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3. 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.

• A "Regular" bit wraps the bare wire around the terminal. A "Modified" bit wraps a portion of insulation around the terminal in addition to the bare wire. This greatly increases the ability to withstand vibration.
• A distinct advantage of wire wrapping is the ease with which a wire may be removed from a terminal to correct errors or modify wiring. An unwrap tool is slipped over the terminal, engaging the first turn of the connection. Rotating the tool, the connection is removed in seconds, without damage to the terminal.
• There is constant surveillance of manufacturing dimensions. Each wrapping bit is subjected to a series of "Qualification Tests". These consist of wrapping groups of wire on various types of test terminals. The wrapped wires are then subjected to a "Strip" test to determine adequate tightness. "Unwrap" tests are also performed to ensure against an "Over tight" wrap.
• Solid wire is used for wire wrapped connections. Copper is the most commonly used wire. Minimum elongation of 15% is required for 24 through 32 AWG; 20% for larger wire.

Wire Size Chart

Bare Wire Diam.		AWG	SWG
Inches	mm	(USA)	(GB)
.0403	1.022	18
.040	1.016		19
.036	0.914	19	20
.032	0.813	20	21
.028	0.711	21	22
.0253	0.643	22
.024	0.61		23
.0226	0.574	23
.022	0.559		24
.0201	0.51	24
.020	0.508		25
.018	0.457		26
.0179	0.455	25
.0164	0.417		27
.0159	0.404	26
.0148	0.376		28
.0142	0.361	27
.0136	0.345		29
.0126	0.320	28
.0124	0.315		30
.0116	0.295		31
.0113	0.287	29
.0108	0.274		32
.0100	0.254	30	33
.0092	0.234		34
.0089	0.226	31
.0084	0.213		35
.008	0.203	32

Making a Wire Wrapped Connection

Step 1: Choose Bit & Sleeve for the pre-stripped wire size to be wrapped. Step 2: Insert the pre-stripped into wire slot. Step 3: Anchor the wire at the notch in the wrapping sleeve. Step 4: Insert the Terminal into the center hole of the wrapping bit. Step 5: Make a finished connection by starting the wrapping tool and rotating the wire around the terminal.

"Strip" Force Chart*

*Conforms to MIL-STD-1130B

Wire Size			Min. number	Min. strip
AWG	Diam.	Diam.	of turns	force
	inch	mm	(Bare Wire)	lbs.	gms
16	.051	1.30	4	15	6800
18	.0403	1.00	4	15	6800
20	.032	0.80	5	8	3600
22	.0253	0.65	5	8	3600
24	.0201	0.50	6	7	3200
26	.0159	0.40	7	6	2700
28	.0126	0.32	7	5	2200
30	.0100	0.25	7	3.3	1500

Terminal Diagonal Chart