wire_wrap_tips

wire_wrap_tips - TIPS FOR RELIABLE WIREWRAPPING Gary Newman...

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TIPS FOR RELIABLE WIREWRAPPING Gary Newman Ampex Corporation Redwood City, California 94063 June 13, 1980 ABSTRACT The unwary technician frequently constructs his first wirewrapped circuit with little or no instruction, while the wary will first seek a source of information. The unwary engineer frequently changes wires on wirewrapped circuits with little or no instruction, while the wary will first seek a source of information. The unfortunate facts show that in both cases the latter is a rare breed. By following a few rules, and understanding why a wrapped wire makes a good connection, a reliable circuit can be produced with little effort. This paper should serve as a road map to both guide the beginner, and improve the style of the more experienced wirewrapper. ============================================================ TIPS FOR RELIABLE WIREWRAPPING Introduction When used properly, wire wrapping has been shown to be the most reliable connection method currently available 1 . It makes connections quickly and efficiently, that may be easily changed with a few tools. However, the wire-wrapper must be well enough informed to choose the correct wire, tool, and pins to make the connections with, and know how to evaluate the quality of the completed connection. These topics will be dealt with first, in the section on "The Wrap". Once the wire-wrapper is capable of making a correct connection, there are other tips that help make for better circuits. The factors that affect the performance of the connection in the electrical circuit, and the ease of changing the circuit will be dealt with in the remaining sections. 2. The Wrap The connection is made by wrapping a solid wire tightly around the corners of a connecting post while applying tension to the wire. This process both cuts a notch in the wire and deforms the post at each corner. At each corner a cold weld is thus created, causing cross migration of the metal atoms of the post and the wire 2 . While the weld does not contribute to the mechanical integrity of the connection, it does contribute to its electrical stability. The contact area is only reliable at the corners, and so the electrical properties of the connection are determined by the number of corners of the wrap. The tension applied to the wire causes it to stretch elastically as it is wrapped. This 1 Belter, Robert E., "Make ECL wire-wrapped panels reliable with proper routing and tough insulation", Electronic Design, June 7, 1979, p. 106 2 Davies, D.G., "Micro-Mechanisms of Solderless Wrapped Joint Formation", The Plessey Company Limited.
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leaves the completed connection with elastic energy stored in the lengths of wire between corners. Thus the mechanical properties of the connection are determined by the type of wire and under what tension it is wrapped. The wrap may then be considered as a collection of cold welds (at the corners), all held together by individually stretched springs (the wire between corners). 2.1. The Post
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This note was uploaded on 04/05/2010 for the course ECEC 304 taught by Professor Peters during the Summer '09 term at Drexel.

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wire_wrap_tips - TIPS FOR RELIABLE WIREWRAPPING Gary Newman...

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