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

Audio Output Transformers – What & Why? – Miracle Electronics

An audio transformer  is one that works in the audio range, with a working frequency range being generally between 10 to 20,000 Hz, and the impedance often used to transform the voltage or change the load. These transformer types are generally used in radios, televisions, voltage amplifiers, and other such applications.

Construction of an audio transformer

The core of the audio transformer is superimposed by a high magnetic material, with the primary and secondary windings tightly coupled, so that the flux across the original winding almost all has a phase chain with the secondary winding, and the coupling coefficient is close to 1.

Working of an audio transformer

The lowest frequency of the passband is determined by the inductance of the original winding, while the highest frequency is determined by the leakage inductance of the transformer. The original winding inductance is large, and the leakage inductance is small, in order to ensure that the transformer has sufficient passband. The saturation of the magnetic circuit and the hysteresis loss of the core can cause signal distortion. To counteract this, there should be proper load distribution and increased load current. Also, the core section should be increased, and an air gap left to reduce the saturation of the magnetic circuit. Doing so can significantly reduce the distortion of the signal.

Audio output transformer

With multiple types of audio transformers available, what we’ll focus on in this blog is the audio output transformer, which is one that is intended to isolate an input circuit from an output circuit, while providing filtering to a signal that passes through it. It is designed to operate on signals with a frequency spectrum in the audible band. Output transformers basically perform two functions – completing the matching of output impedance, and completing the conversion of voltage to current, so that higher voltage signal can be converted to an electrical signal with lower output current.

Note: Close attention should be paid to the matching of the front and back impedance, in order to avoid signal distortion caused by the reflection. Also, the impedance of the load must be consistent with the impedance required by the power amplifier stage, through the impedance of the output transformer, in order to maximize the load.

Designing an audio output transformer

When you’re deciding on the kind of audio output transformer you want for your application, the choice of the core material and its size depends upon the frequency response, power levels, and harmonic distortion. Audio output transformers are generally preferred to use both high-permeability cores and the largest number of coil turns to create high primary inductance. Remember, by changing the number of wire turns in each winding, transformers can be manufactured to have various impedance ratios. You can choose to have your specific customized audio output transformer India to suit your particular application requirements at Miracle Electronics, where every transformer manufactured is of the highest quality, which is proved by their RoHS and REACH compliance certificates. So, get in touch whenever you are looking for the finest quality audio transformers!

Building A Box Build Assembly – Miracle Electronics

When you want a box build assembly made, you’ll try to search for the best and least expensive vendors. Obviously, who doesn’t want to save money! So, you’ll begin by sourcing components from one company, then send them to a manufacturer to sub-assemble the elements, and then forward the parts to another manufacturer who finally tackles the final assembly.

But, doing so can waste valuable time and money, while also compromising on the quality of your product, if any of the vendors are not up to the mark. Instead, why not send your project to only one manufacturer, who is dedicated to your project from start to finish, rather than opting for multiple sub-assemblers? Find a box build electronics manufacturer who can take care of everything, right from component sourcing to the final end product. A box build is a systems integration; a complete electronic assembly placed inside an enclosure, which is why it is advisable to get your project into the hands of an apt integrated service provider  who can handle it all effectively and successfully.

Designing

The designing phase involves the material and component selection, layout, concepts, and tooling. Combining all of this into one complete project is a task, which needs the skills of an expert manufacturer.

Assembling

Assembling involves combining all the components appropriately as per the design layout. In addition, the manufacturer will also help determine the input/output of the power, power sources, mounting options, and environmental constraints.

Cables and wire harnesses

No box build can be complete without the use of a combination of wires and cables. High or low voltage cables and wire harnesses will be incorporated into your box build. This could include standard or customized options, fabricated to meet your specifications, which again is the responsibility of the manufacturer.

Enclosure

The enclosure may require unique dimensions, special spacing, specific routing, or distinct mounting. Your manufacturer must look at all these factors, and determine the best shape and size that can hold every component easily in place, while also checking for the access of sensors and power.

Testing

Testing is a very important task within the manufacturing process of any and every electronic product. Testing ensures the quality and performance of the equipment, thus also ensuring reliability for the product to stand up to everyday use. Testing should be done after every phase of the manufacturing process, as well as after the final assembling of the box build.

Every box build is unique. It can range from a simple PCB in an enclosure to a large cabinet full of wires, complete with electronics and pneumatics. Whether your application requires a simple box build or a complex one, Miracle Electronics has the experience and expertise to meet your requirements. They are apt for surface mount and through hole assembly to cable manufacturing and complete electronic box assemblies in India; all in all a complete package, built with dedication to lean manufacturing techniques.

The Basic Fundamentals About Defense Offset Guidelines – Miracle Electronics

A defense offset policy  is drafted to leverage capital acquisitions in order to develop the Indian defense industry by fostering the development of internationally competitive enterprises, augmenting capacity for R&D, and encouraging the development of synergistic sectors like civil aerospace and internal security.

But, so as to achieve such a partnership, there is a list of defense offset guidelines that need to be followed. While the number of guidelines are umpteen, let’s help you get a brief in this blog below.

Application of provisions

The provisions apply to every capital acquisition, may it be outright purchase from a vendor, or purchase from a vendor that is followed by Licensed Production, where the estimated cost of the acquisition proposal is 300 crores or more. Generally, 30% each of both these costs of acquisition will be the required value of the offset obligations. However, the Defence Acquisition Council may prescribe varying offset obligations in special cases if required. Nevertheless, these provisions will not apply to procurements under the Fast Track procedure, and those under the “Option” clause, where an offset obligation was not stipulated in the original contract.

Discharge of offset obligations

The offset obligations may be discharged by one or more of the following methods –

• Direct purchase or export orders for eligible products manufactured or serviced by Indian enterprises
• Foreign direct investment in joint ventures with Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services
• Investment in ‘kind’ in terms of transfer of TOT (Transfer OF Technology) to Indian enterprises for the manufacture and/or maintenance of eligible products and provision of eligible services
• Investment in ‘kind’ in Indian enterprises in terms of provision of equipment through the non-equity route for the manufacture and/or maintenance of eligible products and provision of eligible services, excluding TOT, civil infrastructure and second-hand equipment.
• Provision of equipment and/or TOT to government institutions and establishments engaged in the manufacture and/or maintenance of eligible products and provision of eligible services.
• Technology Acquisition by the DRDO in areas of high technology

Then, there are a multitude of other offset obligation discharge policies that are divided into different sectors, such as vendor responsibility, performance bond, offset credits, offset banking, value addition, Buy Global procurements, offset valuation, and more.

Submission of offset proposals

Vendors are required to submit a written undertaking to the effect that every offset obligation will be met. Any failure on the part of the vendor to comply with the guidelines may result in disqualification of the vendor from any further participation in the contract. The proposals should be submitted by a specified date, failure of which may render the bid non-responsive, and liable to be rejected.

Evaluation of offset proposals

The Acquisition Wing in the Department of Defence is responsible for technical and commercial evaluation of offset proposals received in response to RFPs, and the conclusion of offset contracts. The Defence Offsets Management Wing in the Department of Defence Production is responsible for the formulation of the offset guidelines, auditing and reviewing or progress reports, and post contract management. And, both these wings work in close collaboration for the smooth implementation of the guidelines.

Processing of offset proposals

Technology acquisition – The Technology Acquisition Committee is responsible for assessing the offset proposals, covering both technical and financial parameters, including valuation of technology, and the timeframe and strategy for utilizing the technology.

Technical evaluation – The Technical Offset Evaluation Committee (TOEC), constituting of representatives of the Service Headquarters, Defence Finance, DRDO, DOMW, and other experts, is responsible for scrutinizing the technical offset proposals to ensure conformity with the offset guidelines. The TOEC report is then forwarded to the Technical Manager, who will then process the report for acceptance.

Approval authority – After the offset proposals are processed by the Acquisition Manager, they will be approved by the Raksha Mantri.

Penalties – If a vendor fails to fulfil the obligations as agreed to, a penalty equivalent to 5% of the unfulfilled offset obligation will be levied, after which the unfulfilled offset value will be re-phased over the remaining period of the contract. The vendor may also be liable for debarment from participation in future defence contracts for a period of up to 5 years, the decision that will depend upon the Director General of Acquisition.

Re-phasing requests – A vendor has the advantage of requesting re-phasing of the offset obligations within the period of the offset contract, providing valid reasons. If justified, the request may be granted.

Annual reporting – An annual report is submitted to the Defence Acquisition Council in June every year, regarding the details of the contracts signed, and the status of implementation of all on-going contracts.

Indian enterprises, institutions, and establishments engaged in the manufacture of eligible products and/or provision of eligible services are referred to as Indian Offset Partners, who are required to comply with all the above guidelines/licensing requirements and many more. Vendors are free to select such a partner. If you’re looking for the same too, Miracle Electronics can prove to the best Offset Partner For Indian Defense, thanks to their complete adherence to the obligations, proven industry capabilities, consistent R&D, and every necessary quality certification in place!

Choosing The Right SMPS Transformer – Miracle Electronics

A multitude of electrical and electronic personal daily-use products, such as computers, mobile phone chargers, automobiles, telecommunications, and security systems, involve the usage of SMPS transformers, making it one of the most in-demand transformers across the globe.

These transformers are used to provide galvanic isolation at the input, meaning a clear barrier that prevents dangerous high voltages from passing to the output, thus providing safety from electrical shock. However, one disadvantage of such isolated power supply is low efficiency, which can range between only 70 to 90%.

What causes low efficiency?

As the power supply is run at high voltage/current, strong magnetic fields are passed into the core of the SMPS transformer, which causes hysteresis in the magnetic core as the input AC signal oscillates. Further, because of such high input current, the core can saturate during operation, leading to even severe hysteresis and heat dissipation. Due to this, almost every SMPS transformer manufacturer in India supplies hysteresis curves with their components, allowing the designer to determine the limits on the input current.

What problem can low efficiency cause? How can it be resolved?

Lower efficiency of the SMPS units can cause heat up to higher temperatures when run at high voltage/current. This is why thermal management strategies are required to remove the heat. Heat sinks can help here, as they provide sufficient cooling when used with chassis-mounted fans.

How to place an SMPS transformer effectively?

SMPS transformers can be placed in one or more locations in a regulator circuit, in any of the multiple power conversion and regulation stages. But, one very common location for the transformer is between the output regulation stage and the switching stage. However, the exact location for the SMPS will depend on the power supply topology – two common topologies being flyback converter and forward converter.

How to choose your SMPS transformer?

There are a variety of SMPS transformers that use different core materials, coil numbers, and winding directions. For instance, different core materials saturate at different magnetic field strengths, which determines the highest voltage that can be used with the transformer. Generally, 2 coil transformers are the most common, while 3 coil transformers are used to provide multiple output power levels from a single SMPS circuit. In this way, you must be able to determine the exact specifications that you require. You must be able to choose the ideal SMPS transformer for your application. It must be one that operates within the linear hysteresis range for your supply, in order to minimize heating and power loss.

Partnering with a professional SMPS transformer manufacturer in India, one like Miracle Electronics, can ensure that every minute detail about designing the transformer is taken care of. That’s because they are skilled and capable of designing unique customized SMPS transformers for your particular application, delivering RoHS and REACH compliant solutions that guarantee minimal power wastage and highest possible efficiency. Miracle Electronics’ SMPS transformers have a high power-to-size ratio, with each segment topology having a unique V-in to V-out transfer function, leading to absolute efficiency. Hence, with a reliable transformer manufacturer  like Miracle Electronics, your transformers produce the desired output voltage, ensuring that the ripple is within your tolerances.

Cable Harnesses – Insulators, Connectors, And Terminals – Miracle Electronics

When you’re looking to protect your wires and cables against environmental conditions like moisture, temperature, and friction, you’ll need to install cable harnesses in your application. Depending upon the intended environment, there are multiple types of cable harnesses available to choose from.

You may opt for standard readily available harnesses, or have your harnesses customized by proficient cable harness manufacturers in India.

When you’re planning to have your cable harnesses customized, you may either tell the manufacturer all about your requirements, or sit with them to design your specialized assemblies. If you choose the latter, you need to first have a basic understanding about the product, before you can sit down to decide on what you want. Considering this, we’ll let you know about the three main components that comprise a cable harness, which are insulators, connectors, and terminals.

Insulator types

The cables or the insulation that covers the wires can be of two types, depending upon the kind of environment or application the harnesses are to be used in. they could either be thermoplastics or thermosets.

• Thermoplastics are the materials that soften or melt when exposed to a sufficiently high temperature, but also easily harden when cooled. They can be repeatedly softened and hardened by heating and cooling, without affecting the performance of the material. This quality enables recycling of the components, which also proves to be economical. Some common thermoplastic insulations include PE, PVC, PVDF, ECTFE, and nylon.
• Thermosets are the materials that don’t soften even at high temperatures, but they’re rubbery and retain their properties at all times. However, once moulded or cast, these materials cannot be reshaped, because the moulding results in a permanent chemical change within the material’s structure. Some common thermoset insulations include CPE, EPR, and XLPE.

Connector types

Connectors are the electromechanical devices used to form a continuous electrical signal between the cable harness and power source. Basically, connectors consist of male plugs and female jacks that are joint together to relay an electronic signal. Such connectors broadly differ in materials, sizes, shapes, and dimensions, which can be chosen from or customized as per the intended application. The mating type, the insulation requirement, the power contacts, and the signal contacts are all the different factors that determine the kind of connector required by the application. When selecting a connector, it is also very crucial to know the wire size, circuit size, circuit density, operating voltage, current rating, and other such important numbers.

Terminal types

Terminals are the electromechanical devices that terminates a conductor to a fixed post, stud, chassis, etc. in order to establish a connection. Available in a variety of designs, shapes, and sizes, terminals may be crimped, soldered, press-fitted, or wire-wrapped. They are available in ring, spade, hook, bullet, butt, and flagged forms. The type of terminals to be used can depend on the requirements of the intended application. The terminals could be insulated or non-insulated. Insulated terminals are better used in harsh environmental conditions to protect the device and components from moisture and temperature extremes. If no such protection is required, non-insulated terminals are an economical choice.

Determining the type of insulator, connector, and terminal is of prime importance to come up with the best performing cable harness. They harness should be very carefully designed while keeping the specific application needs and environmental conditions in mind. The correct materials, sizes, and shapes are vital to ensure that the harnesses are properly placed and appropriately routed, while being completely protected. Professional cable harness manufacturers in India like Miracle Electronics can take care of every such aspect that affects the quality of the end product , so as to come up with a harness that’ll extend the life of the wires, without requiring early replacements or repairs. It’s thus always better to partner with a professional for even the smallest electrical or electronic build.

Is An EI Transformer A Good Choice For You? – Miracle Electronics

With every transformer performing the same task of trading voltage for current in a circuit, without affecting the total electrical power, different types of transformers work differently to achieving the same goal. Also, different types in regards to the shape, size, material, etc. also affects the quality of performance. In this blog today, we’ll speak about one particular kind of transformer – the EI transformer.

What is EI transformer?

As the name itself suggests, EI transformer is one whose core is combined by laminations shaped “E” and “I”. A traditional and economical transformer, the EI transformer is widely used in a variety of electronic equipment and audio applications. The air gap between the E and I laminations can be easily adjusted by filling it with a suitable medium, making it suitable for building output transformers and chokes. This is the reason why many audio output transformers and chokes are designed with the EI transformer.

Why should you opt for an EI transformer?

EI transformers have a very simple structure, making it absolutely easy to manufacture, which is why most transformer factories are able to manufacture these transformers.

It is very easy to find the components required to build an EI transformer in the market, making it an easy-make as well as economical solution. With everything being available easily, the prices automatically go down.

EI cores are flat stampings with no need of any kind of bending or forming, which makes it very economical to manufacture.

The laminations can be removed from a single rectangular sheet without substantial wastage.

The mounting method of the EI transformer is simple.

EI transformer cores are more preferred than other U, C, and L core types, mainly because more surface space is protected by the winding in these cores.

The make of an IE transformer is such that the whole thing can be held together conveniently with simple corner fixings, or just vacuum impregnation with lacquer.

There is very good magnetic coupling between the two ends of the core.

Are there any disadvantages of using an EI transformer?

Just like anything else, EI transformers, in spite of having so many good qualities, also have drawbacks. One major drawback is that these cores don’t have self-shielding quality in them.

After going through the blog, it’s time you decide as to whether you would want to use an EI transformer for your application or not. Despite the fact that an EI transformer doesn’t have self-shielding, there are so many other benefits associated with it. So, whether it is for differential, power, or telecom inductors, converters, or inverter transformers, if EI seems to be the right choice for you, you could approach Miracle Electronics for the same. They’re the most reliable EI transformer manufacturer in India, where you can get durable and highly efficient transformers that come with superior wiring, varnishing, and connection terminators, all of which provide excellent regulation with minimal temperature rise. You can thus make the most of your electrical devices by buying such RoHS and REACH compliant EI transformers that can lower the voltage exactly to a value that is required by your appliance, while keeping it running right and safe.