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The Technology of Wire Wrapping

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The Technology of Wire Wrapping THE TECHNOLOGY OF WIRE WRAPPING A wire wrapped connection is made by coiling the wire around the sharp corners of a terminal under mechanical tension. This method of connection was developed by Bell Telephone Laboratories, Western Electric Company. Five Steps To Make A Regular Modified Wire Size Chart Wire Wrap Connection Bare Wire Dia. AWG SWG (USA) (GB) 1 In. mm .0403 1.022 18 .040 1.016 19 .036 0.914 19 20 2 .032 0.813 20 21 A “Regular” bit wraps the bare wire around the .028 0.711 21 22 terminal. A “Modified” bit wraps a portion of .0253 0.643 22 insulation around the terminal in addition to the .024 0.61 23 bare wire. This greatly increases the ability to 3 withstand vibration. .0226 0.574 23 .022 0.559 24 A distinct advantage of wire wrapping is the .0201 0.51 24 ease with which a wire may be removed from .020 0.508 25 4 a terminal to correct errors or modify wiring. .018 0.457 26 An unwrap tool is slipped over the terminal, .0179 0.455 25 engaging the first turn of the connection. .0164 0.417 27 5 Rotating the tool, the connection is removed in .0159 0.404 26 seconds, without damage to the terminal. .0148 0.376 28 .0142 0.361 27 There is a constant surveillance of manufacturing .0136 0.345 29 dimensions. Each wrapping bit is subjected to a “Strip” Force Chart* .0126 0.320 28 series of “Qualification Tests”. These consist of Minimun .0124 0.315 30 Wire Size Minimum wrapping groups of wire on various types of Number Strip Force terminals. The wrapped wires are then subjected .0116 0.295 31 Dia Dia. of Turns .0113 0.287 29 AWG lbs g to a “strip” test to determine adequate tightness. (in) (mm) (Bare Wire) “Unwrap” tests are also performed to ensure .0108 0.274 32 16 .0510 1.30 4 15 6800 against an “Over Tight” wrap. .0100 0.254 30 33 18 .0403 1.00 4 15 6800 .0092 0.234 34 20 .0320 0.80 5 8 3600 Solid wire is used for wire wrapped connections. .0089 0.225 31 22 .0253 0.65 5 8 3600 Copper is the most commonly used wire. .0084 0.213 35 24 .0201 0.50 6 7 3200 Minimum elongation of 15% is required for 24 0.008 0.203 32 26 .0159 0.40 7 6 2700 through 32 AWG; 20% for larger wire. 28 .0126 0.32 7 5 2200 30 .0100 0.25 7 3.3 1500 * Conforms to MIL-STD-1130B Terminal Diagonal Chart In. 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 0.055 0.06 0.065 0.07 0.075 0.08 0.085 0.09 0.095 0.1 mm 0.25 0.38 0.51 0.64 0.76 0.89 1.02 1.14 1.27 1.4 1.52 1.65 1.78 1.91 2.03 2.16 2.29 2.41 2.54 0.01 0.014 0.018 0.022 0.027 0.032 0.036 0.041 0.046 0.051 0.056 0.061 0.066 0.071 0.076 0.081 0.086 0.091 0.096 0.101 0.25 0.36 0.46 0.56 0.69 0.81 0.91 1.04 1.17 1.3 1.42 1.55 1.68 1.8 1.93 2.06 2.18 2.31 2.44 2.57 0.015 0.018 0.021 0.025 0.029 0.033 0.038 0.043 0.047 0.052 0.057 0.062 0.067 0.072 0.077 0.082 0.087 0.092 0.097 0.102 0.38 0.46 0.53 0.64 0.74 0.84 0.97 1.09 1.19 1.32 1.45 1.58 1.7 1.83 1.96 2.08 2.21 2.34 2.46 2.59 0.02 0.022 0.025 0.028 0.032 0.036 0.04 0.045 0.049 0.053 0.058 0.063 0.068 0.073 0.078 0.083 0.088 0.093 0.098 0.103 0.51 0.56 0.64 0.71 0.81 0.91 1.02 1.14 1.25 1.35 1.47 1.6 1.73 1.85 1.98 2.11 2.24 2.36 2.49 2.62 0.025 0.027 0.029 0.032 0.035 0.039 0.043 0.047 0.05 0.056 0.06 0.065 0.069 0.074 0.079 0.084 0.089 0.094 0.099 0.104 0.64 0.69 0.74 0.81 0.89 0.99 1.09 1.19 1.27 1.42 1.52 1.65 1.75 1.88 2.01 2.13 2.26 2.39 2.52 2.64 0.03 0.032 0.033 0.036 0.039 0.042 0.046 0.05 0.054 0.058 0.062 0.067 0.071 0.076 0.08 0.085 0.09 0.095 0.1 0.105 0.76 0.81 0.84 0.91 0.99 1.07 1.17 1.27 1.37 1.47 1.58 1.7 1.8 1.93 2.03 2.16 2.29 2.41 2.54 2.67 0.035 0.036 0.038 0.04 0.043 0.046 0.049 0.052 0.056 0.06 0.064 0.069 0.073 0.078 0.082 0.087 0.091 0.096 0.101 0.106 0.89 0.91 0.97 1.02 1.09 1.17 1.25 1.32 1.42 1.52 1.63 1.75 1.85 1.98 2.08 2.21 2.31 2.44 2.57 2.69 0.04 0.041 0.043 0.045 0.047 0.05 0.052 0.056 0.06 0.064 0.068 0.072 0.076 0.08 0.084 0.089 0.092 0.097 0.102 0.107 1.02 1.04 1.09 1.14 1.19 1.27 1.32 1.42 1.52 1.63 1.73 1.83 1.93 2.03 2.13 2.26 2.34 2.46 2.59 2.72 0.045 0.046 0.047 0.049 0.05 0.054 0.056 0.06 0.063 0.067 0.071 0.074 0.078 0.083 0.087 0.091 0.096 0.101 0.105 0.109 1.14 1.17 1.19 1.25 1.27 1.37 1.42 1.52 1.6 1.7 1.8 1.88 1.98 2.11 2.21 2.31 2.44 2.57 2.67 2.77 0.05 0.051 0.052 0.053 0.056 0.058 0.06 0.064 0.067 0.071 0.074 0.078 0.082 0.086 0.09 0.094 0.098 0.103 0.107 0.111 1.27 1.3 1.32 1.35 1.42 1.47 1.52 1.63 1.7 1.8 1.88 1.98 2.08 2.18 2.29 2.39 2.49 2.62 2.72 2.82 JDV Products, Inc 22-01 Raphael Street Fair Lawn, NJ 07410 USA 201-796-1720 [email protected] www.jdvproducts.com 2 PNEUMATIC WRAPPING TOOLS The WG300 is perfectly well balanced and is rated for delicate 32 AWG work, as well as heavy duty 18 AWG applications. Free Weight Wire Size Part No. Type Speed (RPM) oz kg AWG mm WG300 Standard 4500 10.6 0.30 18-32 1.0-0.20 WG300BF ABF Backforce 4500 10.6 0.30 18-32 1.0-0.20 • WG300 & WG300BF include 6ft nylon braided air hose (Part No. A-10738) • Full line of wire wrap bits and sleeves on page 7 Repair Service Please contact JDV Products for details. These units are designed for mass production and aircraft maintenance applications. Both models are manufactured from a lightweight, high impact resistant, glass-filled nylon. These tools are lightweight, well balanced, and built to handle the rigors of everyday manufacturing requirements. The handle design reduces operator fatigue, and the high speed 4500 rpm motor produces fast, efficient wraps for 18 to 32 awg wire sizes. Free Weight Wire Size Part No. Type Speed (RPM) oz kg AWG mm SP 6001 Standard 4500 9.0 0.26 18-32 1.0-0.20 SP 6002 ABF Backforce 4500 9.5 0.27 18-32 1.0-0.20 • SP 6001 & SP 6002 include 6ft nylon braided air hose (Part No. A-10738) • Full line of wire wrap bits and sleeves on page 7 CUT & STRIP TOOL ATTACHMENT These cut/strip tool attachments allow the operator to cut to length and strip the wire in one simple operation. The length of wire to be cut is adjustable. Different gauge stripping blades can be changed out quickly and easily. Model# WS 650 Strip Blades Part No. For Wire Size SP 64520 20 AWG SP 64522 22 AWG SP 64524 24 AWG SP 64526 26 AWG Model# WS 650 Model# SP 650 SP 64528 28 AWG For use with For use with Model# SP 650 JDV Products Standard Pneumatic SP 64530 30 AWG brand pneumatic tools brand electric and pneumatic tools SP 64533 22-24 AWG Strip blade (shown) sold separately Strip blade (shown) sold separately OPEN-FACED CUT/STRIP/WRAP (CSW) TOOLS JDV's "Open-Faced" CSW bit is fast and easy to use.
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