Automatic fiber preparation and welding method and system

Abstract

A method for constructing a fiber array includes the steps of: a) selecting one optical fiber spool from one or more optical fiber spools; b) processing a portion of the fiber spool to form an optical fiber having an output end; c) arranging a substrate at one of a plurality of locations; and d) aligning the output end of the optical fiber with the substrate. The method further includes the step of: e) coupling the output end of the optical fiber at one of a plurality of locations on the substrate. The method further includes the steps of f) removing the optical fiber from the fiber spool and forming the input end of the optical fiber, and g) marking the optical fiber. The method further includes repeating steps c) through g) for each of a plurality of positions on the substrate and determining that the substrate has been placed at each of the plurality of positions.

Description

[Technical Field]

[0001] Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 533,285, filed on 17 August 2023, entitled “Automated Fiber Preparation and Welding Method and System,” the disclosures of which are incorporated herein by reference in their entirety for all purposes.

[0002]

[0002] Optical fibers are widely used in optical systems. In some optical systems, multiple optical fibers can be spliced ​​together and joined to optical elements. In the alignment process, it is generally important to align the fibers so that the light emitted from the optical fiber is minimally misaligned with the corresponding end face component. For example, the cutting angle of the cut end of the optical fiber can affect the misalignment and direction of the light emitted from the optical fiber. Misalignment of the emitted light can affect the performance of the optical fiber in the optical system. Despite advances in the field of optical fibers and optical systems, there is still a need for improved methods and systems related to optical fibers and optical systems. [Overview of the project] [Means for solving the problem]

[0003]

[0003] This disclosure relates to methods and systems relating to optical systems including optical fibers. More specifically, embodiments of the present invention provide methods and systems used for the automated manufacturing of fiber arrays including a plurality of optical fibers. This disclosure is applicable to a variety of applications in the laser and optical fields, including the packaging of fiber lasers.

[0004]

[0004] The present disclosure provides numerous advantages over conventional techniques. For example, embodiments of the present invention implement an automatic fiber preparation and welding system. For example, by utilizing embodiments of the present invention in an automated environment, various optical fiber preparation, inspection, and installation processes can be efficiently integrated. Specifically, data related to the quality and cleanliness of various processes may be collected as part of the automatic laser welding system described herein. These and other embodiments of the present disclosure, as well as their many advantages and features, are described in more detail in conjunction with the following text and corresponding drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] [Figure 1] It is a flow chart of one embodiment of the automatic fiber preparation and welding system of the present disclosure. [Figure 2] It is a flow chart illustrating a method for constructing an optical fiber array according to one embodiment of the present disclosure. [Figure 3A] It shows a simplified schematic diagram of an optical fiber presence detection system according to one embodiment of the present invention. [Figure 3B] It shows a simplified schematic diagram of an optical fiber presence detection system according to one embodiment of the present invention. [Figure 4] It is a simplified schematic diagram of an optical fiber presence detection system according to another embodiment of the present invention. [Figure 5] It is a flow chart of one embodiment of the method of the present disclosure. [Figure 6A] It shows a simplified schematic diagram of a cleave angle measurement system according to one embodiment of the present invention. [Figure 6B] It shows a side view of an optical fiber provided in a cleave angle measurement system according to one embodiment of the present invention. [Figure 7A] It shows a calculated image of light-emitting surface measurement values used for calculating a cleave angle measurement value according to one embodiment of the present invention. [Figure 7B] It is a diagram showing the influence of a distance variable in the calculation of a cleave angle according to one embodiment of the present invention. [Figure 8] This figure shows a calculated image of multiple light-emitting surface measurements used to calculate the cutting angle, according to one embodiment of the present invention. [Figure 9A] This figure shows a computational image for calculating and / or verifying the cutting angle using an optical center, according to one embodiment of the present invention. [Figure 9B] This figure shows a computational image for calculating and / or verifying the cutting angle using an optical center, according to one embodiment of the present invention. [Figure 10A] This is a computational image showing one embodiment of one invention, including invalid light-emitting surface measurements. [Figure 10B] This is a computational image showing one embodiment of one invention, including invalid light-emitting surface measurements. [Figure 11A] This is a computational image showing an embodiment of one embodiment that includes invalid light-emitting surface measurements. [Figure 11B] This is a computational image illustrating an embodiment of one embodiment of the present invention, which includes measurement of an invalid light-emitting surface. [Figure 12A] An embodiment of one of the present inventions, a cutting angle measurement system, is shown. [Figure 12B] An embodiment of one of the present inventions, a cutting angle measurement system, is shown. [Figure 13A] An embodiment of the surface of an optical fiber channel according to an embodiment of the present invention is shown. [Figure 13B] An embodiment of the surface of an optical fiber channel according to an embodiment of the present invention is shown. [Figure 13C] An embodiment of the surface of an optical fiber channel according to an embodiment of the present invention is shown. [Figure 14] This is a simplified flowchart illustrating a method for measuring the cutting angle of an optical fiber using a cutting angle measurement system according to one embodiment of the present invention. [Figure 15] This is a simplified flowchart illustrating a method for measuring the cutting angles of multiple optical fibers using a cutting angle measurement system according to one embodiment of the present invention. [Figure 16]This is a simplified schematic diagram of a cutting angle measurement system according to one embodiment of the present invention. [Figure 17] This is a simplified perspective view of a cutting angle measurement system according to one embodiment of the present invention. [Figure 18] This is a simplified flowchart illustrating a method for measuring the cutting angle of an optical fiber using a cutting angle measurement system according to one embodiment of the present invention. [Figure 19] This is a simplified perspective view of a cutting angle measuring system according to another embodiment of the present invention. [Figure 20] This is a simplified flowchart illustrating a method for measuring the cutting angle of an optical fiber using a cutting angle measurement system according to another embodiment of the present invention. [Figure 21] This is a simplified schematic diagram of an optical fiber alignment and positioning system according to one embodiment of the present invention. [Figure 22] Figures 6A-6B show a simplified schematic diagram of a vacuum stage for an optical fiber alignment and positioning system according to one embodiment of the present invention. [Figure 23] Figures 6A-6B show a simplified schematic diagram of a vacuum stage for an optical fiber alignment and positioning system, which has a mechanical fixing device according to one embodiment of the present invention. [Figure 24A] An embodiment of one side of the present invention is shown in which an optical fiber is arranged within an optical fiber channel. [Figure 24B] An embodiment of one side of the present invention is shown in which an optical fiber is arranged within an optical fiber channel. [Figure 24C] An embodiment of one side of the present invention is shown in which an optical fiber is arranged within an optical fiber channel. [Figure 25] This is a simplified flowchart illustrating a method for aligning and positioning an optical fiber using an optical fiber alignment and positioning system according to one embodiment of the present invention. [Figure 26]This is a simplified schematic diagram of a microlens array (MLA) according to one embodiment of the present invention. [Figure 27] This is a simplified schematic diagram of a conventional alignment process for aligning optical fibers to the lenslet of an MLA. [Figure 28A] A simplified schematic diagram of a system for performing MLA alignment according to one embodiment of the present invention, when the optical fiber is in its nominal position, is shown. [Figure 28B] A simplified schematic diagram of a system for performing MLA alignment according to one embodiment of the present invention is shown, in case the rotational position of the optical fiber is misaligned. [Figure 28C] A simplified schematic diagram of a system that performs MLA alignment according to one embodiment of the present invention when the rotational position of the optical fiber is misaligned is shown. [Figure 29A] This figure shows a light-emitting spot used to calculate tilt measurement according to one embodiment of the present invention. [Figure 29B] This figure shows a light-emitting spot arranged according to one embodiment of the present invention, such that the tilt measurement falls within a tilt threshold. [Figure 30A] This is a simplified schematic diagram illustrating the alignment of a lenslet and an optical fiber within an MLA using an MLA alignment system according to one embodiment of the present invention. [Figure 30B] This is a simplified schematic diagram illustrating the alignment of a lenslet and an optical fiber within an MLA using an MLA alignment system according to one embodiment of the present invention. [Figure 31] This is a simplified flowchart illustrating a method for aligning an optical fiber to an MLA using an MLA alignment system according to one embodiment of the present invention. [Figure 32] This is 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. [Modes for carrying out the invention]

[0006]

[0042] Various embodiments of this disclosure describe the construction of laser-welded fiber arrays in a fully automated manner. A system for constructing a laser-welded array may include process steps such as selecting optical fibers from different fiber sources, preparing the optical fibers, aligning the optical fibers to a substrate, mounting the optical fibers to the substrate, marking the optical fibers, removing the welded optical fibers from the spool, and advancing the substrate to position the remaining optical fibers determined by the design of the laser-welded array. In conventional methods, one or more of these processes are performed manually, increasing the cost of the product ultimately paid by the consumer. Therefore, embodiments of the present invention, as described herein, realize low-cost and highly efficient laser arrays.

[0007]

[0043] Figure 1 is a flowchart of one embodiment of the automated fiber preparation and welding system of the present disclosure. System 100 includes a fiber selection step 110, a fiber processing step 120, a cutting and inspection step 130, a rotational alignment step 140, an alignment step 150, a welding step 160, a marking step 170, a removal step 180, a return step 190, and a potting agent application step 195. System 100 may include more or fewer steps than those described herein. In addition to the configuration of System 100 shown in Figure 1, System 100 may include steps in any order or configuration. In various embodiments, System 100 manufactures laser-welded optical fiber arrays in a fully automated manner. The processing performed at each step is conventionally done manually, resulting in increased labor and raw material costs. To increase efficiency, automating System 100 would be beneficial. Each step will be described in more detail below with reference to various diagrams.

[0008]

[0044] Figure 2 is a flowchart of one embodiment of the method of the present disclosure. Various embodiments of Method 200 may be carried out in an automated system such as System 100 shown in Figure 1. Embodiments of Method 200 are described in more detail with respect to Figures 3 to 32, and it will be understood that any combination of embodiments described herein may be carried out without limitation unless otherwise stated herein. For example, Figures 3A to 35 describe the detection of the presence of an optical fiber, such as the fiber selection step 110 in Figure 1. Figures 6A to 620 describe cutting angle measurement, such as the cutting and inspection step 130 in Figure 1. Figures 21 to 25 describe rotational alignment, such as that performed using the rotational alignment step 140 in Figure 1. Figures 26 to 32 describe alignment, such as that performed using the alignment step 150 in Figure 1.

[0009]

[0045] According to various embodiments, a system such as system 100 in Figure 1 is prepared to perform method 200 by combining automated and manual tasks. One or more optical fiber spools may be manually mounted to the system. A laser may be manually mounted to the rear end (e.g., input end) of one or more optical fiber spools. A substrate may be installed manually or automatically, and optical fibers may be positioned (e.g., welded) onto the substrate by method 200 described below. The substrate may be automatically aligned to a first position among several placement locations for the optical fibers, as described later.

[0010]

[0046] Method 200 includes the step of selecting one fiber spool from one or more fiber spools (202). The step of selecting one fiber spool from one or more fiber spools may include the step of locating and grasping the fiber spool in a manner described later. For example, Method 200 may include the step of locating and grasping the optical fiber. The step of selecting one fiber spool from one or more fiber spools may be performed in a fiber selection stage of a system, such as the fiber selection stage 110 of system 100 shown in Figure 1. Figures 3A to 35 describe in more detail below the detection of the presence of an optical fiber for optical fiber spool selection.

[0011]

[0047] Method 200 also includes a process of processing a portion of a fiber spool to form an optical fiber having an output end (204). In various embodiments, a certain length of fiber is drawn from the fiber spool with reduced or minimal twisting. The output end of the optical fiber may be characterized as the end of the optical fiber that outputs a characterization beam when the other end of the optical fiber receives light from a light source. The process may further include a step of transporting the fiber end to a decoating mechanism while removing the coating from the optical fiber and ensuring a snag-free fiber path. The end of the optical fiber may be attached to an optical fiber decoating mechanism, and the coating may be removed from a selected fiber spool to form an optical fiber of a predetermined length.

[0012]

[0048] The processing may further include a step of cleaning the length of the optical fiber. Cleaning the optical fiber may include transporting the optical fiber to a clean location within the system and removing coating fragments and other debris from the optical fiber. As shown in Figure 1, a portion of the fiber spool may be processed in a fiber processing stage of the system, such as fiber processing stage 120 of system 100, to form an optical fiber having an output end.

[0013]

[0049] In various embodiments, the output end of the optical fiber is cut and inspected before proceeding to method 200. Cutting and inspecting the optical fiber may include transporting the optical fiber to a cutting machine and mounting the optical fiber in the cutting machine. The optical fiber is cut to form the input end and removed from the cutting machine. In some embodiments, fiber scraps are removed from the cutting machine. Cutting and inspecting the input end of the optical fiber can be performed in a fiber cutting and inspection stage of a system, such as cutting and inspection stage 130 in Figure 1. In various embodiments, the optical fiber may be inspected by any embodiment described in detail below, and the cutting angle may be verified by measurement or other means. The optical fiber is determined to be pass or fail, and the decision to remove or discard the optical fiber may be made, at least in part, based on predetermined criteria. Figures 6A-620 further illustrate the measurement and verification of the cutting angle, such as in cutting and inspection stage 130 in Figure 1.

[0014]

[0050] The various alignment processes described herein may be performed in an automated manner. For example, the alignment of the output end of an optical fiber may include rotational alignment, which involves identifying the current fiber rotation position and correcting that rotation position to a desired fiber rotation position. In at least some embodiments, the fiber rotation position includes the relative position in three spatial dimensions and two angular dimensions (e.g., tilt / inclination) between the optical fiber and the substrate. According to the various embodiments described herein, the determination and correction of the fiber rotation position may be an automated process within the system. For example, Figures 21-25 illustrate rotational alignment, such as rotational alignment step 140 in Figure 1.

[0015]

[0051] Method 200 also includes the step of positioning the substrate at multiple locations (206). For example, the substrate may include multiple locations for mounting optical fibers, the substrate may be moved to multiple locations, and optical fibers may be positioned at each location for the formation of a fiber array. The substrate may be configured to be positioned within an automated system so that optical fibers are positioned at each predetermined location on the substrate. For example, the substrate may be configured to move in the x, y, and z directions to properly position the optical fibers at each location on the substrate.

[0016]

[0052] Method 200 includes the step of rotating and aligning the output end of the optical fiber to the substrate (208). In at least some embodiments, the output end of the optical fiber is coupled to the substrate. Prior to coupling, the output end of the optical fiber is aligned to a specific position on the substrate to form a fiber array. Various embodiments for aligning the optical fiber to the substrate are described below in detail with reference to other figures. Rotating and aligning the output end of the optical fiber to the substrate may be performed in a fiber alignment stage of a system, such as the rotation alignment step 140 of system 100 shown in Figure 1.

[0017]

[0053] Method 200 includes the step of aligning the output end of an optical fiber to a substrate (210). In at least some embodiments, the output end of an optical fiber is coupled to a substrate. Prior to coupling, the output end of an optical fiber is aligned to a specific position on the substrate to form a fiber array. Various embodiments for aligning an optical fiber to a substrate are described below in detail with reference to other figures. The step of aligning the output end of an optical fiber to a substrate may be performed in a fiber alignment stage of a system, such as alignment step 150 of system 100 shown in Figure 1. Other embodiments for aligning the output end of an optical fiber to a substrate are described with reference to Figures 26-32.

[0018]

[0054] Method 200 also includes the step of coupling the output end of an optical fiber to one of a plurality of locations on a substrate (212). In various embodiments, after the alignment of the optical fiber is complete, the optical fiber may be moved and mounted on the substrate. The optical fiber may be bonded to the substrate by welding, bonding, or other methods known in the art. As those skilled in the art will understand by reading this disclosure, a fiber array is formed on a substrate having a plurality of predetermined locations on which optical fibers are mounted or bonded. In various embodiments, the optical fiber is laser-welded to each of the plurality of locations on the substrate. The mounting may be automatically inspected and verified to ensure that it meets predefined requirements set by the user, system, intended application, etc.

[0019]

[0055] Method 200 also includes the step of removing the optical fiber from the fiber spool to form the input end of the optical fiber (214). Method 200 also includes the step of marking the optical fiber (216). Marking the optical fiber may include a label that includes characteristic information of the optical fiber, such as physical details such as material and / or location. Marking the optical fiber may include a label that includes an index indicating its position within the fiber array. For example, characteristic information may include information on how the optical fiber is indexed to a position on the fiber array. Referring to Figure 26, in one exemplary embodiment, each lenslet 2602 may correspond to an index position such as 1-1, 1-2, 1-3, 2-1, 3-1, 4-1 to indicate its position within the array. When labeling characteristic information to an optical fiber, the index position associated with the optical fiber may also be included. In some embodiments, the optical fiber coupled to the substrate is transported to a fiber labeling station, such as the marking step 170 of System 100 shown in Figure 1, where the label may be printed on the optical fiber, on the coating or plastic cover of the optical fiber, or otherwise added to the optical fiber. In various embodiments, the step of detaching the optical fiber from the fiber spool to form the input end includes winding up the excess fiber and locating and grasping the output end (218). The optical fiber may be cut from the fiber spool to become an optical fiber having an input end and an output end. The input end of the optical fiber may be the end of the optical fiber that receives light from a light source in a manner that can be understood by those skilled in the art.

[0020]

[0056] In some embodiments, the step of detaching the optical fiber from the fiber spool to form the input end of the optical fiber is performed before the steps of processing (204), substrate positioning (206), and / or aligning the output end of the optical fiber to the substrate (208, 210). For example, the length of the optical fiber may be determined and created before the output end of the optical fiber is coupled to one of several locations on the substrate (212).

[0021]

[0057] Method 200 includes the step of repeating this process for each of a plurality of locations on the substrate to confirm that the substrate is positioned at each of the plurality of locations (220). For example, each location on the substrate may be associated with each of a plurality of locations on the substrate, and once the substrate is positioned at each location and Method 200 is performed at each location, optical fibers are coupled to each of the plurality of locations to form a fiber array. In various embodiments, Method 200 may be repeated, the substrate may be moved to the next location, and optical fibers are coupled to the next array point based on a predetermined (e.g., predetermined) geometric array description. This will be understandable to those skilled in the art by reading the present disclosure.

[0022]

[0058] Method 200 also includes the step of applying a potting agent to the fiber-substrate interface. In various embodiments, the potting agent may be applied to the fibers after welding. For example, a chemical adhesive or binder may be applied to the peripheral region of each fiber that comes into contact with the substrate. In some embodiments, a heat source and / or ultraviolet light source may be used to initiate a chemical reaction involving the chemical adhesive or binder. In other embodiments, a different curing agent or initiator may be used. The potting agent provides an additional stress-relieving effect at the fiber-substrate interface, improving the robustness of the product throughout its lifecycle. Furthermore, applying the potting agent can protect the fibers and substrate from environmental damage. The application of the potting agent, and the subsequent curing or finishing steps, may be performed after individual fibers have been welded, after a specified number of fibers have been welded, or after all fibers have been welded.

[0023]

[0059] In various embodiments, a system such as system 100 described with respect to Figure 1 processes multiple optical fibers simultaneously in the manner described above with respect to method 200 and Figure 2. For example, multiple optical fibers may be drawn from a fiber spool and processed simultaneously. According to some embodiments, multiple optical fibers may be arranged adjacent to each other in a fiber array.

[0024]

[0060] Figure 3A is a simplified schematic diagram of an optical fiber presence detection system 300 according to one embodiment of the present invention. Various embodiments of the optical fiber presence detection system 300 may be incorporated into an automated system such as system 100 shown in Figure 1. As shown, the optical fiber presence detection system 300 may comprise an illumination source 302 and a detector 304. The illumination source 302 may be positioned to emit a ray 308 toward the detector 304 along the optical axis 303. As shown in Figure 3A, the optical axis 303 (also called the optical path) is aligned with the z-axis (also called the vertical axis). The ray 308 may be a parallel ray. The illumination source 302 may include a laser, light-emitting diode (LED), arc lamp, optical fiber illuminator, incandescent light source, fluorescent light source, phosphorescent light source, etc. The detector 304 may be a photodiode, photodiode array, camera, etc.

[0025]

[0061] The optical fiber 306 may be positioned along the optical axis 303 between the illumination light source 302 and the detector 304. The optical fiber 306 may be a transparent optical fiber. In some embodiments, the optical fiber 306 may include a sheath or coating provided by the manufacturer. In other embodiments, the optical fiber 306 may not include a sheath or coating. The optical fiber 306 may have a diameter of less than 250 μm. For example, the diameter of the optical fiber 306 may be 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 various embodiments, the optical fiber may be a polarization-maintaining fiber. For example, the optical fiber may be a bowtie fiber, a panda fiber, a multicore fiber, an elliptic fiber, a photonic crystal optical fiber, etc., or may include these.

[0026]

[0062] The optical fiber 306 may be positioned along the optical axis 303 such that the ray 308 illuminates at least a portion of the optical fiber 306. In the embodiment shown in Figure 3A, the optical fiber 306 is centrally positioned along the optical axis 303 and configured so that the ray 308 illuminates the optical fiber 306 over its entire diameter. In Figure 3A, the diameters of the ray 308 and the optical fiber 306 are equal, but this is not mandatory; in other embodiments, the diameter of the ray 308 may be smaller than the diameter of the optical fiber 306, or the diameter of the ray 308 may be larger than the diameter of the optical fiber 306. Furthermore, although the optical fiber 306 is positioned centered at the origin of the xz axis, the optical fiber 306 may be positioned at either a positive or negative z position and a positive or negative x position, as long as there is overlap between the ray 308 and the optical fiber 306. A person with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0027]

[0063] To facilitate discussion, Figure 3B is provided to show a side view of an optical fiber 306 provided to the optical fiber presence detection system 300. As shown in Figure 3B, the optical fiber 306 may include a fiber body 332 and a fiber core / cladding 335. The fiber core / cladding 335 may be terminated at an emitting surface 334. The fiber body 332 includes a covering 330 that surrounds the fiber core / cladding 335 within the fiber body 332. During operation of the optical fiber 306, light is emitted from the emitting surface 334.

[0028]

[0064] In the case of the optical fiber 306 shown in Figure 3B, the fiber core / cladding 335 is characterized by a length L. As will be explained in more detail in relation to Figures 3A and 3B, the fiber core / cladding 335 can be positioned within the optical fiber presence detection system 300 such that the fiber core / cladding 335 of the optical fiber 306 is positioned with a length L perpendicular to the optical axis 303 corresponding to the light ray 308 emitted by the illumination light source 302. The length L of the fiber core / cladding 335 of the optical fiber 306 and the position of the optical fiber 306 relative to the illumination light source 302 will be explained in more detail in Figures 3A and 3B.

[0029]

[0065] Referring again to Figure 3A, the optical fiber 306 may be positioned along the optical axis 303 of the ray 308 emitted from the illumination light source 302. In Figures 3A and 3B, the fiber core / cladding 335 extends along the y-axis and is collinear with the optical axis 303. In other embodiments, the optical fiber 306 may be positioned such that a portion of the ray 308 passes through and refracts at least a portion of the fiber core / cladding 335 of the optical fiber 306. For example, the ray 308 may pass through and refract at one or both of the first side surface 316A (i.e., the upper cylindrical portion of the optical fiber) and the second side surface 316B (i.e., the lower cylindrical portion of the optical fiber) of the optical fiber 306.

[0030]

[0066] Because the fiber core / cladding 335 of the optical fiber 306 is cylindrical, the ray 308 passes through the first side 316A and the second side 316B of the optical fiber 306 and is refracted, forming the first refracted ray 310A and the second refracted ray 310B. The first refracted ray 310A and the second refracted ray 310B are understood to include rays refracted at angles within the angular range 312 between the first refracted ray 310A and the second refracted ray 310B. Because the first refracted ray 310A and the second refracted ray 310B pass through the optical fiber 306, which acts as a cylindrical lens, the first refracted ray 310A and the second refracted ray 310B can form perpendicular lines along the angular range 312 perpendicular to the length of the optical fiber 306. The width of the vertical line is equal to the width of the ray 308 (measured along the y-axis). In some embodiments, the width of the vertical line may also depend on the distance from the illumination source 302 and the divergence angles of the first refracted ray 310A and the second refracted ray 310B. The vertical line (line along the x-axis) is formed along the angular range 312.

[0031]

[0067] To detect the presence of the optical fiber 306, the detector 304 may be positioned off-axis with respect to the light ray 308 emitted from the illumination source 302. That is, the detector 304 may be positioned offset from the optical axis 303. Positioning the detector 304 off-axis means positioning the detector 304 at a predetermined distance along the x-axis above or below the illumination source 302. Since the detector 304 can be aligned with the illumination source 302 in the xz plane (i.e., without shifting in the y-axis direction), it can receive the light refracted through the optical fiber and detect the presence of the optical fiber 306 as a result of the refraction of the light ray 308 by the optical fiber 306. In Figure 3A, the detector 304 is positioned perpendicular to the optical fiber 306, but in some embodiments, the detector 304 may be tilted toward the optical fiber 306.

[0032]

[0068] By positioning the detector 304 offset from the optical axis of the light ray 308 emitted from the illumination light source 302, the detector 304 may receive and detect only a portion of the vertical line formed by the first refracted light ray 310A and the second refracted light ray 310B. Since the first refracted light ray 310A and the second refracted light ray 310B are formed as a result of refraction by the optical fiber 306, if the optical fiber 306 is not present, the first refracted light ray 310A and the second refracted light ray 310B are not formed, and the optical fiber 306 is not detected.

[0033]

[0069] It should be understood that in some embodiments, if the length of the optical fiber 306 is arranged along the x-axis rather than the y-axis, the first refracted ray 310A and the second refracted ray 310B may form a horizontal line along the y-axis rather than a vertical line along the x-axis. In such cases, the detector 304 may be positioned off-axis along the x-axis such that at least a portion of the horizontal line strikes the detector 304.

[0034]

[0070] Figure 4 is a simplified schematic diagram of an optical fiber presence detection system according to another embodiment of the present invention. Referring to Figure 4, an optical fiber presence detection system 400 according to one embodiment of the present invention is shown. Various embodiments of the optical fiber presence detection system 400 may be carried out in an automated system such as system 100 shown in Figure 1. As shown, the optical fiber presence detection system 400 may include a first illumination source 402A and a second illumination source 402B. The first illumination source 402A and the second illumination source 402B may be identical or similar to the first illumination source 402A shown in Figure 4A. The optical fiber presence detection system 400 enables the detection of the location of an optical fiber when it is placed within the optical fiber presence detection system 400.

[0035]

[0071] The optical fiber presence detection system 400 may also include a first detector 404A and a second detector 404B. The first detector 404A and the second detector 404B may be identical or similar to the first detector 404A shown in Figure 4A. The first illumination source 402A may be configured to emit a first ray 408A toward the first detector 404A. The first ray 408A is centered on the first optical axis 403A. The second illumination source 402B may be configured to emit a second ray 408B toward the second detector 404B. The second ray 408B is centered on the second optical axis 403B. The first detector 404A may be positioned off-axis with respect to the first ray 408A generated by the first illumination source 402A. In other words, the first detector 404A may be positioned along the x-axis at a different x-position from the position on the x-axis where the first ray 408A is located. Therefore, the first detector 404A is axially offset from the first ray 408A generated by the first illumination source 402A.

[0036]

[0072] Similarly, the second detector 404B may be positioned off-axis from the second illumination source 402B. In the embodiment shown in Figure 4, the second detector 404B is positioned at an x-position greater than the position of the second optical axis 403B centered on the second ray 408B. The first detector 404A and the second detector 404B may be positioned so that each detector receives only the vertical line formed by the refracted ray generated from their respective rays (i.e., the first ray 408A and the second ray 408B, respectively). For example, the first detector 404A may be positioned to receive only light from the vertical line formed by the refracted ray generated as a result of the interaction between the first ray 408A and the optical fiber 406, and the second detector 404B may be positioned to receive only light from the vertical line formed by the refracted ray generated as a result of the interaction between the optical fiber 406, positioned at any second position 407, and the second ray 408B.

[0037]

[0073] In some embodiments, the first illumination source 402A and the second illumination source 402B may be configured to emit light of different wavelengths. In such embodiments, the first detector 404A and the second detector 404B may be configured to detect the wavelengths of the first illumination source 402A and the second illumination source 402B, respectively. Note that while the example shown in Figure 4 shows two light sources and two detectors, the number of light sources and detectors may be arbitrary. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0038]

[0074] As shown in the figure, the optical fiber 406 may be positioned between the first illumination light source 402A and the first detector 404A. The optical fiber 406 may be positioned such that a portion of the optical fiber 406 is perpendicular to the first ray 408A emitted from the first illumination light source 402A. Similarly, the optical fiber 406 may be positioned at any second position 407, and a portion of the optical fiber 406 positioned at any second position 407 is positioned perpendicular to the second ray 408B emitted from the second illumination light source 402B.

[0039]

[0075] The optical fiber presence detection system 400 enables the detection of the optical fiber 406 at multiple locations. For example, as shown in Figure 4, if the optical fiber 406 is located at a first location, the first detector 404A can detect the presence of the optical fiber 406. If the optical fiber 406 is located at any second location 407, the second detector 404B can detect the presence of the optical fiber 406 at this arbitrary second location 407.

[0040]

[0076] As shown in Figure 4, the first ray 408A may be emitted from at least a portion of the optical fiber 406 in order to detect the optical fiber 406 at a first position. As described above, since the length of the optical fiber 406 is cylindrical, the first ray 408A may be refracted by the optical fiber to form the first refracted ray 410A and the second refracted ray 410B. The first refracted ray 410A and the second refracted ray 410B are understood to include refracted rays at angles within the angular range 412. The first refracted ray 410A and the second refracted ray 410B may form a vertical line. A portion of the vertical line formed by the first refracted ray 410A and the second refracted ray 410B may be received at point 414 of the first detector 404A. Based on receiving a portion of the vertical line formed by the first refracted ray 410A and the second refracted ray 410B, the first detector 404A may detect the presence of the optical fiber 406 at the first position. In embodiments where the optical fiber 406 is at any second position 407, the second detector 404B may similarly detect the presence of the optical fiber 406 at any second position 407.

[0041]

[0077] In some embodiments, the optical fiber presence detection system 400 may include one or more focusing lenses. For example, a first focusing lens 418A may be positioned in front of a first detector 404A. That is, the first focusing lens 418A may be positioned between the optical fiber 406 and the first detector 404A. A second focusing lens 418B may similarly be positioned in front of a second detector 404B. The first focusing lens 418A may be positioned to capture at least a portion of the first refracted rays 410A and the second refracted rays 410B and to guide the first refracted rays 410A and the second refracted rays 410B toward the first detector 404A. Similarly, when positioned at any second position 407, the second focusing lens 418B may be positioned to capture at least a portion of the light refracted by the optical fiber 406 and to guide the refracted light toward the second detector 404B. In some embodiments, the first focusing lens 418A and / or the second focusing lens 418B may include a folding mirror or a beam splitter. Depending on the configuration of the optical fiber presence detection system 400, focusing lenses, folding mirrors, or beam splitters may be used to guide the first refracted ray 410A and the second refracted ray 410B to the first detector 404A and / or the second detector 404B.

[0042]

[0078] As described above, the first detector 404A and the second detector 404B may be positioned off-axis from their respective illumination sources. As shown in Figure 4, if the optical fiber 406 is not in any second position 407, the second detector 404B may be positioned off-axis from the second illumination source 402B so that the second ray 408B is not received by the second detector 404B. When the optical fiber 406 is in the first position shown in Figure 4, the second detector 404B may be positioned so as not to receive either the first refracted ray 410A or the second refracted ray 410B that can be refracted from the optical fiber 406. Similarly, if the optical fiber 406 is not in the first position shown in Figure 4, the first detector 404A may be positioned off-axis from the first illumination source 402A so as not to receive the first ray 408A. Furthermore, when the optical fiber is at any second position 407, the first detector 404A may be positioned so as not to receive light from the second ray 408B refracted by the optical fiber 406. As an example of the positions of the first detector 404A and the second detector 404B, the first detector 404A may be positioned below the first illumination source 402A, off-axis along the x-axis, and the second detector 404B may be positioned above the second illumination source 402B, off-axis along the x-axis.

[0043]

[0079] Figure 5 is a flowchart of one embodiment of the method of the present disclosure. Figure 5 is a simplified flowchart showing a method for detecting the presence of an optical fiber using an optical fiber presence detection system according to one embodiment of the present invention. For the sake of ease of discussion, the method 500 shown in Figure 5 will be described with reference to Figure 3A. However, it should be understood that the systems and techniques described herein are not necessarily applicable. Various embodiments of the method 500 may be performed in an automated system such as the system 100 shown in Figure 1. The method 500 describes the step of selecting one fiber spool from among the multiple fiber spools described with reference to Figure 2. The method 500 describes a process in a system such as the fiber selection step 110 of the system 100 described with reference to Figure 1. Similar numbering may be used to describe similar components, and it should be understood that any component in the figures described herein may be used in combination with other components in any other figures described herein.

[0044]

[0080] A method 500 for detecting the presence of an optical fiber using an optical fiber presence detection system includes the step of providing an optical fiber presence detection system (505). For example, the optical fiber presence detection system 300 comprises a first illumination light source configured to emit a light ray along an optical path. For example, the first light source may be a laser or an LED. The light ray can be emitted along an optical path aligned with the optical axis of the first illumination light source. The optical fiber presence detection system may also comprise a first detector, such as a detector 304 shown in Figure 3. As shown in Figure 3A, the detector may be positioned off-axis with respect to the optical path through which the light ray emitted from the first illumination light source propagates, and may be configured to detect the presence of light.

[0045]

[0081] Method 500 also includes the step of arranging the optical fiber along the optical path (510). In some embodiments, the optical fiber is arranged such that its length is perpendicular to the optical path through which the light rays emitted from the first illumination source propagate. An optical fiber such as the optical fiber 306 shown in Figure 3A may be arranged such that its length L is perpendicular to the optical path of the light rays emitted from the first illumination source.

[0046]

[0082] Method 500 further includes the step of irradiating at least a portion of the optical fiber with a ray (515). For example, as shown in Figure 3A, the first illumination source may emit a ray 308 to irradiate the optical fiber 306.

[0047]

[0083] Method 500 further includes the step of refracting light from a ray by at least a portion of the optical fiber (520). As shown in Figure 3A, when the ray 308 is refracted by the optical fiber 306, a first refracted ray 310A and a second refracted ray 310B are generated. The method also includes the step of detecting the optical fiber using a first detector based at least partially on the refracted beam (525). For example, the optical fiber presence detection system 300 may detect the optical fiber 306 based on the first refracted ray 310A or the second refracted ray 310B. In some embodiments, the detection of the optical fiber may further include detecting at least a portion of the refracted rays using the first detector. For example, the detector 304 may detect one or both of the first refracted ray 310A and the second refracted ray 310B. As described above, the first refracted ray 310A and the second refracted ray 310B may be formed by passing through a portion of the optical fiber 306 and then refracting.

[0048]

[0084] In some embodiments, the optical fiber presence detection system 300 may further include a second illumination source and a second detector. In such embodiments, the method 500 may further include the step of determining the location of the optical fiber using the first and second detectors. For example, as shown in Figure 4, the location of the optical fiber 406 may be determined by the first detector 404A and the second detector 404B.

[0049]

[0085] It should be understood that the specific steps shown in Figure 5 provide a method for detecting optical fibers according to one embodiment of the present invention. According to another embodiment, a sequence of other steps may be performed. For example, another embodiment of the present invention may perform the above steps in a different order. Furthermore, the individual steps shown in Figure 5 may include a plurality of substeps that can be performed in various sequences depending on the individual step. Furthermore, steps may be added or removed depending on the application. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0050]

[0086] A cutting angle measuring system is provided herein for accurately and consistently measuring the cutting angle of an optical fiber with an accuracy of less than 1 degree. Figure 6A shows a simplified schematic diagram of a cutting angle measuring system 600 according to one embodiment of the present invention. The cutting angle measuring system 600 enables the measurement of the cutting angle of an optical fiber 604. Specifically, the cutting angle measuring system 600 can measure the cutting angle of the cut end 608 of the optical fiber 604. As described above, the cut end 608 of the optical fiber 604 may be formed during the manufacturing process of the optical fiber 604. For example, the optical fiber 604 may be cut or otherwise separated from a spool or a longer length of optical fiber. In the cutting process, the cut end 608 may be formed to have a cutting angle. As will be described later, the cutting angle can be an indicator of how perpendicular the cut end 608 of the optical fiber 604 is to the optical axis of the optical fiber 604. The optical axis of the optical fiber 604 may be parallel to the longitudinal length 634 of the optical fiber 604.

[0051]

[0087] The optical fiber 604 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 604 may be, or include, a bowtie fiber, a panda fiber, a multicore fiber, an elliptic fiber, a photonic crystal optical fiber, etc. The diameter of the optical fiber 604 may be less than 250 μm. For example, the diameter of the optical fiber 604 may be less than 225 μm, less than 80 μm, less than 175 μm, less than 150 μm, less than 125 μm, or less than 100 μm. In some embodiments, the diameter of the optical fiber 604 may exceed 250 μm. For example, the diameter of the optical fiber 604 may be greater than 300 μm, 350 μm, or 400 μm. The diameter of the optical fiber 604 may vary depending on the type of optical fiber.

[0052]

[0088] The cutting angle measurement system 600 can measure the cutting angle of the optical fiber 604 with an accuracy of less than 1 degree. In some embodiments, the cutting angle measurement system 600 can measure the cutting angle of the optical fiber with an accuracy of less than 0.5 degrees, less than 0.3 degrees, or less than 0.25 degrees. In other words, the cutting angle measurement system 600 can measure the cutting angle with high precision. The cutting angle measurement system 600 not only achieves high precision but also consistently provides reproducibility of cutting angle measurements. The reproducibility and precise measurement results provided by the cutting angle measurement system 600 demonstrate how accurately the cutting angle measurement system 600 can measure the cutting angle of the optical fiber 604.

[0053]

[0089] To measure the cutting angle of the optical fiber 604, the cutting angle measuring system 600 may include a stage 630, a light source 620, and an image sensor 610. In some embodiments, the stage 630 may include an optical fiber channel 632. The optical fiber channel 632 may be part of the stage 630 configured to receive at least a portion of the longitudinal length 634 of the optical fiber 604. For example, the optical fiber channel 632 may be a V-groove. The optical fiber channel 632 may be optimized or tuned to various cladding diameters of the optical fiber 604.

[0054]

[0090] The optical fiber channel 632 may be configured to hold the optical fiber 604 in place during the cutting angle measurement process. To hold the optical fiber 604 in a desired position, the optical fiber 604 may be held from one side. It is often desirable to hold the optical fiber 604 so that it can be easily released from the desired position without affecting its position. Common methods for holding the optical fiber 604 in a desired position and allowing it to be easily removed may include a vacuum chuck or other clamping mechanism. Therefore, in some embodiments, the optical fiber channel 632 may include a vacuum chuck or clamp for securing the optical fiber 604 within the optical fiber channel 632.

[0055]

[0091] In some embodiments, the optical fiber 604 may be positioned within an optical fiber channel 632 such that at least a portion of the fiber core or cladding of the optical fiber 604 is fixed by the optical fiber channel 632. For ease of discussion, Figure 6B is provided to show a side view of the optical fiber 604 incorporated into the cut angle measuring system 600. As shown in Figure 6B, the optical fiber 604 may include a fiber body 606 and a fiber core / cladding 602. The core / cladding 602 of the optical fiber can be referred to as the internal portion of the optical fiber 604. The core / cladding 602 of the optical fiber may be terminated at an emitting surface 605. The fiber body 606 includes a covering 603 that surrounds the fiber core / cladding 602 within the fiber body 606. For example, the covering 603 may be a plastic coating applied to the fiber core / cladding 602. During operation of the optical fiber 604, light is emitted from the emitting surface 605. The emitting surface 605 may be part of the cut end 608.

[0056]

[0092] As described above, the optical fiber 604 may have various manufacturing characteristics, such as the cutting angle. Other manufacturing characteristics of the optical fiber 604 may include bending or curvature of the optical fiber 604 along its longitudinal length L. During or after the manufacturing process, the optical fiber 604 may be wound into bundles or rolls, and as a result, the optical fiber 604 may be bent or curvature along its longitudinal length 634. Other manufacturing characteristics of the optical fiber 604 may include the material of the optical fiber 604, the material used to form the coating 603, and the coating 603 itself. For example, the coating 603 may be applied in a manner that includes irregularity. Irregularity may include the thickness to which the coating 603 is applied to the optical fiber 604. Irregularity may cause the outer surface of the optical fiber 604 to not be cylindrical. Any irregularity in the coating 603 may adversely affect the measurement of the cutting angle. Furthermore, the coating 603 may cause bending of the optical fiber due to the shape memory effect caused by winding the optical fiber during the manufacturing process.

[0057]

[0093] To prevent the irregularity of the coating 603 from affecting the cut angle measurement, the coating 603 may be removed over a portion of the longitudinal length 634 of the optical fiber 604. For example, the longitudinal length L (also called the inner portion) of the fiber core / cladding 602 may be exposed by removing the coating 603 over that length. The longitudinal length L may start from the cut end 608 of the optical fiber 604 and extend along the longitudinal length 634. In some embodiments, the longitudinal length L may be in the range of 1 mm to 25 mm, 5 mm to 8 mm, or 10 mm to 15 mm. In one embodiment, the longitudinal length L over which the coating 603 is removed may be 10 mm or 1 cm.

[0058]

[0094] The optical fiber 604 may be fixed within the optical fiber channel 632 by the longitudinal length L of the fiber core / cladding 602. By holding the optical fiber 604 using the fiber core / cladding 602, the cutting angle measurement system 600 can achieve more accurate measurements and consistent repeatability of cutting angle measurements.

[0059]

[0095] As those skilled in the art will readily understand, removing the coating 603 from the fiber core / cladding 602 may not affect the functionality of the optical fiber 604. For example, in many applications, the removal or stripping of the coating 603 from the optical fiber 604 is utilized. Furthermore, cutting an optical fiber 604 generally involves removing a portion of the coating 603 from the cut end 608 of the optical fiber 604. Therefore, removing the coating 603 from the longitudinal length L of the fiber core / cladding 602 may not affect the functionality or applicability of the optical fiber 604.

[0060]

[0096] Referring again to Figure 6A, the optical fiber 604 is positioned within the optical fiber channel 632 so that the cut end 608 is optically aligned with the light source 620. Optical alignment means that the light ray 622 transmitted from the light source 620 is directed toward the cut end 608 of the optical fiber 604. The light source 620 may be configured to emit the light ray 622 toward the cut end 608. For example, the light source 620 may include a laser, a light-emitting diode (LED), an arc lamp, an optical fiber illuminator, an incandescent light source, a fluorescent light source, a phosphorescent light source, and the like. In one embodiment, the light source 620 may include an external laser.

[0061]

[0097] As shown in the figure, the light source 620 may transmit the light ray 622 toward the cut end 608 so that the light ray 622 is reflected at the cut end 608. The light ray 622 is reflected at the cut end 608 and becomes reflected light 624. The reflected light 624 may be received by an image sensor 610. The image sensor 610 may be configured to detect the reflected light 624. For example, the image sensor 610 may be a camera, a four-quadrant photodiode, or other device capable of sensing light. In one embodiment, the image sensor 610 may be a silicon imaging camera or an infrared camera.

[0062]

[0098] In some embodiments, the reflected light 624 may be directed to the image sensor 610 by a beam splitter 640. The beam splitter 640 may be positioned axially aligned with the optical fiber 604 and the light source 620. The beam splitter 640 may be positioned along the x-axis between the optical fiber 604 and the light source 620. The beam splitter 640 may be positioned to reflect the reflected light 624 to the image sensor 610. For example, the beam splitter 640 may have a surface 642 that reflects a portion of the reflected light 624 toward the image sensor 610. The surface 642 of the beam splitter 640 may be a reflective surface such as a mirror. In one embodiment, the beam splitter 640 may be an unpolarized beam splitter. For example, the beam splitter 640 may be a standard 50:50 beam splitter.

[0063]

[0099] In some embodiments, the cutting angle measuring system 600 may include a beam collector 650. The beam collector 650 may collect stray light 626. Specifically, the beam collector 650 may prevent stray light 626 from reaching the image sensor 610. For example, the beam collector 650 may be implemented as an empty tube or an optical dump.

[0064]

[0100] As shown in the figure, the cutting angle measuring system 600 does not include additional lenses for directing, refracting, or parallelizing the light ray 622 or reflected light 624. Conventional methods often include one or more lenses to manipulate the optical properties of the light used to measure the cutting angle of an optical fiber. By not including lenses, the cutting angle measuring system 600 has fewer components than conventional systems and can provide a faster and more convenient cutting angle measuring system and technology. For example, the cutting angle measuring system 600 provides a simpler method for measuring the cutting angle because it does not require positioning or illuminating components using lenses.

[0065]

[0101] The image sensor 610 is located at a distance D from the cut end 608 of the optical fiber 604. End It may be placed at the following position: Distance D End This could be the total distance from the cut end 608 to the image sensor 610. For example, the image sensor 610 is at a distance D of at least 10 cm, at least 25 cm, at least 50 cm, or at least 100 cm from the cut end 608. End They may be arranged in such a way.

[0066]

[0102] The image sensor 610 may detect reflected light 624 from the cut end 608. Specifically, the image sensor 610 may detect the light-emitting surface 605 of the optical fiber 604 to generate a light-emitting surface measurement. Next, looking at Figure 7A, a calculated image 700A of the light-emitting surface measurement 705 used to calculate the cut angle measurement is provided. The following description relates to Figures 6A and 6B, but it should be understood that any system or technique described herein may be used.

[0067]

[0103] The computational image 700A may be generated based on reflected light 624 detected by the image sensor 610. For example, the image used to generate the computational image 700A may be acquired by receiving reflected light 624. Several image processing methods can be used to detect and / or identify various components of the optical fiber. In some embodiments, various components of the optical fiber can be identified based on pixel coordinates in the acquired image.

[0068]

[0104] The calculated image 700A may include the light-emitting surface measurement 705. The light-emitting surface measurement 705 may correspond to the light-emitting surface 605 of the optical fiber 604. The calculated image 700A may include the x and y axes. The light-emitting surface measurement 705 may be generated on the calculated image 700A in xy coordinates with respect to the optical center 740. The optical center 740 may be determined by calculation. The optical center 740 may be the optical center of the image sensor 610. For example, as shown, the optical center 740 may be determined to be located at the origin of the x and y axes. Another method for determining the optical center 740 will be described in more detail with respect to Figure 8.

[0069]

[0105] The centroid 750 may be identified in the light-emitting surface measurement 705. The centroid 750 can be calculated as the center point within the light-emitting surface measurement 705. The centroid 750 of the light-emitting surface measurement 705 may be used to determine the cutting angle of the optical fiber 604. For example, the radial distance D of the optical fiber 604. Radmay be determined based on the center of gravity 750. The radial distance D Rad may be a distance from the center of gravity 750 of the optical fiber 604 to the optical center 740. The radial distance D Rad may be measured in units of pixels or millimeters.

[0070]

[0106] Turning next to FIG. 7B, there is provided FIG. 700B illustrating the influence of distance variables in the calculation of a cutting angle. As shown in FIG. 700B, the cutting angle θc is the radial distance D from the image sensor to the cut end Rad and the distance D End may be determined based on.

[0071]

[0107] Specifically, the cutting angle θc may be calculated based on the following cutting angle formula.

Math

[0072]

[0108] The above cutting angle formula can provide higher accuracy than conventional cutting angle measurement techniques. For example, since the cutting angle formula is based on the radial distance D determined by light reflected from the cut end 608 of the optical fiber 604 Rad , sensitivity to changes in cutting angle can be increased. In some embodiments, measuring the cutting angle θc using reflected light 624 can improve sensitivity by 50% compared to conventional methods that use light emitted from the cut end 608 of the optical fiber 604 or conventional methods that use interferometry. The increased sensitivity may enable measurement of the cutting angle with an angular accuracy within 0.5 degrees.

[0073]

[0109] Importantly, since the above cutting angle formula uses reflected light 624, the cutting angle measurement system 600 can measure any type of optical fiber 604. For example, the cutting angle measurement system 600 may utilize the shape of the reflected beam after reflection from the optical fiber 604 to determine the emission surface measurement value 705, which is independent of the wavelength design, core size, and internal microstructure of the optical fiber 604. The cutting angle measurement system 600 may also use light within the visible light spectrum, which allows for easier alignment and a more efficient cutting angle measurement method.

[0074]

[0110] In some embodiments, the optical fiber 604 may be rotated to improve the accuracy of the cutting angle measurement. For example, the optical fiber 604 may be rotated around the x-axis via the stage 630. The optical fiber 604 can be moved from a first position by a predetermined amount of rotation to a second position. At the second position, the image sensor 610 may generate a second light-emitting surface measurement based on the reflected light 624.

[0075]

[0111] Referring to Figure 8, a figure is shown illustrating a calculated image 800 of multiple luminescent surface measurements used to calculate the cutting angle according to one embodiment of the present invention. For the sake of ease of discussion, Figure 8 will be discussed in relation to Figures 6, 7A, and 7B. However, it should be understood that the systems or techniques disclosed herein are applicable.

[0076]

[0112] As shown in the figure, the calculated image 800 may include multiple light-emitting surface measurements 805A to F. Each of the light-emitting surface measurements 805A to F may correspond to a different rotational position of the cut end 608 of the optical fiber 604. For example, the light-emitting surface measurement 805A may be generated based on the optical fiber 604 at a first position. After generating the light-emitting surface measurement 805A, the optical fiber 604 may be rotated by a predetermined amount to move to a second position. At the second position, the light-emitting surface measurement 805B may be generated. The light-emitting surface measurements 805C to F may be generated for the optical fiber 604 at a third, fourth, fifth, and sixth position, respectively, according to the same method. As explained with respect to Figure 7A, the centroid 850 may be determined for each light-emitting surface measurement 805A to F.

[0077]

[0113] In some embodiments, such as the embodiment shown in Figure 8, a calculated image 800 may be used to calibrate the cutting angle measurement system 600. For example, the calculated image 800 may be used to determine the optical center 840 of the image sensor 610. The optical center 840 may vary depending on the orientation of the optical fiber channel 632 and / or the optical fiber 604. For example, the diameter of the optical fiber 604 may affect the optical center 840 of the image sensor 610. Furthermore, the positional relationship between the optical fiber channel 632 and the image sensor 610 may affect the optical center 840 of the image sensor 610.

[0078]

[0114] To determine the optical center 840, the arc 844 of the light-emitting surface may be determined. For example, the arc 844 of the light-emitting surface may be determined based on the centroid 850 for each of the light-emitting surface measurements 805A to F. In other words, the arc 844 of the light-emitting surface may be fitted to the centroid 850 for each of the light-emitting surface measurements 805A to F. Then, based on the arc 844 of the light-emitting surface, the optical center 840 may be determined as the center point of the arc 844 of the light-emitting surface. As shown in this embodiment, the optical center 840 is not the origin 842 of the x and y axes. Instead, the cutting angle measuring system 600 may be calibrated so that the optical center 840 is determined based on the current position of the optical fiber 604 and components in the cutting angle measuring system 600, such as the optical fiber channel 632.

[0079]

[0115] In some embodiments, the arc 844 of the light-emitting surface may be mathematically determined with respect to the light-emitting surface measurements 805A to F. For example, the arc 844 of the light-emitting surface may be determined using the following equations: [I] to [XII] include a method of fitting the least squares equation to the circle. Once determined, the arc 844 of the light-emitting surface can be used to determine whether the light-emitting surface measurements within the light-emitting surface measurements 805A to F are invalid or valid.

[0080]

[0116] Equation [I] begins with the equation of a circle, where a and b correspond to the x and y coordinates of the centroid of the light-emitting surface 844, respectively. Here, the centroid of the circular arc 844 of the light-emitting surface may also be the optical center 840. R is the radius of the circular arc 844 of the light-emitting surface, where R is the radial distance D. Rad That's fine. (xa) 2 +(yb) 2 =R 2 [I]

[0081]

[0117] For measurement point i on the arc 844 of the light-emitting surface, the residual error is d. i It may be defined by and characterized by the following equation [II]:

[0082]

number

[0083]

[0118] The sum of the residuals at n points is a function of a, b, and R, and is characterized by the following equation [III]:

number

[0084]

[0119] Rewriting equation [III] yields the following equation. [IV] is based on equations [V] to [VII].

number

[0085]

[0120] Differentiating the variable F in equation [IV] with respect to B, C, and D yields the following equations [VIII], [IX], and [X].

[0086]

number

number

number

[0087]

[0121] Equations [VIII] to [X] may also be rewritten as matrices, as shown in equation [XI].

[0088]

number

[0089]

[0122] Equation [XI] can take the following form: Mv=p [XII]

[0090]

[0123] By solving equations [I] to [XII], we can determine the variables B, C, and D. Once we know the variables B, C, and D, we can determine the optimal centroid and radius of the circular arc 844 of the luminescent surface.

[0091]

[0124] The arc 844 of the light-emitting surface may correspond to the cutting angle of the optical fiber 604. For example, if the cut end 608 of the optical fiber 604 is completely cut and perfectly perpendicular to the optical axis of the optical fiber 604, the light-emitting surface measurements 805A~F will not precess even if the optical fiber 604 is rotated around the optical axis (e.g., the x-axis), and therefore the arc 844 of the light-emitting surface will not be generated. Instead, the light-emitting surface measurements 805A~F at different positions of the optical fiber 604 will remain at the same position on the calculated image 800. However, as the cutting angle increases, the arc 844 of the light-emitting surface may also increase when the optical fiber 604 is rotated to a different position. Therefore, the illustrated arc 844 of the light-emitting surface may indicate that the cutting angle of the cut end 608 of the optical fiber 604 is not complete.

[0092]

[0125] Then, for each light-emitting surface measurement value 805A~F, the radial distance D Rad The radial distance D may be determined. Rad This is the distance from each light-emitting surface measurement value 805A to F at a specific position to the optical center 840.

[0093]

[0126] To calibrate the cutting angle measurement system 600, a light-emitting surface measurement value 805A~F can be generated using an optical fiber with a known cutting angle. Then, the known cutting angle and the determined radial distance D Rad Using the known cutting angle and radial distance D, Rad The correlation between the radial distance D can be determined. RadSince the cutting angle at is known and the cutting angle at the optical center 840 is known to be zero, the other radial distance D Rad The cutting angle can be extrapolated or calculated.

[0094]

[0127] In some embodiments, calibration of the cutting angle measurement system 600 allows for rapid measurement of the cutting angles of multiple optical fibers. For example, a single measurement may be used to determine the cutting angle of an optical fiber. The optical center 840 is determined based on the calibration process described above, and the cutting angle and radial distance D Rad Since a correlation is determined, the cutting angle may be determined based on a single light-emitting surface measurement. Specifically, the radial distance D in a single light-emitting surface measurement Rad The cutting angle may be determined based on this.

[0095]

[0128] In some embodiments, additional light-emitting surface measurements may be collected to improve the accuracy of the cutting angle measurement and to validate the initial cutting angle measurement. Since noise within the cutting angle measurement system 600 can affect the cutting angle measurement, validating the cutting angle measurement can be beneficial in improving the accuracy of the cutting angle measurement.

[0096]

[0129] Referring to Figures 9A-B, a diagram is shown illustrating a computational image for calculating and / or verifying the cutting angle using an optical center according to one embodiment of the present invention. For the sake of discussion, Figures 9A-B are discussed in relation to Figures 6A-8. However, it should be understood that the systems or techniques disclosed herein are applicable in all cases.

[0097]

[0130] Figure 9A shows the calculated image 900A. As shown, the calculated image 900A includes two emission surface measurements: emission surface measurement 905A and emission surface measurement 905B. Emission surface measurement 905A and emission surface measurement 905B may be generated based on reflected light reflected from the cut end of the optical fiber at a first position and a second position, respectively.

[0098]

[0131] The light-emitting surface measurement value 905B is the first radial distance D of the light-emitting surface measurement value 905A. Rad,1 It may be generated to verify the validity of the cutting angle measurement calculated based on the above. To verify the cutting angle measurement of the light-emitting surface measurement 905A, the first centroid 950A of the light-emitting surface measurement 905A may be determined, and the second centroid 950B of the light-emitting surface measurement 905B may be determined. Next, using the first centroid 950A, the first radial distance D of the light-emitting surface measurement 905A is determined. Rad,1 The second centroid 950B is used to determine the second radial distance D of the light-emitting surface measurement 905B. Rad,2 It may be decided that...

[0099]

[0132] As described above, the radial distance may be determined as the distance from the centroid of the light-emitting surface to the optical center. Therefore, in the first embodiment, the first radial distance D Rad,1 This may be determined as the distance from the first centroid 950A to the optical center 940, and the second radial distance D Rad,2 The first radial distance D may be determined as the distance from the second centroid 950B to the optical center 940. Rad,1 and the second radial distance D Rad,2 If they are equal, the luminescent surface measurement 905B may be verified. The luminescent surface measurement 905B is the first radial distance D Rad,1 and the second radial distance D Rad,2 This can also be verified by the equality of the two values, because as the optical fiber 1804 rotates, an arc 844 of the light-emitting surface is formed, as described above with reference to Figure 8. If both the light-emitting surface measurement 905A and the light-emitting surface measurement 905B are valid, then the xy coordinates of the first centroid 950A and the second centroid 950B should lie along the same arc of the light-emitting surface. Therefore, since the radius of the circle is constant, the first radial distance D Rad,1 and the second radial distance D Rad,2 The first radial distance D must be the same or within a threshold range. Rad,1 and the second radial distance D Rad,2If they are not equal, one or both of the luminous surface measurement values ​​905A and 905B may be invalid.

[0100]

[0133] In the second embodiment, the light-emitting surface measurement value 905B may be verified by another method. Next, looking at Figure 9B, the calculated image 900B is the same as the calculated image 900A, except that the light-emitting surface measurement value 905B is acquired in a different orientation. In this example, the first radial distance D Rad,1 and the second radial distance D Rad,2 This is the first radial distance D Rad,1 and the second radial distance D Rad,2 This may be determined by determining the point 946 where they are equal. If point 946 does not coincide with the optical center 940, either or both of the luminous surface measurement 905A and luminous surface measurement 905B may be invalid. To determine whether luminous surface measurement 905A and / or luminous surface measurement 905B are invalid, one or more luminous surface measurements may be performed and similarly verified.

[0101]

[0134] Figures 10A-10B show calculated images of multiple luminescent surface measurements used to calculate the cutting angle based on one or more validation checks according to one embodiment of the present invention. For the sake of discussion, Figures 10A-10B are discussed in relation to Figures 6A-9B. However, it should be understood that the systems or techniques disclosed herein are applicable in all cases.

[0102]

[0135] Figure 10A shows a calculated image 1000A. Calculated image 1000A may include light-emitting surface measurements 1005A to G. Light-emitting surface measurements 1005A to G may be measured based on the fact that the cut end 608 of the optical fiber 604 is in various positions when the optical fiber 604 is rotated around the optical axis (e.g., the x-axis). The centroid may be determined for each of the light-emitting surface measurements 1005A to G, as shown in the centroid 1050A corresponding to light-emitting surface measurement 1005A.

[0103]

[0136] In the embodiments shown in Figures 10A and 10B, the cutting angle measurement technique may not require a calibration procedure to determine the optical center 1040. Instead, the optical center 1040 may be determined based on the light-emitting surface measurements 1005A to G. For example, the arc 1044 of the light-emitting surface may be determined based on the centroid (e.g., centroid 1050A) for each of the light-emitting surface measurements 1005A to G. Then, the optical center 1040 may be determined as the center point of the arc 1044 of the light-emitting surface.

[0104]

[0137] Once the optical center 1040 is determined, the radial distance D between the light-emitting surface measurements 1005A to G is determined. Rad The radial distance D may be determined. Rad and the distance D of the cut end End The cutting angle of the optical fiber 604 can be calculated using this method.

[0105]

[0138] In some embodiments, one or more of the light-emitting surface measurements 1005A to G may be invalid. Next, Figure 10B provides a calculated image 1000B showing an embodiment that includes an invalid light-emitting surface measurement. Light-emitting surface measurements can be invalid for various reasons, such as noise in the cutting angle measurement system 600 or misalignment of the optical fiber 604 within the optical fiber channel 632. For example, dust within the optical fiber channel 632 may cause the cut end 608 to be positioned improperly during the rotation of the optical fiber 604. Therefore, the light-emitting surface measurement 1005F corresponding to the improper position of the cut end 608 may be an invalid measurement.

[0106]

[0139] To identify that the luminous surface measurement 1005F is an invalid measurement, the arc 1044 of the luminous surface may be determined. The arc 1044 of the luminous surface can be determined by aligning the centroids of as many luminous surface measurements as possible. In the illustrated example, the arc 1044 of the luminous surface is formed by luminous surface measurements 1005A-E and 1005G. If luminous surface measurement 1005C is also invalid, the arc 1044 of the luminous surface can be determined by aligning the centroids of luminous surface measurements 1005A-B, 1005D-E, and 1005G. Invalid luminous surface measurements, such as luminous surface measurement 1005F, may be discarded. In some embodiments, invalid luminous surface measurements may indicate that they can be improved by cleaning or rearranging the cutting angle measuring system 600 before performing other measurements.

[0107]

[0140] In other embodiments, the measurement of the light-emitting surface, and consequently the measurement of the cutting angle, may be verified by comparing it with a threshold. Referring now to Figures 11A-11B, a diagram is provided showing a calculated image of a plurality of light-emitting surface measurements used to calculate the verified cutting angle compared with a threshold, according to one embodiment of the present invention. For ease of discussion, Figures 11A-11B are discussed in relation to Figures 6A and 10A-10B. However, it should be understood that the systems or techniques disclosed herein are applicable in any case.

[0108]

[0141] Figure 11A shows the calculated image 1100A. As shown, the calculated image 1100A includes the light-emitting surface measurements 1105A to G. The light-emitting surface measurements 1105A to G may be the same as or similar to the light-emitting surface measurements 1005A to G. For the light-emitting surface measurements 1105A to G, an arc 1144 of the light-emitting surface similar to the arc 1044 of the light-emitting surface described above may be generated. Furthermore, an optical center 1140 may be determined, similar to the optical center 1040 described above.

[0109]

[0142] A threshold region 1148 may be determined for the light-emitting surface measurement values ​​1105A to G. The threshold region 1148 can determine whether the light-emitting surface measurement values ​​within the range 1105A to G are valid or invalid.

[0110]

[0143] In some embodiments, the threshold region 1148 is D End and cutting angle θ c It may be determined based on the application requirements. Once the threshold region 1148 is determined, the light-emitting surface measurements 1105A to G can be compared with the threshold region 1148 to determine the validity or acceptance of the measurement.

[0111]

[0144] Figure 11B provides a calculated image 1100B in which the luminescence measurement 1105C may be invalid. As shown, the luminescence measurement 1105C is outside the range of the threshold region 1148. In some embodiments, if any portion of the luminescence measurement 1105C is outside the range of the threshold region 1148, the luminescence measurement 1105C may be invalid and discarded. In other embodiments, the luminescence measurement 1105C may be determined to be invalid only if the centroid 1150 of the luminescence measurement 1105C or the entire luminescence measurement 1105C is outside the range of the threshold region 1148.

[0112]

[0145] In some embodiments, the cutting angle measurement systems and techniques provided herein may be used to measure the cutting angles of multiple optical fibers. For example, the cutting angle may be measured for each optical fiber in an optical fiber array. Referring now to Figures 12A-B, schematic diagrams of a cutting angle measurement system according to one embodiment of the present invention are shown. For the sake of ease of discussion, Figures 12A-B are discussed in relation to Figures 6A and 8. However, it should be understood that the systems or techniques disclosed herein are applicable in all cases.

[0113]

[0146] Figures 12A and 12B show the cut angle measurement system 1200. The cut angle measurement system 1200 may be configured to measure the cut angles of multiple optical fibers (i.e., a first optical fiber 1204A, a second optical fiber 1204B, and a third optical fiber 1204C). In one embodiment, the cut angle measurement system 1200 may be used to measure the cut angles of one or more optical fibers in a fiber array. For example, the first optical fiber 1204A, the second optical fiber 1204B, and the third optical fiber 1204C may be part of a fiber array.

[0114]

[0147] The cutting angle measuring system 1200 may include an image sensor 1210 and a light source 1220. The image sensor 1210 may be identical or similar to the image sensor 610, and the light source 1220 may be identical or similar to the light source 620. In some embodiments, the light source 1220 may be wavelength modulated or may be a broadband light source. Similar to the light source 620, the light source 1220 may be configured to emit a ray 1222. The ray 1222 may be directed to the second cut end 1208B of the second optical fiber 1204B.

[0115]

[0148] In some embodiments, the second wavelength ray 1222 may be guided to the second cut end 1208B by one or more optical components. For example, as shown, the cutting angle measuring system 1200 may include a diffraction grating 1216 that guides the diffracted ray 1226B to a certain angle based on wavelength. The diffraction grating 1216 may be positioned so that the diffracted ray 1226B having the second wavelength from the light source 1220 is guided toward the second cut end 1208B.

[0116]

[0149] In some embodiments, a focusing lens 1214 may be positioned between the diffraction grating 1216 and the second cut end 1208B. The focusing lens 1214 may be configured to focus the diffracted light rays 1226B from the diffraction grating 1216 and guide them to the second cut end 1208B. In some embodiments, the focusing lens 1214 may be configured to make the diffracted light rays 1226B after diffraction from the diffraction grating 1216 into parallel light. In other embodiments, the focusing lens 1214 may be configured to filter one or more wavelength ranges from the light ray 1222 so that specific wavelengths of the light ray 1222 reach the second cut end 1208B.

[0117]

[0150] After the diffracted light ray 1226B reaches the second cutting edge 1208B, it is reflected by the second cutting edge 1208B to become reflected light 1224B. The reflected light 1224B may be guided to the image sensor 1210 by the beam splitter 1240. The beam splitter 1240 may be the same as or similar to the beam splitter 640.

[0118]

[0151] Similar to the cutting angle measuring system 1700, the cutting angle measuring system 1200 can measure the cutting angle of the second cut end 1208B by receiving reflected light 1224B with the image sensor 1210. For example, the cutting angle measuring system 1200 may measure the cutting angle according to the techniques described herein. For example, the light-emitting surface of the second cut end 1208B may be measured based on the reflected light 1224B received by the image sensor 1210.

[0119]

[0152] Since optical fibers in an array are often fixed, measuring the cutting angles of multiple fibers in an array may involve changing the transmission path of the light ray 1222. For example, Figure 12B provides an embodiment for measuring the cutting angle of a first optical fiber 1204A. Since the first optical fiber 1204A, the second optical fiber 1204B, and the third optical fiber 1204C are fixed in place, the wavelength of the light ray 1222 may be changed by reflecting light at the first cut end 1208A of the first optical fiber 1204A.

[0120]

[0153] To modify the transmission path of ray 1222 so that it is reflected at the first cut end 1208A, ray 1222 may be modified to have a first wavelength. The diffraction grating 1216 may generate diffracted ray 1226A at a second angle based on the wavelength of ray 1222. The focusing lens 1214 may be configured to focus the diffracted ray 1226A from the diffraction grating 1216 and guide it to the first cut end 1208A. For example, the focusing lens 1214 may adjust the position of the diffracted ray 1226A so that it is transmitted to the first cut end 1208A.

[0121]

[0154] After the diffracted light ray 1226A reaches the first cutting edge 1208A, the diffracted light ray 1226A is reflected by the first cutting edge 1208A to become reflected light 1224A. The reflected light 1224A may be guided to the image sensor 1210 by the beam splitter 1240. The beam splitter 1240 may be the same as or similar to the beam splitter 640.

[0122]

[0155] Similar to the cutting angle measuring system 600, the cutting angle measuring system 1200 may measure the cutting angle of the first cut end 1208A by receiving reflected light 1224A with the image sensor 1210. For example, the cutting angle measuring system 1200 may measure the cutting angle according to the techniques described herein. For example, the light-emitting surface of the first cut end 1208A may be measured based on the reflected light 1224A received by the image sensor 1210.

[0123]

[0156] The focusing lens 1214 may be positioned to focus the diffracted light ray 1226A regardless of where the light ray 1222 contacts the diffraction grating 1216. Similarly, the beam splitter 1240 may be positioned so that the reflected light 1224A reflected from the first cut end 1208A is directed to the image sensor 1210. As disclosed herein, the cutting angle of the first cut end 1208A may be calculated based on the light emission surface measurement obtained from the reflected light 1224A received by the image sensor 1210.

[0124]

[0157] Since it is difficult to rotate the optical fibers in the fiber array, a calibration optical fiber may be used to calibrate the cutting angle measurement system 1200. For example, the cutting angle measurement system 1200 may be calibrated according to the method described above, with reference to Figure 20. Once the calibration of the cutting angle measurement system 1200 is complete, the cutting angles of the first optical fiber 1204A, the second optical fiber 1204B, and the third optical fiber 1204C may be measured without rotating each optical fiber.

[0125]

[0158] Referring to Figures 13A-C, schematic diagrams illustrating various optical fiber channel arrangements according to one embodiment of the present invention are provided. For the sake of discussion, Figures 13A-B are discussed in relation to Figure 6. However, it should be understood that the systems or technologies disclosed herein are applicable in all cases.

[0126]

[0159] To determine the cutting angle of the optical fiber 1304, a ray 1322 from a light source, for example, light source 620, may be reflected at the cut end 1308. To improve the accuracy of the cutting angle measurement, it may be advantageous to reduce or minimize the amount of ray 1322 reflected from surfaces other than the cut end 1308. Figures 13A-C show various modifications that can be made to the surface 1334 of the optical fiber channel 1332, thereby reducing or minimizing the reflection of ray 1322 from the non-cut end face. The optical fiber channel 1332 may be identical or similar to the optical fiber channel 632. The ray 1322 may be identical or similar to the ray 622 in that it may be emitted from a light source such as light source 620. The optical fiber 1304 may be placed within the optical fiber channel 1332 so that the cut end 1308 receives the ray 1322 emitted from the light source. The optical fiber 1304 may be identical or similar to the optical fiber 604.

[0127]

[0160] Figure 13A shows an embodiment 1300A in which the surface 1334 of the optical fiber channel 1332 is colored black or dark. For example, the surface 1334 may include a dark area 1336. The dark area 1336 may be light-absorbing to absorb light rays 1321. Light rays 1321 may be a portion of light rays 1322 that do not contact the cut end 1308 of the optical fiber 1304. The dark area 1336 may absorb light rays 1321 to prevent them from being reflected by the surface 1334. In one embodiment, the dark area 1336 may be a coating applied to the surface 1334.

[0128]

[0161] In other embodiments, the surface 1334 may be angled to reflect the ray 1321 at a different angle than the reflected light 1324. Figures 13B and 13C show embodiments 1300B and 1300C in which the surface 1334 is angled to direct the reflected light 1325 from the ray 1321 in a direction different from the transmission angle of the reflected light 1324. By reflecting the ray 1321 at a different transmission angle than the reflected light 1324, the reflected light 1325 can be directed away from an image sensor such as the image sensor 1210 and not received by the image sensor. Depending on the arrangement of the cutting angle measurement system, the surface 1334 may be angled in a first direction as shown in embodiment 1300B, or in a second direction as shown in embodiment 1300C.

[0129]

[0162] Figure 14 is a simplified flowchart illustrating a method 1400 for measuring the cutting angle of an optical fiber using a cutting angle measuring system, according to one embodiment of the present invention. Various embodiments of method 1400 for measuring the cutting angle of an optical fiber using a cutting angle measuring system may be performed in an automated system such as system 100 shown in Figure 1. For the sake of ease of discussion, Figure 14 will be discussed with reference to Figure 6A, but it should be understood that the systems or techniques disclosed herein are applicable in any case.

[0130]

[0163] Method 1400 may include steps 1405 and 1410. Step 1405 may include a cutting angle measuring system 600. The cutting angle measuring system 600 may include an optical fiber channel 632, an image sensor 610, and a light source 620. Step 1410 may include an optical fiber 604 placed in the optical fiber channel 632. The optical fiber 604 may have a cut end 608, which may be positioned so as to be optically aligned with the light source 620. In some embodiments, the cutting angle measuring system 600 may also include a beam splitter 640. In such embodiments, Method 1400 may also include the steps of passing light from the light source 620 through the beam splitter 640, reflecting the light at the cut end 608 of the optical fiber 604, and reflecting the light reflected at the cut end 608 of the optical fiber 604 to the image sensor 610 by the beam splitter 640.

[0131]

[0164] In yet another embodiment, the cutting angle measuring system 600 may also include a beam collector 650. In such an embodiment, method 1400 may also include the step of collecting stray light generated by light reflected from the cut end 608 of the optical fiber 604 using the beam collector 650.

[0132]

[0165] In some embodiments, before placing the optical fiber 604 into the optical fiber channel 632, Method 1400 may also include the step of removing the coating 603 from the cut end 608 of the optical fiber 604 in order to expose the fiber core / cladding 602 of the optical fiber 604 (e.g., the inside of the optical fiber from which the coating has been removed). For example, the longitudinal length L of the exposed fiber core / cladding 602 of the optical fiber 604 may be in the range of 5 to 20 mm. In such embodiments, Method 1400 may further include the step of securing the fiber core / cladding 602 of the optical fiber 604 into the optical fiber channel 632.

[0133]

[0166] Method 1400 may also include the step of determining the optical center of the image sensor 610 in step 1415. The optical center of the image sensor 610 may be determined by various methods. For example, in some embodiments, determining the optical center of the image sensor 610 may include the steps of: generating a first light-emitting surface measurement of the cut end 608 of the optical fiber 604 at a first position based on the light detected by the image sensor 610; calculating a first optical centroid of the first light-emitting surface measurement; determining a first radial distance of the first light-emitting surface measurement of the optical fiber 604; and calculating the cutting angle of the cut end 608 of the optical fiber 604 based on the first radial distance. After determining the first optical centroid for the first light-emitting surface measurement at the first position, the method may include the step of rotating the optical fiber 604 to a second position. Next, a second light-emitting surface measurement of the optical fiber 604 at the second position may be generated based on the light reflected from the cut end 608 of the optical fiber 604, and a second optical centroid of the second light-emitting surface measurement may be calculated. In some embodiments, the optical fiber 604 may be further rotated to a third position, and a third light-emitting surface measurement of the optical fiber 604 at the third position may be generated based on the light reflected from the cut end 608 of the optical fiber 604, and a third optical centroid of the third light-emitting surface measurement may be generated from there. The optical center of the image sensor 610 may be determined based on the first optical center, the second optical center, and the third optical center.

[0134]

[0167] In other embodiments, the optical center of the image sensor 610 may be determined by a calibration technique. In such embodiments, method 1400 may include the step of positioning a calibration optical fiber at a first position in the optical fiber channel 632, the calibration optical fiber having a cut end with a known cutting angle. The image sensor 610 may also detect light reflected from the cut end of the calibration optical fiber, and based on the light detected by the image sensor 610, a first emission surface measurement of the calibration optical fiber at the first position may be generated. The calibration optical fiber may then be rotated to a second position. At the second position, based on the light reflected from the cut end of the calibration optical fiber, a second emission surface measurement of the calibration optical fiber at the second position may be generated. The optical center of the image sensor 610 may be determined based on the first and second emission surface measurements. In embodiments including a calibration technique, step 1415 may be performed before steps 1405 and 1410.

[0135]

[0168] Method 1400 may include steps 1420 and 1425. In step 1420, light may be reflected from the cut end 608 of the optical fiber 604. The light may be provided by a light source 620. In step 1425, an image sensor 610 may detect the light reflected from the cut end 608 of the optical fiber.

[0136]

[0169] In some embodiments, method 1400 may include a step 1430 for determining whether another luminescence measurement is to be used. To determine whether another luminescence measurement is to be used, a luminescence measurement may be generated and it may be determined whether the luminescence measurement is valid. For example, method 1400 may include the steps of generating a first luminescence measurement of the cut end 608 of the optical fiber 604 at a first position based on light detected by the image sensor 610; calculating a first optical centroid of the first luminescence measurement; and determining a first radial distance of the first luminescence measurement of the optical fiber 604.

[0137]

[0170] In some embodiments, it may be determined that it is necessary to perform another luminescence measurement. In such embodiments, method 1400 may proceed to step 1435, in which case the optical fiber 604 may be rotated to a second position. After the optical fiber 604 has been rotated to the second position, the method may return to step 1420 via an iterative step 1440. For example, method 1400 may include the steps of rotating the optical fiber 604 to a second position (step 1435) and generating a second luminescence measurement of the optical fiber 604 at the second position based on the light reflected from the cut end 608 of the optical fiber 604. The second optical centroid of the second luminescence measurement may be calculated, and it may be determined whether the first or second luminescence measurement is valid (step 1430).

[0138]

[0171] Determining whether a first or second light-emitting surface measurement is valid may include the steps of determining the radius of the circle based on the optical center, determining the second radial distance of the second light-emitting surface measurement based on the radius of the circle, and determining whether the second radial distance and the first radial distance coincide at the optical center. In other embodiments, the step of determining whether a first or second light-emitting surface measurement is valid may include the steps of determining whether the first light-emitting surface measurement is within a threshold and determining whether the second light-emitting surface measurement is within a threshold.

[0139]

[0172] In other embodiments, a decision may be made not to perform any other light-emitting surface measurements based on the first radial distance and the first centroid. In such embodiments, method 1400 may proceed to step 1445. In step 1445, the method may include the step of calculating the cutting angle of the cut end 608 of the optical fiber 604 based on the first radial distance. As described above, this cutting angle measurement system provides accurate cutting angle measurements with an angle measurement accuracy of 0.5 degrees or less.

[0140]

[0173] It will be understood that the specific steps shown in Figure 14 provide a particular method for measuring the cutting angle of an optical fiber using a cutting angle measuring system, according to one embodiment of the present invention. According to another embodiment, other steps may also be performed in a different order. For example, another embodiment of the present invention may perform the steps described above in a different order. Furthermore, the individual steps shown in Figure 14 may include a plurality of substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. A person with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0141]

[0174] Figure 15 is a simplified flowchart illustrating a method 1500 for measuring the cutting angles of multiple optical fibers using a cutting angle measuring system, according to one embodiment of the present invention. Various embodiments of method 1500, in which the cutting angles of multiple optical fibers are measured using a cutting angle measuring system, can be performed in an automated system such as system 100 shown in Figure 1. For the sake of ease of discussion, Figure 15 will be discussed with reference to Figures 12A-B, but it should be understood that the systems or techniques disclosed herein are applicable in any case.

[0142]

[0175] Method 1500 may include steps 1505 and 1510. Step 1505 may include providing a cutting angle measuring system 1200. The cutting angle measuring system 1200 may comprise a first optical fiber channel, a second optical fiber channel, an image sensor 1210, and a light source 1220. Step 1510 may provide a plurality of optical fibers, such as a first optical fiber 1204A, a second optical fiber 1204B, and a third optical fiber 1204C. For example, the first optical fiber 1204A may be located in the first optical fiber channel, and the second optical fiber 1204B may be located in the second optical fiber channel. In some embodiments, the first optical fiber 1204A, the second optical fiber 1204B, and the third optical fiber 1204C may be part of an optical fiber array.

[0143]

[0176] The first optical fiber 1204A, the second optical fiber 1204B, and the third optical fiber 1204C may each have a cut end. For example, the first optical fiber 1204A may include a first cut end 1208A, and the second optical fiber 1204B may include a second cut end 1208B. The first cut end 1208A and the second cut end 1208B may be arranged to face the light source 1220.

[0144]

[0177] In some embodiments, method 1500 may also include removing the coating from the first cut end 1208A of the first optical fiber 1204A to expose the internal portion of the first optical fiber 1204A before placing the first optical fiber 1204A into the first optical fiber channel. Alternatively, the coating may be removed from the second cut end 1208B of the second optical fiber 1204B to expose the internal portion of the second optical fiber 1204B. For example, the longitudinal length L of the exposed internal portions of the first optical fiber 1204A and the second optical fiber 1204B may be in the range of 5 mm to 20 mm. In such embodiments, method 1500 may further include the step of securing the first optical fiber 1204A and the second optical fiber 1204B in their respective internal portions.

[0145]

[0178] In some embodiments, the cutting angle measuring system 1200 may also include a beam splitter 1240. In such embodiments, the method 1500 may include the steps of transmitting a first wavelength and a second wavelength from the light source 1220 through the beam splitter 1240; reflecting the first wavelength at a first cutting edge 1208A; reflecting the second wavelength at a second cutting edge 1208B; and having the beam splitter 1240 reflect the first wavelength reflected at the first cutting edge 1208A and the second wavelength reflected at the second cutting edge 1208B to an image sensor 1210.

[0146]

[0179] In other embodiments, the cutting angle measuring system 1200 may also include a diffraction grating 1216. In such embodiments, the diffraction grating 1216 may be arranged to guide a first wavelength from the light source 1220 to a first cut end 1208A of the first optical fiber 1204A and a second wavelength from the light source 1220 to a second cut end 1208B of the second optical fiber 1204B.

[0147]

[0180] In embodiments where the cutting angle measuring system 1200 includes a diffraction grating 1216, the cutting angle measuring system 1200 may further include a focusing lens 1214 positioned between the diffraction grating 1216 and a beam splitter 1240. In such embodiments, the method 1500 may include the steps of: transmitting a ray from a light source 1220, the ray comprising a first wavelength and a second wavelength; diffracting the ray 1222 with the diffraction grating 1216, such that the focusing lens 1214 selectively positions the diffracted ray 1226B to transmit it to a first cutting edge 1208A; and diffracting the ray 1222 with the diffraction grating 1216, such that the focusing lens 1214 selectively positions the diffracted ray 1226A to the first cutting edge 1208A.

[0148]

[0181] Method 1500 may include step 1515, in which the optical center of the image sensor 1210 can be determined. For example, the optical center of the image sensor 1210 may be determined by any of the methods and techniques described herein, such as the method and technique described with reference to Figure 8.

[0149]

[0182] Method 1500 may include step 1520, in which step 1500 may include reflecting a first wavelength transmitted from the light source 1220 at a first cut end 1208A of the first optical fiber 1204A. Next, in step 1525, Method 1500 may include determining a first cutting angle of the first cut end 1208A based on the first wavelength reflected from the first cut end 1208A. For example, the step of determining the first cutting angle of the first cut end 1208A may include: detecting a first wavelength reflected from the first cut end of the first optical fiber by the image sensor 1210; generating a first light-emitting surface measurement of the first cut end 1208A of the first optical fiber 1204A at a first position based on the first wavelength detected by the image sensor 1210; calculating a first optical centroid at the first light-emitting surface measurement; determining a first radial distance for the first light-emitting surface measurement of the first optical fiber 1204A; and calculating a first cutting angle based on the first radial distance. The first radial distance for the first light-emitting surface measurement may be based on the optical center of the image sensor 1210.

[0150]

[0183] Method 1500 may include steps 1530 and 1535. Step 1530 may include the step of reflecting a second wavelength transmitted by the light source 1220 at a second cut end 1208B of the second optical fiber 1204B. Next, step 1535 may include the step of determining a second cutting angle of the second cut end 1208B based on the second wavelength reflected from the second cut end 1208B. In the embodiment, the first wavelength may be different from the second wavelength.

[0151]

[0184] It will be understood that the specific steps shown in Figure 15 provide a particular method for measuring the cutting angles of multiple optical fibers using a cutting angle measuring system according to one embodiment of the present invention. According to another embodiment, other steps may also be performed in a different order. For example, another embodiment of the present invention may perform the steps described above in a different order. Furthermore, the individual steps shown in Figure 15 may include a number of substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. A person with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0152]

[0185] Figure 16 is a simplified schematic diagram of a cutting angle measurement system according to one embodiment of the present invention. Various embodiments of the cutting angle measurement system may be used in an automated system such as system 100 shown in Figure 1. The cutting angle measurement system 1600 comprises an optical fiber chuck 1601 configured to support an optical fiber 1602 and an image sensor 1604 configured to detect a characterization light source 1606 emitted from the optical fiber 1602. Various distances to the optical fiber 1602 are measured as part of the cutting angle measurement system 1600. Distance d1608 refers to the distance measured along the z-axis between the tip 1612 of the optical fiber 1602 and the image sensor 1604.

[0153]

[0186] The first distance x11614 refers to the distance measured along the x-axis between the tip 1612 of the optical fiber 1602 and the z-axis. The second distance x21616 refers to the distance along the x-axis between the point where the characterization light source 1606 meets the image sensor 1604 and the z-axis. The angle θ is the angle between the propagation direction of the characterization light source 1606 and the z-axis. The first distance x11614 and the angle θ may be measured by one or more cameras not shown. The second distance x21616 may be measured by the image sensor 1604. As shown, the optical fiber 1602 is offset from the z-axis (e.g., tilted with respect to the z-axis). In various embodiments, the optical fiber 1602 substantially coincides with the z-axis, and the longitudinal axis 1607 of the optical fiber 1602 is parallel to the z-axis. The cutting angle α is measured as the distance from the first axis 1609, defined by the cut tip 1612, to the second axis 1611, which is perpendicular to the longitudinal axis 1607.

[0154]

[0187] According to various embodiments of this disclosure, the refractive index may be assumed (e.g., known) and the camera position is predetermined. For example, the refractive index corresponding to the optical fiber 1602 used in one or more calculations described throughout this disclosure may be the effective refractive index n1 of the optical fiber cladding and / or the refractive index (i.e., core refractive index) n2 of the core of the optical fiber 1602. Furthermore, the distance d1608 refers to the distance measured along the z-axis between the tip of the optical fiber and the image sensor 1604 (e.g., a position detection device).

[0155]

[0188] In some embodiments, the second distance x21616 may be calculated as follows:

number

[0156]

[0189] Therefore, the cutting angle α may be calculated as follows:

number

[0157]

[0190] Static and active methods for measuring cutting angles using the systems described herein include embodiments described in detail below. Static methods do not include a multi-axis stage (such as the multi-axis stage 1918 described in Figures 19 and 20). Static methods offer a cost-reducing and system-complexity-reducing solution by eliminating parts that require maintenance and components that can cause failure. Active methods that include a multi-axis stage (such as the multi-axis stage 1918 described in Figures 19 and 20) can improve accuracy. For example, high-magnification cameras have a shallow depth of field. Optical fibers that are slightly off-center from the plane can be an additional source of error because their position cannot be precisely determined. By incorporating a multi-axis stage and moving the optical fiber to a stable area, the accuracy of optical measurements is improved.

[0158]

[0191] According to at least some embodiments, the positions of one or more cameras are predetermined, the origin of a position detection device is predetermined, a distance d pointing to the z-axis between the tip of an optical fiber and an image sensor (e.g., a position detection device) is known, and the refractive indices (n1 and n2) are known. The optical fiber is inserted into an optical fiber chuck, and the tip of the optical fiber is imaged. The displacement of the tip of the optical fiber may be calculated (for example, if the optical fiber is tilted, the angle θ as described above may be calculated). From the image, a first distance x1 pointing to the x-axis distance between the tip of the optical fiber and the z-axis at a predetermined x-position is determined. Similarly, a distance z1 pointing to the z-axis distance taking into account the error of the nominal distance d is determined from the image.

[0159]

[0192] Figure 17 is a simplified perspective view of a cutting angle measuring system according to one embodiment of the present invention. Various embodiments of the cutting angle measuring system may be used in an automated system such as system 100 shown in Figure 1. The cutting angle measuring system 1700 may be used to perform at least some embodiments of the static method described herein. The cutting angle measuring system 1700 includes an optical fiber chuck 1716 configured to receive an optical fiber 1702 having a proximal end 1704, a tip 1706, and a nominal optical axis 1708. A light source (not shown) may be provided on the proximal side of the proximal end 1704 of the optical fiber 1702, and the light source may be configured to emit light. For example, the light source may be a laser coupled to the proximal end 1704 of the optical fiber 1702, and the light emitted from the light source travels through the optical fiber 1702 toward the tip 1706. Thus, the optical fiber 1702 is configured to receive light emitted from a light source at its proximal end 1704 and to emit characterization light 1710 from its tip 1706.

[0160]

[0193] In various embodiments, the cutting angle measuring system 1700 includes one or more cameras that focus on and measure the position and orientation (i.e., attitude) of the tip 1706 of the optical fiber 1702. The cutting angle measuring system 1700 includes a pair of cameras for detecting and / or measuring the attitude of the tip 1706 of the optical fiber 1702. The attitude of the tip 1706 of the optical fiber 1702 referred to throughout this disclosure includes the six-degree-of-freedom (DOF) attitude of the optical fiber 1702, specifically the attitude of the tip 1706 of the optical fiber 1702. In particular, the attitude of the optical fiber 1702 refers to the six mechanical degrees of freedom of a rigid body (such as the optical fiber 1702) in three-dimensional space, which include forward / backward (surge), up / down (heave), and left / right (sway) movement on three vertical axes, and changes in direction by rotation around three vertical axes, often called yaw (normal axis), pitch (horizontal axis), and roll (vertical axis). For example, the orientation of the tip 1706 of the optical fiber 1702 includes the position and angle in the x-axis and y-axis directions, respectively. According to embodiments described herein, the position may be detected, measured, determined, reported, etc., as a coordinate pair (e.g., (x, y)) or a coordinate trio (e.g., (x, y, z)), which will be understood by those skilled in the art upon reading this disclosure.

[0161]

[0194] As shown in the figure, the cutting angle measuring system 1700 includes a first camera 1712 facing the optical fiber 1702. In some embodiments, the first camera 1712 is positioned on the x-axis higher than the position of the optical fiber 1702 on the x-axis, and the first camera 1712 is positioned above the optical fiber 1702 and aligned with it. Furthermore, the first camera 1712 may be positioned downward and facing the optical fiber 1702. The first camera 1712 is configured to measure a first position of the tip 1706 of the optical fiber 1702 and a first angle corresponding to the nominal optical axis 1708 (e.g., longitudinal axis) of the optical fiber 1702. In this particular configuration, the nominal optical axis 1708 of the optical fiber 1702 coincides with the z-axis and is also called the longitudinal axis. In other configurations, the nominal optical axis 1708 of the optical fiber 1702 is inclined with respect to the z-axis, and the angle θ between the nominal optical axis 1708 of the optical fiber 1702 and the z-axis is measured. For example, the angle θ described with respect to Figure 16. In various embodiments, the first camera 1712 is positioned in a plane perpendicular to the nominal optical axis 1708 of the optical fiber 1702 (in this configuration, the longitudinal axis, i.e., the z-axis).

[0162]

[0195] The cutting angle measuring system 1700 further comprises a second camera 1714 facing the optical fiber 1702. In some embodiments, the second camera 1714 is positioned at an x-position equal to or close to the x-position of the optical fiber 1702, and the second camera 1714 is aligned with the tip 1706 of the optical fiber 1702. The second camera 1714 is configured to measure a second position of the tip 1706 of the optical fiber 1702 and a second angle corresponding to the nominal optical axis 1708 of the optical fiber 1702. The second camera 1714 is positioned in a plane perpendicular to the nominal optical axis 1708 of the optical fiber 1702 (in this configuration, the longitudinal axis, i.e., the z-axis). For example, in at least some embodiments, the first camera 1712 and the second camera 1714 are positioned along a direction perpendicular to the longitudinal axis, and the first camera 1712 is positioned along a direction perpendicular to the direction in which the second camera 1714 is positioned.

[0163]

[0196] In various embodiments, the first camera 1712 and the second camera 1714 each detect (e.g., measure) the orientation of the tip 1706 of the optical fiber 1702, report the orientation-related measurements, and use them for the calculation of the cutting angle, as described later.

[0164]

[0197] In various embodiments, the cutting angle measuring system 1700 includes one or more processors 1701 for performing various aspects of the method described herein. One or more processors 1701 cause various components of the cutting angle measuring system 1700 to perform one or more functions. For example, one or more processors 1701 are configured to cause a first camera 1712 and a second camera 1714 to image the tip 1706 of the optical fiber 1702. Furthermore, one or more processors 1701 perform various operations, including determining the orientation of the tip 1706 of the optical fiber 1702 based on the images, and determining the cutting angle of the optical fiber 1702 based on the characterization light 1710 and the orientation of the tip 1706 of the optical fiber 1702. These operations are described in more detail below with respect to Figure 18 and Method 1800.

[0165]

[0198] The cutting angle measuring system 1700 may include an optical fiber chuck 1716 configured to support an optical fiber 1702. In some embodiments, the optical fiber chuck 1716 may include a mechanical clamp, a vacuum clamp, or other clamping mechanism known in the art. In some embodiments, the optical fiber chuck 1716 is configured to align the nominal optical axis 1708 of the optical fiber 1702 with the longitudinal axis (e.g., the z-axis), as shown in the configuration in Figure 17. In some embodiments, the optical fiber chuck 1716 is configured to move along the z-axis, and the optical fiber 1702 moves along the z-axis while being supported by the optical fiber chuck 1716. For example, by moving the optical fiber chuck 1716 and / or the optical fiber 1702 along the z-axis, the optical fiber chuck 1716 and / or the optical fiber 1702 can be positioned at different z-positions along the z-axis.

[0166]

[0199] The cutting angle measuring system 1700 may further include one or more backlights for illuminating the tip 1706 of the optical fiber 1702. In other embodiments, reflected illumination may be used to illuminate the tip 1706 of the optical fiber 1702. In the embodiment shown in Figure 17, the cutting angle measuring system 1700 includes a first backlight 1720 located opposite the first camera 1712. The first backlight 1720 is operable to illuminate at least the tip 1706 of the optical fiber 1702. The cutting angle measuring system 1700 may also include a second backlight 1722 located opposite the second camera 1714. The second backlight 1722 is operable to illuminate at least the tip 1706 of the optical fiber 1702. In various embodiments, the first backlight 1720 is located in a plane perpendicular to the plane in which the second backlight 1722 is located. In further embodiments, the first camera 1712, the first backlight 1720, the second backlight 1722, and the second camera 1714 may be arranged in directions orthogonal to each other, or they may be arranged in directions orthogonal to an axis (for example, a longitudinal axis, in this case the nominal optical axis 1708 of the optical fiber 1702). In other embodiments, other configurations of the first camera 1712, the first backlight 1720, the second backlight 1722, and the second camera 1714 may be used, as can be understood by those skilled in the art by reading this disclosure.

[0167]

[0200] The cutting angle measurement system 1700 further comprises a position detection device 1724 that operates to measure characterization light 1710 emitted from the tip 1706 of the optical fiber 1702. The position detection device 1724 may be a camera, a four-quadrant photodiode, an image sensor, etc. The characterization light 1710 emitted from the tip 1706 of the optical fiber 1702 is irradiated onto the light-receiving surface of the position detection device 1724. The detected (e.g., measured) position of the characterization light 1710 on the position detection device 1724 is reported and used for the calculation of the cutting angle, which will be described below.

[0168]

[0201] Figure 18 is a simplified flowchart illustrating a method for measuring the cutting angle of an optical fiber using an optical fiber cutting angle measuring system according to one embodiment of the present invention. Various embodiments of the method using a cutting angle measuring system for measuring the cutting angle of an optical fiber may be used in an automated system such as system 100 shown in Figure 1. Method 1800 includes the step of providing an optical fiber having a tip characterized by a longitudinal axis and a cutting angle (1802). The cut end of the optical fiber may be the end of an optical fiber having a cut or cut portion perpendicular to the longitudinal direction of the optical fiber. The cutting angle is an indicator of how perpendicular the cut end of an optical fiber is to the optical axis of the fiber. Typically, the optical axis of an optical fiber is along the longitudinal direction of the optical fiber, and therefore, as described above, the cutting angle represents the degree to which the cut surface is perpendicular to the length of the optical fiber.

[0169]

[0202] The method also includes the step of imaging the tip of the optical fiber (1804). In various embodiments, imaging is performed by a first camera and a second camera. For example, the first camera may be positioned facing the optical fiber, or it may be positioned at a higher x-position on the x-axis containing the optical fiber so that the first camera is positioned above the optical fiber and aligned with the optical fiber. Furthermore, the first camera may be positioned downward and in the direction of the optical fiber in order to photograph the tip of the optical fiber. The second camera may be positioned facing the optical fiber. In some embodiments, the second camera is positioned at or near the x-position of the optical fiber on the x-axis containing the optical fiber so that the second camera is aligned with the tip of the optical fiber. The first and second cameras may each be positioned in directions perpendicular to the longitudinal axis. In at least some embodiments, the first camera may be positioned in a direction perpendicular to the direction in which the second camera is positioned.

[0170]

[0203] The method further includes the step of determining the orientation of the tip of the optical fiber based on imaging (1806). The orientation of the tip of the optical fiber includes at least the position and angle of the tip. For example, a first camera detects (e.g., measures) a first position of the tip and a first angle corresponding to the longitudinal axis, and a second camera detects (e.g., measures) a second position of the tip and a second angle corresponding to the longitudinal axis. In various embodiments, the orientation of the tip of the optical fiber includes measurements related to each of the six degrees of freedom of the optical fiber.

[0171]

[0204] According to at least some embodiments of the static method, the positions of one or more cameras are predetermined, the origin of a position detection device is predetermined, a distance d is known, referring to the distance along the z-axis between the tip of an optical fiber and an image sensor (e.g., a position detection device), and the refractive indices (n1 and n2) are known. The optical fiber is inserted into an optical fiber chuck, and the tip of the optical fiber is photographed. The displacement of the tip of the optical fiber may be calculated (e.g., if the optical fiber is tilted, the angle θ described above may be calculated). From the image, a first distance x1 is determined, referring to the distance along the x-axis between the tip of the optical fiber and the z-axis at a predetermined x-position. Similarly, from the image, a distance z1 is determined, referring to the distance along the z-axis taking into account the error of the nominal distance d.

[0172]

[0205] In at least some embodiments, determining the orientation of the tip of an optical fiber involves moving the optical fiber chuck and the optical fiber along the longitudinal axis. Moving the optical fiber chuck and the optical fiber along the longitudinal axis also includes displacing the optical fiber along the longitudinal axis. In some embodiments, a multi-axis stage may be used to move the optical fiber chuck and the optical fiber along the longitudinal axis (e.g., the z-axis) and the x-axis.

[0173]

[0206] The method further includes the step of emitting light from a light source (1808). The light source may be provided near the proximal end of the optical fiber and may be configured to emit light. For example, the light source may be a laser beam, which can be coupled to the optical fiber from the proximal end so that the light emitted from the light source travels through the optical fiber toward the tip. The optical fiber is configured to receive the light emitted from the light source. The light travels along the longitudinal direction of the optical fiber. The method further includes the step of emitting characterization light from the tip of the optical fiber (1810).

[0174]

[0207] In various embodiments, method 1800 may optionally include the step of illuminating the tip through a first backlight positioned opposite the first camera and a second backlight positioned opposite the second camera. According to at least some embodiments, a reflected illumination method may be used.

[0175]

[0208] The method also includes the step of detecting characterization light in an image sensor (1812). According to various embodiments, the image sensor may be a camera or a four-quadrant photodiode. The step of detecting characterization light in an image sensor includes the step of determining the position of the characterization light. Characterization light emitted from the tip of an optical fiber is emitted onto the light-receiving surface of the image sensor. The detection (e.g., measurement) position of the characterization light on the image sensor may be reported along with measurements from a first camera and a second camera.

[0176]

[0209] The method further includes the step of determining the cutting angle of the optical fiber based on the characterization light and the orientation of the tip of the optical fiber (1814). According to various embodiments of the present disclosure, the refractive index is assumed (e.g., known) and the position of the camera may be predefined. For example, in one or more calculations described throughout the present disclosure, a refractive index including the effective refractive index and / or core refractive index may be assumed. Furthermore, a distance d, which refers to the distance along the z-axis between the tip of the optical fiber and an image sensor (e.g., a position detection device), is known.

[0177]

[0210] Light passes through the optical fiber and can be measured by a position detection device with respect to the positions of the first and second cameras. The cutting angle α in the x-direction. x This may be calculated based on the following formula:

number

[0178]

[0211] Repeat the above procedure to obtain the cutting angle α in the y-direction based on the following equation. y We seek.

number

[0179]

[0212] The cutting angle α is determined by the following formula.

number

[0180]

[0213] It should be understood that the specific steps shown in Figure 18 provide a particular method for measuring the cutting angle of an optical fiber using a cutting angle measuring system, according to one embodiment of the present invention. According to another embodiment, other steps may also be performed in a different order. For example, another embodiment of the present invention may perform the steps described above in a different order. Furthermore, the individual steps shown in Figure 18 may include a plurality of substeps that can be performed in various orders depending on the individual step. Furthermore, depending on the application, steps may be added or removed. A person with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0181]

[0214] Figure 19 is a simplified perspective view of a cutting angle measuring system according to another embodiment of the present invention. Various embodiments of the cutting angle measuring system may be used in an automated system such as system 100 shown in Figure 1. Figure 19 includes components similar to those shown and described with respect to Figure 20. Thus, similar numbering may be used to describe components having similar configurations and / or functions, and the descriptions provided in relation to Figure 29 can be appropriately applied to the elements shown in Figure 19.

[0182]

[0215] The cutting angle measuring system 1900 includes an optical fiber chuck 1916 configured to receive an optical fiber 1902 having a proximal end 1904, a tip 1906, and a nominal optical axis 1908. A light source (not shown) may be provided proximal to the proximal end 1904 of the optical fiber, and the light source may be configured to emit light. For example, the light source may be a laser coupled from the proximal end 1904 to the optical fiber 1902, and the light emitted from the light source travels through the optical fiber 1902 toward the tip 1906. The optical fiber 1902 is configured to receive the light emitted from the light source at its proximal end 1904 and to emit a characterization light 1910 from its tip 1906.

[0183]

[0216] In various embodiments, the cutting angle measuring system 1900 includes one or more cameras focused on the orientation of the tip 1906 of the optical fiber 1902. The cutting angle measuring system 1900 comprises a pair of cameras for detecting and / or measuring the orientation of the tip 1906 of the optical fiber 1902. The orientation of the tip 1906 of the optical fiber 1902 as referred to throughout this disclosure includes the six degrees of freedom (DOF) of the optical fiber 1902. In particular, the orientation of the optical fiber 1902 refers to the six mechanical degrees of freedom of a rigid body (such as the optical fiber 1902) in three-dimensional space, including forward / backward (surge), up / down (heave), and left / right (sway) movement on the three vertical axes, in addition to changes in direction due to rotation around three vertical axes (often called yaw (normal axis), pitch (horizontal axis), and roll (vertical axis)). For example, the orientation of the optical fiber 1902 includes the position and angle in the x-axis and z-axis directions, respectively.

[0184]

[0217] As shown in the figure, the cutting angle measuring system 1900 includes a first camera 1912 facing the optical fiber 1902. In some embodiments, the first camera 1912 is positioned at a higher x-position on the x-axis including the optical fiber 1902, and the first camera 1912 is positioned above the optical fiber 1902 and aligned with it. Furthermore, the first camera 1912 may be positioned downward and facing the optical fiber 1902. The first camera 1912 is configured to measure a first position of the tip 1906 of the optical fiber 1902 and a first angle corresponding to the nominal optical axis 1908 (e.g., longitudinal axis) of the optical fiber 1902. In this particular configuration, the nominal optical axis 1908 of the optical fiber 1902 is aligned with the z-axis, and the nominal optical axis 1908 may also be called the longitudinal axis. In other configurations, the nominal optical axis 1908 of the optical fiber 1902 is inclined with respect to the z-axis, and the angle θ between the nominal optical axis 1908 of the optical fiber 1902 and the z-axis is measured. For example, the angle θ described with respect to Figure 16. In various embodiments, the first camera 1912 is positioned in a plane perpendicular to the nominal optical axis 1908 of the optical fiber 1902 (in this configuration, the longitudinal axis, i.e., the z-axis).

[0185]

[0218] The cutting angle measuring system 1900 further comprises a second camera 1914 facing the optical fiber 1902. In some embodiments, the second camera 1914 is positioned at or near the x-position of the optical fiber 1902 and on the x-axis containing the optical fiber 1902, and is positioned so as to be aligned with the optical fiber 1902. The second camera 1914 is configured to measure a second position of the tip 1906 of the optical fiber 1902 and a second angle corresponding to the nominal optical axis 1908 of the optical fiber 1902. The second camera 1914 is positioned in a plane perpendicular to the nominal optical axis 1908 of the optical fiber 1902 (in this configuration, the longitudinal axis, i.e., the z-axis). For example, in at least some embodiments, the first camera 1912 and the second camera 1914 are positioned along a direction perpendicular to the longitudinal axis, and the first camera 1912 is positioned along a direction perpendicular to the direction in which the second camera 1914 is positioned.

[0186]

[0219] In various embodiments, the first camera 1912 and the second camera 1914 each detect (e.g., measure) the orientation of the tip 1906 of the optical fiber 1902, report the orientation-related measurements, and use them for the calculation of the cutting angle described later.

[0187]

[0220] The cutting angle measuring system 1900 may include an optical fiber chuck 1916 configured to support an optical fiber 1902. In some embodiments, the optical fiber chuck 1916 may include a mechanical clamp, a vacuum clamp, or other clamping mechanism known in the art. In some embodiments, the optical fiber chuck 1916 is configured to align the nominal optical axis 1908 of the optical fiber 1902 with the longitudinal axis (e.g., the z-axis), as shown in the configuration in Figure 19. In some embodiments, the optical fiber chuck 1916 is configured to move along the z-axis and further configured to move the optical fiber 1902 supported by the optical fiber chuck 1916 along the z-axis. For example, the optical fiber chuck 1916 and / or the optical fiber 1902 may be moved to different z-positions along the z-axis.

[0188]

[0221] In various embodiments, Figure 19 illustrates an "active" method of cutting angle measurement. For example, the cutting angle measurement system 1900 comprises a multi-axis stage 1918. The multi-axis stage 1918 is coupled to an optical fiber chuck 1916 and / or an optical fiber 1902, which may move in both directions along the x-axis and along the z-axis. Thus, a gradual change in the orientation of the tip 1906 of the optical fiber 1902 (e.g., position and angle in at least the x and y directions) may be detected (e.g., measured) and reported by a first camera 1912, a second camera 1914, and a position detection device 1924.

[0189]

[0222] In various embodiments, the cutting angle measuring system 1900 includes one or more processors 1901 for performing various aspects of the method described herein. One or more processors 1901 cause various components of the cutting angle measuring system 1900 to perform one or more functions. For example, one or more processors 1901 are configured to cause a first camera 1912 and a second camera 1914 to image the tip 1906 of the optical fiber 1902. Furthermore, one or more processors 1901 perform various operations, including determining the orientation of the tip 1906 of the optical fiber 1902 based on the imaging, and determining the cutting angle of the optical fiber 1902 based on the characterization light 1910 and the orientation of the tip 1906 of the optical fiber 1902. These operations are described in more detail below with respect to Figure 20 and Method 2000.

[0190]

[0223] The cutting angle measuring system 1900 may further include one or more backlights for illuminating the tip 1906 of the optical fiber 1902. In some embodiments, reflected illumination may be used to illuminate the tip 1906 of the optical fiber 1902. In some embodiments, the cutting angle measuring system 1900 includes a first backlight 1920 located opposite the first camera 1912. The first backlight 1920 is operable to illuminate at least the tip 1906 of the optical fiber 1902. The cutting angle measuring system 1900 may further include a second backlight 1922 located opposite the second camera 1914. The second backlight 1922 is operable to illuminate at least the tip 1906 of the optical fiber 1902. In various embodiments, the first backlight 1920 is positioned perpendicular to the second backlight 1922. In yet another embodiment, the first camera 1912, the first backlight 1920, the second backlight 1922, and the second camera 1914 are orthogonal to each other and are arranged on a plane perpendicular to the z-axis (for example, in this case the longitudinal axis which is the nominal optical axis 1908 of the optical fiber 1902). In other embodiments, other configurations of the first camera 1912, the first backlight 1920, the second backlight 1922, and the second camera 1914 may be used, as can be understood by those skilled in the art by reading this disclosure.

[0191]

[0224] The cutting angle measuring system 1900 further comprises a position detection device 1924 that operates to measure characterization light 1910 emitted from the tip 1906 of the optical fiber 1902. The position detection device 1924 may be a camera, a four-quadrant photodiode, an image sensor, etc. The characterization light 1910 emitted from the tip 1906 of the optical fiber 1902 is emitted onto the light-receiving surface of the position detection device 1924. The detected (e.g., measured) position of the characterization light 1910 on the position detection device 1924 is reported and used to calculate the cutting angle, which is described in detail below.

[0192]

[0225] Figure 20 is a simplified flowchart illustrating a method for measuring the cutting angle of an optical fiber using a cutting angle measuring system according to another embodiment of the present invention. Various embodiments of the method for measuring the cutting angle of an optical fiber using a cutting angle measuring system may be used in an automated system such as system 100 shown in Figure 1. Method 2000 includes the step of providing an optical fiber having a tip characterized by a longitudinal axis and a cutting angle (2002). The cut end of an optical fiber may be the end of an optical fiber having a cut or cut portion perpendicular to the longitudinal direction of the optical fiber. The cutting angle is an indicator of how perpendicular the cut end of an optical fiber is to the optical axis of the fiber. Typically, the optical axis of an optical fiber is along the longitudinal direction of the optical fiber, and therefore the cutting angle can represent the degree to which the cut end face is perpendicular to the length of the optical fiber. This is as described in detail above.

[0193]

[0226] The method also includes the step of imaging the tip of the optical fiber (2004). In various embodiments, imaging is performed by a first camera and a second camera. For example, the first camera may be facing the optical fiber and may be positioned at a higher x-position on the x-axis including the optical fiber, with the first camera positioned above the optical fiber and aligned with it. Furthermore, the first camera may be positioned downward and in the direction of the optical fiber in order to photograph the tip of the optical fiber. The second camera may be positioned facing the optical fiber. In some embodiments, the second camera is positioned at or near the x-position of the optical fiber on the x-axis including the optical fiber, with the second camera positioned to be aligned with the tip of the optical fiber. The first and second cameras may each be positioned in directions perpendicular to the longitudinal axis. In at least some embodiments, the first camera may be positioned in a direction perpendicular to the direction in which the second camera is positioned.

[0194]

[0227] The method further includes the step of moving the optical fiber through a multi-axis to reduce or minimize the distance between the tip of the optical fiber and the longitudinal axis (2006). According to the active method, the multi-axis stage may be moved in the x-direction until a first distance x1 is reduced or minimized. For example, the multi-axis stage may be moved downward so that the tip of the optical fiber is aligned with the longitudinal axis and / or the tip of the optical fiber is not tilted with respect to the longitudinal axis. In some embodiments, a multi-axis stage may be used to move an optical fiber chuck and the optical fiber in the longitudinal axis (e.g., z-axis) and x-axis directions.

[0195]

[0228] The method further includes the step of determining the orientation of the tip of the optical fiber based on imaging (2008). The orientation of the tip of the optical fiber includes at least the position and angle of the tip. For example, a first camera detects (e.g., measures) a first position of the tip and a first angle corresponding to the longitudinal axis, and a second camera detects (e.g., measures) a second position of the tip and a second angle corresponding to the longitudinal axis. In various embodiments, the orientation of the tip of the optical fiber includes measurements related to each of the six degrees of freedom of the optical fiber.

[0196]

[0229] According to at least some embodiments of the active method, the positions of one or more cameras are predetermined, the origin of the position detection device is predetermined, a distance d is known which refers to the distance along the z-axis between the tip of the optical fiber and the image sensor (e.g., the position detection device), and the refractive indices (n1 and n2) are known. The optical fiber is inserted into an optical fiber chuck, and the tip of the optical fiber is imaged. The offset of the tip of the optical fiber may be calculated (for example, if the optical fiber is tilted, the angle θ as described above may be calculated). From the image, a first distance x1 is determined which represents the distance along the x-axis between the tip of the optical fiber and the z-axis at a predetermined x-position.

[0197]

[0230] The method further includes the step of emitting light from a light source (2010). The light source may be located near the proximal end of the optical fiber and may be configured to emit light. For example, the light source may be a laser coupled to the optical fiber from the proximal end so that the light emitted from the light source travels through the optical fiber toward the tip. The optical fiber is configured to receive the light emitted from the light source. The light travels along the longitudinal direction of the optical fiber. The method further includes the step of emitting characterization light from the tip of the optical fiber (2012).

[0198]

[0231] In various embodiments, method 2000 may optionally include the step of illuminating the tip through a first backlight positioned opposite the first camera and a second backlight positioned opposite the second camera. According to at least some embodiments, a reflected illumination method may be used.

[0199]

[0232] The method also includes the step of detecting characterization light with an image sensor (2014). According to various embodiments, the image sensor may be a camera or a four-quadrant photodiode. The step of detecting characterization light with an image sensor includes the step of determining the position of the characterization light. Characterization light emitted from the tip of an optical fiber is emitted onto the light-receiving surface of the image sensor. The detection (e.g., measurement) position of the characterization light on the image sensor may be reported along with measurements from a first camera and a second camera.

[0200]

[0233] The method further includes the step of determining the cutting angle of the optical fiber based on the characterization light and orientation of the tip of the optical fiber (2016). According to various embodiments of the present disclosure, the refractive index may be assumed (e.g., known), and the position of the camera is predefined. For example, in one or more calculations described throughout the present disclosure, a refractive index including the effective refractive index and / or core refractive index may be assumed. Furthermore, a distance d, which refers to the distance along the z-axis between the tip of the optical fiber and the image sensor (e.g., a position detection device), is known.

[0201]

[0234] Light may pass through an optical fiber, and the positions of the first camera and the second camera may be measured by a position detection device. According to some embodiments of the active method, the multi-axis stage may be moved in the x-direction and the z-direction until the first distance x1 and the first distance z1 are minimized to zero, and the cutting angle α relative to the x-direction x may be calculated based on the following formula. [Numerical formula]

[0202]

[0235] Repeat the above steps to obtain the cutting angle α relative to the y-direction y . [Numerical formula]

[0203]

[0236] The cutting angle α is determined by the following formula. [Numerical formula]

[0204]

[0237] According to some embodiments of the active method, the multi-axis stage may be moved in the x-direction and the z-direction, and rotated around the y-axis until the first distance x1, the first distance z1, and the angle θ are minimized, and the equation for obtaining the cutting angle α relative to the x-direction x is as follows. [Numerical formula]

[0205]

[0238] The cutting angle α relative to the y-direction y is as follows. [Numerical formula]

[0206]

[0239] The cutting angle α is determined by the following formula.

number

[0207]

[0240] In another embodiment, the tip of the optical fiber may be centrally located, and the focal position and angle may be selected as the reference origin. The optical fiber may be mounted in an optical fiber chuck and moved to a preset origin. Light may pass through the optical fiber, and its position and angle are measured and recorded for both the x and z axes. The above steps may be repeated when creating a circular trajectory of points on the sensor plane from multiple samples by rotating the optical fiber between measurements. If a multi-axis stage is not used, each sampling point is transformed to correspond to the measured x1 and θ positional deviations. This method will be apparent to those skilled in the art upon reading this disclosure. The center of the trajectory defines the nominal sensor center of the system, and this center may be saved and used as the reference origin for future measurements.

[0208]

[0241] During the alignment process, the optical fiber may be aligned with an external object. For example, optical fibers are often fused to various external objects such as other optical fibers or optical instruments, and precise alignment between the optical fiber and the external object is used to maximize power transmission between the optical fiber and the external object.

[0209]

[0242] In the alignment process, it is generally important to align the fiber so that the light emitted from the fiber is misaligned with the corresponding end-face component. For example, the cutting angle of the cut end of an optical fiber can affect the misalignment and direction of the light emitted from the fiber. Misalignment of the emitted light can affect the performance of the optical fiber in an optical system. Conventional cutting angle measurement systems and techniques often have difficulty measuring the cutting angle with an accuracy of less than 1 degree, and often have low reproducibility.

[0210]

[0243] However, the manufacturing characteristics of the optical fiber may affect the alignment process. For example, an optical fiber may have a cut end. The cut end of an optical fiber may be the end face of an optical fiber that has been cut or cut in a direction generally perpendicular to the longitudinal direction of the optical fiber. Cutting is usually performed during the manufacturing process of the optical fiber. The angle of the cut end, referred to herein as the cut angle, may affect the alignment process. The cut angle is an indicator of how perpendicular the cut end of an optical fiber is to the optical axis of the fiber. Since the optical axis of an optical fiber is usually aligned along the longitudinal direction of the optical fiber, the cut angle represents the angle at which the cut end face is perpendicular to the longitudinal direction of the optical fiber.

[0211]

[0244] The cutting angle of an optical fiber can affect the optical fiber alignment process. Specifically, the cutting angle can affect the angle and direction (e.g., misalignment) of light emitted from the cut end of the optical fiber. However, conventional methods for measuring the cutting angle of an optical fiber often have difficulty measuring the cutting angle with an accuracy of less than 1 degree, and their reproducibility is extremely low. Furthermore, conventional methods may be specific to the type of optical fiber, requiring mode matching and wavelength matching between the optical fiber and the measuring device. Therefore, improved methods and systems for measuring the cutting angle of optical fibers are needed in this technical field.

[0212]

[0245] It should be understood that the specific steps shown in Figure 20 provide a particular method for measuring the cutting angle of an optical fiber using a cutting angle measuring system, according to one embodiment of the present invention. Other sequences of steps may also be performed according to other embodiments. For example, in another embodiment of the present invention, the steps described above may be performed in a different order. Furthermore, the individual steps shown in Figure 20 may include a plurality of substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0213]

[0246] Figure 21 is a simplified schematic diagram of an optical fiber alignment and positioning system 2100 according to one embodiment of the present invention. Various embodiments of the optical fiber alignment and positioning system 2100 can be used in automated systems such as system 100 shown in Figure 1. The optical fiber alignment and positioning system 2100 may be used to position and align a polarization-maintaining fiber, such as an optical fiber 2110, to one or more external objects (e.g., another optical fiber, a microlens array, etc.). As shown, the optical fiber 2110 may include a first end 2112 and a second end 2114 extending axially along the x-axis. The optical fiber alignment and positioning system 2100 may be used to position and align the first end 2112 of the optical fiber to one or more external objects.

[0214]

[0247] To align the optical fiber 2110 with an external object, it is sometimes desirable to maintain the polarization of the light output from the optical fiber 2110 relative to the external object. For example, optical fibers are often fused to various external objects, such as other optical fibers or types of optical instruments, and precise alignment between the optical fiber and the external object is used to maintain the polarization state of the light within the external object. One way to maintain the polarization of the light output between the optical fiber 2110 and the external object is to align the internal components of the optical fiber 2110 (e.g., stress rods, cores, microstructures, etc.) with one or more components of the external object. Therefore, precise alignment and positioning of the internal components of the optical fiber 2110 are often used for proper alignment of the optical fiber 2110.

[0215]

[0248] During the alignment or mounting process, an axial load or pressure may be applied to the first end 2112 of the optical fiber 2110. For example, the first end 2112 of the optical fiber 2110 may be pressed against an external object, or the external object may be pressed against the first end 2112 of the optical fiber 2110. To prevent the optical fiber 2110 from moving during the alignment and / or mounting process, the optical fiber alignment and positioning system 2100 may include a vacuum stage. The vacuum stage 2102 may include a first end 2104 and a second end 2106. The vacuum stage 2102 may be configured to receive the optical fiber 2110. For example, the vacuum stage 2102 may include an optical fiber channel 2108. The optical fiber channel 2108 may extend from the first end 2104 to the second end 2106 of the vacuum stage 2102. The optical fiber channel 2108 may be configured to receive the optical fiber 2110. The optical fiber 2110 may be positioned within the optical fiber channel 2108 such that a portion 2116 of the optical fiber 2110 is in contact with the optical fiber channel 2108. The vacuum stage 2102, which includes the optical fiber channel 2108, is described in more detail above.

[0216]

[0249] In some embodiments, the optical fiber alignment and positioning system 2100 may also include a mechanical fixing device 2130. The mechanical fixing device 2130 may be part of the vacuum stage 2102 or may be separate from the vacuum stage 2102. The mechanical fixing device 2130 may be positioned to contact a portion 2132 of the optical fiber 2110 that protrudes from the optical fiber channel 2108 toward the image sensor 2150. As shown in the figure, in some embodiments, the mechanical fixing device 2130 may be positioned between the vacuum stage 2102 and the second end 2114 of the optical fiber 2110, and in other embodiments, the mechanical fixing device 2130 may be positioned between the vacuum stage 2102 and the image sensor 2150. The position of the mechanical fixing device 2130 may vary depending on the application.

[0217]

[0250] The mechanical fixing device 2130 may be configured to securely hold the optical fiber 2110 during the alignment and mounting process. For example, the mechanical fixing device 2130 may include two pads positioned on either side of the optical fiber 2110, which may contact the optical fiber 2110 along portion 2132. As described above, the position of portion 2132 in contact with the optical fiber 2110 may vary depending on the configuration of the mechanical fixing device 2130. The mechanical fixing device 2130 may be configured to hold the optical fiber 2110 in a fixed position relative to the vacuum stage 2102.

[0218]

[0251] When placed on a vacuum stage 2102, the optical fiber 2110 may be positioned so that its first end 2112 faces the image sensor 2150. In some embodiments, the optical fiber 2110 may emit a ray 2118 from its first end 2112. The first end 2112 of the optical fiber 2110 may be the cut end of the optical fiber 2110. The image sensor 2150 may be positioned to receive at least a portion of the ray 2118 emitted from the optical fiber 2110. For example, the image sensor 2150 may be positioned to be axially aligned with the first end 2112 of the optical fiber 2110. The ray 2118 may be light emitted from the optical fiber 2110 as light propagates along the length 2116 of the optical fiber 2110. For example, the ray 2118 can be generated by irradiating the second end 2114 or length 2116 of the optical fiber 2110 with a light source (not shown), such as a laser.

[0219]

[0252] The image sensor 2150 may be used to identify one or more internal components of the optical fiber 2110. Therefore, the image sensor 2150 may be positioned to generate an image of the light-emitting surface of the optical fiber 2110. For example, the light-emitting surface of the optical fiber 2110 may be the first end 2112 of the optical fiber 2110. To generate an image of the light-emitting surface of the optical fiber 2110, the image sensor 2150 may include any sensor capable of detecting a ray 2118 emitted from the first end 2112 of the optical fiber 2110. In one embodiment, the image sensor 2150 may be a camera. As described herein, identification of internal components of the optical fiber 2110 (e.g., stress rods and / or cores) may be utilized in the alignment and positioning process. For example, the misalignment of the optical fiber 2110 may be determined based on the image acquired by the image sensor 2150. Misalignment is the difference between the position of the light-emitting surface of the optical fiber 2110 and the alignment position. The alignment position may be the position where the light-emitting surface of the optical fiber 2110 is aligned with an external object.

[0220]

[0253] In some embodiments, the optical fiber alignment and positioning system 2100 may also include a controller 2140. The controller 2140 may be operationally coupled to a vacuum stage 2102 via a communication line 2142. In some embodiments, the controller 2140 may be operationally coupled to an image sensor 2150 and / or a mechanical fixing device 2130. For example, after the image sensor 2150 generates an image of the light-emitting surface of the optical fiber 2110, the image sensor 2150 transmits the image to the controller 2140. The controller 2140 may perform various steps of the method described herein. For example, the controller 2140 may determine one or more changes to the position of the optical fiber 2110 based on the image acquired by the image sensor 2150. In such an example, based on this determination, the controller 2140 may send an instruction to the vacuum stage 2102 to release the vacuum from the optical fiber 2110. After the vacuum is released, the position of the optical fiber 2110 may be changed or adjusted, as will be described later.

[0221]

[0254] The optical fiber alignment and positioning system 2100 and related methods described herein may also be used for other types of fibers and / or for the configuration of stress rods and cores of fibers. In various embodiments, the optical fiber alignment and positioning system may be other types of alignment systems, such as bowtie fibers, panda fibers, multicore fibers, elliptic fibers, and photonic crystalline optical fibers.

[0222]

[0255] FIG. 22 is a simplified schematic diagram of a vacuum stage 2202 for the optical fiber alignment and positioning system 2100 shown in FIG. 21, according to one embodiment of the present invention. Various embodiments of the vacuum stage 2202 for the optical fiber alignment and positioning system 2100 may be used in an automated system such as the system 100 shown in FIG. 1. The vacuum stage 2202 may be the same as or similar to the vacuum stage 2102 shown in FIG. 21. The vacuum stage 2202 may be part of an optical fiber alignment and positioning system, for example, the optical fiber alignment and positioning system 2100.

[0223]

[0256] The vacuum stage 2202 may include a main body 2220. The optical fiber channel 2208 may be formed as a part of the main body 2220. The optical fiber channel 2208 may extend from a first end 2204 to a second end 2206 of the main body 2220 of the vacuum stage 2202, and the optical fiber channel 2208 may be the same as or similar to [a corresponding channel]. The optical fiber channel 2208 may be configured to receive an optical fiber such as the optical fiber 2110 shown in FIG. 21.

[0224]

[0257] The vacuum stage 2202 may be configured to apply a vacuum to a portion of an optical fiber (not shown). For example, a vacuum may be applied to the portion of the optical fiber disposed within the optical fiber channel 2208. To apply the vacuum, the vacuum stage 2202 may include a vacuum inlet 2222. The vacuum inlet 2222 may be operable to be in fluid communication with a vacuum source (not shown). When in fluid communication with the vacuum source, a vacuum may be drawn through the vacuum inlet 2222.

[0225]

[0258] FIG. 2224 shows an enlarged view of the optical fiber channel 2208. As illustrated, the optical fiber channel 2208 may include at least two walls. For example, the optical fiber channel 2208 may be formed in the shape of a V-groove. The optical fiber channel 2208 will be described in further detail with reference to FIGS. 24A to 24C.

[0226]

[0259] To create a vacuum in the optical fiber portion located within the optical fiber channel 2208, the optical fiber channel 2208 may have a plurality of vacuum ports 2226. The vacuum ports 2226 may extend along a predetermined portion of the optical fiber channel 2208 between a first end 2204 and a second end 2206 of a vacuum stage 2202. For example, the vacuum ports 2226 may extend along the optical fiber channel 2208 for a predetermined length (e.g., 2 to 25 mm) between the first end 2204 and the second end 2206. In some embodiments, the vacuum ports 2226 may penetrate one or more walls of the optical fiber channel 2208. For example, if the optical fiber channel 2208 is a V-groove, the vacuum ports 2226 may penetrate the first and second walls of the V-groove.

[0227]

[0260] The vacuum port 2226 may be fluidically connected to one or more passages (not shown) that penetrate the body 2220 of the vacuum stage 2202. One or more passages may also be fluidly connected to the vacuum inlet 2222 and configured to extend the vacuum from the vacuum inlet 2222 to the vacuum port 2226.

[0228]

[0261] As described above, a vacuum may be applied to the optical fibers placed within the optical fiber channel 2208. For example, a vacuum force or vacuum pressure may be applied to the optical fibers placed within the optical fiber channel 2208 via a plurality of vacuum ports 2226. The size (e.g., length and width) of each vacuum port may vary depending on the diameter of the optical fibers placed within the optical fiber channel 2208. Furthermore, the size and number of vacuum ports 2226 may affect the size of the vacuum stage 2202. For example, an increase in the length or number of vacuum ports may increase the size and weight of the vacuum stage 2202, and in some cases may reduce the structural rigidity of the vacuum stage 2202.

[0229]

[0262] By applying a vacuum to the optical fiber, the optical fiber may be held within the optical fiber channel 2208 by frictional force. The following equation characterizes the force that holds the optical fiber within the optical fiber channel 2208, where F is the frictional force applied to the optical fiber, μ is the coefficient of friction (also called the coefficient of friction here), and N is the normal force applied to the optical fiber by the vacuum. F=μN

[0230]

[0263] The normal force N may be controlled by the vacuum pressure applied to the optical fiber by the vacuum port 2226. For example, the normal force N is expressed by the following equation: N=P vac nA port

[0231]

[0264] As shown in the figure, the design of the vacuum port 2226 and the pressure applied to the optical fiber by the vacuum port 2226 may affect the frictional force that holds the optical fiber in place. In the normal force equation above, N,P vac is the vacuum pressure (force / area) applied to the optical fiber, n is the number of vacuum ports 2226, A port This is the cross-sectional area of ​​the vacuum port 2226.

[0232]

[0265] Figure 23 is a simplified schematic diagram of a vacuum stage for an optical fiber alignment and positioning system shown in Figure 21, having a mechanical fixing device, according to one embodiment of the present invention. Various embodiments of the vacuum stage for an optical fiber alignment and positioning system may be used in automated systems such as system 100 shown in Figure 1. Referring to Figure 23, a vacuum stage 2302 is shown that can be used in conjunction with the optical fiber alignment and positioning system 2100 shown in Figure 21, and has a mechanical fixing device. The vacuum stage 2302 may be identical or similar to the vacuum stage 2202 and may be used as part of the optical fiber alignment and positioning system 2100, as shown in Figure 21. The following discussion will be conducted with reference to Figures 21 and 22, but it should be understood that the systems and techniques described herein are not necessarily applicable.

[0233]

[0266] As shown in Figure 21, in some embodiments, the optical fiber alignment and positioning system 2100 may include a mechanical fixing device 2130. The mechanical fixing device 2330 shown in Figure 23 may be identical or similar to the mechanical fixing device 2130. In some embodiments, the mechanical fixing device 2330 may be part of the body 2320 of the vacuum stage 2302, but in other embodiments, the mechanical fixing device 2330 may be separate from the body 2320 of the vacuum stage 2302. As described above, the mechanical fixing device 2330 may be configured to fix an optical fiber, such as the optical fiber 2110 shown in Figure 21, when it is placed in the optical fiber channel 2308. The optical fiber channel 2308 may be identical or similar to the optical fiber channel 2108 and / or the optical fiber channel 2208.

[0234]

[0267] Similar to the vacuum stage 2202, the vacuum stage 2302 may be configured to operate to apply a vacuum to the optical fiber located within the optical fiber channel 2308. To connect the body 2320 of the vacuum stage 2302 to a vacuum source, the vacuum stage 2302 may be provided with a vacuum inlet 2322.

[0235]

[0268] Figure 23 may also show that the body 2320 of the vacuum stage 2302 consists of two main components. As shown, the body 2320 may include a first portion 2324 and a second portion 2326. The first portion 2324 and the second portion 2326 may be fastened by a plurality of mounting mechanisms 2328. In one embodiment, the mounting mechanisms 2328 may be screws, but those skilled in the art will readily understand the various mounting means that can be used to fasten the first portion 2324 to the second portion 2326. In the illustrated embodiment, the optical fiber channel 2308 may be formed by the first portion 2324 and the second portion 2326. For example, the first side of the optical fiber channel 2308 may be formed from the first portion 2324, and the second side of the optical fiber channel 2308 may be formed from the second portion 2326. Thus, when the first portion 2324 and the second portion 2326 are fastened, the optical fiber channel 2308 is formed.

[0236]

[0269] Figures 24A-C are simplified schematic diagrams of an optical fiber channel 2408 with optical fibers arranged therein, according to one embodiment of the present invention. For the sake of ease of discussion, Figures 24A-C will be explained in relation to Figures 21-23, but it should be understood that all systems and technologies described herein are applicable. Various embodiments of the optical fiber channel 2408 with optical fibers arranged therein may be used in automated systems such as system 100 shown in Figure 1.

[0237]

[0270] Figure 24A shows embodiment 2400A in which an optical fiber 2410 is arranged within an optical fiber channel 2408. The optical fiber channel 2408 may be identical or similar to optical fiber channel 2108, optical fiber channel 2208, or optical fiber channel 2308. For example, the optical fiber channel 2408 may be an optical fiber channel in an optical fiber alignment and positioning system 2100. The optical fiber channel 2408 may be configured to receive and hold the optical fiber 2410. The optical fiber 2410 may be identical or similar to the optical fiber 2110.

[0238]

[0271] In some embodiments, the optical fiber channel 2408 may be a V-shaped groove. Therefore, the optical fiber channel 2408 may include a first wall 2460 and a second wall 2462. As described above with respect to Figure 23, in some embodiments, the first wall 2460 may be formed as part of a first portion 2324 of the body 2320 of the vacuum stage 2302, and the second wall 2462 may be formed as part of a second portion 2326 of the body 2320 of the vacuum stage 2302. In other embodiments, the optical fiber channel 2408, including the first wall 2460 and the second wall 2462, may be separated from the body 2220 of the vacuum stage 2202. As described above with respect to Figure 22, the optical fiber channel 2408 may include a plurality of vacuum ports 2426. If the optical fiber channel 2408 is a V-shaped groove, the plurality of vacuum ports 2426 may penetrate a portion of the first wall 2460 and / or a portion of the second wall 2462.

[0239]

[0272] If the optical fiber 2410 is located within the optical fiber channel 2408, the optical fiber 2410 may be rotated along a rotational direction 2470. The rotational direction 2470 may be centered on the x-axis or longitudinal direction of the optical fiber 2410. For example, during alignment, one or more internal components 2464 exposed through the first end 2412 of the optical fiber 2410 may be aligned with an external object. Since the first end 2412 may be the cut end of the optical fiber 2410, the internal components 2464 may be exposed through the first end 2412. In some embodiments, the internal components 2464 may be exposed to the first end 2412 by removing a coating or sheath applied to the optical fiber 2410. As shown in the figure, the internal components 2464 of the optical fiber 2410 may include a stress rod. Other internal components 2464 may include a core or microstructure.

[0240]

[0273] To align the internal component 2464 with an external object, it may be used to rotate the optical fiber 2410 along the rotational direction 2470. As shown in Figure 24B, when the optical fiber 2410 is rotated along the rotational direction 2470, the optical fiber 2410 may move axially along the axial direction 2472. The axial direction 2472 may extend along the axis 2418 of the optical fiber. The axis 2418 may extend from the first end 2412 of the optical fiber 2410 to the second end 2414 of the optical fiber 2410.

[0241]

[0274] During the alignment, positioning, or mounting process, it may be undesirable for the optical fiber 2410 to move along the axial direction 2472. For example, if the optical fiber 2410 moves along the axial direction 2472 during the alignment process, the first end 2412 of the optical fiber 2410 may no longer be in the correct alignment position relative to the external object. Another example is a bonding process in which the first end 2412 of the optical fiber is pressed against an external object for bonding. For example, if the optical fiber 2410 moves along the axial direction 2472 during the bonding process, if the optical fiber 2410 moves axially away from the external body along the axial direction 2472, the bonding between the first end 2412 and the external body may not be fully formed, or the bonding may fail.

[0242]

[0275] In some embodiments, additional pressure may be applied to the optical fiber 2410 in a direction perpendicular to the axial direction 2472 in order to suppress movement of the optical fiber 2410 along the axial direction 2472. For example, some methods may include increasing the vacuum pressure applied to the optical fiber 2410 or attaching clamps to both sides of the optical fiber 2410 to prevent axial movement. However, these methods may affect the accuracy of the alignment and positioning process. For example, reducing axial movement by increasing the pressure applied to the optical fiber 2410 by vacuum or clamps can inhibit movement of the optical fiber 2410 in the rotational direction 2470. Since rotating the optical fiber 2410 along the rotational direction 2470 is commonly used during the alignment process, inhibiting this movement may adversely affect the accuracy of the alignment process.

[0243]

[0276] In addition to hindering movement in the rotational direction 2470, several methods of applying additional pressure to the optical fiber 2410 can cause deformation along the length of the optical fiber 2410. For example, returning to Figure 22, increasing the vacuum pressure applied to an optical fiber placed within the optical fiber channel 2208 to prevent movement of the optical fiber in the axial direction 2472 can cause deformation or bending of the optical fiber in that portion due to the additional pressure applied to the portion of the optical fiber above the vacuum port 2226. Bending or deformation of the optical fiber can negatively impact the accuracy of the alignment process because, after the pressure (such as vacuum) is released, the optical fiber may return to its previous state, potentially resulting in it ultimately returning to a different position than the one used for alignment. Other problems arising from increasing the vacuum pressure applied to the optical fiber 2410 may include the optical fiber 2410 becoming stuck or adhering within the optical fiber channel 2408 due to the pressure not being released.

[0244]

[0277] A directional friction surface 2416 is provided to provide an optical fiber channel 2408 that allows the optical fiber 2410 to move in the rotational direction 2470 while preventing or minimizing movement in the axial direction 2472. The directional friction surface 2416 may be characterized by a plurality of friction factors (e.g., coefficients of friction). For example, the directional friction surface 2416 may be characterized by a first coefficient of friction and a second coefficient of friction. In other words, the directional friction surface 2416 may be characterized by a first coefficient of friction for friction measured in a first direction and a second coefficient of friction for friction measured in a second direction. The first coefficient of friction may be oriented in the first direction to provide a frictional force for movement in the first direction. The second coefficient of friction may be oriented in the second direction to provide a frictional force for movement in the second direction. The first and second directions may be different directions. In one embodiment, the first direction may be the axial direction 2472 and the second direction may be the rotational direction 2470. Therefore, the second direction can be the circumferential direction (i.e., the tangential direction) that makes an angle of 240° with respect to the first direction.

[0245]

[0278] To reduce the movement of the optical fiber 2410 in the axial direction 2472, the first coefficient of friction corresponding to the directional friction surface 2416 may be greater than the second coefficient of friction. In this example, since the first coefficient of friction is greater than the second coefficient of friction, the frictional force applied to the optical fiber 2410 in the axial direction 2472 may be greater than the frictional force applied to the optical fiber 2410 in the rotational direction 2470. This allows the optical fiber 2410 to rotate in the rotational direction 2470, while simultaneously preventing or minimizing the movement of the optical fiber 2410 in the axial direction 2472.

[0246]

[0279] The directional friction surface may be in contact with at least a portion of the optical fiber 2410. For example, the directional friction surface may be in contact with a portion of the optical fiber 2410 that is located within the optical fiber channel 2408. As shown in Figure 24C, internal walls such as the first wall 2460 and the second wall 2462 may have a directional friction surface 2416. If the optical fiber channel 2408 is not a V-groove, one or more walls forming the optical fiber channel 2408 may include a directional friction surface 2416.

[0247]

[0280] In some embodiments, the directional friction surface 2416 may be part of the first wall 2460 and the second wall 2462, while in other embodiments, the directional friction surface 2416 may be a coating or material applied to the first wall 2460 and the second wall 2462. For example, the directional friction surface 2416 may be formed from the material of the first wall 2460 and the second wall 2462. Since the first wall 2460 and the second wall 2462 are formed by the optical fiber channel 2408, the directional friction surface 2416 may be formed from the material of the optical fiber channel 2408. Referring to Figure 23, the optical fiber channel 2308 may be formed by a first portion 2324 and a second portion 2326 of the body 2320. In such an example, the directional friction surface 2416 may be formed from the material of the first portion 2324 and / or the second portion 2326 of the body 2320. In other words, the directional friction surface 2416 may be formed by the material or as part of the vacuum stage 2302.

[0248]

[0281] In other embodiments, the directional friction surface 2416 may be a coating applied to the surface of the optical fiber channel 2408, for example, the first wall 2460 and the second wall 2462 of the optical fiber channel 2408. In other examples, the directional friction surface 2416 may be a coating applied to the surface of the vacuum stage 2302.

[0249]

[0282] The material forming the directional friction surface 2416 may be softer than the material used for the first wall 2460 and the second wall 2462. For example, the directional friction surface 2416 may be composed of or contain a composite material. For example, the directional friction surface 2416 may be a glass fiber or ceramic matrix composite containing a soft polymer binder or polymer matrix composite. Conventionally, optical fiber channels, such as optical fiber channel 2408, may be composed of a hard material such as steel to prevent the optical fiber 2410 from deforming or depressurizing into the material of the optical fiber channel 2408. However, hard materials are often characterized by a single coefficient of friction (e.g., coefficient of friction), which allows for similar motion in both the axial direction 2472 and the rotational direction 2470. In contrast, the softer material for the directional friction surface 2416 provided herein may result in a difference in the coefficient of friction between the axial direction 2472 and the rotational direction 2470. By setting the first coefficient of friction of the directional friction surface 2416 to be greater than the second coefficient of friction, the directional friction surface 2416 may restrict movement in the first direction (e.g., axial direction 2472) while allowing movement in the second direction (e.g., rotational direction 2470).

[0250]

[0283] It should be understood that the arrangement of the first and second friction coefficients on the directional friction surface 2416 may vary depending on the desired movement of the optical fiber 2410. For example, in certain applications, it may be advantageous to move the optical fiber 2410 axially 2472 while restricting its movement in the rotational direction 2470. In such cases, the first friction coefficient may be smaller than the second friction coefficient. The direction, orientation, and arrangement of the first and second friction coefficients may affect the directions in which the movement of the optical fiber 2410 is permitted and restricted.

[0251]

[0284] Figure 25 is a simplified flowchart illustrating a method 2500 for optical fiber alignment and positioning using an optical fiber alignment and positioning system, according to one embodiment of the present invention. Various embodiments of method 2500 may be carried out using automated systems such as system 100 shown in Figure 1. For example, method 2500 may consist of optical fiber alignment and positioning steps using optical fiber alignment and positioning system 600. For clarity, the following discussion will be conducted with reference to Figures 21-24C. However, it should be understood that the systems or techniques described herein are also applicable to method 2500.

[0252]

[0285] In step 2505, method 2500 may include the step of providing an optical fiber alignment and positioning system, such as the optical fiber alignment and positioning system 2100 shown in Figure 21. As shown in Figure 21, the optical fiber alignment and positioning system 2100 may comprise a vacuum stage 2102 having a first end 2112 and a second end 2114. The vacuum stage 2102 may comprise a vacuum inlet, e.g., a vacuum inlet 2222, which is operable to fluidly communicate with a vacuum source. The vacuum stage 2102 may also comprise one or more passages extending through the vacuum stage and fluidly communicating with a plurality of vacuum ports (e.g., vacuum port 2226). One or more passages may fluidly connect the plurality of vacuum ports to a vacuum source.

[0253]

[0286] The vacuum stage 2102 may include an optical fiber channel, for example, an optical fiber channel 2108. The optical fiber channel 2108 may extend from a first end 2112 to a second end 2114 of the vacuum stage 2102. Multiple ports may pass through the optical fiber channel 2108. As described above, the optical fiber channel 2108 may include a V-groove, as shown in the optical fiber channel 2408 in Figure 24A. In such embodiments, the optical fiber channel 2108 may be formed by a first wall (e.g., a first wall 2460) and a second wall (e.g., a second wall 2462). If the optical fiber channel 2108 includes a V-groove, multiple vacuum ports, such as a vacuum port 2426, may pass through the first wall 2460 and the second wall 2462, as shown in Figure 24A.

[0254]

[0287] In some embodiments, the optical fiber channel 2108 may include a directional friction surface, such as a directional friction surface 2416. For example, the first wall 2460 and the second wall 2462 of the optical fiber channel 2408 may include a directional friction surface 2416. The directional friction surface 2416 may be formed as part of the optical fiber channel 2108, but in other embodiments, the directional friction surface 2416 may be a coating applied to the surface of the optical fiber channel 2108.

[0255]

[0288] The directional friction surface 2416 may include a first coefficient of friction in a first direction and a second coefficient of friction in a second direction. In one embodiment, the first coefficient of friction may be higher than the second coefficient of friction. As described above with respect to Figures 24A-C, the first direction may be axial, for example, the axial direction 2472, and the second direction may be rotational or tangential, for example, the rotational direction 2470.

[0256]

[0289] The optical fiber channel 2108 may be configured to receive at least a portion of an optical fiber, such as the optical fiber 2110. Thus, the method may include step 2510. In step 2510, the method 2500 may include the step of arranging an optical fiber within the optical fiber channel. For example, the method 2500 may include the step of arranging the optical fiber 2410 within the optical fiber channel 2408 such that at least a portion of the optical fiber 2410 is in contact with the directional friction surface 2416. In some embodiments, the method may include the step of vacuuming a portion of the optical fiber 2110. For example, a portion of the optical fiber 2410 may be vacuumed through a plurality of vacuum ports 2426.

[0257]

[0290] In step 2515, method 2500 may include the step of changing the position of the optical fiber 2110 by moving the optical fiber 2110 in a second direction to a changed position. For example, moving the optical fiber 2110 in a second direction to change its position may include rotating the optical fiber 2110 in a rotational direction to the changed position. Referring to Figure 24A, the optical fiber 2410 may be rotated in a rotational direction 2470. After changing the optical fiber 2110 to a predetermined position, the mechanical fixing device 2130 can be opened to release the optical fiber 2110.

[0258]

[0291] Step 2520 may include a step of determining the misalignment of the optical fiber 2110. The misalignment may be the amount by which the optical fiber 2110 is deviated from its alignment position relative to an external object. Step 2525 may include a step of determining whether the misalignment is within an alignment threshold. In some embodiments, the alignment threshold may vary depending on the application. For example, in some applications, such as fusion splicing, the tolerance for alignment may be small, thereby minimizing the variation between the position of the optical fiber 2110 and the external object. In other applications, the tolerance range of the alignment threshold may be large, thereby allowing greater flexibility with respect to the orientation of the optical fiber 2110.

[0259]

[0292] If, in step 2525, it is determined that the misalignment of the optical fiber 2110 is not within the misalignment threshold, method 2500 may return to step 2515 via iterative step 2530. In step 2515, the optical fiber 2110 may be further modified to a predetermined position by moving the optical fiber in a second direction. After the optical fiber 2110 has been further modified to a new position, a second misalignment may be determined in step 2520. In step 2525, the second misalignment may be compared to the alignment threshold.

[0260]

[0293] If, in step 2525, it is determined that any repeated misalignment (e.g., a first misalignment, a second misalignment, etc.) is within the alignment threshold, the method may proceed to step 2535. In step 2535, the method 2500 may include the step of attaching the optical fiber to an external object. For example, the first end 2112 of the optical fiber 2110 may be attached to an external body. In one embodiment, the first end 2112 of the optical fiber 2110 may be glued or otherwise fixed to the external body.

[0261]

[0294] In some embodiments, method 2500 may include the step of securing a portion of the optical fiber 2110 using a mechanical fixing device, such as a mechanical fixing device 2130. The mechanical fixing device is closed to surround a portion of the optical fiber 2110 and secures the optical fiber 2110 to prevent misalignment before mounting the optical fiber 2110 to an external body. The mechanical fixing device may be used when a holding force greater than the vacuum holding force is required to prevent misalignment.

[0262]

[0295] It should be understood that the specific steps shown in Figure 25 provide a particular method for aligning and positioning optical fibers using an optical fiber alignment and positioning system according to one embodiment of the present invention. Other sequences of steps may also be performed according to other embodiments. For example, another embodiment of the present invention may perform the above steps in a different order. Furthermore, the individual steps shown in Figure 25 may include a plurality of substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0263]

[0296] Figure 26 is a simplified schematic diagram of a microlens array (MLA) 2600 according to one embodiment of the present invention. Various embodiments of the MLA 2600 may be used in an automated system such as system 100 shown in Figure 1. As shown, the MLA 2600 may include a plurality of lenslets 2602. Each lenslet 2602 may be a microlens. Microlenses may be small lenses, generally with a diameter of less than 1 millimeter (mm) and as small as 10 microns (μm). Each lenslet 2602 may be a single microlens having a plane and a convex (e.g., spherical) surface for refracting light. In some cases, the lenslet 2602 may consist of multiple optical material layers or include multiple layers to achieve desired optical properties. In some embodiments, the MLA 2600 may be formed by an array of one-dimensional or two-dimensional lenslets 2602 formed on a support substrate. The lenslets 2602 may serve to focus and concentrate light from one or more optical fibers.

[0264]

[0297] Referring to Figure 27, a simplified schematic diagram 2700 of a conventional alignment process for aligning an optical fiber 2704 to the lenslet of an MLA is shown. Conventional approaches often utilize an orifice plate 2706 having multiple orifices 2708. In some embodiments, the MLA may be part of the orifice plate 2706. In other embodiments, the orifice plate 2706 may be aligned with the MLA so that each orifice 2708 aligns with the lenslet of the MLA. For example, the orifices 2708 may be manufactured using lithography techniques.

[0265]

[0298] In the conventional method of aligning the optical fiber 2704 to the lenslet, the optical fiber 2704 may be inserted into one of the orifices 2708. Since the orifices are aligned with the lenslet, the optical fiber 2704 is aligned with the lenslet by inserting it into one of the orifices 2708. However, using the orifice plate 2706 for alignment can compensate for various shortcomings in the alignment process. For example, the orifice plate 2706 does not allow for the alignment of independent fibers, nor can it compensate for manufacturing imperfections in the fibers or align the tip and inclination of the optical fiber 2704. While reducing the diameter of the orifice may improve the tolerance of the alignment, reducing the diameter of the orifice often leads to damage to the optical fiber or problems during insertion.

[0266]

[0299] This specification provides an MLA alignment system for achieving independent, active optical fiber alignment with the MLA. Figure 28A is a simplified schematic diagram of a system 2800 for performing MLA alignment according to one embodiment of the present invention, showing the case where the optical fiber is in a nominal position. System 2800 may be used to align one or more optical fibers, such as optical fiber 2804, to an MLA, such as MLA2840. Specifically, the system may include an MLA alignment system 2810 for positioning and aligning optical fiber 2804 to lenslet 2802 of MLA2840. As shown, MLA2840 may include multiple lenslets, and MLA alignment system 2810 may be used to position and align multiple optical fibers to multiple lenslets of the MLA.

[0267]

[0300] The optical fiber 2804 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 2804 may include, but is not limited to, bowtie-type fibers, panda-type fibers, multicore fibers, elliptic fibers, photonic crystal optical fibers, and the like. System 2800 has the advantage of being independent of the optical polarization state of the optical fiber 2804. Therefore, in other embodiments, the optical fiber 2804 may be a single-mode fiber, a multimode fiber, or other types of optical fiber. The diameter of the optical fiber 2804 may be less than 250 μm. For example, the diameter of the optical fiber 2804 may be 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.

[0268]

[0301] As described above, the optical fiber 2804 may have individual manufacturing characteristics or properties. For example, the optical fiber 2804 may have a cut end 2808 with a different cutting angle than other optical fibers. The cut end 2808 of the optical fiber 2804 may be the end of an optical fiber having a cut or cut portion substantially perpendicular to the longitudinal length 2806 of the optical fiber 2804 during the manufacturing process.

[0269]

[0302] Other manufacturing characteristics of optical fiber 2804 may include bending or curving of the optical fiber 2804 along its longitudinal length 2806. During or after the manufacturing process, the optical fiber 2804 may be wound or coiled into bundles, which may result in bending or curving along its longitudinal length 2806. Other manufacturing characteristics of optical fiber 2804 may include the material of the optical fiber 2804 and whether the optical fiber 2804 has a coating or sheath. Additional manufacturing characteristics of optical fiber 2804 may include the center position of the optical core relative to the diameter of the outer fiber cylinder. Misalignment of the optical core may result in the mechanical axis and optical axis of the optical fiber being different.

[0270]

[0303] The manufacturing characteristics of the optical fiber 2804 may affect the direction and / or deviation of the light emitted from the optical fiber 2804. For example, if the cutting angle of the cut end 2808 of the optical fiber 2804 is not zero (a zero cutting angle would result in a cut perfectly perpendicular to the longitudinal length 2806 of the optical fiber 2804), the light emitted from the cut end 2808 of the optical fiber 2804 may be deviated by an angle proportional to the non-zero cutting angle. This deviation of the light emitted from the cut end 2808 may affect the performance of the optical fiber 2804.

[0271]

[0304] The positioning and alignment of the cut end 2808 and the lenslet 2802 may also affect the characteristics of the light emitted from the optical fiber 2804. As described above, the optical fiber 2804 may be positioned and aligned with the lenslet 2802. Specifically, the cut end 2808 of the optical fiber 2804 may be aligned with the lenslet 2802 such that a ray 2822 passes through the lenslet 2802 and produces a refracted ray 2823. The refracted ray 2823 may be formed by the refraction of the ray 2822 passing through the lenslet 2802.

[0272]

[0305] During the assembly of the optical fiber and MLA system, the cut end 2808 of the optical fiber 2804 is aligned with the lenslet 2802. The alignment of the optical fiber cut end 2808 with the lenslet 2802 as used herein may mean that the optical fiber 2804 is positioned such that the refracted rays 2823 propagating through the lenslet 2802 are maximized and the intensity of the rays 2822 is maintained. In some embodiments, the MLA 2840 may be positioned at a predetermined distance from the optical fiber 2804. Specifically, the MLA 2840 may be positioned such that the lenslet 2802 is at a predetermined distance from the cut end 2808 of the optical fiber 2804. For example, the predetermined distance may be less than 10 μm, less than 100 μm, less than 500 μm, or less than 1 mm. In other embodiments, the MLA 2840 may be positioned such that the lenslet 2802 is in contact with or close to the cut end 2808 of the optical fiber 2804.

[0273]

[0306] The MLA alignment system 2810 can be used to align the optical fiber 2804 to the lenslet 2802. To achieve precise alignment between the cut end 2808 and the lenslet 2802 and to advantageously compensate for the manufacturing characteristics of individual optical fibers, the MLA alignment system 2810 may include one or more position detection devices. For example, as shown in Figure 28A, the MLA alignment system 2810 may include a tilt detection device 2812 and a position detection device 2814. The tilt detection device 2812 and / or the position detection device 2814 may be a camera, a four-quadrant photodiode, or other device capable of detecting the output position of the optical fiber 2804, or may include such devices.

[0274]

[0307] The tilt detection device 2812 may be configured and positioned to detect the tilt of the optical fiber 2804. The tilt of the optical fiber 2804 may be the orientation and position of the cut end 2808 relative to the longitudinal length 2806 of the optical fiber 2804, or may include both. For example, if a measurement along the longitudinal length 2806 of the optical fiber 2804 shows that the cut end 2808 of the optical fiber 2804 is higher in the y-axis direction than the rest of the optical fiber 2804, then the optical fiber 2804 may be tilted. The tilt of the optical fiber 2804 may be caused by curvature or bending of the optical fiber 2804.

[0275]

[0308] The position detection device 2814 may be configured and positioned to detect the latitude (z-axis) and longitude (y-axis) position of the optical fiber 2804. To align the cut end 2808 with the lenslet 2802, the cut end 2808 may need to be positioned at specific xyz coordinates. Furthermore, to maximize the intensity of the refracted rays 2823 refracted through the lenslet 2802, the cut end 2808 may also need to be positioned at specific xyz coordinates. The position detection device 2814 may detect and provide output values ​​for the xyz coordinates of the optical fiber 2804.

[0276]

[0309] To guide the refracted rays 2823 to both the tilt detection device 2812 and the position detection device 2814, the MLA alignment system 2810 may include a beam splitter 2816. The beam splitter 2816 may be positioned to axially align with the optical fiber 2804 and the MLA 2840. The beam splitter 2816 may be positioned along the x-axis between the MLA 2840 and the tilt detection device 2812. The beam splitter 2816 may be positioned to generate reflected rays 2824 to the position detection device 2814. For example, the beam splitter 2816 may include a surface 2818 that reflects a portion of the refracted rays 2823 as reflected rays 2824 toward the position detection device 2814. The surface 2818 may be a reflective surface such as a mirror. As shown in the figure, the beam splitter 2816 may reflect a portion of the ray 2822 toward the position detection device 2814, and transmit the remaining portion of the refracted ray 2823 as a transmitted ray 2826 to the tilt detection device 2812. The position detection device 2814 is shown to receive reflected light from the beam splitter 2816, but this is not essential in one embodiment of the present invention, and in other embodiments, the position detection device 2814 may be replaced with the tilt detection device 2812 so that the tilt detection device 2812 receives reflected light from the beam splitter 2816. A person with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0277]

[0310] In some embodiments, the MLA alignment system 2810 may include a focusing lens 2820. The focusing lens 2820 may be positioned between the beam splitter 2816 and the position detection device 2814. Reflected rays 2824 may be received by the focusing lens 2820 and guided to the position detection device 2814. The focal length of the focusing lens 2820 and the distance from the beam splitter 2816 to the focusing lens 2820 may be determined based on the specific wavelength of the rays 2822 and the characteristics of the MLA 2840.

[0278]

[0311] To position and align the optical fiber 2804, the MLA alignment system 2810 may generate a reference output for the optical fiber 2804. The position detection device 2814 may generate a position reference output 2850, and the tilt detection device 2812 may generate a tilt reference output 2852. Although the position reference output 2850 and the tilt reference output 2852 are illustrated as part of system 2800, it should be understood that the position reference output 2850 and the tilt reference output 2852 are not physical components of system 2800. Rather, the position reference output 2850 and the tilt reference output 2852 are provided to illustrate the measurements or outputs provided by their respective detection devices. The position reference output 2850 and the tilt reference output 2852 are described in more detail with reference to Figures 29A and 29B.

[0279]

[0312] In the illustrated embodiment, the position reference output 2850 and the tilt reference output 2852 are images of the focused beam incident on the position detection device 2814 and the tilt detection device 2812, respectively. In other embodiments, the position reference output 2850 and the tilt reference output 2852 may be one or more analog or digital signals focused by a four-quadrant photodiode or similar positioning tool. A person with ordinary skill in the art will recognize that many variations, modifications, and alternatives exist for this design.

[0280]

[0313] To generate a position reference output 2850 and a tilt reference output 2852 for the optical fiber 2804, a position detection device 2814 and a tilt detection device 2812 may measure the position and tilt of the optical fiber, respectively. Based on the tilt and position measurements obtained by the tilt detection device 2812 and the position detection device 2814, respectively, the MLA alignment system 2810 may determine whether to adjust or change the position and / or orientation of the optical fiber 2804. For example, the MLA alignment system 2810 may determine, based on the position measurement, that the optical fiber 2804 needs to be moved along the x-axis, and adjust, for example, the focal position of the ray 2822.

[0281]

[0314] To adjust or change the position of the optical fiber 2804, the system 2800 may include a stage 2830. In some embodiments, the stage 2830 may be part of the MLA alignment system 2810. In other embodiments, the stage 2830 may be separate from the MLA alignment system 2810. The stage 2830 may be configured to hold and adjust the position of the optical fiber 2804. For example, the stage 2830 may move the optical fiber along the x, y, or z axis. In some embodiments, the stage 2830 may be configured to adjust the tilt of the optical fiber 2804 by rotating the optical fiber 2804. For example, the stage 2830 may be a rotating stage configured to rotate the optical fiber 2804, or may include a rotating stage. The rotating stage may rotate the optical fiber 2804 about the x axis, which is also called u rotation, about the y axis, which is also called v rotation, or about the z axis, which is also called w rotation. As used herein, “tilt” may include v-rotation or w-rotation of the optical fiber 2804. As used herein, “move or adjust the position of the optical fiber 2804” should be understood as moving the optical fiber 2804 along one or more of the x-axis, y-axis, and / or z-axis, or rotating the optical fiber 2804 along one or more of the u-rotation, v-rotation, or w-rotation.

[0282]

[0315] Figure 28B shows a simplified schematic diagram of a system 2800 for performing MLA alignment according to one embodiment of the present invention when the optical fiber 2804 is in a rotational misalignment state. For example, Figure 28B may show the MLA alignment system 2810 when the optical fiber 2804 is displaced in the positive v direction by rotation around the z axis. The light rays 2822 and 2826 are also tilted with the same displacement in the v direction, resulting in a change in the tilt reference output 2852 measured by the tilt detection device 2812. The refracted light ray 2824 is also tilted at the same angle until it reaches the focusing lens 2820. The focusing lens 2820 is selected so that the position reference output 2850 of the position detection device 2814 does not change with respect to any displacement in the v or w direction.

[0283]

[0316] Figure 28C shows a simplified schematic diagram of a system 2800 for performing MLA alignment according to one embodiment of the present invention when the optical fiber 2804 is experiencing translational misalignment. For example, Figure 28C shows the MLA alignment system 2810 when the optical fiber 2804 is displaced in the negative y direction. The refracted ray 2823 and transmitted ray 2826 from the lenslet 2802 are also displaced by the same amount in the y direction, resulting in a positive change in the tilt reference output 2852 measured by the tilt detection device 2812. The refracted ray 2824 is also displaced, resulting in a negative change in the position reference output 2850 measured by the position detection device 2814.

[0284]

[0317] After adjusting or changing the position of the optical fiber 2804, the MLA alignment system 2810 may collect one or more measurements to determine whether the position of the optical fiber 2804 is within the positional tolerance range. If the optical fiber 2804 is within the positional tolerance range, tilt measurements and position measurements may be performed on the position of the optical fiber 2804. A tilt detection device 2812 may measure the tilt, and a position detection device 2814 may measure the position.

[0285]

[0318] Figure 29A shows Figure 2900A of the light spot 2902 used to calculate the tilt measurement. Figure 2900A may also be used to generate the tilt reference output 2852. The following description concerns tilt measurement, but position measurement may be collected and corrected using one or more of the following techniques or steps to generate a corrected reference output. For the sake of discussion, Figures 29A and 29B are discussed with reference to Figures 28A-C. However, it should be understood that the systems described in this document can be used in any case.

[0286]

[0319] The light-emitting spot 2902 can be generated by a ray incident on and captured by the tilt detection device 2812. In the case of position measurement, the position detection device 2814 can be used to capture a ray incident on the position detection device and generate the light-emitting spot 2902. The light-emitting spot 2902 may correspond to the cut end 2808 of the optical fiber 2804. Several image processing methods can be used to detect and / or identify various components of the optical fiber. For example, in one embodiment, the z,y coordinates of the centroid 2914 of the light-emitting spot 2902 can be determined using intensity-weighted centroid calculation. In another embodiment, the z,y coordinates may be determined from a calculation algorithm that fits an ideal spot to the measured light-emitting spot 2902. Those skilled in the art will readily understand variations of other calculation methods.

[0287]

[0320] The rays used to generate Figure 2900A can be captured by receiving reflected rays 2824 and transmitted rays 2826. While expanding the beam spot can increase the sensitivity of the measurements collected by the tilt detector 2812 and / or position detector 2814, it should be understood that the overall beam spot may be limited by the physical size of the tilt detector 2812 and / or position detector 2814.

[0288]

[0321] The tilt angle of the light-emitting spot 2902 can be calculated. The degree of tilt may correspond to the tilt measurement of the optical fiber 2804. To calculate the degree of tilt, the tilt displacement 2950 of the light-emitting spot 2902 may be determined. For example, in some embodiments, the degree of tilt may be determined by the centroid 2914 of the light-emitting spot 2902. The difference between the zy coordinate identified by the tilt displacement 2950 and the origin 2954 (e.g., zy coordinate 0,0) may be used to determine the tilt of the optical fiber 2804 (e.g., the tilt measurement). The tilt measurement may be determined based on the tilt of the light-emitting spot 2902.

[0289]

[0322] Similar techniques can be used for position measurement; for example, the centroid 2914 of the light-emitting spot 2902 may be used to determine the position of the cut end 2808 of the optical fiber 2804 based on the light rays captured by the position detection device 2814.

[0290]

[0323] Tilt and position measurements may be part of the misalignment used to determine whether the light-emitting spot 2902 (for example, corresponding to the cut end 2808 of the optical fiber 2804) is in the alignment position. The alignment position may be a position where the light-emitting spot 2902 is located within a predetermined tolerance range from the reference zero position.

[0291]

[0324] For example, when aligning a fiber to a system, initial measurements of the position reference output 2850 and the tilt reference output 2852 are performed. First, the fiber is rotated to a second rotational position in the v and w directions until the tilt reference output falls below a predetermined threshold. Next, the fiber is rotated to a second movement position in the y and z directions until the position reference output 2850 falls below a predetermined threshold. Once the process is complete, the tilt reference output 2852 is regenerated. If the tilt reference output 2852 exceeds a predetermined threshold, the optical fiber is moved to a third rotational position, and this entire process is repeated until both the position reference output 2850 and the tilt reference output 2852 are below their corresponding thresholds.

[0292]

[0325] In some embodiments, it may be desirable to place the cut end 2808 of the optical fiber 2804 at the alignment position before positioning and aligning the MLA in order to obtain a reference alignment output. For example, the alignment position of the light-emitting spot 2902 may be used as part of the reference output for positioning and aligning the MLA. The reference output may include tilt values ​​(e.g., tilt measurements) and position values ​​(e.g., position measurements). The reference output may provide orientation readings or coordinates, including the position and rotation (e.g., tilt) of the light-emitting surface of the optical fiber 2804. The readings or coordinates of the reference output may be used as reference points during positioning and aligning the MLA. For example, as described later, the reference output may be used to determine the alignment threshold of the MLA. In one embodiment, the MLA may be positioned and adjusted so that the spot beam received by the tilt detection device 2812 and the position detection device 2814 after the MLA is positioned is similar to or identical to the spot beam received before the MLA is positioned in the system 2800.

[0293]

[0326] A reference output may be generated from tilt measurements and position measurements. In some embodiments, the reference output may be the sum or readings of the tilt and position measurements. After a reference output is generated, it may be compared to an alignment threshold. For example, tilt measurements may be compared to a tilt threshold, and position measurements may be compared to a position threshold.

[0294]

[0327] As shown in Figure 2900A, the light-emitting spot 2902 of the optical fiber 2804 may have a tilt misalignment 2950. The tilt measurement generated from the tilt misalignment 2950 may be compared with a tilt threshold 2952. In some embodiments, the light-emitting spot 2902 may include a misalignment. Similar to the tilt measurement, the position measurement generated from the misalignment may be compared with a position threshold.

[0295]

[0328] If the tilt measurement is within the range of the tilt threshold 2952 and the position measurement is within the range of the position threshold, the MLA may be placed in the system 2800. However, if either the tilt measurement or the position measurement is not within the range of the tilt threshold 2952 or the position threshold, the cut end 2808 of the optical fiber 2804 may be rotated, moved, or otherwise adjusted to direct the light-emitting spot 2902 to the changed position. For example, the optical fiber 2804 may be placed in a first position to generate tilt and position measurements. If either the tilt measurement or the position measurement is not within the range of the tilt threshold 2952 or the position threshold, the optical fiber 2804 may be placed in a second position. In 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 2952 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 2800. However, if the second tilt measurement and the second position measurement are not within their respective thresholds, the optical fiber 2804 may be positioned at a third position. Thus, generating the reference output and adjusting the optical fiber so that the reference output falls within the alignment threshold can be an iterative process.

[0296]

[0329] If the tilt measurement or position measurement is not within the respective threshold, the cut end 2808 of the optical fiber 2804 may be positioned in a corrected position. The optical fiber 2804 may be positioned or adjusted using the stage 2830. As described above, moving or adjusting the position of the optical fiber 2804 should be understood as moving the optical fiber 2804 along one or more of the x, y, or z axes, or rotating the optical fiber 2804 around one or more of the u, v, or w rotations.

[0297]

[0330] In some embodiments, the degree or amount of movement used to position the optical fiber 2804 so that the tilt measurement or position measurement falls within the respective threshold may be determined by calculation. For example, using Figure 2900A, a rotation angle may be determined based on the tilt misalignment 2950 and / or the misalignment of the light-emitting spot 2902. The rotation angle may be the degree or amount of rotation required for the tilt misalignment 2950 to be aligned with the horizontal x-axis. In some cases, after rotating the cut end 2808 of the optical fiber 2804 based on the tilt angle, another Figure 2900A of the light-emitting spot 2902 at the changed position may be generated.

[0298]

[0331] Tilt misalignment and / or misalignment may result from either the orientation of the optical fiber 2804 or the orientation of the cut end 2808, or both. For example, as described above, the cut end 2808 may include a cutting angle. The cutting angle may determine the direction or angle at which the ray 2822 is emitted from the cut end 2808. If the cutting angle is not zero, or not perfectly perpendicular to the longitudinal length 2806 of the optical fiber, the ray 2822 may be emitted at an angle not parallel to the longitudinal length 2806 of the optical fiber 2804, i.e., an angle not parallel to the x-axis. In other words, if the cutting angle is zero, the ray 2822 will be emitted approximately parallel to the longitudinal length 2806 of the optical fiber 2804. Even a slight deviation of the cutting angle from zero may affect the angle at which the ray 2822 is emitted.

[0299]

[0332] In embodiments where the cutting angle is zero, the tilt measured by the tilt detection device 2812 may be due to the orientation of the optical fiber 2804. The tilt due to the orientation of the optical fiber 2804 may mean that the cut end 2808 is in a different plane from the opposite end 2838. For example, even if the optical fiber 2804 is tilted, if the cutting angle is zero, the cut end 2808 may be in a different position along the y, x, or z axis than the opposite end 2838. To compensate for the tilt of the optical fiber 2804, the stage 2830 may move the optical fiber 2804 in each direction to fix the tilt.

[0300]

[0333] In embodiments where the cut end 2808 lies on the same plane as the opposite end 2838, the optical fiber 2804 may have a tilt due to the cut end 2808. For example, if the cutting angle of the cut end 2808 is not zero, the ray 2822 may be emitted at a certain angle with respect to the x-axis. The angular emission rate of the ray 2822 may be measured as a tilt by a tilt detection device 2812. To compensate for the tilt caused by a non-zero cutting angle, the optical fiber 2804 may be rotated around the y-axis or v-rotated. In other words, the cut end 2808 may be raised or lowered, while the opposite end 2838 may be lowered or raised, respectively. The degree to which the optical fiber rotates under v-rotation may correspond to the degree to which the cutting angle of the cut end 2808 changes from zero.

[0301]

[0334] It should be understood that the type of rotation may change depending on the orientation of the cutting angle of the cut end 2808. For example, if the cutting angle along the y-axis is non-zero, the optical fiber 2804 may rotate along a v-rotation (e.g., rotation around the y-axis). If the cutting angle along the z-axis is non-zero, the optical fiber 2804 may rotate along a u-rotation. It should be understood that in some embodiments, the optical fiber 2804 may be symmetrical. Therefore, there may only be two possible cutting angles. Variations in the x-direction can make the fiber surface more complex than the cutting angle. It should also be understood that the cutting angle may be non-zero for any combination of yz coordinates. Therefore, each combination of vw rotations may be performed to rotate the optical fiber 2804 to accommodate non-zero cutting angles.

[0302]

[0335] Figure 29B shows Figure 2900B of the light-emitting spot 2902 positioned so that the tilt measurement is within the range of the tilt threshold 2952. Figure 2900B may also show how the light-emitting spot 2902 is positioned so that the position measurement falls within the position threshold. Figure 2900B may be used to generate the tilt reference output 2852.

[0303]

[0336] Similarly, if there is a misalignment in the light-emitting spot 2902, the optical fiber 2804 may be moved until the position measurement of the light-emitting spot 2902 falls within a position threshold. For example, the optical fiber 2804 may be moved until the light-emitting spot 2902 aligns with the origin 2954 of the zy axis or is located at a predetermined zy coordinate.

[0304]

[0337] It should be understood that aligning the light-emitting spot 2902 to the tilt threshold 2952 and the position threshold may be an iterative process. For example, if the cut end 2808 is not zero and a tilt measurement has been determined, the optical fiber 2804 may first be rotated along its respective rotational direction based on the tilt misalignment 2950. For example, based on Figure 2900A, the optical fiber 2804 may be rotated along a v rotation such that the cut end 2808 moves downward in the y-axis direction and the opposite end 2838 moves upward in the y-axis direction. Rotating the optical fiber 2804 along a v rotation may cause the position of the light-emitting spot 2902 to move downward. Therefore, the position measurement generated by the position detection device 2814 may determine the misalignment. Based on the misalignment, the longitudinal length 2806 of the optical fiber 2804 may be moved upward in the y-axis direction. Moving the longitudinal length 2806 of the optical fiber 2804 upward in the y-axis direction may affect the tilt measurement generated by the tilt detection device 2812. The optical fiber 2804 is rotated to perform tilt measurements, and this process may continue until the tilt measurement falls within the range of the tilt threshold 2952 and the position measurement falls within the range of the position threshold.

[0305]

[0338] If the tilt and position measurements of the light-emitting spot 2902 are within the ranges of the tilt threshold 2952 and the position threshold, respectively, reference outputs such as position reference output 2850 and tilt reference output 2852 may be generated. The reference outputs may be generated by at least one of the tilt and / or position measurements obtained at the position (i.e., within the threshold) of the optical fiber 2804. In some embodiments, the tilt threshold 2952 and / or position threshold may vary depending on the application. For example, in some applications such as fusion splicing, the tolerance range of the tilt threshold 2952 and / or position threshold may be small, thereby minimizing the variation in the orientation of the light-emitting spot 2902. In other applications, the tolerance range of the tilt threshold 2952 and / or position threshold may be large, thereby providing greater flexibility with respect to the angular direction of the light-emitting spot 2902.

[0306]

[0339] After the reference output is generated, the MLA2840 may be placed within the system 2800. It should be understood that the MLA2840 may not be present within the system 2800 when generating the tilt and position measurements, and consequently the reference output. Instead, an image of the light-emitting spot 2902 may be captured from the cut end 2808 of the optical fiber 2804 before the MLA2840 is placed within the system. As described herein, after the reference output is generated, the MLA2840 may be placed between the cut end 2808 of the optical fiber 2804 and the MLA alignment system 2810. The MLA tilt value, MLA position value, and MLA ray output may then be determined using the same or similar methods as described above to acquire the tilt and position measurements and generate the reference output from them. For example, the MLA tilt value may be determined in the same manner as the tilt measurement, the MLA position value may be determined in the same manner as the position measurement, and the MLA ray output may be generated in the same manner as the reference output.

[0307]

[0340] The MLA2840 may be placed in the system 2800 with the lenslet 2802 roughly aligned with the cut end 2808 of the optical fiber. As used herein, “rough alignment” may mean alignment based on human perception. For example, the MLA2840 may be placed in the system 2800 so that the lenslet 2802 is visually aligned with the cut end 2808 of the optical fiber 2804. Due to the small size of the optical fiber and the lenslet 2802 of the MLA, even with rough alignment, the cut end 2808 and the lenslet 2802 may not be precisely aligned. Therefore, in order to position and align the lenslet 2802 with the cut end 2808 of the optical fiber 2804, the tilt detection device 2812 may measure the MLA tilt value and the position detection device 2814 may measure the MLA position value. The MLA tilt value may be measured in the same manner as the tilt value, and the MLA position value may be measured in the same manner as the position value.

[0308]

[0341] The MLA ray output may be generated from at least one of the MLA slope value and / or MLA position value. As previously stated, the MLA ray output may be generated using a method similar to that used to generate the reference output. The main difference is that the reference output may be generated even if no MLA is present in system 2800, while the MLA ray output may be generated even if an MLA is present in system 2800. The MLA ray output may be compared to an alignment threshold. In one embodiment, comparing the MLA ray output to an alignment threshold may include comparing the MLA slope value to an MLA slope threshold and / or comparing the MLA position value to an MLA position threshold. The alignment threshold may include either or both of the MLA slope threshold and the MLA position threshold.

[0309]

[0342] The generation of the MLA ray output may be an iterative process similar to the generation of the reference output, in that the MLA slope value and / or MLA position value may be measured and compared to their respective thresholds. However, if the MLA slope value and / or MLA position value are not within their respective thresholds, the position of MLA2840 may be changed or adjusted instead of that of optical fiber 2804.

[0310]

[0343] Returning to Figure 28A, the MLA2840 may be positioned and held within the system 2800 on the MLA stage 2842. The MLA stage 2842 may be configured to change or adjust the position of the MLA2840 along the x, y, and z axes, and to rotate the MLA2840 along w, u, or v rotations. The position of the MLA2840 may be changed or adjusted until the output of the MLA ray falls within the alignment threshold. For example, the MLA2840 may be modified or adjusted until the MLA tilt value and MLA position are within the ranges of the MLA tilt threshold and MLA position threshold, respectively. As mentioned above, the tolerance range of the alignment threshold may vary depending on the application.

[0311]

[0344] Once the MLA ray output is within the alignment threshold, the optical fiber 2804 may be attached to the lenslet 2802 of the MLA 2840. Moving to Figure 30A, a simplified schematic diagram 3000A is shown illustrating the alignment of the lenslet and optical fiber in the MLA using the MLA alignment system shown in Figure 28A. The following explanation of Figures 30A and 30B will be made with reference to Figure 28A. However, it should be understood that any of the systems described herein are usable.

[0312]

[0345] As shown in the simplified schematic diagram 3000A, the optical fiber 3004A may be aligned with the lenslet 3002 of the MLA 3040. The optical fiber 3004A may be identical or similar to the optical fiber 2804. The optical fiber 3004A may be positioned and aligned with the lenslet 3002 using the system 2800, in particular the MLA alignment system 2810, as described above. As described above, once the MLA ray output from the MLA 3040 falls within the alignment threshold, the cut end 3008 of the optical fiber 3004A may be attached to the lenslet 3002. Methods for attaching the cut end 3008 to the lenslet 3002 may include fixing, bonding, joining, welding, optically contacting, or fusing the cut end 3008 to the lenslet 3002.

[0313]

[0346] In some embodiments, optical fiber 3004A may differ from optical fiber 2804. In such cases, optical fiber 2804 may become a “golden fiber.” A “golden fiber” may refer to a fiber with desirable manufacturing characteristics, such as a desirable cutting angle. When used as a golden fiber, optical fiber 2804 may be used for alignment of MLA3040, but after MLA3040 has entered the alignment threshold, it may be removed from system 2800, and optical fiber 3004A can be inserted and fixed into the system. Optical fiber 2804 (golden fiber) may be used for alignment of each lenslet within MLA3040. This has the advantage that each lenslet can be aligned using the same cut end 2808, providing a common alignment reference for each lenslet.

[0314]

[0347] Figure 30B is a simplified schematic diagram 3000B showing the alignment of multiple optical fibers 3004A-E and lenslets 3002A-E (i.e., multiple lenslets) within the MLA 3040 using the MLA alignment system shown in Figure 28A. In some embodiments, each lenslet 3002A-E of the MLA 3040 may be aligned with any of the multiple optical fibers 3004A-E. For example, lenslet 3002A may be aligned with optical fiber 3004A, lenslet 3002B with optical fiber 3004B, lenslet 3002C with optical fiber 3004C, lenslet 3002D with optical fiber 3004D, and lenslet 3002E with optical fiber 3004E.

[0315]

[0348] As described above, the golden fiber may be used to align each lenslet 3002A-E. For example, optical fiber 2804 may be used to align each lenslet 3002A-E using the MLA alignment system 2810. In such an example, MLA2840 may be the same as MLA3040. When each of the lenslets 3002A-E reaches the alignment position based on the alignment threshold, optical fiber 2804 may be removed from the system 2800 and replaced with one of the multiple optical fibers 3004A-E corresponding to each lenslet 3002A-E. For example, optical fiber 2804 may be used to align lenslet 3002A. When lenslet 3002A enters the alignment threshold (based on the MLA tilt value and MLA position value of optical fiber 2804), optical fiber 2804 in the system 2800 may be replaced with optical fiber 3004A. Optical fiber 3004A may then be fixed to lenslet 3002A. Once optical fiber 3004A is secured to lenslet 3002A, MLA3040 may be repositioned, and optical fiber 2804 may be repositioned on stage 2830. MLA3040 may be positioned so that lenslet 3002B is roughly aligned with optical fiber 2804. Subsequently, the process may be followed by aligning lenslet 3002B with optical fiber 2804, replacing optical fiber 2804 with optical fiber 3004B, and securing optical fiber 3004B to lenslet 3002B. This process may be continued for each of the multiple optical fibers 3004A-E. It should be understood that any number of multiple optical fibers 3004A-E and any number of lenslets 3002A-E can be aligned and / or secured using the systems and techniques described herein.

[0316]

[0349] Figure 31 is a simplified flowchart illustrating a method 3100 for aligning an optical fiber to an MLA using an MLA alignment system, according to one embodiment of the present invention. Various embodiments of the method 3100 for aligning an optical fiber to an MLA using an MLA alignment system may be performed in an automated system such as system 100 shown in Figure 1. The following discussion will proceed with reference to Figures 28A-28B. However, it should be understood that the method 3100 may be performed using any system or technique described herein.

[0317]

[0350] Method 3100 may include step 3105, in which an optical fiber having a first end and a second end, such as optical fiber 2804, may be provided. One end of the optical fiber may include one or more predefined manufacturing characteristics. For example, the first end of optical fiber 2804 may be a cut end 2808 having a predetermined cutting angle.

[0318]

[0351] In step 3110, method 3100 may include arranging the optical fiber such that the first end of the optical fiber faces the MLA alignment system. For example, in step 3110, the optical fiber 2804 may be arranged such that the cut end 2808 faces the MLA alignment system 2810. The MLA alignment system may include a tilt detection device (e.g., tilt detection device 2812) and a position detection device (e.g., position detection device 2814).

[0319]

[0352] Step 3115 may include emitting a ray of light from a first end of an optical fiber toward the MLA alignment system. For example, a ray of light may be emitted toward the MLA alignment system 2810 from the cut end 2808 of the optical fiber 2804. In some embodiments, the MLA alignment system 2810 may further include a beam splitter 2816 and a focusing lens (also called a focusing lens, e.g., a focusing lens 2820). In such cases, step 3115 may further include passing a first portion of the ray from the cut end 2808 of the optical fiber 2804 through the beam splitter 2816 before reaching the position detection device 2814, and reflecting a second portion of the ray from the cut end 2808 of the optical fiber 2804 through the beam splitter 2816 and passing through the focusing lens 2820 before reaching the tilt detection device 2812.

[0320]

[0353] Step 3120 may include the step of generating a reference output of the optical fiber 2804 at a first position. The reference output may be generated before the MLA 2840 is placed between the optical fiber 2804 and the MLA alignment system 2810. As described above with respect to Figures 29A and 29B, the reference output may include at least one of a tilt measurement or a position measurement. Therefore, in some embodiments, step 3120 may include the step of measuring a first tilt measurement based on a ray emitted from a first end of the optical fiber at a first position via a tilt detection device, and the step of measuring a first position measurement based on a ray emitted from a first end of the optical fiber at a first position via a position detection device. The first tilt measurement may be compared to a tilt threshold, and the first position measurement may be compared to a position threshold.

[0321]

[0354] If the first tilt measurement and / or the first position measurement are not within the ranges of the tilt threshold and the position threshold, respectively, the method 3100 may further include the step of positioning the optical fiber to a second position. For example, the optical fiber may be moved or adjusted from the first position to the second position by moving it along the x, y, and z axes, or by rotating it along the w, v, and u rotations. At the second position, a second tilt measurement and a second position measurement may be obtained by the tilt detection device 2812 and the position detection device 2814, respectively.

[0322]

[0355] 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 described above, method 3100 may be an iterative process in which the position of the optical fiber 2804 is corrected until the tilt measurement and / or position measurement are within the ranges of the tilt threshold and the position threshold, respectively. Once the tilt measurement and the position measurement are within their respective thresholds, method 3100 may proceed to the next step.

[0323]

[0356] Step 3125 may include providing an MLA, for example, an MLA2840, having a plurality of lenslets at a first position between the first end of an optical fiber and the MLA's alignment system. In some embodiments, the MLA2840 may be positioned such that the lenslet 2802 roughly aligns with the cut end 2808 of the optical fiber 2804. For example, the MLA2840 may be positioned at the first position such that a ray emitted from the cut end 2808 of the optical fiber 2804 passes through the lenslet 2802 of the MLA2840.

[0324]

[0357] If MLA2840 is in the first position, an MLA beam output may be generated in step 3130. 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 detection device 2812 and the first MLA position value via the position detection device.

[0325]

[0358] Step 3135 may include a step of comparing the MLA beam output with the alignment threshold. In some embodiments, the comparison of the MLA beam output with the alignment threshold may include comparing a first MLA tilt value with the MLA tilt threshold and comparing a first MLA position value with the MLA position threshold. In one embodiment, the alignment threshold may include a first MLA tilt threshold and a first MLA position threshold.

[0326]

[0359] If the MLA beam output is not within the alignment threshold, method 3100 may proceed to step 3140. In step 3140, the MLA 2840 may be moved from a first position to a second position. For example, moving the MLA 2840 from a first position to a second position may involve moving or adjusting the MLA 2840 along at least one of the x, y, z axes, w rotation, u rotation, or v rotation. Once the MLA 2840 has reached the second position, method 3100 may return to step 3130 via iterative step 3145. In step 3130, 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 detection device 2812 and a second MLA position value may be measured via position detection device 2814.

[0327]

[0360] Next, the second MLA beam output may be compared to the alignment threshold of step 3135. For example, the second MLA tilt value may be compared to the MLA tilt threshold, and the second MLA position value may be compared to the MLA position threshold. Method 3100 is an iterative process, and steps 3130 to 3145 may be repeated until the MLA beam output is within the alignment threshold.

[0328]

[0361] If the MLA beam output is within the alignment threshold, method 3100 may proceed to step 3150. In step 3150, optical fiber 2804 may be attached to the lenslet 2802 of MLA2840. In some embodiments, a different optical fiber may be attached to the lenslet 2802 than optical fiber 2804. For example, as described in Figures 30A and 30B, optical fiber 2804 may be a golden fiber, and if MLA2840 is in the alignment position, optical fiber 2804 may be replaced with optical fiber 3004A. Optical fiber 3004A may be attached to or fixed to the lenslet 2802. The step of attaching optical fiber 2804 (or optical fiber 3004A) to the lenslet 2802 of MLA2840 may include the step of fixing or bonding the cut end 2808 of optical fiber 2804 to the lenslet 2802.

[0329]

[0362] It should be understood that the specific steps shown in Figure 31 provide a particular method for 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 also be performed according to other embodiments. For example, another embodiment of the present invention may perform the above steps in a different order. Furthermore, the individual steps shown in Figure 31 may include a plurality of substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0330]

[0363] Figure 32 is 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 description will proceed with reference to other figures, but it should be understood that Method 3200 can be carried out using any system or technique described herein.

[0331]

[0364] Step 3205 may include the step of providing a plurality of optical fibers. For example, a plurality of optical fibers 3004A to E may be provided. The plurality of optical fibers 3004A to E 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. In step 3210, the first optical fiber, such as optical fiber 3004A, is positioned such that its first end (e.g., cut end 2808) faces an MLA alignment system, such as MLA alignment system 2810. The MLA alignment system may include a tilt detection device, such as a tilt detection device 2812, and a position detection device, such as a position detection device 2814.

[0332]

[0365] In step 3215, an MLA having multiple lenslets may be provided at the first position. For example, an MLA 2840 having multiple lenslets may be provided between the cut end 2808 of the optical fiber 2804 and the MLA alignment system 2810. As described with reference to Figures 30A and 30B, the MLA may comprise multiple lenslets, such as lenslets 3002A to E, including a first lenslet and a second lenslet. For example, lenslet 3002A may be the first lenslet, and lenslet 3002B may be the second lenslet.

[0333]

[0366] In some embodiments, method 3200 may include emitting a ray of light from a first end of a first optical fiber. In one embodiment, the MLA alignment system 2810 may include a beam splitter, such as a beam splitter 2816, and a focusing lens, such as a focusing lens 2820. In such an example, the ray of light emitted from a first end of a first optical fiber may include the steps of: passing a first portion of the ray from the first end of the first optical fiber through the beam splitter 2816 before reaching the position detection device 2814; and reflecting a second portion of the ray from the first end of the first optical fiber through the beam splitter 2816 and passing it through the focusing lens 2820 before reaching the tilt detection device 2812.

[0334]

[0367] In step 3220, the first end of the optical fiber may be adjusted to roughly align with the first lenslet. For example, the cut end of the optical fiber 3004A may be adjusted to roughly align with the lenslet 3002A. In some embodiments, the adjustment to roughly align the first end of the optical fiber with the first lenslet may include positioning the first end of the optical fiber at a predetermined distance from the surface of the first lenslet. As mentioned above, rough alignment may mean aligning one end of the optical fiber with the first lenslet based on human perception (for example, visually aligning the first end with the first lenslet).

[0335]

[0368] In step 3225, an output may be generated. For example, a first MLA beam output may be generated for a 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 a tilt detection device 2812, and the first position value may be measured by a position detection device 2814.

[0336]

[0369] In step 3230, 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 3230, the MLA beam output is not within the alignment threshold, method 3200 may proceed to step 3235. In step 3235, the optical fiber may be moved from the first position to the second position. For example, the optical fiber 2804 may be moved or adjusted along the x, y, and z axes and rotated along the w, u, and v rotations.

[0337]

[0370] Method 3200 may return to step 3225 via iterative step 3240. In step 3225, a second MLA beam output may be generated for the optical fiber at the second position. For example, a second MLA tilt value may be measured via tilt detection device 2812 and a second MLA position value may be measured via position detection device 2814. The second output may be generated based on the second MLA tilt value and the second MLA position value.

[0338]

[0371] In step 3230, 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 3200 may be an iterative process, and steps 3225-3240 may be performed until the MLA beam output is within the alignment threshold.

[0339]

[0372] If the MLA beam output is within the alignment threshold, the method may proceed to step 3245. In step 3245, the optical fiber may be attached to the lenslet. For example, the first end of the first optical fiber may be attached to the first lenslet of a plurality of lenslets. As described above with reference to Figure 30B, the first end of the optical fiber 3004A may be attached to the lenslet 3002A. The step of attaching the optical fiber to the lenslet may include the step of fixing or bonding the optical fiber to the lenslet.

[0340]

[0373] Once the first end of the first optical fiber is attached to the first lenslet, in step 3250, the MLA may be moved from the first position to the second position. Moving the MLA to the second position requires moving the MLA to a second position between the third end of the second optical fiber and the MLA alignment system. Method 3200 may return to step 3220 via iterative step 3255. In step 3220, the third end of the second optical fiber may be adjusted to roughly align with the second lenslet. For example, referring to Figure 30B, after the optical fiber 3004A is attached to the lenslet 3002A, the MLA 3040 may be moved to the second position so that the optical fiber 3004B is roughly align with the lenslet 3002B. Specifically, the third end of the optical fiber 3004B may be adjusted to roughly align with the lenslet 3002B.

[0341]

[0374] After the third end of optical fiber 3004B is roughly aligned with lenslet 3002B, a second MLA beam output for optical fiber 3004B may be generated, and method 3200 may continue through steps 3230-3240 until the second MLA beam output for optical fiber 3004B is within the alignment threshold. At this point, in step 3245, optical fiber 3004B may be attached to lenslet 3002B. Next, in step 3250, the MLA may be moved to a third position between the fifth end of a third optical fiber, such as optical fiber 3004C, and the MLA alignment system, so that in step 3220, the fifth end of the third optical fiber is roughly aligned with a third lenslet, such as lenslet 3002C.

[0342]

[0375] Method 3200 may continue until all of the optical fibers are attached to their respective lenslets within the MLA. At this point, Method 3200 may proceed to step 3260, where the alignment process ends.

[0343]

[0376] It should be understood that the specific steps shown in Figure 32 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 also be performed according to other embodiments. For example, another embodiment of the present invention may perform the above steps in a different order. Furthermore, the individual steps shown in Figure 32 may include multiple substeps that can be performed in various orders depending on the individual step. Furthermore, steps may be added or removed depending on the application. Those with ordinary skill in the art will recognize many variations, modifications, and substitutions.

[0344]

[0377] Various embodiments of this disclosure are shown below. Where used below, references to a series of examples shall be understood as selective references to each of those examples (for example, “Examples 1-4” shall be understood as “Examples 1, 2, 3, or 4”).

[0345]

[0378] Example 1 is a method for constructing a fiber array, comprising: a) selecting one fiber spool from one or more fiber spools; b) processing a portion of the fiber spool to form an optical fiber having an output end; c) positioning a substrate at one of a plurality of locations; d) aligning the output end of the optical fiber with the substrate; e) coupling the output end of the optical fiber at one of a plurality of locations on the substrate; f) removing the optical fiber from the fiber spool to form the input end of the optical fiber; g) marking the optical fiber; repeating steps c) through g) for each of the plurality of locations on the substrate; and confirming that the substrate is positioned at each of the plurality of locations.

[0346]

[0379] Example 2 is the method of Example 1, wherein the step of selecting one fiber spool from one or more fiber spools is a first illumination light source configured to emit light rays along an optical path, and a first detector, wherein the first detector is positioned off-axis with respect to the optical path. The present invention provides an optical fiber presence detection system comprising: a first detector configured to detect the presence of light; arranging an optical fiber along the optical path; irradiating at least a portion of the optical fiber with a ray of light; refracting light from the ray by at least a portion of the optical fiber to generate a refracted ray; and detecting the optical fiber at least partially based on the refracted ray and using the first detector.

[0347]

[0380] Example 3 is the method of Examples 1 and 2, wherein the step of processing a portion of a fiber spool to form an optical fiber having an output end includes the steps of drawing a certain length of fiber from the fiber spool to form an optical fiber, transporting the end of the optical fiber from the fiber spool to a stripper, attaching the optical fiber to the stripper, and stripping any coatings along the entire length of the optical fiber.

[0348]

[0381] Example 4 is the method of Examples 1 to 3, wherein the step of processing a portion of a fiber spool to form an optical fiber having an output end includes the steps of transporting the optical fiber from the fiber spool to a clean place, removing coating fragments from the optical fiber, and cleaning the optical fiber.

[0382] Example 5 is the method of Examples 1 to 4, wherein the step of processing a part of a fiber spool to form an optical fiber having an output end includes the steps of transporting a certain length of the optical fiber to a cutting machine, attaching the entire length of the optical fiber to the cutting machine, cutting the optical fiber, and removing the optical fiber from the fiber spool.

[0349]

[0383] Example 6 is the method of Examples 1 to 5, wherein the steps of processing a portion of a fiber spool to form an optical fiber having an output end include providing an optical fiber having a tip characterized by a longitudinal axis and a cutting angle, and imaging the tip of the optical fiber. The steps include: determining the orientation of the tip of the optical fiber based on imaging; emitting light from a light source, wherein the optical fiber is configured to receive the light emitted from the light source; The method includes the steps of: emitting a characterization light from the tip of an optical fiber; detecting the characterization light with an image sensor; and determining the cutting angle of the optical fiber based on the characterization light and the orientation of the tip of the optical fiber.

[0350]

[0384] Example 7 is a method of Examples 1 to 6, comprising the steps of: providing an optical fiber having a tip characterized by a longitudinal axis and a cutting angle, wherein the step of processing a portion of a fiber spool to form an optical fiber having an output end; imaging the tip of the optical fiber; reducing or minimizing the distance between the tip of the optical fiber and the longitudinal axis by moving the optical fiber on a multi-stage axis; determining the orientation of the tip of the optical fiber based on the imaging; emitting light from a light source, wherein the optical fiber is configured to receive the light emitted from the light source; emitting characterization light from the tip of the optical fiber; detecting the characterization light with an image sensor; and determining the cutting angle of the optical fiber based on the characterization light and the orientation of the tip of the optical fiber.

[0351]

[0385] Example 8 is a method of Examples 1 to 7, wherein the step of aligning the optical fiber to the substrate includes the steps of moving the optical fiber to a rotating station, placing the optical fiber on a rotating stage, fixing the optical fiber on the rotating stage, illuminating the optical fiber on the rotating stage, collecting an initial image of the light-emitting surface of the optical fiber, calculating the rotational misalignment of the optical fiber based on the initial image, rotating the optical fiber on the rotating stage if the rotational misalignment of the optical fiber is not within an acceptable range, repeatedly collecting at least one more additional image of the light-emitting surface of the optical fiber, and releasing the optical fiber if the rotational misalignment of the optical fiber is within an acceptable range.

[0352]

[0386] Example 9 is the method of Examples 1 to 8, wherein the step of aligning the optical fiber to the substrate is to move the optical fiber to a rotating station, to place the first optical fiber on the first rotating stage, and to place the second optical fiber on the second rotating stage. The method includes the steps of: fixing a first optical fiber on a first rotating stage; fixing a second optical fiber on a second rotating stage; collecting initial images of the first light-emitting surface of the first optical fiber and the second light-emitting surface of the second optical fiber; calculating the alignment misalignment based on the initial images; rotating the first optical fiber to a modified position if the alignment misalignment is not within an acceptable range; repeatedly collecting at least one more additional image of the first light-emitting surface of the first optical fiber and the second light-emitting surface of the second optical fiber; and releasing the optical fiber if the alignment misalignment is within an acceptable range.

[0353]

[0387] Example 10 is the method of Examples 1 to 9, wherein the step of aligning the optical fiber to the substrate is to move the optical fiber to a rotating station, to position the optical fiber on a rotating stage, wherein the optical fiber has a cantilevered end, to fix the optical fiber on the rotating stage, and to collect a plurality of images, wherein each of the plurality of images is associated with a different rotational position of the cantilevered end of the optical fiber. The method includes the steps of determining whether multiple images have reached a threshold, calculating the deflection of the cantilevered end of the optical fiber based on the multiple images, which is associated with different rotational positions of the cantilevered end of the optical fiber, and calculating the radius of curvature of the optical fiber based on the deflection of the cantilevered end of the optical fiber.

[0354]

[0388] Example 11 is the method of Examples 1 to 10, wherein the step of removing the optical fiber from the fiber spool and forming the input end of the optical fiber includes the steps of winding up at least a portion of the optical fiber, finding and grasping the output end of the optical fiber, and cutting at least a portion of the optical fiber.

[0355]

[0389] Example 12 is the method of Examples 1 to 11, wherein the step of marking the optical fiber includes the step of transporting the optical fiber coupled to the substrate to a labeling station, and the step of labeling the optical fiber coupled to the substrate.

[0356]

[0390] Example 13 is the method of Examples 1 to 12, wherein the step of coupling the output end of an optical fiber to multiple locations on a substrate includes laser welding.

[0357]

[0391] Example 14 is the method of Examples 1 to 13, further comprising the step of applying a potting agent to each fiber substrate.

[0358]

[0392] Example 15 is the method of Examples 1 to 14, further comprising the step of curing the potting agent.

[0359]

[0393] Example 16 is the method of Examples 1 to 15, wherein the step of processing the portion of the fiber spool includes the step of removing the fiber coating from the portion of the fiber spool.

[0360]

[0394] Example 17 is a method of Examples 1 to 16, in which optical fibers are placed at each of a plurality of locations in order to form an optical fiber array.

[0361]

[0395] Example 18 is the same as the method of Examples 1 to 17, wherein the input end of the optical fiber is configured to receive light from a light source.

[0362]

[0396] Example 19 is the method of Examples 1 to 18, wherein the step of marking the optical fiber includes the step of labeling the optical fiber with an index indicating its position within the optical fiber array.

[0363]

[0397] Example 20 is the same method as in Examples 1 to 19, in which multiple fiber spools are selected and processed in parallel.

[0364]

[0398] Please note that the methods, systems, and devices described above are merely illustrative. Various embodiments may omit, substitute, or add various procedures and components as needed. For example, in a different embodiment, these methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Furthermore, features described in relation to a particular embodiment may be combined in various other embodiments. Various aspects and elements of an embodiment may be combined in a similar manner. Also, please note that, as technology evolves, many elements are illustrative and should not be interpreted as limiting the scope of the invention.

[0365]

[0399] The description includes specific details to ensure a full understanding of the embodiments. However, those skilled in the art will understand that the embodiments can be carried out even without these specific details. For example, well-known processes, structures, and techniques are shown with unnecessary details omitted to avoid obscuring the embodiments. This description provides only exemplary embodiments and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the above description of embodiments provides a practicable explanation for those skilled in the art to carry out embodiments of the invention. Various modifications can be made to the function and arrangement of the elements without departing from the spirit and scope of the invention.

[0366]

[0400] It should also be noted that embodiments may be described as processes shown in flow charts or block diagrams. Each operation may be described as a sequential process, many operations may be performed in parallel or simultaneously. Furthermore, the order of operations may be changed. The process may include additional steps not shown in the diagrams.

[0367]

[0401] While several embodiments have been described, those skilled in the art will understand that various modifications, alternative configurations, and equivalents may be used without departing from the spirit of the invention. For example, the elements described above are merely components of a larger system in which other rules may take precedence over the application of the invention and may otherwise alter its application. Furthermore, several steps may be taken before, during, or after the consideration of the elements described above. Therefore, the above description should not be construed as limiting the scope of the invention.

Claims

1. A method for constructing a fiber array, a) The step of selecting one fiber spool from one or more fiber spools, b) The step of processing a part of the fiber spool to form an optical fiber having an output end, c) The step of placing the substrate in one of several positions, d) The step of aligning the output end of the optical fiber with the substrate, e) The step of coupling the output end of the optical fiber to one of a plurality of positions on the substrate, f) The steps of removing the optical fiber from the fiber spool and forming the input end of the optical fiber, g) The step of marking the optical fiber, Steps c) through g) are repeated for each of the plurality of positions on the substrate, The steps include confirming that the substrate is positioned at each of the plurality of positions, The method, including the method described above.

2. The step of selecting one fiber spool from the one or more fiber spools is, A step of providing an optical fiber presence detection system, A first illumination light source configured to emit light rays along an optical path, A first detector, wherein the first detector is Arranged off-axis with respect to the aforementioned optical path, A step comprising: a first detector configured to detect the presence of light; The steps include arranging the optical fiber along the optical path, The steps include irradiating at least a portion of the optical fiber with the light beam, The steps of generating a refracted ray by refracting light from the ray using at least a portion of the optical fiber, The steps of detecting the optical fiber, at least partially based on the refracted light and using the first detector, The method according to claim 1, including the method described in claim 1.

3. The step of processing a part of the fiber spool to form an optical fiber having an output end is, To form the optical fiber, the steps include drawing a fiber of a certain length from the fiber spool, The steps include transporting the end of the optical fiber from the fiber spool to the stripper, The steps include attaching the optical fiber of a certain length to the stripper, The steps include: removing an arbitrary coating from the optical fiber of a certain length; The method according to claim 1, including the method described in claim 1.

4. A portion of the aforementioned fiber spool is processed to form an optical fiber having an output end, The steps include transporting the optical fiber from the fiber spool to a clean location, The steps include removing coating fragments from the optical fiber of a certain length, The steps include cleaning the optical fiber, The method according to claim 1, including the method described in claim 1.

5. The step of processing a part of the fiber spool to form an optical fiber having an output end is, The steps include transporting the optical fiber of a certain length to a cutting machine, The steps include attaching the optical fiber of a certain length to the cutting machine, The steps include cutting the optical fiber, The steps include removing the optical fiber from the fiber spool, The method according to claim 1, including the method described in claim 1.

6. The step of processing a part of the fiber spool to form an optical fiber having an output end is, The steps of providing an optical fiber having a longitudinal axis and a tip characterized by a cutting angle, The steps include imaging the tip of the optical fiber, The steps include determining the tip of the optical fiber based on the imaging, A step of emitting light from a light source, wherein the optical fiber is configured to receive the light emitted from the light source; The steps include: emitting characteristic evaluation light from the tip of the optical fiber; The steps include detecting the characteristic evaluation light with an image sensor, A step of determining the cutting angle of the optical fiber based on the characteristic evaluation light and the orientation of the tip of the optical fiber, The method according to claim 1, including the method described in claim 1.

7. The step of processing a part of the fiber spool to form an optical fiber having an output end is, The steps of providing an optical fiber having a longitudinal axis and a tip characterized by a cutting angle, The steps include imaging the tip of the optical fiber, The steps include reducing or minimizing the distance between the tip of the optical fiber and the longitudinal axis by moving the optical fiber along multiple axes, The steps include determining the orientation of the tip of the optical fiber based on the image, A step of emitting light from a light source, wherein the optical fiber is configured to receive the light emitted from the light source; The steps include: emitting characteristic evaluation light from the tip of the optical fiber; The steps include detecting the characteristic evaluation light with an image sensor, A step of determining the cutting angle of the optical fiber based on the characteristic evaluation light and the orientation of the tip of the optical fiber, The method according to claim 1, including the method described in claim 1.

8. The step of aligning the optical fiber with the substrate is: The steps include moving the optical fiber to a rotating station, Steps include: positioning the optical fiber on a rotating stage, The steps include fixing the optical fiber on the rotating stage, The steps include irradiating the optical fiber on the rotating stage, The steps include: collecting an initial image of the light-emitting surface of the optical fiber; A step of calculating the rotational position displacement of the optical fiber based on the initial image, If the rotational misalignment of the optical fiber is not within an acceptable range, the optical fiber is rotated on the rotating stage. The steps include repeatedly collecting additional images of the light-emitting surface of the optical fiber, each image being at least one more additional image, If the rotational displacement of the optical fiber is within the allowable range, the optical fiber is released. The method according to claim 1, including the method described in claim 1.

9. The step of aligning the optical fiber with the substrate is: The steps include moving the optical fiber to a rotating station, The steps include: placing the first optical fiber on the first rotating stage, The steps include: placing the second optical fiber on the second rotating stage; The steps include fixing the first optical fiber on the first rotating stage, The steps include fixing the second optical fiber on the second rotating stage, The steps include: collecting initial images of the first light-emitting surface of the first optical fiber and the second light-emitting surface of the second optical fiber; A step of calculating the alignment error based on the initial image, If the aforementioned misalignment is not within the acceptable range, the first optical fiber is rotated to the changed position. The steps include repeatedly collecting at least one additional image of the first light-emitting surface of the first optical fiber and the second light-emitting surface of the second optical fiber, If the misalignment is within the allowable range, the optical fiber is released. The method according to claim 1, including the method described in claim 1.

10. The step of aligning the optical fiber with the substrate is: The steps include moving the optical fiber to a rotating station, A step of placing an optical fiber on a rotating stage, wherein the optical fiber has a cantilevered end; The steps include fixing the optical fiber on the rotating stage, A step of collecting multiple images, wherein each of the multiple images is associated with a different rotational position of the cantilevered end of the optical fiber, The steps include determining whether the multiple images have reached a threshold, The steps include: calculating the deflection of the cantilevered end of the optical fiber based on the aforementioned multiple images, which is associated with different rotational positions of the cantilevered end of the optical fiber; A step of calculating the radius of curvature of the optical fiber based on the deflection of the cantilevered end of the optical fiber, The method according to claim 1, including the method described in claim 1.

11. The steps of removing the optical fiber from the fiber spool and forming the input end of the optical fiber are: The steps of winding up at least a portion of the optical fiber, The steps of finding and grasping the output end of the optical fiber, The steps of cutting at least a portion of the optical fiber, The method according to claim 1, including the method described in claim 1.

12. The method according to claim 1, wherein the step of marking the optical fiber includes the steps of transporting the optical fiber coupled to the substrate to a labeling station and labeling the optical fiber coupled to the substrate.

13. The method according to claim 1, wherein the step of coupling the output end of the optical fiber to a plurality of positions on the substrate includes laser welding.

14. The method according to claim 1, further comprising the step of applying a potting agent to each fiber substrate.

15. The method according to claim 14, further comprising the step of curing the potting agent.

16. The method according to claim 1, wherein processing the portion of the fiber spool includes the step of removing the fiber coating from the portion of the fiber spool.

17. The method according to claim 1, wherein optical fibers are arranged at each of the plurality of positions in order to form the optical fiber array.

18. The method according to claim 1, wherein the input end of the optical fiber is configured to receive light from a light source.

19. The method according to claim 1, wherein the step of marking the optical fiber includes the step of labeling the optical fiber, which includes an index indicating its position within the optical fiber array.

20. The method according to claim 1, wherein multiple fiber spools are selected and processed in parallel.

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