of vinyl, thermoplastic rubber, or shrink-wrapped thermoplastics. When exposure to environmental elements is a design consideration, a cable assembly is utilized to hold the wires or cables in place as well as to provide further protection against heat, abrasion, friction, and moisture. Individual wires and multicore cables can both be used in a cable assembly's design. The benefits of the protective wrapping against the weather are the main justification for choosing a cable assembly over a wiring harness, even if it is more expensive and loses the ability to physically trace the individual wires.

Wire loom

Wire looms are fundamentally more complicated than assemblies and harnesses, as they combine various cables and wire kinds into various groupings, frequently employing a variety of binding techniques. Wiring looms can range from being simple, integrating only a few wires, to being a complicated network of cabling, as those used in contemporary automobiles and aircraft. By lowering the wiring footprint of a product, wire looms offer space-saving as well as cost-saving designs by reducing material waste. Additionally, wire looms enable partial or full drop-in solutions for applications such as those in automobiles, aviation, and home appliances. This can significantly shorten installation timeframes and lower overall expenses.

Whatever you choose for your applications, Miracle Electronics offers subcontractors and final product manufacturers unique wire harnesses, cable assemblies, and wire looms for a variety of industries. The skilled staff at Miracle, a flexible harness, assembly, and looms manufacturer in India, can collaborate with your product design team to create custom products that are made exactly to your specifications.

For more information, visit: https://www.miracle.net.in/

Aerospace Cable Assemblies – What They Call For

When you talk about aerospace or aviation, you get multiple things boggling in your mind, such as the aircraft, the metal, the design, the engine, the control systems, the navigation systems, the communication systems, and everything else. But, how often do you think one thinks about cable assemblies when the words aerospace and aviation are considered or spoken about? Not too often, isn’t it? Yet, what an irony it is that these tiny often-so-overlooked components are so crucial to the success of communications and control systems used in both commercial and military aircrafts!

Over more than the past two decades, Miracle Electronics has become a primary source for such crucial cable assemblies used in both commercial and military avionics. Technological advances can make it difficult to know how to choose the right assembly for your needs. But, with the expertise and experience of the technicians and certified engineers at Miracle Electronics, one of the finest aircraft cable assembly manufacturers in India, there should be no trouble at all!

Requirements of aerospace applications

Technological advancements are creating new challenges for such cable manufacturers. Not only do they need to meet high-performance standards, they also need to come up with lighter and smaller designs more cost-effectively. Even though the devices are getting smaller, they still need to meet the same rugged requirements. They should be capable of operating in tough environmental conditions at extreme temperatures, accepting every kind of shock, vibration, and pressure that comes their way. Military component manufacturers are under pressure to accomplish all of this, while keeping costs down, and maintaining safety.

Two basic types of aerospace cable systems

Cables for aerospace applications range in high-speed data cables and RF assemblies to power distribution cables.

High-speed data cables

With tremendous amount of data being transmitted and received, aerospace cable assemblies are required to deliver high-speed connectivity for the demanding aerospace communications, in spite of the harsh environments they pass through on their way. The best options of cables that can serve this purpose are Cat 7 cables that support high-speed voice, video, and data traffic, and are completely compatible with Cat 6A couplers and adapters. Other high-temperature-rated Ethernet cables, specifically designed for aerospace environments are Cat 6A and Cat 5E. These cables meet all RoHS requirements, and are successfully used in cabin management systems, in-flight systems, backbone avionics, ground vehicle trunks, and general aerospace usage.

RF cable assemblies

Over time, the sheer amount and complexity of information to be transmitted in aerospace applications has substantially increased. The RF circuit building blocks have thus been through many changes to accommodate the latest advancements in the industry including miniaturization, increased reliability, and the ability to rapidly transmit even complex data. Spaces are becoming smaller, reducing the usage of bulky devices, bringing upon a challenge to fit more components into smaller device form factors, while ensuring optimal functionality. Aerospace cables are required to operate at higher frequencies, sending more information in a given amount of time, or sending the same things within a fraction of the time. All of this needs to be considered while building cable assemblies for aerospace applications, testing every cable thoroughly for all kinds of mechanical, electrical, and functional aspects. Lighter, smaller designs, that are critical for ever-growing space-constrained aerospace applications, coupled with compliance, stringent safety, and environmental requirements, will continue to drive the industry to make advances in designs and processes. You need to thus always be in touch with aircraft cable assembly manufacturers in India who know the ins-and-outs of the business, and are always up with the latest trends and technologies, so as to provide you with the most appropriate solutions for your particular application.

For more information, visit: https://www.miracle.net.in/

How To Customize A Toroidal Transformer?

While there are a number of high quality standard toroidal products available, many want to request customized designs for their specific applications. This is so because customized designs are specially tailored to meet the size, capacity, and performance required by the application, which means a perfect ideal fit.

When you’re looking for such customizable solutions, there are two ways you can work it out – first being where you provide with all the details and have the product only manufactured; the other being where you just convey your requirements and have the entire design-to-manufacture task taken care of by the manufacturer.

When you want to provide your own drawing

If you are the first sort, where you provide a specification or detailed drawing depicting all that you need within your transformer, it doesn’t mean that the drawing will be blindly followed. The manufacturer will first analyze the information, working on every detail, to see that the purpose of the transformer is served, without any chances of error. In case any such doubtful specification is seen, it will be brought to your notice, after which the required changes will be made. Only when both the manufacturer and the client are satisfied with the drawing, will the transformer be put into production.

When you want the entire process to be outsourced

If you’re not too sure about the specifications or drawings, you can have the entire process taken care of by a manufacturer. All you have to do is convey what your application is about, what purpose you want the transformer to serve, any specific environments the transformer will need to work in, any space constraints or other limitations, and the quantity and deadline. Once every such detail is conveyed by you, it becomes the duty of the manufacturer to design and manufacture the perfect toroidal product for you.

Do you want a prototype?

It’s absolutely alright if you want to see a prototype first, before putting the entire production into practice. Whether the design is made by you, or the manufacturer, you may be unsure of the outcome, and want to first look at a prototype. Manufacturers can use a software to create the plan for such a prototype, by inputting all the information on the drawing, and crafting a digital design of the product you need. This practice is a more accurate way of ensuring that the final product will be appropriate, and meet your specifications. Any adjustments required in the prototype are made, before moving on to manufacturing the complete project.

Where to get your toroidal transformers? Miracle Electronics’ highly-trained engineers oversee every step of the manufacturing process, right from designing to prototyping to production to testing. Only when the final product is proven to be effective, is it shipped to the client. With everything being done in-house, it saves on a lot of time that may otherwise be spent collaborating with different facilities. This not only avoids shipping delays, but also helps in carefully monitoring the entire manufacturing process. You’ll thus get toroidal transformers that enable the highest level of accuracy and reliability, meeting any regulatory requirements. So, when you need one-of-a-kind toroidal transformers for your applications, look no further than Miracle Electronics, where everything will be carried out within their ISO-certified facilities. Whether you’re in the manufacturing, medical, audio, energy, or any other industry, you can ensure that the final product is effective, efficient, reliable, and safe.

For more information, visit: https://www.miracle.net.in/

 

Making The Correct Toroidal Transformer Choice

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

What is a toroidal transformer?

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

Pros and cons of a toroidal transformers

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

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

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

Applications where toroidal transformers are the best choice

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

Considerations to be made while making a toroidal transformer choice

Configuration

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

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

Mounting

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

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

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

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

Why Choose Laser Marking Over Other Wire Marking Methods?

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

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

Laser marking vs. hot stamping

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

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

Laser marking vs. heat shrinking

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

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

Laser marking vs. ink jet printing

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

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

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

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