Dynamic Caterpuller for Buffer Tube EFL Control
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Solution Overview
Problem
Conventional buffer tube manufacturing processes deform small-diameter tubes due to high mechanical forces, especially when the tubes are still soft after extrusion, as they rely on direct contact methods that cannot effectively control excess fiber length without causing deformation.
Innovation Solution
A dynamic caterpuller system using a high-speed water stream to generate an accelerating force on the buffer tube, allowing for EFL adjustment without direct mechanical contact, which also cools and controls the tube's temperature, replacing traditional clinching caterpullers to prevent deformation and maintain tube shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a clinching caterpuller with belts is used to tension the buffer tube, then excess fiber length can be controlled, but the buffer tube gets deformed when forces are too high and the tube is still soft
Solution Approach 1:
The patent replaces the traditional mechanical belt-based caterpuller system with a water stream-based dynamic caterpuller system. High-speed water streams are directed against the buffer tube to provide the necessary tensioning force through fluid dynamic pressure rather than mechanical contact, thereby controlling excess fiber length without deforming the soft buffer tube
Solution Approach 2:
The invention uses hydraulic principles by employing high-speed water streams to apply force to the buffer tube. The water streams create dynamic pressure that tensions the tube and controls fiber length without the mechanical contact and deformation caused by traditional belt systems
2Manufacturing precision
If direct contact mechanical forces are applied to control EFL, then fiber length can be adjusted, but the tube surface may get damaged or deformed
Solution Approach 1:
The patent substitutes mechanical belt contact with fluid dynamic contact using high-speed water streams. This replacement eliminates direct mechanical friction and contact pressure that cause surface damage, while still providing the necessary force to control excess fiber length through water pressure
3Manufacturing precision
If high forces are applied by belts to tension the tube, then EFL control is achieved, but the buffering process becomes complex and requires close contact
Solution Approach 1:
The invention simplifies the buffering process by using water streams instead of complex mechanical belt systems. The hydraulic approach requires no complex alignment, contact pressure control, or synchronization mechanisms, thereby reducing device complexity while maintaining EFL control capability
Solution Approach 2:
The water stream acts as an intermediary between the propulsion system and the buffer tube, transferring force without requiring direct mechanical contact. This intermediary approach simplifies the overall system by eliminating the need for complex mechanical interfaces and close contact requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of small-diameter buffer tubes with precise excess fiber length control and reduced deformation, achieving a round cross-section with low ovality, suitable for narrower cables and improved mechanical performance.
Implementation Method 1
The acceleration of the tube is achieved by a high-speed water stream along the buffer tube that influences the tube via friction between the surface of the tube and the water of the water stream
Implementation Method 2
the water may be used to cool the buffer tube, and may be temperature controlled to facilitate a desired rate of cooling
Data Source
AI summary
A manufacturing line includes an extruder and a dynamic caterpuller system located after the extruder along the manufacturing line. During manufacturing, a fiber optic assembly is produced, where the fiber optic assembly includes a tube containing at least on optical fiber. The tube is extruded via the extruder and loaded via the dynamic caterpuller, which includes a closed pipe through which passes a liquid and the fiber optic assembly. The flow rate of the liquid is different than the speed of the fiber optic assembly through the pipe such that drag is imparted on the fiber optic assembly by the liquid.