Various Processes Involved In Constructing Cable Harnesses


Any kind of cable harnesses you wish to install into any of your applications, you need to be sure that they meet industry standards and application requirements. And for this, you need to purchase your products from a trusted dealer like Miracle Electronics, one of the largest suppliers and leading cable harness manufacturers in India. Cable harnesses can be entitled as perfect if they are checked and tested for various confirmations, and comply with every requirement and standard. There are various processes that ensure proper wiring and electrical aspects, which ultimately result in 100% positive results while performing the tests. Below mentioned are some of the most important processes involved in the construction of cable harnesses.

Understanding The Switch Mode Power Supply Better


The most important element of an electronic circuit is the power supply that provides current to the entire circuit. Different circuits require different kinds of power of different ranges. This is why different power converters are used to change the power into the range that is required by the individual application it is applied to. This is where the Switch Mode Power Supply (SMPS) comes in handy, which is an electronic circuit that converts power using switching devices and inductors or capacitors to change the electrical power from one form to another as required. The power supply is generally used to achieve regulated DC output voltage from DC input voltage or unregulated AC.

All You Need To Know About Toroid Inductors


Toroidal inductors are passive electronic components that consist of a circular ring or doughnut-shaped magnetic core, made of ferromagnetic materials like ferrite, silicon steel, nickel, laminated iron, or iron powder, around which wire is wound. The circular shape of the core helps very less amount of magnetic flux to escape outside the core, thus making the inductor more efficient by radiating lesser electromagnetic interference. These toroid inductors are used to achieve energy efficiency, mainly when low frequencies require inductance. The various applications that use toroid inductors include air conditioners, refrigerators, computers, televisions, amplifiers, etc.

How Are Wire Harness And Cable Assembly Different?


Wire harnesses and cable assemblies are generally used interchangeably, but are actually quite different from each other. Although they both have similar basic functions, they are different in terms of their purpose. This blog will help you learn about both wire harnesses and cable assemblies differently, so that you can better understand the difference between the two.

Benefits And Applications Of Automotive Wire Harnesses


Wire harnesses are assemblies of electrical cables that transmit signals in electrical applications. They are a bundle of loose wires grouped together into a single covering for a more organized system. Such wire harnesses are used in various industries, with the automotive industry being one of the largest consumers.

Automotive wire harnesses use a wide variety of wire harnesses for the best possible performance. These harnesses combine wiring of different electrical and electronic devices into a single system. Therefore, they aid in signal transmission and powering up of different electronic and electrical devices. They are also use to set up electrical circuits in automobiles, and are designed to operate in extreme conditions effectively.

Can Wire Harness Production Be Completely Automated?


A wire harness, also called as cable harness, cable assembly, wire loom, or wiring assembly, is a group of wires clubbed together into one unit to transmit signals and provide electrical power to various applications. These harnesses consist of multiple components along with the many wires they constitute of. The wires clubbed together could be of any type ranging in hook-up wires, multi-pair cables, multi-conductor cables, and coaxes. There could be a combination of any of these wires, depending upon the design of the harness. These equipment are designed according to the geometric and electrical requirements of the equipment they will be installed in. Miracle Electronics is a leading wire harness manufacturer in India who undertakes requests for custom design and development of wire harnesses. This is where you can get all your required wire harnesses that are certified for quality to ISO 9001, AS9100C; and are approved by DGAQA and MSQAA for platform specific applications.

What Are The Different Parts That Make Up A Power Transformer?


The electrical devices that transfer electrical energy from one circuit to another through electromagnetic induction to step up or step down voltage levels are known as transformers. These equipment are made up of lots of different parts performing different functions. Every big and tiny part of a transformer plays a very vital role in its functioning. Listed below are some of the most important parts of power transformers in India.

Coil Power Supply Or Switch Mode Power Supply – Which Is Better?


When it comes to electrical and electronic circuits, it is crucial to have a power supply that delivers the exact amount of current and voltage required for the circuit to run, without exceeding the limits. There are two most common types of power supplies – coil (or linear as it is more popularly called) and switched mode. Although both these power supplies supply DC power, they differ in the way they produce the power and in the way they operate. Depending on the application they are used with, both the power supplies have their own advantages and disadvantages.

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.