Why Are Cable Assemblies Used In Clean Technology Applications?


Clean Technology or Clean Tech is a term used to describe products and services that reduce waste and require very few non-renewable resources. This technology reduces the negative environmental impacts through significant energy efficiency improvements, sustainable use of resources, and environmental protection activities. This technology relates to recycling, renewable energy, information technology, green transportation, and a lot more, all of which provide superior performance at competitive costs.

How Are Wire Harnesses Manufactured?


You may know what a wire harness is and what all applications it can be used in. but do you know how it is built? It could be a small bundle with two wires and two connectors, or a large and complicated one that has 5000 wires and more than 100 connectors, but they are all manufactured following the same procedures. There are five basic steps that need to be followed while building a wire harness – simple or complicated. Miracle Electronics is a professional wire harness manufacturer in India who not only follows these basic steps to manufacture great wire harnesses, but also makes sure to use the best quality materials and test its products before letting it be delivered to the clients.

Cutting the wires

The first and foremost step for constructing every wire harness is measuring, marking, and cutting each wire involved individually. Laser wire marking is the method to place a permanent mark on a wire using a laser. Therefore, a laser wire marking machine can be used to carry out all three tasks properly. After marking and cutting the wires, the next step is to lay out these wires properly.

Laying out the wires

Once all the wires are cut, the assembler lays down each wire individually onto a Harness Assembly Drawing (HAD) – a drawing used to help in the manufacturing of electrical wire harnesses by showing how wires are routed from one end point to another. Before manufacturing a harness, a HAD is printed in full scale to ensure that the exact dimensions are met. Once the HAD is created and printed, it is placed on a table where the harness is then assembled on top of it. Different wires have different gauges. Also, some wires have a metal shield around the main conductor while others do not. But, all these wires need to be perfectly routed. Once routed, these wires are grouped together using a tape or string tie. Now, these grouped wires go in for wire termination.

Wire termination

Wire termination is a process utilized on the end of every wire to allow it to connect to a connector, switch, terminal, or any other relevant device. There are two types of wire termination processes that can be carried out – crimp termination and solder termination. Crimp termination is when the device requires a contact or terminal. Here, the wire insulation is stripped, and the contact or terminal is attached to the wire using a crimp tool. Solder termination, on the other hand, is when the wire conductors directly attach to the device. This requires stripping off the wire insulation and applying solder and flux to connect the wire to the device. It is highly important that all wire terminations are performed correctly. The wire harness is then moved on to the testing stage.


After the wire harness is constructed, it is tested for any faults. The two main tests carried out are the continuity testing and insulation resistance testing. A continuity test will verify the flow of current in the electrical circuit, meaning that the circuit is continuous. This test is performed by placing a small voltage between two or more endpoints of the circuit. An insulation resistance test uses an applied DC voltage to test for current resistance and to keep the current on its path along the conductor. The wire harness is then sent for dressing out.

Dressing out

Dressing out of a wire harness includes heating up and shrinking down tubing, making sure that the reference designator labels and wire harness identifiers are located properly, putting dust cover caps on connectors to protect them, and final inspection. Once all of this is done properly, the wire harness is then packaged and shipped to the client.

What All Must You Consider For A Box Build Assembly Process?


A box build, also known as systems integration, is an electromechanical assembly process that includes enclosure fabrication, installation and routing of cable harnesses, and installation of sub-assemblies and components. You can say that box build is a printed circuit board assembly in a big cabinet full of wires, or a complex fully integrated electromechanical system with pneumatics and electronics.

What Are The Benefits Of Using Wire Harnesses?


A wire harness, also known as cable assembly, is the synthetic integrated arrangement of cables within an insulated material that transmits electrical power, which is why it is used in the electrical system of machines. The cables of different colours and sizes, each representing a unique function, are bound together by straps, cable ties, sleeves, electrical tape, cable lacing, and other combinations. Instead of different cables running individually, a wire harness provides a common connection point that is much safer and less messy.

Different Types Of Transformers Based On Classifications


Transformers are devices used to transfer electrical energy between two or more circuits through electromagnetic induction to increase or decrease the alternating voltages in electric power applications. These devices mainly consist of a laminated magnetic core, and windings wound over it, which are insulated from the core as well as from each other. There are a variety of transformers available in the market. You must choose the most appropriate transformer based on where and how you would want to use it. To learn about and get the most suitable transformer for your application and purpose, you can get in touch with Miracle Electronics, the leading transformer manufacturer in India, who not only provides a wide range of high quality devices, but can also help you customize your transformer. In this blog, we will help you generally know about the various types of most popularly used transformers based on a variety of parameters.

Do You Believe In These Transformer Myths Too?


Any kind of myths can be problematic. And when it comes to something as important as a transformer, wrong beliefs can definitely lead to transformer failures with an increase in the costs incurred. Listed below are the most common transformer myths found within people. Read further to know if you also believe in these false statements, and clear off your doubts for the same.

Smart Cities And Power Transformers


The Indian Government has announced to build up more than 100 smart cities in India. With the project and planning in process since the past 2 years, India is soon to experience a new experience of being ‘smart’. So, what exactly makes a smart city? It is a combination of hygiene, health and education, information and communication technology, adequate water supply, efficient public transport, affordable housing, safety and security, and uninterrupted power supply.

Role And Advantages Of Smart Transformers In Distribution System


Smart transformers are solid state transformers that play a managerial role in the electric distribution grid. They work independently to constantly regulate the voltage while maintaining contact with the smart grid so that information and feedback about the transformer and power supply can be provided even through remote administration. These transformers are designed to provide a voltage optimized power supply to address the energy needs of the facility, which is why large commercial facilities are using these devices more and more today so that they can use power more efficiently and cost-effectively.

Power Transformer Protection Devices


Transformers rarely go down, but when they do, they highly affect the entire working environment with devastating effects. In case of a transformer failure, there is great loss of operational capability with the entire process being interrupted and the assembly line coming to a stop. Additionally, there could be subsequent fires, security lapses and great loss of income. Therefore, it is very essential to take care of transformer protection.

What To Do When Your Transformer Goes Down?

what-to-do-when-your-transformer-goes-downA transformer going down means an emergency replacement is required to keep the production on line! How equipped are you for such an emergency? And, how much can you afford to lose during replacement? These questions need to be well answered for any CEO, manager, or anyone in charge of the plant.