Wire wrap-Overview-A-Custom Design
Circuit Board Electronic Pcb
The tool is rapidly twisted. The result is that 1.5 to 2 turns of insulated wire are wrapped around the post, and above that, 7 to 9 turns of bare wire are wrapped around the post. The post has room for three such connections, although usually only one or two are needed. This permits manual wire-wrapping to be used for repairs.
The turn and a half of insulated wire helps prevent wire fatigue where it meets the post.
Above the turn of insulated wire, the bare wire wraps around the post. The corners of the post bite in with pressures of tons per square inch. This forces all the gases out of the area between the wire's silver plate and the post's gold or tin corners. Further, with 28 such connections (seven turns on a four-cornered post), a very reliable connection exists between the wire and the post. Furthermore, the corners of the posts are quite "sharp": they have a quite-small radius of curvature.
There are three ways of placing wires on a board.
In professionally built wire-wrap boards, long wires are placed first so that shorter wires mechanically secure the long wires. Also, to make an assembly more repairable, wires are applied in layers. The ends of each wire are always at the same height on the post, so that at most three wires need to be replaced to replace a wire. Also, to make the layers easier to see, they are made with different colors of insulation. In space-rated or airworthy wire-wrap assemblies, the wires are boxed, and may be conformally coated with wax to reduce vibration. Epoxy is never used for the coating because it makes an assembly unrepairable.
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