Method and system for aligning and positioning optical fibers and microlens arrays - Patents.com

Abstract

A system and method for aligning an optical fiber is provided herein. The method can include providing an optical fiber having a first end and a second end, where the first end of the optical fiber has a predetermined manufacturing characteristic. For example, the predetermined manufacturing characteristic of the first end of the optical fiber can include a predetermined cleave angle. The method can also include positioning the optical fiber such that the first end of the optical fiber faces a microlens array (MLA) alignment system. In an example embodiment, the MLA alignment system can include a tilt sensing device and a position sensing device. The method can also include emitting a light beam from the first end of the optical fiber toward the MLA alignment system.

Description

[Technical field]

[0001]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 323,655, filed March 25, 2022, and entitled "METHOD AND SYSTEM FOR ALIGNING AND POINTING AN OPTICAL FIBER AND MICROLENS ARRAY," and U.S. Provisional Patent Application No. 63 / 324,445, filed March 28, 2022, and entitled "SYSTEMS AND METHODS FOR MEASURING A CLEAVE ANGLE OF AN OPTICAL FIBER," the entire contents of which are incorporated herein by reference for all purposes. [Background technology]

[0002]

[0002] When optical fibers are spliced ​​together or glued to an optical element, the optical fibers may be positioned and aligned for splicing and / or gluing. A microlens array is an optical element to which the optical fibers are often glued. A microlens array may contain a large number of lenslets. An optical fiber may be aligned and glued to each of the large number of lenslets in the microlens array. Despite progress in the development of microlens array alignment systems, there is a need in the art for improved methods and systems relating to alignment of optical fibers with microlens arrays.

[0003]

[0003] Additionally, optical fibers have a structure that supports the propagation of light by total internal reflection. When optical fibers are spliced ​​together or bonded to optical elements, the fibers may be positioned and aligned for splicing and / or bonding. Despite progress in the development of cleavage angle measurement systems and techniques, there is a need in the art for improved methods and systems relating to measuring the cleavage angle of optical fibers. Summary of the Invention [Problem to be solved by the invention]

[0004]

[0004] The present disclosure generally relates to methods and systems associated with optical systems including optical fibers. More specifically, embodiments of the present invention provide methods and systems that can be used to align one or more optical fibers to a microlens array and to measure the cleavage angle of an optical fiber. The present disclosure is applicable to a variety of applications in lasers and optics, including fiber laser implementations. [Means for solving the problem]

[0005] In aspects, a method of aligning an optical fiber is provided. The method can include providing an optical fiber having a first end and a second end, where the first end of the optical fiber has a predetermined manufacturing characteristic. For example, the predetermined manufacturing characteristic of the first end of the optical fiber can include a predetermined cleave angle. The method can also include positioning the optical fiber such that the first end of the optical fiber faces a microlens array (MLA) alignment system. In an example embodiment, the MLA alignment system can include a tilt sensing device and a position sensing device. The method can also include emitting a light beam from the first end of the optical fiber toward the MLA alignment system. In some embodiments, the MLA alignment system can also include a beam splitter and a focusing lens. In such an embodiment, emitting the light beam from the first end of the optical fiber can include transmitting a first portion of the light beam from the first end of the optical fiber through a beam splitter before reaching the position sensing device, and reflecting a second portion of the light beam from the first end of the optical fiber through a focusing lens from the beam splitter before reaching the tilt sensing device.

[0006]

[0006] The method may also include generating a reference output from the MLA alignment system based on the light beam. The reference output may include at least one of a tilt measurement and / or a position measurement. In some embodiments, generating a reference output from the MLA alignment system based on the light beam may include placing the optical fiber at a first position, measuring a first tilt measurement based on the light beam emitted from a first end of the optical fiber at the first position via a tilt sensing device, measuring a first position measurement based on the light beam emitted from the first end of the optical fiber at the first position via a position sensing device, comparing the first tilt measurement to a tilt threshold, and comparing the first position measurement to a position threshold. Placing the optical fiber at the first position may include moving the optical fiber along at least one of an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation. In such an embodiment, the method may further include the steps of placing the optical fiber at a second position; measuring a second tilt measurement from the tilt sensing device based on a light beam emitted from the first end of the optical fiber via the tilt sensing device; measuring a second position measurement based on a light beam emitted from the first end of the optical fiber at the first position via the position sensing device; comparing the second tilt measurement to a tilt threshold; and comparing the second position measurement to a position threshold.

[0007]

[0007] The method may also include, after generating the reference output, providing a microlens array (MLA) having a plurality of lenslets at a first position between the first end of the optical fiber and the MLA alignment system. For example, providing the MLA at a first position between the first end of the optical fiber and the MLA alignment system may include placing the MLA at the first position such that a light beam emitted from the first end of the optical fiber passes through one of the plurality of lenslets.

[0008]

[0008] The method may also include generating a first MLA beam output for a first position of the MLA, the first MLA beam output comprising at least one of a first MLA tilt value or a first MLA position value. For example, generating a first MLA beam output for a first position of the MLA may comprise measuring a first MLA tilt value of the MLA at the first position via a tilt sensing device, measuring a first MLA position value of the MLA at the first position via a position sensing device, comparing the first MLA tilt value to an MLA tilt threshold, and comparing the first MLA position value to an MLA position threshold, wherein the alignment threshold comprises an MLA tilt threshold and an MLA position threshold. In some embodiments, this example can further include moving the MLA from a first position to a second position based on the first MLA beam output, generating a second MLA beam output for the second position of the MLA, where generating the second MLA beam output includes measuring a second MLA tilt value of the MLA at the second position via a tilt sensing device and measuring a second MLA position value of the MLA at the second position via a position sensing device, and comparing the second MLA beam output to an alignment threshold, where comparing the second MLA beam output to the alignment threshold includes comparing the second MLA tilt value to an MLA tilt threshold and comparing the second MLA position value to an MLA position threshold. In some embodiments, moving the MLA from the first position to the second position can include moving the MLA along at least one of an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation.

[0009]

[0009] The method may also include comparing the first MLA beam output to an alignment threshold. In some embodiments, the method may further include attaching a first end of a second optical fiber to one of a plurality of lenslets of the MLA. In such embodiments, the first end of the second optical fiber may be the first end of the optical fiber.

[0010] In another aspect, a method of aligning an optical fiber array is provided. The method can include providing a plurality of optical fibers. The plurality of optical fibers can include a first optical fiber having a first end and a second end, and a second optical fiber having a third end and a fourth end. The method can also include positioning the first optical fiber such that the first end of the optical fiber faces an MLA alignment system. The MLA alignment system can include a tilt sensing device and a position sensing device. In some embodiments, the MLA alignment system can further include a beam splitter and a collecting lens. In such embodiments, the method can further include emitting a light beam from the first end of the first optical fiber. The emitting of the light beam from the first end of the first optical fiber can include transmitting a first portion of the light beam from the first end of the first optical fiber through a beam splitter before reaching the position sensing device, and reflecting a second portion of the light beam from the first end of the first optical fiber through a collecting lens before reaching the tilt sensing device.

[0011]

[0011] The method may also include providing a microlens array (MLA) having a number of lenslets at a first location between a first end of the first optical fiber and an MLA alignment system, the lenslets including a first lenslet and a second lenslet. The method may also include adjusting the first end of the first optical fiber into rough alignment with a first lenslet of the plurality of lenslets. For example, adjusting the first end of the first optical fiber into rough alignment with the first lenslet may include positioning the first end of the first optical fiber a predetermined distance from a surface of the first lenslet.

[0012]

[0012] The method may also include generating a first MLA beam output of a first optical fiber, the first MLA beam output comprising at least one of a first MLA tilt value or a first MLA position value, and comparing the first MLA beam output to an alignment threshold, the alignment threshold comprising at least one of an MLA tilt threshold or an MLA position threshold. The method may also include attaching a first end of the first optical fiber to a surface of the first lenslet, and moving the MLA to a second position between a third end of the second optical fiber and the MLA alignment system such that the third end of the second optical fiber is roughly aligned with the second lenslet. For example, moving the first optical fiber to the second position may include moving the first optical fiber along an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation to the second position.

[0013]

[0013] In some embodiments, the method may further include generating a first MLA beam output of the first optical fiber and comparing the first MLA beam output to an alignment threshold. For example, generating a first MLA beam output of the first optical fiber may include measuring a first MLA tilt value via a tilt sensing device and measuring a first MLA position value via a position sensing device. Comparing the first MLA beam output to an alignment threshold may include comparing the first MLA tilt value to an MLA tilt threshold and comparing the first MLA position value to an MLA position threshold, where the alignment threshold includes an MLA tilt threshold and an MLA position threshold.

[0014]

[0014] In some embodiments, the method may further include moving the first optical fiber to a second position based on the first MLA beam output and generating a second MLA beam output for the first optical fiber at the second position. Generating the second MLA beam output may include measuring a second MLA tilt value from the tilt sensing device via the tilt sensing device, and measuring a second MLA position value via the position sensing device. In such embodiments, the method may also include comparing the second MLA beam output to an alignment threshold, and comparing the second MLA beam output to an alignment threshold includes comparing the second MLA tilt value to the MLA tilt threshold, and comparing the second MLA position value to the MLA position threshold.

[0015] In some embodiments, the multiple optical fibers can further include a third optical fiber having a fifth end and a sixth end, and the plurality of lenslets includes a third lenslet. In such embodiments, the method can further include attaching a third end of the second optical fiber to a surface of the second lenslet, and moving the MLA to a third position between the fifth end of the third optical fiber and the MLA alignment system such that the fifth end of the third optical fiber is roughly aligned with the third lenslet.

[0016]

[0016] Systems and methods are provided herein for measuring the cleavage angle of an optical fiber using a cleavage angle measurement system. In one aspect, a method for measuring the cleavage angle of an optical fiber is provided. The method can include providing a cleavage angle measurement system. The cleavage angle measurement system can include an optical fiber channel, an image sensor, and a light source. The method can include placing an optical fiber in the optical fiber channel. The optical fiber can include a cleaved end and can be positioned such that the cleaved end is optically aligned with the light source. In some embodiments, the cleavage angle measurement system can also include a beam splitter. In such embodiments, the method can also include transmitting light from the light source through the beam splitter, reflecting the light from the cleaved end of the optical fiber, and reflecting the light reflected from the cleaved end of the optical fiber by the beam splitter to the image sensor. In yet other embodiments, the cleavage angle measurement system can also include a beam collector. In such an embodiment, the method may also include collecting, with a beam collector, stray light generated by light reflecting from the cleaved end of the optical fiber.

[0017]

[0017] In some embodiments, the method may also include removing a coating from the cleaved end of the optical fiber to expose an inner portion of the optical fiber prior to placing the optical fiber in the optical fiber channel. For example, the exposed inner portion of the optical fiber may have a longitudinal length L between 5 mm and 20 mm. In such embodiments, the method may further include fixing the inner portion of the optical fiber in the optical fiber channel.

[0018]

[0018] The method may also include determining an optical center of the image sensor. The optical center of the image sensor may be determined by various techniques as described herein. For example, in some embodiments, determining the optical center of the image sensor may include generating a first exit face measurement of the cleaved end of the optical fiber at a first position based on the light detected by the image sensor, calculating a first optical centroid of the first exit face measurement, determining a first radial distance of the first exit face measurement of the optical fiber, and calculating a cleavage angle of the cleaved end of the optical fiber based on the first radial distance. After determining the first optical centroid of the first exit face measurement at the first position, rotating the optical fiber to a second position. A second exit face measurement of the optical fiber at a second position may then be generated based on the light reflected from the cleaved end of the optical fiber, and a second optical centroid of the second exit face measurement may be calculated. In some embodiments, the optical fiber can be further rotated to a third position, and a third exit face measurement of the optical fiber at the third position can be generated based on light reflected from the cleaved end of the optical fiber, from which a third optical centroid of the third exit face measurement can be generated. An optical center of the image sensor can be determined based on the first optical centroid, the second optical centroid, and the third optical centroid.

[0019]

[0019] In other embodiments, the optical center of the image sensor may be determined by a calibration technique. In such embodiments, the method may include placing a calibration optical fiber at a first position within the optical fiber channel, the calibration optical fiber comprising a cleaved end having a known cleavage angle. The image sensor may detect light reflected from the cleaved end of the calibration optical fiber, and a first exit face measurement of the calibration optical fiber at the first position may be generated based on the light detected by the image sensor. The calibration optical fiber may then be rotated to a second position. At the second position, a second exit face measurement may be generated for the calibration optical fiber at the second position based on the light reflected from the cleaved end of the calibration optical fiber. The optical center of the image sensor may be determined based on the first exit face measurement and the second exit face measurement.

[0020]

[0020] The method may also include reflecting light transmitted by the light source from the cleaved end of the optical fiber, and detecting the light reflected from the cleaved end of the optical fiber with an image sensor.

[0021]

[0021] In some embodiments, the method can include determining whether another exit surface measurement should be performed. To determine whether another exit surface measurement should be performed, an exit surface measurement can be generated and a determination can be made whether the exit surface measurement is valid. For example, the method can include generating a first exit surface measurement of a cleaved end of the optical fiber at a first position based on light detected by the image sensor, calculating a first optical centroid of the first exit surface measurement, and determining a first radial distance of the first exit surface measurement of the optical fiber.

[0022] In some embodiments, a determination may be made that another exit surface measurement should be performed. In such embodiments, the method may include rotating the optical fiber to a second position and then generating a second exit surface measurement of the optical fiber at the second position based on light reflected from the cleaved end of the optical fiber. A second optical centroid of the second exit surface measurement may be calculated, and a determination may be made whether the first exit surface measurement or the second exit surface measurement is valid.

[0023]

[0023] Determining whether the first exit surface measurement or the second exit surface measurement is valid can include determining a circular radius based on the optical center, determining a second radial distance of the second exit surface measurement based on the circular radius, and determining whether the second radial distance and the first radial distance align to the optical center. In another embodiment, determining whether the first exit surface measurement or the second exit surface measurement is valid can include determining whether the first exit surface measurement is within a threshold value and determining whether the second exit surface measurement is within a threshold value.

[0024] In other embodiments, a determination may be made based on the first radial distance and the first centroid that no other exit face measurements should be performed. In such embodiments, the method may include calculating a cleave angle of the cleaved end of the optical fiber based on the first radial distance. As described above, the cleave angle measurement system provides accurate cleave angle measurements with an accuracy to an angle measurement of 0.5 degrees or less.

[0025]

[0025] In another aspect, a method is provided for measuring cleavage angles of a plurality of optical fibers using a cleavage angle measurement system. The method can include providing a cleavage angle measurement system. The cleavage angle measurement system can include a first optical fiber channel, a second optical fiber channel, an image sensor, and a light source. In some embodiments, the multiple optical fibers can be part of an optical fiber array. Each of the optical fibers can have a cleaved end. For example, the first optical fiber can include a first cleaved end and the second optical fiber can include a second cleaved end. The first cleaved end and the second cleaved end can be positioned toward the light source.

[0026]

[0026] In some embodiments, the method may also include removing a coating from a first cleaved end of the first optical fiber to expose an inner portion of the first optical fiber prior to placing the first optical fiber in the first optical fiber channel. A coating may also be removed from a second cleaved end of the second optical fiber to expose an inner portion of the second optical fiber. For example, the longitudinal length L of the exposed inner portions of the first and second optical fibers may be between 5 and 20 mm. In such embodiments, the method may further include fixing the first and second optical fibers at their respective inner portions.

[0027] In some embodiments, the cleavage angle measurement system can also include a beam splitter. In such embodiments, the method can also include transmitting the first wavelength and the second wavelength from the light source through the beam splitter, reflecting the first wavelength from the first cleaved end, reflecting the second wavelength from the second cleaved end, and reflecting the first wavelength reflected from the first cleaved end and the second wavelength reflected from the second cleaved end with the beam splitter to the image sensor.

[0028] In yet another embodiment, the cleave angle measurement system can also include a diffraction grating, which can be positioned to direct a first wavelength from the light source to a first cleaved end of the first optical fiber and a second wavelength from the light source to a second cleaved end of the second optical fiber.

[0029] In such an embodiment, the method may include transmitting a light beam from a light source, the light beam including a first wavelength and a second wavelength. For example, the method may include diffracting the light beam with a diffraction grating such that a lens selectively positions the first wavelength from the light beam to transmit onto the first cleaved edge, and diffracting the light beam with a diffraction grating such that a lens selectively positions the second wavelength from the light beam to transmit onto the second cleaved edge.

[0030]

[0030] The method may include determining an optical center of the image sensor. For example, the optical center of the image sensor may be determined by any of the methods or techniques described herein. The method may also include reflecting a first wavelength transmitted by the light source from a first cleaved end of the first optical fiber. The method may then include determining a first cleavage angle of the first cleaved end based on the first wavelength reflected from the first cleaved end. For example, determining the first cleavage angle of the first cleaved end may include detecting with an image sensor a first wavelength reflected from the first cleaved end of the first optical fiber, generating a first exit face measurement of the first cleaved end of the first optical fiber at a first position based on the first wavelength detected by the image sensor, calculating a first optical centroid of the first exit face measurement, determining a first radial distance of the first exit face measurement of the first optical fiber, and calculating the first cleavage angle based on the first radial distance. The first radial distance of the first exit face measurement may be based on an optical center of the image sensor.

[0031]

[0031] The method may also include reflecting the second wavelength transmitted by the optical source from a second cleaved end of the second optical fiber. The method may then include determining a second cleavage angle of the second cleaved end based on the second wavelength reflected from the second cleaved end. In example embodiments, the first wavelength may be different from the second wavelength. [Brief description of the drawings]

[0032] [Figure 1] FIG. 1 is a simplified schematic diagram of a microlens array (MLA) according to one embodiment of the present invention. [Diagram 2] FIG. 1 is a simplified schematic of aligning an optical fiber to a lenslet of the MLA. [Figure 3A] FIG. 2 is a simplified schematic diagram of an MLA alignment system according to one embodiment of the present invention when the optical fiber is placed in a nominal position. [Figure 3B] FIG. 2 is a simplified schematic diagram of an MLA alignment system in accordance with one embodiment of the present invention when the optical fiber is in a rotational misalignment state. [Figure 3C] FIG. 2 is a simplified schematic diagram of an MLA alignment system according to one embodiment of the present invention when the optical fiber is in a translational shear. [Figure 4A] 4 is a simplified diagram illustrating illumination by a light emitting spot used to calculate a tilt measurement according to one embodiment of the present invention. [Figure 4B] 1 is a simplified diagram illustrating illumination with light emitting spots positioned such that the tilt measurement is within a tilt threshold in accordance with an embodiment of the present invention; [Figure 5A] FIG. 3B is a simplified schematic diagram illustrating alignment of an optical fiber with a lenslet of an MLA using the MLA alignment system shown in FIG. [Figure 5B] FIG. 3B is a simplified schematic diagram illustrating the alignment of multiple optical fibers with multiple lenslets of an MLA using the MLA alignment system shown in FIG. [Figure 6] 1 is a simplified flowchart illustrating a method of aligning an optical fiber to an MLA using the MLA alignment system in accordance with an embodiment of the present invention. [Figure 7]1 is a simplified flowchart illustrating a method for aligning multiple optical fibers to multiple lenslets of an MLA using the MLA alignment system in accordance with an embodiment of the present invention. [Figure 8A] FIG. 1 is a simplified schematic diagram of a cleave angle measurement system according to one embodiment of the present invention. [Figure 8B] FIG. 8B is a side view of an optical fiber provided in the cleavage angle measurement system shown in FIG. 8A. [Figure 9A] 11 is a simplified diagram illustrating calculated images of exit facet measurements used to calculate cleavage angle according to an embodiment of the present invention. [Figure 9B] 1 is a diagram illustrating the effect of distance variables on calculating cleavage angle according to an embodiment of the present invention. [Figure 10] 1 is a simplified diagram illustrating computed images of multiple exit facets used to calculate a cleavage angle according to an embodiment of the present invention. [Figure 11A] 13 is a simplified diagram illustrating a calculated image using the optical center to calculate the cleavage angle according to an embodiment of the present invention. [Figure 11B] 11 is another diagram illustrating a calculated image using the optical center to calculate the cleave angle according to an embodiment of the present invention. [Figure 12A] 11 is a simplified diagram illustrating computed images of multiple exit facet measurements used to calculate a cleave angle based on one or more validity checks in accordance with an embodiment of the present invention. [Figure 12B] 11 is another simplified diagram illustrating a calculated image of multiple exit facet measurements used to calculate a cleave angle based on one or more validity checks in accordance with an embodiment of the present invention. [Figure 13A] 13 is a simplified diagram illustrating computed images of multiple exit facet measurements used to calculate a cleave angle verified against a threshold in accordance with an embodiment of the present invention. [Figure 13B] 13 is another simplified diagram illustrating calculated images of multiple exit facet measurements used to calculate a cleave angle verified against a threshold in accordance with an embodiment of the present invention; [Figure 14A] FIG. 1 is a schematic diagram illustrating a cleavage angle measurement system according to an embodiment of the present invention. [Figure 14B] FIG. 2 is another schematic diagram illustrating a cleavage angle measurement system according to an embodiment of the present invention. [Figure 15A] 1 is a schematic diagram illustrating an optical fiber channel arrangement according to one embodiment of the present invention; [Figure 15B] 2 is a schematic diagram illustrating another optical fiber channel arrangement according to an embodiment of the present invention. [Figure 15C] 2 is a schematic diagram illustrating another optical fiber channel arrangement according to an embodiment of the present invention. [Figure 16] 4 is a simplified flow chart illustrating a method for measuring the cleave angle of an optical fiber using a cleave angle measurement system according to an embodiment of the present invention. [Figure 17] 4 is a simplified flow chart illustrating a method for measuring the cleave angles of a plurality of optical fibers using a cleave angle measurement system according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033]

[0055] The present disclosure generally relates to methods and systems related to optical systems including optical fibers. More specifically, embodiments of the present invention provide methods and systems that can be used to align and bond an optical fiber to an MLA. Additionally, embodiments of the present invention provide methods and systems that can be used to determine the cleave angle of an optical fiber. The present disclosure is applicable to a variety of applications in lasers and optics, including fiber laser implementations.

[0034]

[0056] The optical fiber can be glued to a microlens. In some cases, the microlens can be part of a microlens array (MLA). Often, the microlens, also called a lenslet, can be sized to have a diameter approximately equal to the outer diameter of the optical fiber. Therefore, alignment of the optical fiber to the lenslet can be difficult because the alignment tolerances for aligning the optical fiber to the MLA are tight. For example, the alignment tolerances can be ±1.0 microns and ±0.5 millidegrees. Alignment of the optical fiber with the lenslet can be difficult because the diameter of the lenslet is approximately equal to the outer diameter of the optical fiber.

[0035]

[0057] In addition to tight alignment tolerances, alignment of the optical fiber with the MLA may also need to compensate for variations in manufacturing features or characteristics of the optical fiber. For example, each optical fiber may have variations in the cleavage angle and centering of the optical fiber's core. To compensate for the manufacturing features of the optical fiber and meet the tight alignment tolerances, an MLA alignment system is provided herein.

[0036]

[0058] FIG. 1 is a simplified schematic diagram of an MLA 100 according to one embodiment of the present invention. As shown, the MLA 100 can include a number of lenslets 102. Each lenslet 102 can be a microlens. A microlens can be a small lens, typically with a diameter less than 1 millimeter (mm) and as small as 10 microns (μm). Each lenslet 102 can be a single microlens with one flat surface and one convex surface (e.g., spherical) that refracts light. In some cases, the lenslets 102 can be or include several layers of optical material to achieve desired optical properties. In some embodiments, the MLA 100 can be formed by a one-dimensional or two-dimensional array of lenslets 102 on a supporting substrate. The lenslets 102 can serve to focus and concentrate light from one or more optical fibers.

[0037]

[0059] 2, a simplified schematic diagram 200 of a conventional alignment process for aligning optical fibers 204 to the lenslets of an MLA is provided. Conventional approaches often require an orifice plate 206 having multiple orifices 208. In some embodiments, the MLA may be part of the orifice plate 206. In other embodiments, the orifice plate 206 may be aligned to the MLA such that each of the orifices 208 is in alignment with a lenslet of the MLA. In one example, the orifices 208 may be fabricated using lithographic techniques.

[0038]

[0060] To align the optical fiber 204 to the lenslet under conventional techniques, the optical fiber 204 may be inserted into one of the orifices 208. Since the orifice is aligned to the lenslet, inserting the optical fiber 204 into one of the orifices 208 is used to align the optical fiber 204 to the lenslet. However, using the orifice plate 206 for alignment may result in various imperfections in the alignment process. For example, the orifice plate 206 does not allow for independent fiber alignment, cannot compensate for fiber manufacturing imperfections, and cannot align the tip and tilt of the optical fiber 204. Also, although a smaller diameter of the orifice can improve alignment tolerances, a smaller diameter of the orifice often leads to damage or failure of the optical fiber during the insertion process.

[0039]

[0061] To enable independent, active optical fiber alignment with an MLA, an MLA alignment system is provided herein. Figure 3A provides a simplified schematic diagram of a system 300 for performing MLA alignment according to one embodiment of the present invention when the optical fiber is positioned at a nominal position. System 300 may be used to align one or more optical fibers, such as optical fiber 304, to an MLA, such as MLA 340. Specifically, the system may include an MLA alignment system 310 for positioning and aligning optical fiber 304 to lenslet 302 of MLA 340. As shown, MLA 340 may include multiple lenslets, and MLA alignment system 310 may be used to position and align multiple optical fibers to multiple lenslets of the MLA.

[0040]

[0062] The optical fiber 304 may be a polarization-maintaining fiber having one or more stress rods, patterned microstructures, or one or more cores. In some embodiments, the optical fiber 304 may be or include a bowtie fiber, a panda fiber, a multicore fiber, an elliptical fiber, a photonic crystal optical fiber, or the like. Advantageously, the system 300 may not depend on the optical polarization state of the optical fiber 304. Thus, in other embodiments, the optical fiber 304 may be a single mode fiber, a multimode fiber, or any other type of optical fiber. The optical fiber 304 may have a diameter of less than 250 μm. For example, the optical fiber 304 may have a diameter of less than 225 μm, less than 200 μm, less than 175 μm, less than 850 μm, less than 125 μm, or less than 100 μm.

[0041]

[0063] As discussed above, the optical fiber 304 can have individual manufacturing features or characteristics. For example, the optical fiber 304 can have a cleaved end 308 that has a different cleavage angle than another optical fiber. The cleaved end 308 of the optical fiber 304 can be an end of the optical fiber that has a cleaved or cut surface that is substantially perpendicular to the longitudinal length 306 of the optical fiber 304 created during the manufacturing process.

[0042]

[0064] Other manufacturing characteristics of the optical fiber 304 may include the bend or curvature of the optical fiber 304 along its longitudinal length 306. During or after the manufacturing process, the optical fiber 304 may be coiled or rolled into a bundle, which may cause the optical fiber 304 to bend or curve along its longitudinal length 306. Additional manufacturing characteristics of the optical fiber 304 may include the material of the optical fiber 304, as well as whether the optical fiber 304 includes a jacket or coating. Additional manufacturing characteristics of the optical fiber 304 may include the centering of the optical core relative to the outer fiber cylinder diameter. Centering errors of the optical core may result in an optical axis that differs from the mechanical axis of the optical fiber.

[0043]

[0065] Manufacturing features of the optical fiber 304 can affect the orientation and / or offset of the light emitted from the optical fiber 304. For example, if the cleaved end 308 of the optical fiber 304 has a non-zero cleave angle (a zero cleave angle is a cleave that is perfectly perpendicular to the longitudinal length 306 of the optical fiber 304), the light emitted from the cleaved end 308 of the optical fiber 304 can be offset by an angle proportional to the non-zero cleave angle. Any offset in the light emitted from the cleaved end 308 can affect the performance of the optical fiber 304.

[0044]

[0066] The placement of the cleaved end 308 and the alignment of the cleaved end 308 with the lenslet 302 can also affect the characteristics of the light emitted from the optical fiber 304. As described above, the optical fiber 304 can be positioned and aligned to the lenslet 302. Specifically, the cleaved end 308 of the optical fiber 304 can be aligned to the lenslet 302 such that a light beam 322 transmits through the lenslet 302 and generates a refracted light beam 323. The refracted light beam 323 can be formed by the refraction of the light beam 322 through the lenslet 302.

[0045]

[0067] During assembly of the fiber and MLA system, the cleaved end 308 of the optical fiber 304 is aligned to the lenslet 302. Aligning the cleaved end 308 of the optical fiber to the lenslet 302, as used herein, can mean that the optical fiber 304 is positioned such that the refracted light beam 323 is maximized to preserve the intensity of the light beam 322 as it propagates through the lenslet 302. In some embodiments, the MLA 340 can be positioned a predetermined distance from the optical fiber 304. Specifically, the MLA 340 can be positioned such that the lenslet 302 is a predetermined distance from the cleaved end 308 of the optical fiber 304. For example, the predetermined distance can be less than 10 μm, less than 100 μm, less than 500 μm, or less than 1 mm. In other embodiments, the MLA 340 can be positioned such that the lenslet 302 is in contact or near contact with the cleaved end 308 of the optical fiber 304.

[0046]

[0068] MLA alignment system 310 can be used to align optical fiber 304 to lenslet 302. To enable precise alignment between cleaved end 308 and lenslet 302 and advantageously compensate for any manufacturing characteristics of the individual optical fibers, MLA alignment system 310 can include one or more position sensing devices. For example, as shown in FIG. 3A , MLA alignment system 310 can include tilt sensing device 312 and position sensing device 314. Tilt sensing device 312 and / or position sensing device 314 can be or include a camera, a quadrant photodiode, or other device capable of sensing the output position of optical fiber 304.

[0047]

[0069] The tilt sensing device 312 may be configured and arranged to sense the tilt of the optical fiber 304. The tilt of the optical fiber 304 may be or may include the orientation and position of the cleaved end 308 relative to the longitudinal length 306 of the optical fiber 304. For example, if the cleaved end 308 of the optical fiber 304 is higher on the y-axis than other portions of the optical fiber 304 as measured along the longitudinal length 306 of the optical fiber 304, the optical fiber 304 may be tilted. The tilt of the optical fiber 304 may be caused by a curvature or bending of the optical fiber 304.

[0048]

[0070] The position sensing device 314 may be constructed and arranged to sense the latitudinal (z-axis) and longitudinal (y-axis) positions of the optical fiber 304. To align the cleaved end 308 with the lenslet 302, the cleaved end 308 may need to be located at specific x, y and z coordinates. Furthermore, to maximize the intensity of the refracted light beam 323 refracted through the lenslet 302, the cleaved end 308 may need to be located at specific x, y and z coordinates. The position sensing device 314 may detect and provide output readings of the x, y and z coordinates of the optical fiber 304.

[0049]

[0071] To direct the refracted light beam 323 to both the tilt sensing device 312 and the position sensing device 314, the MLA alignment system 310 may include a beam splitter 316. The beam splitter 316 may be positioned in axial alignment with the optical fiber 304 and the MLA 340. The beam splitter 316 may be positioned along the x-axis between the MLA 340 and the tilt sensing device 312. The beam splitter 316 may also be positioned to generate a reflected light beam 324 to the position sensing device 314. For example, the beam splitter 316 may include a surface 318 that reflects a portion of the refracted light beam 323 toward the position sensing device 314 as the reflected light beam 324. The surface 318 may be a reflective surface, such as a mirror. As shown, beam splitter 316 may reflect a portion of light beam 322 towards position sensing device 314 while transmitting the remaining portion of refracted light beam 323 as transmitted light beam 326 to tilt sensing device 312. Although position sensing device 314 is shown as receiving light reflected from beam splitter 316, this is not required by embodiments of the invention and in other embodiments, position sensing device 314 may be switched with tilt sensing device 312 such that tilt sensing device 312 receives light reflected from beam splitter 316. Those skilled in the art will recognize many variations, modifications, and alternatives.

[0050]

[0072] In some embodiments, the MLA alignment system 310 can include a collecting lens 320. The collecting lens 320 can be disposed between the beam splitter 316 and the position sensing device 314. The reflected light beam 324 can be received by the collecting lens 320 and directed toward the position sensing device 314. The focal length of the collecting lens 320 and the distance from the beam splitter 316 to the collecting lens 320 can be determined based on a given wavelength of the light beam 322 and the characteristics of the MLA 340.

[0051]

[0073] To position and align the optical fiber 304, the MLA alignment system 310 can generate a reference output for the optical fiber 304. The position sensing device 314 can generate a position reference output 350, and the tilt sensing device 312 can generate a tilt reference output 352. Although the position reference output 350 and the tilt reference output 352 are shown as part of the system 300, it should be understood that the position reference output 350 and the tilt reference output 352 are not physical components of the system 300. Rather, the position reference output 350 and the tilt reference output 352 are provided to indicate measurements or outputs provided by the sensing devices. The position reference output 350 and the tilt reference output 352 are described in more detail with reference to Figures 4A and 4B.

[0052]

[0074] In the illustrated embodiment, the position reference output 350 and the tilt reference output 352 are images of the collected beams incident on the position sensing device 314 and the tilt sensing device 312, respectively. In other embodiments, the position reference output 350 and the tilt reference output 352 can be one or more analog or digital signals collected by a quadrant photodiode or similar positioning tool. Those skilled in the art will recognize many variations, modifications, and alternatives to this design.

[0053]

[0075] Position sensing device 314 and tilt sensing device 312 can measure the position and tilt of optical fiber 304, respectively, to generate position reference output 350 and tilt reference output 352 of optical fiber 304. Based on the tilt and position measurements obtained by tilt sensing device 312 and position sensing device 314, respectively, MLA alignment system 310 can determine whether to adjust or modify the position and / or orientation of optical fiber 304. For example, MLA alignment system 310 can determine based on the position measurements that optical fiber 304 may need to be moved along the x-axis, e.g., to adjust the focus of light beam 322.

[0054]

[0076] To adjust or correct the position of the optical fiber 304, the system 300 can include a stage 330. In some embodiments, the stage 330 can be part of the MLA alignment system 310. In other embodiments, the stage 330 can be separate from the MLA alignment system 310. The stage 330 can be configured to hold and adjust the position of the optical fiber 304. For example, the stage 330 can move the optical fiber along an x-axis, along a y-axis, or along a z-axis. In some embodiments, the stage 330 can be configured to adjust the tilt of the optical fiber 304 by rotating the optical fiber 304. For example, the stage 330 can be or include a rotational stage configured to rotate the optical fiber 304. The rotational stage can rotate the optical fiber 304 about the x-axis, also known as u-rotation, about the y-axis, also known as v-rotation, or about the z-axis, also known as w-rotation. Tilt, as used herein, can include v-rotation or w-rotation of the optical fiber 304. As used herein, moving or adjusting the position of the optical fiber 304 may be understood as moving the optical fiber 304 along one or more of the x-axis, y-axis, and / or z-axis, or rotating the optical fiber 304 along one or more of the u-rotation, v-rotation, or w-rotation.

[0055]

[0077] FIG. 3B provides a simplified schematic diagram of a system 300 for performing MLA alignment according to an embodiment of the present invention when the optical fiber 304 is in a rotational misalignment state. For example, FIG. 3B can show the MLA alignment system 310 when the optical fiber 304 is displaced in the positive v direction by rotation about the z axis. The light beam 322 and the transmitted light beam 326 are also tilted by the same displacement in the v direction, resulting in a change in the tilt reference output 352, as measured by the tilt sensing device 312. The reflected light beam 324 is also tilted by this same angle until it reaches the collecting lens 320. The collecting lens 320 is selected such that the position reference output 350 of the position sensing device 314 remains unchanged with displacement in the v or w direction.

[0056]

[0078] 3C provides a simplified schematic diagram of a system 300 for performing MLA alignment according to an embodiment of the present invention when optical fiber 304 is in a translational shear. For example, FIG. 3C shows MLA alignment system 310 when optical fiber 304 is displaced in the negative y-direction. Refracted light beam 323 from lenslet 302 and transmitted light beam 326 are also displaced by the same amount in the y-direction, resulting in a positive change in tilt reference output 352, as measured by tilt sensing device 312. Reflected light beam 324 is also displaced, resulting in a negative change in position reference output 350, as measured by position sensing device 314.

[0057]

[0079] After adjusting or correcting the position of optical fiber 304, MLA alignment system 310 can collect one or more measurements to determine if the position of optical fiber 304 is within a position tolerance. If optical fiber 304 is within the position tolerance, a tilt measurement and a position measurement of the position of optical fiber 304 can be measured. Tilt sensing device 312 can measure the tilt measurement and position sensing device 314 can measure the position measurement.

[0058]

[0080] 4A is a diagram showing a schematic 400A of an emitting spot 402 used to calculate a tilt measurement. The schematic 400A may be used to generate a tilt reference output 352. Although the following discussion is in terms of tilt measurements, position measurements may be collected and corrected to generate a corrected reference output using one or more of the following techniques or steps. For ease of discussion, FIGS. 4A and 4B are discussed with reference to FIGS. 3A-3C, but it should be understood that any of the systems provided herein may be used.

[0059]

[0081] The light emission spot 402 may be generated from a light beam incident on and captured by the tilt sensing device 312. In the case of position measurements, the position sensing device 314 may capture a light beam incident on the position sensing device and used to generate the light emission spot 402. The light emission spot 402 may correspond to the cleaved end 308 of the optical fiber 304. One of several image processing methods may be utilized to detect and / or identify various components of the optical fiber. For example, in one embodiment, the z,y coordinates of the centroid 414 of the light emission spot 402 may be determined using an intensity weighted centroid calculation. In an alternative embodiment, the z,y coordinates may be determined from a computational fitting algorithm of an ideal spot to the measured light emission spot 402. Alternative computational variations will be apparent to one skilled in the art.

[0060]

[0082] The light beams used to generate diagram 400A may be captured by receiving reflected light beam 324 and transmitted light beam 326. It should be understood that allowing the beam spot to widen can increase the sensitivity of measurements collected by tilt sensing device 312 and / or position sensing device 314, but the overall beam spot may be limited by the physical size of tilt sensing device 312 and / or position sensing device 314.

[0061]

[0083] A tilt degree may be calculated for the light emission spot 402. The tilt degree may correspond to a tilt measurement of the optical fiber 304. To calculate the tilt degree, a tilt offset 450 may be determined for the light emission spot 402. For example, in some embodiments, the tilt degree may be determined by the centroid 414 of the light emission spot 402. The difference between the zy coordinate identified by the tilt offset 450 and the origin 454 (e.g., a zy coordinate of 0,0) may be used to determine the tilt degree (e.g., a tilt measurement) of the optical fiber 304. The tilt measurement may be determined based on the tilt degree of the light emission spot 402.

[0062]

[0084] Similar techniques can be used for position measurements, for example, the centroid 414 of the emission spot 402 can be used to determine the position of the cleaved end 308 of the optical fiber 304 based on the light beam captured by the position sensing device 314.

[0063]

[0085] The tilt and position measurements may be part of an alignment offset used to determine whether the emission spot 402 (e.g., corresponding to the cleaved end 308 of the optical fiber 304) is in an aligned position. The aligned position may be a position where the emission spot 402 is located within a predetermined tolerance from a reference zero position.

[0064]

[0086] For example, when aligning a fiber to a system, an initial measurement of the position reference output 350 and the tilt reference output 352 is made. The fiber is first rotated in the v and w directions to a second rotational position until the tilt reference output falls below a predetermined threshold. The fiber is then rotated in the y and z directions to a second translational position until the position reference output 350 falls below a predetermined threshold. Once complete, the tilt reference output 352 is regenerated. If the tilt reference output 352 increases beyond the predetermined threshold, the optical fiber is moved to a third rotational position and the entire process is repeated until both the position reference output 350 and the tilt reference output 352 decrease to values ​​below their corresponding thresholds.

[0065]

[0087] In some embodiments, it may be desirable to position the cleaved end 308 of the optical fiber 304 in an alignment position prior to positioning and aligning the MLA in order to collect a reference alignment output. For example, the alignment position of the light emitting spot 402 can be used as part of the reference output for positioning and aligning the MLA. The reference output can include a tilt value (e.g., a tilt measurement) and a position value (e.g., a position measurement). The reference output can provide a reading or coordinate for the orientation (e.g., tilt), including the position and rotation, of the output face of the optical fiber 304. The reading or coordinate of the reference output can be used as a reference point while positioning and aligning the MLA. For example, as described in more detail below, the reference output can be used to determine an alignment threshold for the MLA. In one embodiment, the MLA can be positioned and aligned such that the spot beam received by the tilt sensing device 312 and the position sensing device 314 after positioning the MLA is similar or the same as the spot beam received prior to placing the MLA in the system 300.

[0066]

[0088] A reference output may be generated from the tilt and position measurements. In some embodiments, the reference output may be a sum or reading of the tilt and position measurements. After the reference output is generated, the reference output may be compared to an alignment threshold. For example, the tilt measurement may be compared to a tilt threshold and the position measurement may be compared to a position threshold.

[0067]

[0089] As diagram 400A shows, the emission spot 402 of the optical fiber 304 can have a tilt offset 450. A tilt measurement generated from the tilt offset 450 can be compared to a tilt threshold 452. In some embodiments, the emission spot 402 can also include a position offset. Similar to the tilt measurement, a position measurement generated from the position offset can be compared to a position threshold.

[0068]

[0090] If the tilt measurement is within the tilt threshold 452 and the position measurement is within the position threshold, the MLA may be placed in the system 300. However, if either the tilt measurement is not within the tilt threshold 452 or the position measurement is not within the position threshold, the cleaved end 308 of the optical fiber 304 may be rotated, moved, or otherwise adjusted to orient the light emission spot 402 at a corrected position. For example, to generate the tilt measurement and the position measurement, the optical fiber 304 may be in a first position. If either the tilt measurement is not within the tilt threshold 452 or the position measurement is not within the position threshold, the optical fiber 304 may be placed in a second position. At the second position, a second tilt measurement and a second position measurement may be measured. The second tilt measurement and the second position measurement may be compared to the tilt threshold 452 and the position threshold, respectively. If the second tilt measurement and the second position measurement are within their respective thresholds, the MLA may be placed in the system 300. However, if the second tilt measurement and the second position measurement are not within the respective thresholds, the optical fiber 304 may be placed in a third position. In this manner, generating a reference output and adjusting the optical fiber so that the reference output is within the alignment threshold may be an iterative process.

[0069]

[0091] When the tilt or position measurements are not within the respective thresholds, the cleaved end 308 of the optical fiber 304 may be positioned in a corrected position. The optical fiber 304 may be positioned or adjusted using the stage 330. As discussed above, moving or adjusting the position of the optical fiber 304 may be understood to move the optical fiber 304 along one or more of an x-axis, a y-axis, or a z-axis, or to rotate the optical fiber 304 along one or more of a u-rotation, a v-rotation, or a w-rotation.

[0070]

[0092] In some embodiments, the degree or amount of movement utilized to position the optical fiber 304 such that the tilt or position measurements are within the respective thresholds may be computationally determined. For example, the schematic 400A may be used to determine a rotation angle based on the tilt offset 450 and / or position offset of the emission spot 402. The rotation angle may be the degree or amount of rotation required to align the tilt offset 450 with the horizontal x-axis. In some cases, after rotating the cleaved end 308 of the optical fiber 304 based on the tilt degree, another schematic 400A of the emission spot 402 may be generated at the corrected position.

[0071]

[0093] The tilt offset and / or position offset may result from one or both of the orientation or cleaved end 308 of the optical fiber 304. For example, as discussed above, the cleaved end 308 may include a cleavage angle. The cleavage angle may determine the orientation or angle at which the light beam 322 is emitted from the cleaved end 308. If the cleavage angle is non-zero or not exactly perpendicular to the longitudinal length 306 of the optical fiber, the light beam 322 may be emitted at an angle that is not parallel to the longitudinal length 306 of the optical fiber 304, i.e., not parallel to the x-axis. In other words, if the cleavage angle is zero, the light beam 322 will be emitted approximately parallel to the longitudinal length 306 of the optical fiber 304. Any variation from a zero cleavage angle may affect the angle at which the light beam 322 is emitted.

[0072]

[0094] In embodiments where the cleave angle is zero, any tilt measured by the tilt sensing device 312 may be due to the orientation of the optical fiber 304. Tilting the optical fiber 304 due to orientation may mean that the cleaved end 308 is in a different plane than the opposite end 338. For example, if the optical fiber 304 is tilted but has a zero cleave angle, the cleaved end 308 may be at a different position along the y-axis, x-axis, or z-axis than the opposite end 338. To address tilt in the optical fiber 304, the stage 330 may move the optical fiber 304 in that direction to fix the tilt.

[0073]

[0095] In embodiments where the cleaved end 308 is on the same plane as the opposing end 338, the optical fiber 304 can have a tilt due to the cleaved end 308. For example, if the cleavage angle of the cleaved end 308 is non-zero, the light beam 322 can be emitted at an angle relative to the x-axis. The emittance of the light beam 322 at an angle can be measured as a tilt by the tilt sensing device 312. To compensate for the tilt caused by the non-zero cleavage angle, the optical fiber 304 can be rotated about the y-axis or v-rotation. In other words, the cleaved end 308 can be raised while lowering the opposing end 338, or can be lowered while raising the opposing end 338. The degree to which the optical fiber is rotated under the v-rotation can correspond to the degree to which the cleavage angle of the cleaved end 308 changes from zero.

[0074]

[0096] It should be appreciated that the type of rotation may vary depending on the orientation of the cleave angle of the cleaved end 308. For example, if the cleave angle is non-zero along the y-axis, the optical fiber 304 may be rotated along a v-rotation (e.g., about the y-axis). If the cleave angle is non-zero along the z-axis, the optical fiber 304 may be rotated along a u-rotation. It should be appreciated that in some embodiments, the optical fiber 304 may be symmetric. Thus, there may be only two angles for the cleave angle. Variations in the x-direction may result in more complex fiber faces than the cleave angle. It should also be appreciated that the cleave angle may be non-zero at any combination of yz coordinates, and thus rotation of the optical fiber 304 to address a non-zero cleave angle may be performed by that combination of vw-rotations.

[0075]

[0097] 4B is a diagram showing a diagram 400B of light emitting spots 402 positioned such that the tilt measurement is within a tilt threshold 452. Diagram 400B may also show light emitting spots 402 positioned such that the position measurement is within a position threshold. Diagram 400B may be used to generate a tilt reference output 352.

[0076]

[0098] Similarly, if the emission spot 402 has a position offset, the optical fiber 304 can be moved until the position measurement of the emission spot 402 is within a position threshold. For example, the optical fiber 304 can be modified until the emission spot 402 is aligned with the zy-axis origin 454 or at some predetermined zy coordinate.

[0077]

[0099] It should be appreciated that aligning the emission spot 402 with the tilt threshold 452 and the position threshold may be an iterative process. For example, if the cleaved end 308 is non-zero and a tilt measurement is determined, the optical fiber 304 may first be rotated along that rotation based on the tilt offset 450. For example, based on the schematic diagram 400A, the optical fiber 304 may be rotated along a v rotation to move the cleaved end 308 down the y axis and move the opposite end 338 up the y axis. By rotating the optical fiber 304 along the v rotation, the position of the emission spot 402 may be moved downward. Thus, the position measurement generated by the position sensing device 314 may determine the position offset. Then, based on the position offset, the longitudinal length 306 of the optical fiber 304 may be moved upward on the y axis. Moving the longitudinal length 306 of the optical fiber 304 up the y axis may affect the tilt measurement generated by the tilt sensing device 312. The optical fiber 304 can be rotated to accommodate the tilt measurement, and this process can continue until the tilt measurement is within the tilt threshold 452 and the position measurement is within the position threshold.

[0078]

[0100] When the tilt and position measurements of the light emission spot 402 are within the tilt threshold 452 and position threshold, respectively, a reference output, such as the position reference output 350 and the tilt reference output 352, may be generated. The reference output may be generated by at least one of the tilt and / or position measurements taken at a position of the optical fiber 304 that is within the threshold. In some embodiments, the tilt threshold 452 and / or the position threshold may vary depending on the application. For example, in some applications, such as fusion splicing, the tilt threshold 452 and / or the position threshold may have a small tolerance, allowing for minimal changes in the orientation of the light emission spot 402. In other applications, the tilt threshold 452 and / or the position threshold may have a larger tolerance, allowing for more flexibility in the angular orientation of the light emission spot 402.

[0079]

[0101] After the reference output is generated, the MLA 340 can be placed in the system 300. It should be understood that the MLA 340 need not be present in the system 300 when generating the tilt and position measurements, thereby generating the reference output. Instead, an image of the light emission spot 402 may be captured from the cleaved end 308 of the optical fiber 304 before the MLA 340 is placed in the system. After the reference output is generated, the MLA 340 may be placed between the cleaved end 308 of the optical fiber 304 and the MLA alignment system 310, as described herein. The MLA tilt value, MLA position value, and MLA beam output may then be determined using the same or similar techniques as described above to capture the tilt and position measurements and generate the reference output therefrom. For example, the MLA tilt value may be determined in a manner similar to how the tilt measurements are determined, the MLA position value may be determined in a manner similar to how the position measurements are determined, and the MLA beam output may be generated in a manner similar to how the reference output is generated.

[0080]

[0102] The MLA 340 can be positioned in the system 300 such that the lenslet 302 is roughly aligned with the cleaved end 308 of the optical fiber. Rough alignment, as used herein, can refer to alignment by human perception. For example, the MLA 340 can be positioned in the system 300 such that the lenslet 302 appears to be visually aligned with the cleaved end 308 of the optical fiber 304. Despite the rough alignment, the cleaved end 308 and the lenslet 302 may not be truly aligned due to the small size of the optical fiber and the MLA lenslet 302. Thus, to position and align the lenslet 302 with the cleaved end 308 of the optical fiber 304, the tilt sensing device 312 can measure MLA tilt values ​​and the position sensing device 314 can measure MLA position values. The MLA tilt values ​​may be measured in a manner similar to the tilt measurements, and the MLA position values ​​may be measured in a manner similar to the position measurements.

[0081]

[0103] The MLA beam output may be generated from at least one of the MLA tilt value and / or the MLA position value. As described above, the MLA beam output may be generated using a similar method as used to generate the reference output. The main difference is that the reference output may be generated without an MLA present in the system 300, and the MLA beam output may be generated with an MLA present in the system 300. The MLA beam output may be compared to an alignment threshold. In an example embodiment, comparing the MLA beam output to an alignment threshold may include comparing the MLA tilt value to an MLA tilt threshold and / or comparing the MLA position value to an MLA position threshold. The alignment threshold may include one or both of an MLA tilt threshold and an MLA position threshold.

[0082]

[0104] The generation of the MLA beam output may be an iterative process similar to the generation of the reference output, in that the MLA tilt and / or MLA position values ​​may be measured and then compared to their respective thresholds. However, if the MLA tilt and / or MLA position values ​​are not within the respective thresholds, the position of the MLA 340 may be modified or adjusted and the position of the optical fiber 304 may not be modified or adjusted.

[0083]

[0105] Returning now to FIG. 3A, MLA 340 may be placed and held within system 300 on MLA stage 342. MLA stage 342 may be configured to correct or adjust the position of MLA 340 along the x-, y-, and z-axes, as well as rotate MLA 340 along w-, u-, or v-rotations. The position of MLA 340 may be corrected or adjusted until the MLA beam output is within an alignment threshold. For example, MLA 340 may be corrected or adjusted until the MLA tilt value and MLA position value are within the MLA tilt threshold and MLA position threshold, respectively. As discussed above, the tolerance of the alignment threshold may vary based on the application.

[0084]

[0106] Once the MLA beam output is within the alignment threshold, the optical fiber 304 may be attached to the lenslet 302 of the MLA 340. Referring now to Figure 5A, a simplified schematic diagram 500A is provided illustrating alignment of an optical fiber with a lenslet of an MLA using the MLA alignment system shown in Figure 3A. The following discussion of Figures 5A and 5B is made with reference to Figure 3A, however it should be understood that any of the systems described herein may be used.

[0085]

[0107] As simplified schematic 500A shows, optical fiber 504A may be aligned to lenslet 502 of MLA 540. Optical fiber 504A may be the same as or similar to optical fiber 304. Optical fiber 504A may be positioned and aligned to lenslet 502 using system 300, specifically MLA alignment system 310, as described above. Once the MLA beam output to MLA 540 is within an alignment threshold, a cleaved end 508 of optical fiber 504A may be attached to lenslet 502, as described above. Attaching cleaved end 508 to lenslet 502 may include fixing, adhering, bonding, welding, optically contacting, or fusing cleaved end 508 to lenslet 502.

[0086]

[0108] In some embodiments, the optical fiber 504A may be different from the optical fiber 304. In such a case, the optical fiber 304 may be a "golden fiber." The "golden fiber" may be a fiber that has desired manufacturing characteristics, such as a desired cleave angle. When utilized as a golden fiber, the optical fiber 304 may be used to align the MLA 540, but may be removed from the system 300 after the MLA 540 is within the alignment threshold, and the optical fiber 504A may be placed in the system 300 for the fixturing process. The optical fiber 304 as a golden fiber may be used to align each lenslet in the MLA 540. This advantageously allows each of the lenslets to be aligned using the same cleaved end 308, thereby providing a common alignment reference for each of the lenslets.

[0087]

[0109] 5B provides a simplified schematic diagram 500B illustrating the alignment of multiple optical fibers 504A-504E with lenslets 502A-502E of MLA 540, i.e., multiple lenslets, using the MLA alignment system shown in FIG. 3A. In some embodiments, each of lenslets 502A-E of MLA 540 may be aligned with one of multiple optical fibers 504A-E. For example, lenslet 502A may be aligned with optical fiber 504A, lenslet 502B may be aligned with optical fiber 504B, lenslet 502C may be aligned with optical fiber 504C, lenslet 502D may be aligned with optical fiber 504D, and lenslet 502E may be aligned with optical fiber 504E.

[0088]

[0110] As discussed above, the golden fiber can be used to align each of the lenslets 502A-E. For example, the optical fiber 304 can be used to align each of the lenslets 502A-E using the MLA alignment system 310. In such an example, the MLA 340 can be the same as the MLA 540. Once each of the lenslets 502A-E is in an aligned position based on the alignment threshold, the optical fiber 304 can be removed from the system 300 and replaced with one of the multiple optical fibers 504A-E for each of the respective lenslets 502A-E. For example, the optical fiber 304 can be used to align the lenslet 502A. Once the lenslet 502A is within the alignment threshold (based on the MLA tilt value and the MLA position value of the optical fiber 304), the optical fiber 304 can be replaced with the optical fiber 504A in the system 300. The optical fiber 504A can then be secured to the lenslet 502A. Once optical fiber 504A is secured to lenslet 502A, MLA 540 may be repositioned and optical fiber 304 may be placed back in its original position on stage 330. MLA 540 may be positioned such that lenslet 502B is roughly aligned with optical fiber 304. The process may then continue by aligning lenslet 502B to optical fiber 304, then replacing optical fiber 304 with optical fiber 504B and securing optical fiber 504B to lenslet 502B. The process may continue for each of multiple optical fibers 504A-E. It should be understood that any number of multiple optical fibers 504A-E and any number of lenslets 502A-E may be aligned and / or secured using the systems and techniques used herein.

[0089]

[0111] 6 provides a simplified flowchart illustrating a method 600 of aligning an optical fiber to an MLA using an MLA alignment system according to one embodiment of the present invention. The following discussion is made with reference to Figures 3-5B, but it should be understood that method 600 may be performed using any of the systems or techniques described herein.

[0090]

[0112] The method 600 may include step 605. In step 605, an optical fiber may be provided, such as optical fiber 304 having a first end and a second end. The first end of the optical fiber may include one or more predetermined manufacturing characteristics. For example, the first end of the optical fiber 304 may be a cleaved end 308 having a predetermined cleavage angle.

[0091]

[0113] At step 610, method 600 can include positioning the optical fiber such that a first end of the optical fiber faces an MLA alignment system. For example, at step 610, optical fiber 304 can be positioned such that cleaved end 308 faces MLA alignment system 310. The MLA alignment system can include a tilt sensing device, such as tilt sensing device 312, and a position sensing device, such as position sensing device 314.

[0092]

[0114] In step 615, method 600 can include emitting a light beam from a first end of the optical fiber toward the MLA alignment system. For example, the light beam can be emitted from the cleaved end 308 of the optical fiber 304 toward the MLA alignment system 310. In some embodiments, the MLA alignment system 310 can further include a beam splitter 316 and a focusing lens, also referred to as a collecting lens, such as focusing lens 320. In such a case, step 615 can further include transmitting a first portion of the light beam from the cleaved end 308 of the optical fiber 304 through the beam splitter 316 before reaching the position sensing device 314, and reflecting a second portion of the light beam from the cleaved end 308 of the optical fiber 304 from the beam splitter 316 through the focusing lens 320 before reaching the tilt sensing device 312.

[0093]

[0115] In step 620, the method 600 can include generating a reference output for the optical fiber 304 in a first position. The reference output can be generated prior to placing the MLA 340 between the optical fiber 304 and the MLA alignment system 310. As described above with respect to FIGS. 4A and 4B, the reference output can include at least one of a tilt measurement or a position measurement. Thus, in some embodiments, step 620 can include measuring a first tilt measurement based on a light beam emitted from a first end of the optical fiber in the first position via a tilt sensing device, and measuring a first position measurement based on a light beam emitted from the first end of the optical fiber in the first position via a position sensing device. The first tilt measurement can be compared to a tilt threshold, and the first position measurement can be compared to a position threshold.

[0094]

[0116] If the first tilt measurement and / or the first position measurement are not within the tilt and position thresholds, respectively, the method 600 may further include placing the optical fiber in a second position. For example, the optical fiber may be moved or adjusted from the first position to a second position by moving the optical fiber along an x-axis, a y-axis, or a z-axis, or rotating the optical fiber along a w-rotation, a v-rotation, or a u-rotation. At the second position, a second tilt measurement and a second position measurement may be collected by the tilt sensing device 312 and the position sensing device 314, respectively.

[0095]

[0117] A second reference output may be generated based on the second tilt measurement and the second position measurement. In some embodiments, the second tilt measurement may be compared to a tilt threshold and the second position measurement may be compared to a position threshold. As discussed above, method 600 may be an iterative process in which the positioning of optical fiber 304 may be modified until the tilt measurement and / or the position measurement are within the tilt and position thresholds, respectively. Once the tilt and position measurements are within their respective thresholds, method 600 may proceed to the next step.

[0096]

[0118] In step 625, the method may include providing an MLA, such as MLA 340 having multiple lenslets, at a first position between the first end of the optical fiber and the MLA alignment system. In some embodiments, the MLA 340 may be positioned such that the lenslet 302 is roughly aligned with the cleaved end 308 of the optical fiber 304. For example, the MLA 340 may be placed in the first position such that a light beam emanating from the cleaved end 308 of the optical fiber 304 is transmitted through the lenslet 302 of the MLA 340.

[0097]

[0119] Once the MLA 340 is in the first position, an MLA beam output may be generated in step 630. The MLA beam output may include at least one of a first MLA tilt value or a first MLA position value. The MLA beam output may be generated by measuring the first MLA tilt value via the tilt sensing device 312 and measuring the first MLA position value via the position sensing device.

[0098]

[0120] In step 635, the method may include comparing the MLA beam power to an alignment threshold. In some embodiments, comparing the MLA beam power to an alignment threshold may include comparing the first MLA tilt value to an MLA tilt threshold and / or comparing the first MLA position value to an MLA position threshold. In an example embodiment, the alignment threshold may include a first MLA tilt threshold and a first MLA position threshold.

[0099]

[0121] If the MLA beam output is not within the alignment threshold, method 600 may proceed to step 640. In step 640, MLA 340 may be moved from a first position to a second position. For example, moving MLA 340 from a first position to a second position may include moving or adjusting MLA 340 along at least one of x-axis, y-axis, z-axis, w-rotation, u-rotation, or v-rotation. Once MLA 340 is in the second position, method 600 may return to step 630 via iterative step 645. In step 630, a second MLA beam output may be generated based on the second position of the MLA. To generate the second MLA beam output, a second MLA tilt value may be measured via tilt sensing device 312 and a second MLA position value may be measured via position sensing device 314.

[0100]

[0122] The second MLA beam output can then be compared to an alignment threshold in step 635. For example, the second MLA tilt value can be compared to an MLA tilt threshold and the second MLA position value can be compared to an MLA position threshold. Method 600 is an iterative process in that steps 630-645 can be repeated until the MLA beam output is within the alignment threshold.

[0101]

[0123] Once the MLA beam output is within the alignment threshold, method 600 may proceed to step 650. In step 650, optical fiber 304 may be attached to lenslet 302 of MLA 340. In some embodiments, an optical fiber different from optical fiber 304 may be attached to lenslet 302. For example, as described with respect to FIGS. 5A and 5B, optical fiber 304 may be a golden fiber, and when MLA 340 is in the aligned position, optical fiber 304 may be replaced with optical fiber 504A. Optical fiber 504A may be attached or secured to lenslet 302. Attaching optical fiber 304 (or optical fiber 504A) to lenslet 302 of MLA 340 may include securing or gluing a cleaved end 308 of optical fiber 304 to lenslet 302.

[0102]

[0124] It should be understood that the specific steps illustrated in FIG. 6 provide a particular method of aligning an optical fiber to an MLA using an MLA alignment system according to one embodiment of the present invention. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 6 may include multiple sub-steps that may be performed in various orders depending on the individual step. Additionally, additional steps may be added or removed depending on the particular application. Those skilled in the art will recognize many variations, modifications, and alternatives.

[0103]

[0125] 7 provides a simplified flowchart illustrating a method for aligning multiple optical fibers to multiple lenslets of an MLA using an MLA alignment system according to one embodiment of the present invention. The following discussion is made with reference to Figures 3-5B, but it should be understood that method 700 may be performed using any of the systems or techniques described herein.

[0104]

[0126] At step 705, method 700 may include providing a plurality of optical fibers. For example, multiple optical fibers 504A-504E may be provided. Multiple optical fibers 504A-504E may include a first optical fiber having a first end and a second end, and a second optical fiber having a third end and a fourth end. At step 710, a first optical fiber, such as optical fiber 504A, may be positioned such that a first end (e.g., cleaved end 308) faces an MLA alignment system, such as MLA alignment system 310. The MLA alignment system may include a tilt sensing device, such as tilt sensing device 312, and a position sensing device, such as position sensing device 314.

[0105]

[0127] At step 715, an MLA having multiple lenslets may be provided at a first location. For example, an MLA having multiple lenslets 340 may be provided between the cleaved end 308 of the optical fiber 304 and the MLA alignment system 310. As discussed with reference to Figures 5A and 5B, the MLA may have multiple lenslets, such as lenslets 502A-502E, including a first lenslet and a second lenslet. For example, lenslet 502A may be a first lenslet and lenslet 502B may be a second lenslet.

[0106]

[0128] In some embodiments, method 700 can include emitting a light beam from a first end of a first optical fiber. In an example embodiment, MLA alignment system 310 can include a beam splitter, such as beam splitter 316, and a focusing lens, such as focusing lens 320. In such an example, emitting a light beam from the first end of the first optical fiber can include transmitting a first portion of the light beam from the first end of the first optical fiber through beam splitter 316 before reaching position sensing device 314, and reflecting a second portion of the light beam from the first end of the first optical fiber from beam splitter 316 through focusing lens 320 before reaching tilt sensing device 312.

[0107]

[0129] In step 720, the first end of the optical fiber may be adjusted into rough alignment with the first lenslet. For example, the cleaved end of the optical fiber 504A may be adjusted into rough alignment with the lenslet 502A. In some embodiments, adjusting the first end of the optical fiber into rough alignment with the first lenslet may include positioning the first end of the optical fiber a predetermined distance from a surface of the first lenslet. As discussed above, rough alignment may refer to aligning the first end of the optical fiber with the first lenslet according to human perception (e.g., visually aligning the first end with the first lenslet).

[0108]

[0130] In step 725, an output may be generated. For example, a first MLA beam output may be generated for the first optical fiber. The first MLA beam output may include at least one of a first tilt value or a first position value. The first tilt value may be measured by the tilt sensing device 312 and the first position value may be measured by the position sensing device 314.

[0109]

[0131] In step 730, the first MLA beam output may be compared to an alignment threshold. The alignment threshold may include at least one of an MLA tilt threshold or an MLA position threshold. If in step 730, the MLA beam output is not within the alignment threshold, method 700 may proceed to step 735. In step 735, the optical fiber may be moved from a first position to a second position. For example, the optical fiber 304 may be moved or adjusted along an x-axis, a y-axis, a z-axis, or rotated along a w-rotation, a u-rotation, or a v-rotation.

[0110]

[0132] Method 700 may return to step 725 via iterative step 740. In step 725, a second MLA beam output may be generated for the optical fiber in the second position. For example, a second MLA tilt value may be measured via tilt sensing device 312 and a second MLA position value may be measured via position sensing device 314. A second output may be generated based on the second MLA tilt value and the second MLA position value.

[0111]

[0133] In step 730, the second MLA beam output may be compared to an alignment threshold. In some embodiments, the second MLA tilt value may be compared to an MLA tilt threshold and the second MLA position value may be compared to an MLA position threshold. Method 700 may be an iterative process in that steps 725-740 may be performed until the MLA beam output is within the alignment threshold.

[0112]

[0134] Once the MLA beam output is within the alignment threshold, the method may proceed to step 745. In step 745, the optical fiber may be attached to the lenslet. For example, a first end of a first optical fiber may be attached to a first lenslet of the plurality of lenslets. As described above with reference to FIG. 5B, a first end of the optical fiber 504A may be attached to the lenslet 502A. Attaching the optical fiber to the lenslet may include fixing or gluing the optical fiber to the lenslet.

[0113]

[0135] Once the first end of the first optical fiber is attached to the first lenslet, the MLA may be moved from the first position to a second position in step 750. Moving the MLA to the second position may include moving the MLA to a second position between the third end of the second optical fiber and the MLA alignment system. Method 700 may return to step 720 via an iterative step 755. In step 720, the third end of the second optical fiber may be adjusted into rough alignment with the second lenslet. For example, with reference to FIG. 5B, after optical fiber 504A is attached to lenslet 502A, MLA 540 may be moved to a second position such that optical fiber 504B is in rough alignment with lenslet 502B. Specifically, the third end of optical fiber 504B may be adjusted into rough alignment with lenslet 502B.

[0114]

[0136] After the third end of optical fiber 504B is roughly aligned with lenslet 502B, a second MLA beam output of optical fiber 504B may be generated, and method 700 may proceed via steps 730-740 until the second MLA beam output of optical fiber 504B is within an alignment threshold. At that point, optical fiber 504B may be attached to lenslet 502B in step 745. The MLA may then be moved to a third position between a fifth end of a third optical fiber, such as optical fiber 504C, and the MLA alignment system in step 750, such that the fifth end of the third optical fiber is roughly aligned with a third lenslet, such as lenslet 502C in step 720.

[0115]

[0137] Method 700 may continue until all of the multiple optical fibers are attached to their respective lenslets of the MLA, at which point method 700 may proceed to step 760, where the alignment process ends.

[0116]

[0138] It should be appreciated that the specific steps illustrated in FIG. 7 provide a particular method for aligning multiple optical fibers to multiple lenslets of an MLA using an MLA alignment system according to one embodiment of the present invention. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 7 may include multiple sub-steps that may be performed in various orders depending on the individual step. Additionally, additional steps may be added or removed depending on the particular application. Those skilled in the art will recognize many variations, modifications, and alternatives.

[0117]

[0139] During the alignment process, the optical fiber may be aligned to the external body. For example, optical fibers are often spliced ​​to various external bodies, such as other optical fibers or optical instruments, and precise alignment between the optical fiber and the external body is utilized to maximize power transfer to and from the external body.

[0118]

[0140] During the alignment process, it is generally important to align the fiber such that the light emitted by the optical fiber is minimally offset relative to the corresponding end component. For example, the cleave angle of the cleaved end of the optical fiber can affect the offset or orientation of the light emitted by the optical fiber. Any offset in the emitted light can affect the performance of the optical fiber in an optical system. Conventional cleave angle measurement systems and techniques often cannot measure cleave angles to a certain degree and often have minimal repeatability.

[0119]

[0141] However, manufacturing characteristics of the optical fiber may affect the alignment process. For example, the optical fiber may include a cleaved end. The cleaved end of the optical fiber may be the end of the optical fiber having a cleaved or cut surface that is approximately perpendicular to the longitudinal length of the optical fiber. The cleaved surface is typically created during the manufacturing process of the optical fiber. The angle of the cleaved end, referred to herein as the cleavage angle, may affect the alignment process. The cleavage angle is a measure of how perpendicular the cleaved end of the optical fiber is to the optical axis of the fiber. Typically, the optical axis of the optical fiber is aligned to the longitudinal length of the optical fiber, and therefore the cleavage angle may be the degree to which the cleaved end is perpendicular to the length of the optical fiber.

[0120]

[0142] The cleavage angle of an optical fiber can affect the alignment process of the optical fiber. Specifically, the cleavage angle of an optical fiber can affect the angle and orientation (e.g., offset) at which light is emitted from the cleaved end of the optical fiber. However, conventional techniques for measuring the cleavage angle of an optical fiber often cannot measure the cleavage angle to a certain angle and often have minimal repeatability. Furthermore, conventional methods are specific to the type of fiber and may require mode matching and wavelength matching between the optical fiber and the measurement instrument. Thus, there is a need in the art for improved methods and systems related to measuring the cleavage angle of an optical fiber.

[0121]

[0143] To provide accurate and consistent measurements of the cleave angle of an optical fiber down to an angle of less than one degree, a cleave angle measurement system is provided herein. FIG. 8A provides a simplified schematic diagram of a cleave angle measurement system 800 according to one embodiment of the present invention. The cleave angle measurement system 800 can enable measurement of the cleave angle of an optical fiber 804. Specifically, the cleave angle measurement system 800 can measure the cleave angle of a cleaved end 808 of the optical fiber 804. As described above, the cleaved end 808 of the optical fiber 804 can be formed during a manufacturing process of the optical fiber 804. For example, the optical fiber 804 can be cleaved or otherwise cut from a spool or a longer length of optical fiber. During the cleaving process, the cleaved end 808 can be formed having a cleavage angle. As discussed in more detail below, the cleave angle may be a measure of how perpendicular the cleaved end 808 of the optical fiber 804 is to the optical axis of the optical fiber 804. The optical axis of the optical fiber 804 may be parallel to the longitudinal length 834 of the optical fiber 804.

[0122]

[0144] The optical fiber 804 may be a polarization-maintaining fiber having one or more stress rods, patterned microstructures, or one or more cores. In some embodiments, the optical fiber 804 may be or include a bowtie fiber, a panda fiber, a multicore fiber, an elliptical fiber, a photonic crystal optical fiber, or the like. The optical fiber 804 may have a diameter less than 250 μm. For example, the optical fiber 804 may have a diameter less than 225 μm, less than 200 μm, less than 175 μm, less than 150 μm, less than 125 μm, or less than 100 μm. In some embodiments, the optical fiber 804 may have a diameter greater than 250 μm. For example, the diameter of the optical fiber 804 may be greater than 300 μm, 350 μm, or 400 μm. The diameter of the optical fiber 804 may depend on the type of optical fiber.

[0123]

[0145] The cleave angle measurement system 800 may be able to measure the cleave angle of the optical fiber 804 to a certain degree. In some embodiments, the cleave angle measurement system 800 may be able to measure the cleave angle of the optical fiber to within 0.5 degrees, to within 0.3 degrees, or to within 0.25 degrees. In other words, the cleave angle measurement system 800 can measure the cleave angle with precise accuracy. In addition to the precise accuracy achievable by the cleave angle measurement system 800, the cleave angle measurement system 800 provides consistent repeatability of the cleave angle measurements. The repeatability and precise measurements provided by the cleave angle measurement system 800 indicate the precision with which the cleave angle measurement system 800 can measure the cleave angle of the optical fiber 804.

[0124]

[0146] To measure the cleave angle of the optical fiber 804, the cleave angle measurement system 800 can include a stage 830, a light source 820, and an image sensor 810. In some embodiments, the stage 830 can include a fiber optic channel 832. The fiber optic channel 832 can be a portion of the stage 830 configured to receive at least a portion of the longitudinal length 834 of the optical fiber 804. For example, the fiber optic channel 832 can be a v-groove. The fiber optic channel 832 can be optimized or tuned for various cladding diameters of the optical fiber 804.

[0125]

[0147] The optical fiber channel 832 may also be configured to secure the optical fiber 804 during the cleave angle measurement process. To hold the optical fiber 804 in a desired position, the optical fiber 804 may be held in place on one side. Often, it is desirable to hold the optical fiber 804 in a manner that allows it to be easily released from the desired position without affecting the position of the optical fiber 804. Common means of holding the optical fiber 804 in a desired position that allows for easy release of the optical fiber 804 may include a vacuum chuck or other clamping mechanism. Thus, in some embodiments, the optical fiber channel 832 may include a vacuum chuck or clamp to secure the optical fiber 804 within the optical fiber channel 832.

[0126]

[0148] In some embodiments, the optical fiber 804 may be placed within the optical fiber channel 832 such that at least a portion of the fiber core or cladding of the optical fiber 804 is secured by the optical fiber channel 832. For ease of discussion, FIG. 8B is provided to show a side view of the optical fiber 804 disposed within the cleave angle measurement system 800. As FIG. 8B shows, the optical fiber 804 may include a fiber body 806 and a fiber core / cladding 802. The fiber core / cladding 802 may be referred to as an inner portion of the optical fiber 804. The fiber core / cladding 802 may terminate at an output face 805. The fiber body 806 includes a jacket 803 that surrounds the fiber core / cladding 802 within the fiber body 806. For example, the jacket 803 may be a plastic coating applied to the fiber core / cladding 802. During operation of the optical fiber 804, light is emitted from the output face 805. The exit face 805 may be a portion of a cleaved tip 808 .

[0127]

[0149] As discussed above, the optical fiber 804 can include various manufacturing characteristics, such as the cleave angle. Other manufacturing characteristics of the optical fiber 804 can include the bend or curvature of the optical fiber 804 along the longitudinal length L of the optical fiber 804. During or after the manufacturing process, the optical fiber 804 can be wound or rolled into a bundle, which can cause the optical fiber 804 to bend or curve along the longitudinal length 834. Additional manufacturing characteristics of the optical fiber 804 can include the material of the optical fiber 804, the material used to form the jacket 803, and the jacket 803 itself. For example, the jacket 803 can be applied such that the jacket 803 includes irregularities. The irregularities can include the thickness at which the jacket 803 is applied to the optical fiber 804. The irregularities can cause the outer surface of the optical fiber 804 to be non-cylindrical. Any irregularities in the jacket 803 can adversely affect the measurement of the cleave angle. Additionally, the jacket 803 can cause bending of the optical fiber due to memory caused by spooling the optical fiber during the manufacturing process.

[0128]

[0150] To prevent irregularities in the jacket 803 from affecting the cleave angle measurement, the jacket 803 may be removed over a portion of the longitudinal length 834 of the optical fiber 804. For example, a longitudinal length L of the fiber core / cladding 802, also referred to as the inner portion, may be exposed by removing the jacket 803 over that length. The longitudinal length L may begin at the cleaved end 808 of the optical fiber 804 and extend along the longitudinal length 834. In some embodiments, the longitudinal length L may range from 1 mm to 25 mm, from 5 mm to 20 mm, or from 10 mm to 15 mm. In an example embodiment, the longitudinal length L over which the jacket 803 is removed may be 10 mm or 1 cm.

[0129]

[0151] The optical fiber 804 can be secured within the optical fiber channel 832 by the longitudinal length L of the fiber core / cladding 802. By using the fiber core / cladding 802 to hold the optical fiber 804, the cleave angle measurement system 800 can provide more accurate measurements and consistent repeatability of cleave angle measurements.

[0130]

[0152] As one skilled in the art would readily appreciate, removing the jacket 803 from the fiber core / cladding 802 may not affect the functionality of the optical fiber 804. For example, many applications utilize the removal or stripping of the jacket 803 of the optical fiber 804. Additionally, cleaving the optical fiber 804 generally involves removing a portion of the jacket 803 from the cleaved end 808 of the optical fiber 804. Thus, removing the jacket 803 from the longitudinal length L of the fiber core / cladding 802 may not affect the functionality and applicability of the optical fiber 804.

[0131]

[0153] 8A , the optical fiber 804 may be positioned within the optical fiber channel 832 such that the cleaved end 808 is optically aligned with the light source 820. Optical alignment may mean that the light beam 822 is directed onto the cleaved end 808 of the optical fiber 804 when transmitted by the light source 820. The light source 820 may be configured to emit the light beam 822 toward the cleaved end 808. For example, the light source 820 may include a laser, a light emitting diode (LED), an arc lamp, a fiber optic illuminator, an incandescent light source, a fluorescent light source, a phosphorescent light source, or the like. In an example embodiment, the light source 820 may include an external laser.

[0132]

[0154] As shown, the light source 820 can transmit a light beam 822 towards the cleaved end 808 such that the light beam 822 is reflected from the cleaved end 808. The light beam 822 can be reflected from the cleaved end 808 as reflected light 824. The reflected light 824 can be received by an image sensor 810. The image sensor 810 can be configured to detect the reflected light 824. For example, the image sensor 810 can be or include a camera, a quadrant photodiode, or other device capable of sensing light. In an example embodiment, the image sensor 810 can be a silicon imaging camera or an infrared camera.

[0133]

[0155] In some embodiments, the reflected light 824 may be directed to the image sensor 810 by a beam splitter 840. The beam splitter 840 may be disposed in axial alignment with the optical fiber 804 and the light source 820. The beam splitter 840 may be disposed along the x-axis between the optical fiber 804 and the light source 820. The beam splitter 840 may also be disposed to reflect the reflected light 824 to the image sensor 810. For example, the beam splitter 840 may include a surface 842 that reflects a portion of the reflected light 824 toward the image sensor 810. The surface 842 of the beam splitter 840 may be a reflective surface, such as a mirror. In an example embodiment, the beam splitter 840 may be a non-polarizing beam splitter. For example, the beam splitter 840 may be a standard 50:50 beam splitter.

[0134]

[0156] In some embodiments, the cleave angle measurement system 800 can include a beam collector 850. The beam collector 850 can collect the stray light 826. Specifically, the beam collector 850 can block the stray light 826 from reaching the image sensor 810. For example, the beam collector 850 can be implemented as an empty tube or a light dump.

[0135]

[0157] As shown, the cleave angle measurement system 800 may not include additional lenses to direct, refract, or collimate the light beam 822 or the reflected light 824. Conventional methods often include one or more lenses to manipulate the optical properties of the light used to measure the cleave angle of the optical fiber. By not including lenses, the cleave angle measurement system 800 may include fewer components than conventional systems, providing a faster and more convenient system and technique for measuring cleave angles. For example, the cleave angle measurement system 800 does not require positioning and illumination of components with lenses, thereby providing a more convenient method of measuring cleave angles.

[0136]

[0158] The image sensor 810 is located at a distance D from the cleaved end 808 of the optical fiber 804. 端 The distance D 端 may be the total distance that the reflected light 824 travels from the cleaved end 808 to reach the image sensor 810. For example, the image sensor 810 may be a distance D 端 may be positioned such that it is at least 10 cm, at least 25 cm, at least 50 cm, or at least 100 cm from the cleaved end 808.

[0137]

[0159] The image sensor 810 can detect reflected light 824 from the cleaved end 808. Specifically, the image sensor 810 can detect the exit face 805 of the optical fiber 804 to generate an exit face measurement. Referring now to Figure 9A, a calculated image 900A of the exit face measurement 905 used to calculate the cleavage angle measurement is provided. Although the following discussion is with respect to Figures 8A and 8B, it should be understood that any system or technique provided herein may be used.

[0138]

[0160] The calculated image 900A may be generated based on the reflected light 824 detected by the image sensor 810. For example, the image used to generate the calculated image 900A may be captured by receiving the reflected light 824. One of several image processing methods may be utilized to detect and / or identify the various components of the optical fiber. In some embodiments, the various components of the optical fiber may be identified based on pixel coordinates in the captured image.

[0139]

[0161] The calculated image 900A may include an exit face measurement 905. The exit face measurement 905 may correspond to the exit face 805 of the optical fiber 804. The calculated image 900A may include an x-axis and a y-axis. The exit face measurement 905 may be generated on the calculated image 900A in xy coordinates relative to an optical center 940. The optical center 940 may be computationally determined. The optical center 940 may be the optical center of the image sensor 810. For example, as shown, the optical center 940 may be determined to be at the origin of the xy axis. Another method of determining the optical center 940 is discussed in more detail with respect to FIG. 10.

[0140]

[0162] A centroid 950 may be identified for the exit face measurement 905. The centroid 950 may be computationally determined as a center point within the exit face measurement 905. The centroid 950 of the exit face measurement 905 may be used to determine the cleave angle of the optical fiber 804. For example, the radial distance D 半径 may be determined based on the centroid 950. 半径 may be the distance from the centroid 950 to the optical center 940 of the optical fiber 804. 半径 can be measured in pixels or mm.

[0141]

[0163] 9B, a diagram 900B is provided illustrating the effect of distance variables on calculating the cleavage angle. As shown in diagram 900B, the cleavage angle θ C is the radial distance D 半径and the distance D from the image sensor to the cleavage end 端 It can be determined based on:

[0142]

[0164] Specifically, the cleavage angle θ C can be calculated based on the cleavage angle equation:

number

[0143]

[0165] The above cleavage angle equation can provide greater accuracy than conventional cleavage angle measurement techniques. For example, the cleavage angle equation is 半径 Based on the radial distance D 半径 is determined by light reflected from the cleaved end 808 of the optical fiber 804, which can increase sensitivity to cleave angle variations. In some embodiments, the reflected light 824 is used to determine the cleave angle θ as opposed to conventional methods using light emitted from the cleaved end 808 of the optical fiber 804 or conventional methods using interferometry techniques. C The sensitivity gained by measuring the cleavage angle can be increased by 50%. The increase in sensitivity can allow for cleavage angle measurements within 0.5 degrees of angle measurement.

[0144]

[0166] Importantly, because the above cleave angle equation uses reflected light 824, the cleave angle measurement system 800 can measure any style of optical fiber 804. For example, the cleave angle measurement system 800 can use the geometry of the reflected beam after reflection from the optical fiber 804 to determine an exit facet measurement 905 that is independent of the fiber wavelength design, core size, and microstructure within the optical fiber 804. The cleave angle measurement system 800 uses light in the visible spectrum, which can allow for easier alignment and more efficient cleave angle measurement methods.

[0145]

[0167] In some embodiments, the optical fiber 804 can be rotated to improve the cleave angle measurement. For example, the optical fiber 804 can be rotated about the x-axis via the stage 830. The optical fiber 804 can be rotated from a first position a predetermined rotational amount to a second position. At the second position, the image sensor 810 can generate a second exit face measurement based on the reflected light 824.

[0146]

[0168]

[0013] Referring now to Figure 10, a diagram is provided illustrating a calculated image 1000 of multiple exit facet measurements used to calculate a cleavage angle according to one embodiment of the present invention. For ease of discussion, Figure 10 will be discussed in conjunction with Figures 8, 9A, and 9B, although it should be understood that any system or technique disclosed herein may be applicable.

[0147]

[0169] As shown, the calculated image 1000 may include multiple exit surface measurements 1005A-1005F. Each of the exit surface measurements 1005A-1005F may correspond to the cleaved end 808 of the optical fiber 804 at a different rotational position. For example, the exit surface measurement 1005A may be generated based on the optical fiber 804 in a first position. After generating the exit surface measurement 1005A, the optical fiber 804 may be rotated a predetermined amount of rotation to a second position. At the second position, the exit surface measurement 1005B may be generated. The exit surface measurements 1005C-1005F may be generated following the same technique for the optical fiber 804 in a third position, a fourth position, a fifth position, and a sixth position, respectively. A centroid 1050 may be determined for each of the exit surface measurements 1005A-1005F as discussed with respect to FIG. 9A.

[0148]

[0170] 10, the calculated image 1000 may be used to calibrate the cleave angle measurement system 800. For example, the calculated image 1000 may be used to determine the optical center 1040 of the image sensor 810. The optical center 1040 may vary depending on the orientation of the fiber optic channel 832 and / or the optical fiber 804. For example, the optical fiber 804 may have a diameter that may affect the optical center 1040 of the image sensor 810. Additionally, the positioning of the fiber optic channel 832 relative to the image sensor 810 may affect the optical center 1040 of the image sensor 810.

[0149]

[0171] To determine the optical center 1040, an exit face arc 1044 can be determined. For example, the exit face arc 1044 can be determined based on the centroid 1050 of each of the exit face measurements 1005A-1005F. In other words, the exit face arc 1044 can be fitted to the centroid 1050 of each of the exit face measurements 1005A-1005F. Then, based on the exit face arc 1044, the optical center 1040 can be determined as the center point of the exit face arc 1044. As shown in this embodiment, the optical center 1040 does not have to be the origin 1042 of the xy axis. Instead, the cleave angle measurement system 800 can be calibrated such that the optical center 1040 is based on the optical fiber 804 and the current positioning of components within the cleave angle measurement system 800, such as the optical fiber channel 832.

[0150]

[0172] In some embodiments, the exit surface arc 1044 may be mathematically determined for the exit surface measurements 1005A-1005F. For example, the exit surface arc 1044 may be determined using the following equations [I]-[XII], which involve fitting a least squares equation to a circle. Once determined, the exit surface arc 1044 may be used to determine whether the exit surface measurements within the exit surface measurements 1005A-1005F are invalid or valid.

[0151]

[0173] Equation [I] begins with the equation of a circle, where a and b correspond to the x and y coordinates, respectively, of the centroid of the exit face arc 1044, which may be the optical center 1040. R is the radius of the exit face arc 1044, where R is the radial distance D 半径 It can be said that: [I](xa) 2 +(yb) 2 =R 2

[0152]

[0174] For a given measurement point i on the exit surface arc 1044, the residual is characterized by the following equation [II]: i It can be defined by: [II]

number

[0153]

[0175] The sum of the n-point residuals is a function of a, b, and R, characterized by the following equation [III]: [III]

number

[0154]

[0176] Rewriting equation [III] gives equation [IV] based on equations [V]-[VII]. [IV]

number

[0155]

[0177] Then, differentiating the variable F in equation [IV] with respect to B, C, and D, we obtain the following equations [VIII], [IX], and [X]. [VIII]

number

number

number

[0156]

[0178] Equations [VIII]-[X] can be reduced to matrices, as shown in equation [XI]. [XI]

number

[0157]

[0179] Equation [XI] can be taken in the following form: [XII] Mv=p

[0158]

[0180] By solving equations [I]-[XII], the variables B, C, and D can be determined. Once the variables B, C, and D are known, the optimal centroid and radius of the exit face arc 1044 can be determined.

[0159]

[0181] The exit face arc 1044 may correspond to the cleavage angle of the optical fiber 804. For example, if the cleaved end 808 of the optical fiber 804 is perfectly cleaved and therefore exactly perpendicular to the optical axis of the optical fiber 804, the exit face measurements 1005A-1005F will not precess when rotating the optical fiber 804 about the optical axis (e.g., the x-axis), and therefore the exit face arc 1044 will not be generated. Instead, the exit face measurements 1005A-1005F at various positions of the optical fiber 804 will remain in the same place on the calculated image 1000. However, as the cleavage angle increases, the exit face arc 1044 may also increase when rotating the optical fiber 804 to various positions. Thus, the illustrated exit face arc 1044 may indicate an incomplete cleavage angle of the cleaved end 808 of the optical fiber 804.

[0160]

[0182] Next, the radial distances D of the emission surface measurements 1005A to 1005F are 半径 The radial distance D can be determined. 半径 may be the distance of each exit surface measurement 1005A-1005F at a given position relative to the optical center 1040.

[0161]

[0183] To calibrate the cleave angle measurement system 800, an optical fiber having a known cleave angle can be used to generate the exit facet measurements 1005A-1005F. Then, the known cleave angle and the determined radial distance D 半径 Using the known cleavage angle and radial distance D 半径 It is possible to determine the correlation between the radial distance D 半径 Since the cleavage angle at the optical center 1040 is known and the cleavage angle at the optical center 1040 is known to be zero, the other radial distances D 半径 The cleavage angle can be extrapolated or calculated for

[0162]

[0184] In some embodiments, calibration of the cleave angle measurement system 800 can enable rapid processing of cleave angle measurements for a large number of optical fibers. For example, a single measurement can be used to determine the cleave angle of an optical fiber. The optical center 1040 is determined based on the calibration process described above, and the cleave angle and radial distance D 半径 The cleavage angle can be determined based on a single exit face measurement since a correlation between the radial distance D for a single exit face measurement is determined. 半径 It can be determined based on:

[0163]

[0185] In some embodiments, additional exit facet measurements can be collected to improve the accuracy of the cleave angle measurements or to verify the validity of the initial cleave angle measurements. Since any noise in the cleave angle measurement system 800 can affect the cleave angle measurements, verifying the validity of the cleave angle measurements can be advantageous in improving the accuracy of the cleave angle measurements.

[0164]

[0186] 11A and 11B, diagrams are provided illustrating computational images using optical centers to calculate and / or verify cleavage angles according to one embodiment of the present invention. For ease of discussion, FIGS. 11A and 11B are discussed in conjunction with FIGS. 8A-10, but it should be understood that any system or technique disclosed herein may be applicable.

[0165]

[0187] 11A provides a calculated image 1100A. As shown, the calculated image 1100A includes two exit surface measurements, exit surface measurement 1105A and exit surface measurement 1105B. The exit surface measurement 1105A and the exit surface measurement 1105B may be generated based on reflected light 824 reflected from the cleaved end 808 of the optical fiber 804 at a first position and a second position, respectively.

[0166]

[0188] The exit surface measurement 1105B is a first radial distance D of the exit surface measurement 1105A. 半径,1To verify the cleavage angle measurement of the exit face measurement 1105A, a first centroid 1150A of the exit face measurement 1105A may be determined, and a second centroid 1150B of the exit face measurement 1105B may be determined. The first centroid 1150A may then be used to determine a first radial distance D of the exit face measurement 1105A. 半径,1 Similarly, a second centroid 1150B can be used to determine a second radial distance D of the exit surface measurement 1105B. 半径,2 can be determined.

[0167]

[0189] As mentioned above, the radial distance may be determined as the distance from the centroid of the exit face to the optical center. Thus, in the first example embodiment, the first radial distance D 半径,1 may be determined as the first centroid 1150A to the optical center 1140, and the second radial distance D 半径,2 may be determined as the distance from the second centroid 1150B to the optical center 1140. The first radial distance D 半径,1 and a second radial distance D 半径,2 If the first radial distance D is equal to the first radial distance D, then the validity of the exit surface measurement 1105B can be confirmed. 半径、1 and a second radial distance D 半径、2 may be validated by the equality of , because rotating the optical fiber 804 may form an exit face arc 1044, as described above with reference to FIG. 10. If both the exit face measurement 1105A and the exit face measurement 1105B are valid, then the first centroid 1150A and the second centroid 1150B should have x,y coordinates along the same exit face arc. Thus, the first radial distance D 半径,1 and a second radial distance D半径,2 should be the same or within a threshold since the radius of the circle is constant. Therefore, the first radial distance D 半径,1 and a second radial distance D 半径,2If they are not equal, then one or both of the exit surface measurements 1105A and 1105B may be invalid.

[0168]

[0190] In a second example embodiment, the exit surface measurement 1105B may be validated by a different method. Referring now to FIG. 11B, calculated image 1100B may be the same as calculated image 1100A, except that the exit surface measurement 1105B may be captured at a different orientation. In this example, the first radial distance D 半径,1 and a second radial distance D 半径,2 is the first radial distance D 半径,1 and a second radial distance D 半径,2 are equal. If point 1146 is not the same as the optical center 1140, then one or both of exit surface measurement 1105A and exit surface measurement 1105B may be invalid measurements. One or more exit surface measurements may be taken and validated as well to determine if exit surface measurement 1105A and / or exit surface measurement 1105B are invalid.

[0169]

[0191] 12A and 12B provide a schematic diagram illustrating a calculated image of multiple exit facet measurements used to calculate a cleavage angle based on one or more validity checks according to an embodiment of the present invention. For ease of discussion, FIGS. 12A and 12B are discussed in conjunction with FIGS. 8A-11B, but it should be understood that any system or technique disclosed herein may be applicable.

[0170]

[0192] 12A provides a calculated image 1200A. The calculated image 1200A can include exit face measurements 1205A-1205G. The exit face measurements 1205A-1205G can be measured based on the cleaved end 808 of the optical fiber 804 being at various positions as the optical fiber 804 rotates about an optical axis (e.g., the x-axis). A centroid can be determined for each of the exit face measurements 1205A-1205G, as shown by centroid 1250A corresponding to the exit face measurement 1205A.

[0171]

[0193] 12A and 12B, the cleave angle measurement technique may not require a calibration procedure to determine the optical center 1240. Instead, the optical center 1240 may be determined based on the exit face measurements 1205A-1205G. For example, an exit face arc 1244 may be determined based on the respective centroids (e.g., 1250A) of the exit face measurements 1205A-1205G. The optical center 1240 may then be determined as the center point of the exit face arc 1244.

[0172]

[0194] Once the optical center 1240 is determined, the radial distance D 半径 The radial distance D can be determined. 半径 and the cleavage end distance D 端 Using this, the cleavage angle of the optical fiber 804 can be calculated.

[0173]

[0195] In some embodiments, one or more of the exit face measurements 1205A-1205G may not be valid. Referring now to FIG. 12B, a calculated image 1200B is provided illustrating an embodiment including an invalid exit face measurement. The exit face measurements may be invalid for a variety of reasons including noise in the cleave angle measurement system 800 or incorrect positioning of the optical fiber 804 in the optical fiber channel 832. In one illustrative example, a dust piece in the optical fiber channel 832 may cause the cleaved end 808 to be positioned in an improper position during rotation of the optical fiber 804. Thus, the exit face measurement 1205F corresponding to an improper position of the cleaved end 808 may be an invalid measurement.

[0174]

[0196] To identify exit face measurement 1205F as an invalid measurement, an exit face arc 1244 may be determined. The exit face arc 1244 may be determined by aligning the centroids of as many of the exit face measurements as practicable. In the illustrated example, the exit face arc 1244 is formed by exit face measurements 1205A-1205E and 1205G. In an example where exit face measurement 1205C was also invalid, the exit face arc 1244 may be determined by aligning the centroids of exit face measurements 1205A, 1205B, 1205D, 1205E, and 1205G. Any invalid exit face measurements, such as exit face measurement 1205F, may be discarded. In some embodiments, an invalid exit face measurement may indicate that the cleavage angle measurement system 800 would benefit from cleaning or repositioning before other measurements.

[0175]

[0197] In other embodiments, the exit facet measurements, and thereby the cleavage angle measurements, may be verified against a threshold. Referring now to Figures 13A and 13B, diagrams are provided illustrating computed images of multiple exit facet measurements used to calculate a cleavage angle verified against a threshold in accordance with an embodiment of the present invention. For ease of discussion, Figures 13A and 13B are discussed in conjunction with Figures 8A, 12A, and 12B, although it should be understood that any system or technique disclosed herein may be applicable.

[0176]

[0198] 13A provides a calculated image 1300A. As shown, the calculated image 1300A can include exit surface measurements 1305A-1305G. The exit surface measurements 1305A-1305G can be the same as or similar to the exit surface measurements 1205A-1205G. An exit surface arc 1344 can be generated for the exit surface measurements 1305A-1305G similar to the exit surface arc 1244, as described above. Additionally, an optical center 1340 can be determined similar to the optical center 1240, as described above.

[0177]

[0199] A threshold region 1348 may be determined for the exit surface measurements 1305A-1305G. The threshold region 1348 may determine whether the exit surface measurements within the exit surface measurements 1305A-1305G are invalid or valid.

[0178]

[0200] In some embodiments, the threshold region 1348 is D 端 and cleavage angle θ C Once the threshold region 1348 is determined, the exit surface measurements 1305A-1305G may be compared to the threshold region 1348 to determine the validity or acceptability of the measurements.

[0179]

[0201] 13B provides a calculated image 1300B in which an exit surface measurement 1305C may be invalid. As shown, the exit surface measurement 1305C is outside of a threshold region 1348. In some embodiments, if any portion of the exit surface measurement 1305C is outside of the threshold region 1348, the exit surface measurement 1305C may be invalid and may be discarded. In other embodiments, the exit surface measurement 1305C may be determined to be invalid only if the centroid 1350 of the exit surface measurement 1305C or the entirety of the exit surface measurement 1305C is outside of the threshold region 1348.

[0180]

[0202] In some embodiments, the cleave angle measurement system and techniques provided herein may be used to measure the cleave angles of multiple optical fibers. For example, a cleave angle may be measured for each optical fiber in a fiber array. Referring now to Figures 14A and 14B, a schematic diagram is provided illustrating a cleave angle measurement system according to an embodiment of the present invention. For ease of discussion, Figures 14A and 14B are discussed in conjunction with Figures 8A and 10, but it should be understood that any system or technique disclosed herein may be applicable.

[0181]

[0203] 14A and 14B show a cleave angle measurement system 1400. The cleave angle measurement system 1400 may be configured to measure the cleave angles of multiple optical fibers, namely, a first optical fiber 1404A, a second optical fiber 1404B, and a third optical fiber 1404C. In an example embodiment, the cleave angle measurement system 1400 may be used to measure the cleave angles of one or more optical fibers in a fiber array. In such an example, the first optical fiber 1404A, the second optical fiber 1404B, and the third optical fiber 1404C may be part of a fiber array.

[0182]

[0204] The cleavage angle measurement system 1400 can include an image sensor 1410 and a light source 1420. The image sensor 1410 can be the same as or similar to the image sensor 810, and the light source 1420 can be the same as or similar to the light source 820. In some embodiments, the light source 1420 can be capable of wavelength modulation or can be a broadband light source. Similar to the light source 820, the light source 1420 can be configured to emit a light beam 1422. The light beam 1422 can be directed to the second cleaved end 1408B of the second optical fiber 1404B.

[0183]

[0205] In some embodiments, a light beam 1422 having a second wavelength can be directed by one or more optical components to the second cleaved end 1408B. For example, as shown, the cleavage angle measurement system 1400 can include a diffraction grating 1416 that directs a diffracted light beam 1426B at an angle based on the wavelength. The diffraction grating 1416 can be positioned to generate a diffracted light beam 1426B having a second wavelength that is directed from the light source 1420 toward the second cleaved end 1408B.

[0184]

[0206] In some embodiments, a collecting lens 1414 may be disposed between the diffraction grating 1416 and the second cleaved end 1408B. The collecting lens 1414 may be configured to collect and direct the diffracted light beam 1426B from the diffraction grating 1416 toward the second cleaved end 1408B. In some embodiments, the collecting lens 1414 may be configured to collimate the diffracted light beam 1426B after diffraction from the diffraction grating 1416. In other embodiments, the collecting lens 1414 may be configured to filter out one or more wavelength ranges from the light beam 1422 such that certain wavelengths of the light beam 1422 reach the second cleaved end 1408B.

[0185]

[0207] After the diffracted light beam 1426B reaches the second cleaved end 1408B, the diffracted light beam 1426B may be reflected from the second cleaved end 1408B as reflected light 1424B. The reflected light 1424B may be directed to the image sensor 1410 by a beam splitter 1440. The beam splitter 1440 may be the same as or similar to the beam splitter 840.

[0186]

[0208] Similar to the cleavage angle measurement system 800, the cleavage angle measurement system 1400 can measure the cleavage angle of the second cleavage tip 1408B by receiving the reflected light 1424B at the image sensor 1410. For example, the cleavage angle measurement system 1400 can measure the cleavage angle according to the techniques discussed herein. For example, the exit surface of the second cleavage tip 1408B can be measured based on the reflected light 1424B received by the image sensor 1410.

[0187]

[0209] Because the optical fibers in the array are often fixed in place, measuring the cleave angles of multiple fibers in the array can include altering the transmission path of the light beam 1422. For example, referring now to Figure 14B, an embodiment is provided in which the cleave angle of a first optical fiber 1404A is measured. Because the first optical fiber 1404A, the second optical fiber 1404B, and the third optical fiber 1404C are fixed in place, the wavelength of the light beam 1422 can be altered to reflect light from the first cleaved end 1408A of the first optical fiber 1404A.

[0188]

[0210] To change the transmission path of the light beam 1422 such that the light beam 1422 reflects from the first cleaved end 1408A, the light beam 1422 can be changed to have a first wavelength. The diffraction grating 1416 can generate the diffracted light beam 1426A at a second angle based on the wavelength of the light beam 1422. The focusing lens 1414 can be configured to focus and direct the diffracted light beam 1426A from the diffraction grating 1416 to the first cleaved end 1408A. For example, the focusing lens 1414 can position the diffracted light beam 1426A such that the diffracted light beam 1426A is transmitted to the first cleaved end 1408A.

[0189]

[0211] After the diffracted light beam 1426A reaches the first cleaved end 1408A, the diffracted light beam 1426A may be reflected from the first cleaved end 1408A as reflected light 1424A. The reflected light 1424A may be directed to the image sensor 1410 by a beam splitter 1440. The beam splitter 1440 may be the same as or similar to the beam splitter 840.

[0190]

[0212] Similar to the cleavage angle measurement system 800, the cleavage angle measurement system 1400 can measure the cleavage angle of the first cleavage tip 1408A by receiving the reflected light 1424A at the image sensor 1410. For example, the cleavage angle measurement system 1400 can measure the cleavage angle according to the techniques discussed herein. For example, the exit surface of the first cleavage tip 1408A can be measured based on the reflected light 1424A received by the image sensor 1410.

[0191]

[0213] The collecting lens 1414 can be positioned to collect the diffracted light beam 1426A regardless of where the light beam 1422 contacts the diffraction grating 1416. Similarly, the beam splitter 1440 can be positioned to direct the reflected light 1424A reflected from the first cleaved end 1408A to the image sensor 1410. The cleavage angle of the first cleaved end 1408A can be calculated based on exit facet measurements collected from the reflected light 1424A received by the image sensor 1410, as disclosed herein.

[0192]

[0214] Because the optical fibers in a fiber array are difficult to rotate, a calibration optical fiber may be used to calibrate the cleave angle measurement system 1400. For example, the cleave angle measurement system 1400 may be calibrated according to the techniques described above with reference to FIG. 10. Then, once the cleave angle measurement system 1400 is calibrated, the cleave angles of each of the first optical fiber 1404A, the second optical fiber 1404B, and the third optical fiber 1404C may be measured without requiring rotation of each optical fiber.

[0193]

[0215] 15A-15C, schematic diagrams are provided illustrating various fiber optic channel arrangements in accordance with one embodiment of the present invention. For ease of discussion, Figures 15A and 15B will be discussed in conjunction with Figure 8, however it should be understood that any system or technique disclosed herein may be applicable.

[0194]

[0216] A light beam 1522 from a light source, e.g., light source 820, may be reflected from the cleaved end 1508 to determine the cleavage angle of the optical fiber 1504. To increase the accuracy of the cleavage angle measurement, it may be advantageous to reduce or minimize the amount of light beam 1522 that is reflected from surfaces that are not the cleaved end 1508. FIGS. 15A-15C provide various modifications that may be made to the surface 1534 of the optical fiber channel 1532 to reduce or minimize reflection of the light beam 1522 from the non-cleaved end surface. The optical fiber channel 1532 may be the same as or similar to the optical fiber channel 832. The light beam 1522 may be the same as or similar to the light beam 822 in that the light beam 1522 may be emitted by a light source, such as light source 820. The optical fiber 1504 may be positioned within the optical fiber channel 1532 such that the cleaved end 1508 is oriented to receive the light beam 1522 emitted from the light source. The optical fiber 1504 may be the same as or similar to the optical fiber 804 .

[0195]

[0217] 15A illustrates an embodiment 1500A in which a surface 1534 of the optical fiber channel 1532 is blackened or otherwise darkened. For example, the surface 1534 can include a dark portion 1536. The dark portion 1536 can be light absorbing to absorb the light beam 1521. The light beam 1521 can be a portion of the light beam 1522 that does not contact the cleaved end 1508 of the optical fiber 1504. The dark portion 1536 can absorb the light beam 1521 to prevent the light beam 1521 from reflecting off the surface 1534. In an example embodiment, the dark portion 1536 can be a coating applied to the surface 1534.

[0196]

[0218] In other embodiments, the surface 1534 may be angled to reflect the light beam 1521 at a different angle than the reflected light 1524. Figures 15B and 15C show embodiments 1500B and 1500C in which the surface 1534 is angled to direct any reflected light 1525 from the light beam 1521 at a different orientation than the transmission angle of the reflected light 1524. By reflecting the light beam 1521 at a different transmission angle than the reflected light 1524, the reflected light 1525 may be directed away from an image sensor, such as image sensor 810, and thus not received by the image sensor. Depending on the configuration of the cleave angle measurement system, the surface 1534 may be angled in a first direction as shown by embodiment 1500B, or in a second direction as shown by embodiment 1500C.

[0197]

[0219]

[0013] Figure 16 is a simplified flow chart illustrating a method 1600 of measuring the cleave angle of an optical fiber using a cleave angle measurement system according to one embodiment of the present invention. For ease of discussion, Figure 16 is discussed with reference to Figure 8A, however, it should be understood that any of the systems and techniques described herein may be applied.

[0198]

[0220] Method 1600 may include steps 1605 and 1610. In step 1605, a cleave angle measurement system 800 may be provided. The cleave angle measurement system 800 may include a fiber optic channel 832, an image sensor 810, and a light source 820. In step 1610, an optical fiber 804 may be placed in the fiber optic channel 832. The optical fiber 804 may include a cleaved end 808 and may be positioned such that the cleaved end 808 is optically aligned with the light source 820. In some embodiments, the cleavage angle measurement system 800 may also include a beam splitter 840. In such an embodiment, the method 1600 may also include transmitting light from the light source 820 through a beam splitter 840, reflecting the light from the cleaved end 808 of the optical fiber 804, and reflecting the light reflected from the cleaved end 808 of the optical fiber 804 by the beam splitter 840 to the image sensor 810.

[0199]

[0221] In yet other embodiments, the cleave angle measurement system 800 can also include a beam collector 850. In such embodiments, the method 1600 can also include collecting, with the beam collector 850, stray light generated by light reflecting from the cleaved end 808 of the optical fiber 804.

[0200]

[0222] In some embodiments, the method 1600 may also include removing the jacket 803 from the cleaved end 808 of the optical fiber 804 to expose the fiber core / cladding 802 of the optical fiber 804 (e.g., the inner portion of the optical fiber from which the coating has been removed) prior to placing the optical fiber 804 within the optical fiber channel 832. For example, the exposed longitudinal length L of the fiber core / cladding 802 of the optical fiber 804 may be between 5 and 20 mm. In such embodiments, the method 1600 may further include fixing the fiber core / cladding 802 of the optical fiber 804 within the optical fiber channel 832.

[0201]

[0223] The method 1600 may also include determining an optical center of the image sensor 810 in step 1615. The optical center of the image sensor 810 may be determined by various techniques. For example, in some embodiments, determining the optical center of the image sensor 810 may include generating a first exit face measurement of the cleaved end 808 of the optical fiber 804 at a first position based on light detected by the image sensor 810, calculating a first optical centroid of the first exit face measurement, determining a first radial distance of the first exit face measurement of the optical fiber 804, and calculating a cleavage angle of the cleaved end 808 of the optical fiber 804 based on the first radial distance. After determining the first optical centroid of the first exit face measurement at the first position, the method may include rotating the optical fiber 804 to a second position. A second exit face measurement of the optical fiber 804 at the second position can then be generated based on the light reflected from the cleaved end 808 of the optical fiber 804, and a second optical centroid of the second exit face measurement can be calculated. In some embodiments, the optical fiber 804 can be further rotated to a third position, and a third exit face measurement of the optical fiber 804 at the third position can be generated based on the light reflected from the cleaved end 808 of the optical fiber 804, from which a third optical centroid of the third exit face measurement can be generated. The optical center of the image sensor 810 can be determined based on the first optical centroid, the second optical centroid, and the third optical centroid.

[0202]

[0224] In other embodiments, the optical center of the image sensor 810 may be determined by a calibration technique. In such an embodiment, the method 1600 may include placing a calibration optical fiber at a first position in the optical fiber channel 832, the calibration optical fiber comprising a cleaved end having a known cleavage angle. The image sensor 810 may detect light reflected from the cleaved end of the calibration optical fiber, and a first exit face measurement of the calibration optical fiber at the first position may be generated based on the light detected by the image sensor 810. The calibration optical fiber may then be rotated to a second position. At the second position, a second exit face measurement may be generated for the calibration optical fiber at the second position based on the light reflected from the cleaved end of the calibration optical fiber. The optical center of the image sensor 810 may be determined based on the first exit face measurement and the second exit face measurement. In an embodiment including a calibration technique, step 1615 may be performed before steps 1605 and 1610.

[0203]

[0225] The method 1600 may include steps 1620 and 1625. In step 1620, light may be reflected from the cleaved end 808 of the optical fiber 804. The light may be provided by the light source 820. In step 1625, the image sensor 810 may detect the light reflected from the cleaved end 808 of the optical fiber.

[0204]

[0226] In some embodiments, the method 1600 may include step 1630, where it is determined whether another exit face measurement is utilized. To determine whether another exit face measurement is utilized, an exit face measurement may be generated and a determination may be made whether the exit face measurement is valid. For example, the method 1600 may include generating a first exit face measurement of the cleaved end 808 of the optical fiber 804 at a first position based on light detected by the image sensor 810, calculating a first optical centroid of the first exit face measurement, and determining a first radial distance of the first exit face measurement of the optical fiber 804.

[0205]

[0227] In some embodiments, a determination may be made that another exit face measurement should be performed. In such embodiments, the method 1600 may proceed to step 1635, where the optical fiber 804 may be rotated to a second position. After rotating the optical fiber 804 to the second position, the method may return to step 1620 via an iterative step 1640. For example, the method 1600 may include rotating the optical fiber 804 to a second position (step 1635), and then generating a second exit face measurement of the optical fiber 804 at the second position based on light reflected from the cleaved end 808 of the optical fiber 804. A second optical centroid of the second exit face measurement may be calculated, and a determination may be made whether the first exit face measurement or the second exit face measurement is valid (step 1630).

[0206]

[0228] Determining whether the first exit surface measurement or the second exit surface measurement is valid can include determining a circular radius based on the optical center, determining a second radial distance of the second exit surface measurement based on the circular radius, and determining whether the second radial distance and the first radial distance align to the optical center. In other embodiments, determining whether the first exit surface measurement or the second exit surface measurement is valid can include determining whether the first exit surface measurement is within a threshold value and determining whether the second exit surface measurement is within a threshold value.

[0207]

[0229] In other embodiments, a determination may be made based on the first radial distance and the first centroid that no other exit face measurements should be performed. In such embodiments, method 1600 may proceed to step 1645. In step 1645, the method may include calculating a cleave angle of the cleaved end 808 of the optical fiber 804 based on the first radial distance. As described above, the cleave angle measurement system provides accurate cleave angle measurements with an accuracy to an angle measurement of 0.5 degrees or less.

[0208]

[0230] It should be appreciated that the specific steps illustrated in FIG. 16 provide a particular method of measuring the cleave angle of an optical fiber using a cleave angle measurement system according to one embodiment of the present invention. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 16 may include multiple sub-steps that may be performed in various orders depending on the individual step. Additionally, additional steps may be added or removed depending on the particular application. Those skilled in the art will recognize many variations, modifications, and alternatives.

[0209]

[0231]

[0013] Figure 17 is a simplified flow chart illustrating a method 1700 of measuring the cleave angles of multiple optical fibers using a cleave angle measurement system according to one embodiment of the present invention. For ease of discussion, Figure 17 is discussed with reference to Figures 14A and 14B, however, it should be understood that any of the systems and techniques described herein may be applied.

[0210]

[0232] The method 1700 may include steps 1705 and 1710. In step 1705, the method 1700 may include providing a cleave angle measurement system 1400. The cleave angle measurement system 1400 may include a first fiber optic channel, a second fiber optic channel, an image sensor 1410, and a light source 1420. In step 1710, a number of optical fibers may be provided, for example, a first optical fiber 1404A, a second optical fiber 1404B, and a third optical fiber 1404C. For example, the first optical fiber 1404A may be disposed in the first optical fiber channel, and the second optical fiber 1404B may be disposed in the second optical fiber channel. In some embodiments, the first optical fiber 1404A, the second optical fiber 1404B, and the third optical fiber 1404C may be part of an optical fiber array.

[0211]

[0233] The first optical fiber 1404A, the second optical fiber 1404B, and the third optical fiber 1404C can each include a cleaved end. For example, the first optical fiber 1404A can include a first cleaved end 1408A, and the second optical fiber 1404B can include a second cleaved end 1408B. The first cleaved end 1408A and the second cleaved end 1408B can be disposed facing the light source 1420.

[0212]

[0234] In some embodiments, the method 1700 may also include removing a coating from the first cleaved end 1408A of the first optical fiber 1404A to expose an inner portion of the first optical fiber 1404A prior to placing the first optical fiber 1404A in the first optical fiber channel. The coating may also be removed from the second cleaved end 1408B of the second optical fiber 1404B to expose an inner portion of the second optical fiber 1404B. For example, the longitudinal length L of the exposed inner portions of the first optical fiber 1404A and the second optical fiber 1404B may be between 5 mm and 20 mm. In such embodiments, the method 1700 may further include fixing the first optical fiber 1404A and the second optical fiber 1404B at their respective inner portions.

[0213]

[0235] In some embodiments, the cleave angle measurement system 1400 can also include a beam splitter 1440. In such embodiments, the method 1700 can also include transmitting a first wavelength and a second wavelength from the light source 1420 through the beam splitter 1440, reflecting the first wavelength from the first cleaved end 1408A and reflecting the second wavelength from the second cleaved end 1408B, and reflecting the first wavelength reflected from the first cleaved end 1408A and the second wavelength reflected from the second cleaved end 1408B by the beam splitter 1440 to the image sensor 1410.

[0214]

[0236] In yet other embodiments, the cleave angle measurement system 1400 can also include a diffraction grating 1416. In such embodiments, the diffraction grating 1416 can be positioned to direct a first wavelength from the light source 1420 to a first cleaved end 1408A of the first optical fiber 1404A and a second wavelength from the light source 1420 to a second cleaved end 1408B of the second optical fiber 1404B.

[0215]

[0237] In embodiments in which the cleave angle measurement system 1400 includes a diffraction grating 1416, the cleave angle measurement system 1400 may further include a collection lens 1414 disposed between the diffraction grating 1416 and the beam splitter 1440. In such embodiments, the method 1700 may include transmitting a light beam from a light source 1420, the light beam including a first wavelength and a second wavelength, diffracting the light beam 1422 by the diffraction grating 1416 such that the collection lens 1414 selectively positions the diffracted light beam 1426B to transmit onto the first cleaved end 1408A, and diffracting the light beam 1422 by the diffraction grating 1416 such that the collection lens 1414 selectively positions the diffracted light beam 1426A onto the first cleaved end 1408A.

[0216]

[0238] The method 1700 may include a step 1715 in which an optical center of the image sensor 1410 may be determined. For example, the optical center of the image sensor 1410 may be determined by any of the methods or techniques described herein, such as those described with reference to FIG.

[0217]

[0239] The method 1700 may include step 1720. In step 1720, the method 1700 may include reflecting a first wavelength transmitted by the light source 1420 from a first cleaved end 1408A of the first optical fiber 1404A. Then, in step 1725, the method 1700 may include determining a first cleavage angle of the first cleaved end 1408A based on the first wavelength reflected from the first cleaved end 1408A. For example, determining the first cleavage angle of the first cleaved end 1408A may include detecting a first wavelength reflected from the first cleaved end of the first optical fiber with the image sensor 1410, generating a first exit face measurement of the first cleaved end 1408A of the first optical fiber 1404A at a first position based on the first wavelength detected by the image sensor 1410, calculating a first optical centroid of the first exit face measurement, determining a first radial distance of the first exit face measurement of the first optical fiber 1404A, and calculating the first cleavage angle based on the first radial distance. The first radial distance of the first exit face measurement may be based on the optical center of the image sensor 1410.

[0218]

[0240] The method 1700 may include steps 1730 and 1735. In step 1730, the method 1700 may include reflecting the second wavelength transmitted by the light source 1420 from the second cleaved end 1408B of the second optical fiber 1404B. Then, in step 1735, the method 1700 may include determining a second cleavage angle of the second cleaved end 1408B based on the second wavelength reflected from the second cleaved end 1408B. In example embodiments, the first wavelength may be different from the second wavelength.

[0219]

[0241] It should be appreciated that the specific steps illustrated in FIG. 17 provide a particular method for measuring the cleave angles of a plurality of optical fibers using a cleave angle measurement system according to an embodiment of the present invention. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present invention may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 17 may include numerous sub-steps that may be performed in various orders depending on the individual step. Additionally, additional steps may be added or removed depending on the particular application. Those skilled in the art will recognize many variations, modifications, and alternatives.

[0220]

[0242] The examples and embodiments described herein are for illustrative purposes only. In light of the above, various modifications or changes will be apparent to those skilled in the art. These are to be included within the spirit and scope of this application and the appended claims.

Claims

1. 1. A method for aligning optical fibers, comprising the steps of: providing an optical fiber having a first end and a second end, the first end of the optical fiber including a predetermined manufacturing characteristic; Positioning the optical fiber such that the first end of the optical fiber faces a microlens array (MLA) alignment system, the MLA alignment system comprising: A tilt sensor, and Position Detection Device and emitting a light beam from the first end of the optical fiber towards the MLA alignment system; generating a reference output from the MLA alignment system based on the light beam, the reference output including at least one of a tilt measurement or a position measurement; thereafter, providing a microlens array (MLA) having a plurality of lenslets at a first location between the first end of the optical fiber and the MLA alignment system; generating a first MLA beam output for the first position of the MLA, the first MLA beam output comprising at least one of a first MLA tilt value or a first MLA position value; comparing the first MLA beam output to an alignment threshold; A method comprising:

2. 2. The method of claim 1 , wherein providing the MLA at the first position between the first end of the optical fiber and the MLA alignment system comprises positioning the MLA at the first position such that the light beam emanating from the first end of the optical fiber is transmitted through one lenslet of the plurality of lenslets.

3. generating the reference output from the MLA alignment system based on the light beam, placing the optical fiber at a first position; measuring, via the tilt sensing device, a first tilt measurement based on the light beam emitted from the first end of the optical fiber at the first position; measuring, via the position sensing device, a first position measurement based on the light beam emitted from the first end of the optical fiber at the first position; comparing the first tilt measurement to a tilt threshold; and Comparing the first position measurement to a position threshold. The method of claim 1 , comprising:

4. placing the optical fiber at a second location; measuring a second tilt measurement from the tilt sensing device based on the light beam emitted from the first end of the optical fiber via the tilt sensing device; measuring, via the position sensing device, a second position measurement based on the light beam emitted from the first end of the optical fiber at the first position; comparing the second tilt measurement to the tilt threshold; comparing the second position measurement to the position threshold; The method of claim 3 further comprising:

5. The method of claim 3 , wherein the reference output includes the first tilt measurement and the first position measurement.

6. 4. The method of claim 3, wherein placing the optical fiber at the first position comprises moving the optical fiber along at least one of an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation.

7. Generating the first MLA beam output to the first position of the MLA includes: measuring the first MLA tilt value of the MLA at the first position via the tilt sensing device; measuring, via the position sensing device, the first MLA position value of the MLA at the first location; comparing the first MLA slope value to an MLA slope threshold; and comparing the first MLA position value to an MLA position threshold, the alignment threshold including the MLA tilt threshold and the MLA position threshold. The method of claim 1 , comprising:

8. moving the MLA from a first position to a second position based on the first MLA beam output; generating a second MLA beam output for the second position of the MLA, the generating of the second MLA beam output comprising: measuring a second MLA tilt value of the MLA at the second position via the tilt sensing device; and Measuring a second MLA position value of the MLA at the second location via the position sensing device. and Comparing the second MLA beam output to the alignment threshold, comprising: comparing the second MLA slope value to the MLA slope threshold; and Comparing the second MLA position value to the MLA position threshold. Steps The method of claim 7 further comprising:

9. 8. The method of claim 7, wherein moving the MLA from the first position to the second position comprises moving the MLA along at least one of an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation.

10. The MLA alignment system further comprises a beam splitter and a focusing lens, and the step of emitting the light beam from the first end of the optical fiber comprises: transmitting the first portion of the light beam from the first end of the optical fiber through the beam splitter before reaching the position sensing device; and reflecting a second portion of the light beam from the first end of the optical fiber off of the beam splitter through the collecting lens before reaching the tilt sensor device. The method of claim 1 further comprising:

11. The method of claim 1 , wherein the predetermined manufacturing characteristics of the first end of the optical fiber include a predetermined cleave angle.

12. The method of claim 1 , further comprising attaching a first end of a second optical fiber to one lenslet of the plurality of lenslets of the MLA.

13. The method of claim 1 , further comprising attaching the first end of the optical fiber to one lenslet of the plurality of lenslets of the MLA.

14. 1. A method for aligning an optical fiber array, comprising: Providing a plurality of optical fibers, the plurality of optical fibers comprising: a first optical fiber having a first end and a second end; and a second optical fiber having a third end and a fourth end; and Positioning the first optical fiber such that the first end of the optical fiber faces an MLA alignment system, the MLA alignment system comprising: A tilt sensor, and Position Detection Device and providing a microlens array (MLA) having a plurality of lenslets at a first MLA location between the first end of the first optical fiber and the MLA alignment system, the plurality of lenslets comprising a first lenslet and a second lenslet; adjusting the first end of the first optical fiber into rough alignment with the first lenslet of the plurality of lenslets; generating a first MLA beam output of the first optical fiber, the first MLA beam output comprising at least one of a first MLA tilt value or a first MLA position value; comparing the first MLA beam output to an alignment threshold, the alignment threshold including at least one of an MLA tilt threshold or an MLA position threshold; attaching the first end of the first optical fiber to a surface of the first lenslet; moving the MLA to a second MLA position between the third end of the second optical fiber and the MLA alignment system such that the third end of the second optical fiber is roughly aligned with the second lenslet; A method comprising:

15. Producing the first MLA beam output of the first optical fiber includes: measuring the first MLA slope value via the slope sensing device; and Measuring the first MLA position value via the position sensing device. Including, The step of comparing the first MLA beam output to the alignment threshold comprises: comparing the first MLA slope value to the MLA slope threshold; and comparing the first MLA position value to the MLA position thresholds, the alignment thresholds including the MLA tilt threshold and the MLA position threshold.

15. The method of claim 14, comprising:

16. moving the first optical fiber to a second fiber position based on the first MLA beam output; generating a second MLA beam output of the first optical fiber at the second fiber position, the generating of the second MLA beam output comprising: measuring, via the tilt sensing device, a second MLA tilt value from the tilt sensing device; and Measuring the second MLA position value via the position sensing device. and Comparing the second MLA beam output to the alignment threshold, comprising: comparing the second MLA slope value to the MLA slope threshold; and Comparing the second MLA position value to the MLA position threshold. Steps The method of claim 15 further comprising:

17. the plurality of optical fibers comprises a third optical fiber having a fifth end and a sixth end, the plurality of lenslets comprises a third lenslet, and the method further comprises: attaching the third end of the second optical fiber to a surface of the second lenslet; moving the MLA to a third MLA position between the fifth end of the third optical fiber and the MLA alignment system such that the fifth end of the third optical fiber is roughly aligned with the third lenslet; 20. The method of claim 16, further comprising:

18. 15. The method of claim 14, wherein moving the first optical fiber to a second fiber position comprises moving the first optical fiber along an x-axis, a y-axis, a z-axis, a w-rotation, a u-rotation, or a v-rotation.

19. The MLA alignment system further comprises a beam splitter and a focusing lens, and the method further comprises emitting a light beam from the first end of the first optical fiber, the emitting of the light beam from the first end of the first optical fiber comprising: transmitting a first portion of the light beam from the first end of the first optical fiber through the beam splitter before reaching the position sensing device; and reflecting a second portion of the light beam from the first end of the first optical fiber off the beam splitter and through the collecting lens before reaching the tilt sensing device.

15. The method of claim 14, comprising:

20. 15. The method of claim 14, wherein adjusting the first end of the first optical fiber into rough alignment with the first lenslet comprises positioning the first end of the first optical fiber a predetermined distance from the surface of the first lenslet.

21. 1. A method for measuring a cleavage angle of an optical fiber, comprising: Providing a cleavage angle measurement system, the cleavage angle measurement system comprising: Fiber optic channel, Image sensors, and light source and placing an optical fiber having a cleaved end within the optical fiber channel such that the cleaved end is positioned in optical alignment with the light source; determining an optical center of the image sensor; reflecting light transmitted by the light source from the cleaved end of the optical fiber; detecting light reflected from the cleaved end of the optical fiber with the image sensor; determining the cleavage angle of the optical fiber based on the light reflected from the cleaved end; A method comprising:

22. The step of determining the cleavage angle of the optical fiber comprises: generating a first exit facet measurement of the cleaved end of the optical fiber at a first position based on the light detected by the image sensor; calculating a first optical centroid of the first exit surface measurement; determining a first radial distance of the first exit face measurement of the optical fiber; and calculating the cleavage angle of the cleaved end of the optical fiber based on the first radial distance; 22. The method of claim 21 further comprising:

23. rotating the optical fiber to a second position; generating a second exit facet measurement of the optical fiber at the second location based on light reflected from the cleaved end of the optical fiber; calculating a second optical centroid of the second exit surface measurement; determining whether the first exit surface measurement or the second exit surface measurement is valid; 23. The method of claim 22, further comprising:

24. Determining whether the first exit surface measurement or the second exit surface measurement is valid comprises: determining a circular radius based on the optical center; determining a second radial distance of the second exit face measurement based on the circular radius; and determining whether the second radial distance and the first radial distance are aligned to an optical center; 24. The method of claim 23, further comprising:

25. Determining whether the first exit surface measurement or the second exit surface measurement is valid comprises: determining whether the first exit surface measurement is within a threshold; and determining whether the second exit surface measurement is within the threshold value; 24. The method of claim 23, further comprising:

26. The step of determining an optical center of the image sensor comprises: rotating the optical fiber to a second position; generating a second exit facet measurement of the optical fiber at the second location based on light reflected from the cleaved end of the optical fiber; calculating a second optical centroid of the second exit surface measurement; rotating the optical fiber to a third position; generating a third exit facet measurement of the optical fiber at the third location based on light reflected from the cleaved end of the optical fiber; calculating a third optical centroid of the third exit surface measurement; and determining the optical center of the image sensor based on the first optical centroid, the second optical centroid, and the third optical centroid; 23. The method of claim 22, further comprising:

27. The step of placing the optical fiber in the optical fiber channel comprises: removing a coating from the cleaved end of the optical fiber to expose an inner portion of the optical fiber; and Securing the inner portion of the optical fiber within the optical fiber channel.

22. The method of claim 21 , comprising:

28. 28. The method of claim 27, wherein the length of the exposed inner portion of the optical fiber is between 5 mm and 20 mm.

29. The step of determining the optical center of the image sensor comprises: placing a calibration optical fiber at a first location within the optical fiber channel, the calibration optical fiber having a cleaved end having a known cleavage angle; detecting light reflected from the cleaved end of the calibration optical fiber with the image sensor; generating a first exit face measurement of the calibration optical fiber at the first position based on the light detected by the image sensor; rotating the calibration optical fiber to a second position; generating a second exit face measurement of the calibration optical fiber at the second position based on light reflected from the cleaved end of the calibration optical fiber; and determining the optical center of the image sensor based on the first exit surface measurement and the second exit surface measurement; 22. The method of claim 21 , comprising:

30. The cleavage angle measurement system further comprises a beam splitter, and the method further comprises: transmitting light from the light source through the beam splitter; reflecting light from the cleaved end of the optical fiber; reflecting the light reflected from the cleaved end of the optical fiber by the beam splitter to the image sensor; 22. The method of claim 21 , comprising:

31. 31. The method of claim 30, wherein the cleave angle measurement system further comprises a beam collector, the method further comprising collecting, with the beam collector, stray light generated by the light reflecting from the cleaved end of the optical fiber.

32. 22. The method of claim 21, wherein the cleave angle comprises an angular measurement of 0.5 degrees or less.

33. 1. A method for measuring cleavage angles of a plurality of optical fibers, comprising: Providing a cleavage angle measurement system, the cleavage angle measurement system comprising: a first fiber optic channel; a second fiber optic channel; Image sensors, and light source and Providing the plurality of optical fibers, the plurality of optical fibers includes a first optical fiber having a first cleaved end and a second optical fiber having a second cleaved end; the first cleaved end and the second cleaved end are disposed toward the light source; Steps and determining an optical center of the image sensor; reflecting a first wavelength transmitted by the optical source from the first cleaved end of the first optical fiber; determining a first cleavage angle of the first cleaved tip based on the first wavelength reflected from the first cleaved tip; reflecting a second wavelength transmitted by the optical source from the second cleaved end of the second optical fiber; determining a second cleavage angle of the second cleaved tip based on the second wavelength reflected from the second cleaved tip; Including, the first wavelength is different from the second wavelength; method.

34. The method of claim 33 , wherein the plurality of optical fibers is part of a fiber array.

35. The step of determining the first cleavage angle of the first cleavage tip includes: detecting, with the image sensor, the first wavelength reflected from the first cleaved end of the first optical fiber; generating a first exit facet measurement of the first cleaved end of the first optical fiber at a first location based on the first wavelength sensed by the image sensor; calculating a first optical centroid of the first exit surface measurement; determining a first radial distance of the first exit face measurement of the first optical fiber; and Calculating the first cleavage angle based on the first radial distance.

34. The method of claim 33, comprising:

36. 36. The method of claim 35, wherein determining the first radial distance of the first exit face measurement is based on the optical center of the image sensor.

37. The step of providing a plurality of optical fibers comprises: removing a coating from the first cleaved end of the first optical fiber to expose an inner portion of the first optical fiber; and removing a coating from the second cleaved end of the second optical fiber to expose an inner portion of the second optical fiber; 34. The method of claim 33, comprising:

38. The cleavage angle measurement system further comprises a beam splitter, and the method further comprises: transmitting the first wavelength and the second wavelength from the light source through the beam splitter; reflecting the first wavelength from the first cleaved end; reflecting the second wavelength from the second cleaved end; reflecting, by the beam splitter, the first wavelength reflected from the first cleaved end and the second wavelength reflected from the second cleaved end to the image sensor; 34. The method of claim 33, further comprising:

39. The cleavage angle measurement system includes: directing the first wavelength from the light source toward the first cleaved tip; Directing the second wavelength from the light source toward the second cleaved end.

40. The method of claim 38, further comprising a diffraction grating arranged such that

40. The cleavage angle measurement system further comprises a lens disposed between the diffraction grating and the beam splitter, and the method further comprises: transmitting a light beam from the light source, the light beam comprising the first wavelength and the second wavelength; diffracting the light beam with the diffraction grating such that the lens selectively positions and transmits the first wavelength from the light beam onto the first cleaved tip; diffracting the light beam with the diffraction grating such that the lens selectively positions and transmits the second wavelength from the light beam onto the second cleaved end; 40. The method of claim 39, further comprising:

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