Automatic Injection System for Multi-Bore Ferrule Adhesive Filling
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Solution Overview
Problem
Existing methods for manufacturing ferrule assemblies suffer from low efficiency and inaccurate adhesive injection, affecting the quality and optical performance of the ferrule assembly due to manual adhesive injection.
Innovation Solution
An automatic injection system with two stations is employed to fill the multi-bore ferrule with adhesive before and after optical fiber insertion, using clamps and an injector with visual feedback for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adhesive injection is used, then device complexity is reduced, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The injection system is segmented into two distinct stations: a first adhesive injection station for initial filling and a second adhesive injection station for compensating adhesive loss. This segmentation allows each station to perform a specific function, improving overall productivity while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
The system employs visual feedback mechanisms that enable automatic control of the injection process. The injection amount is determined based on visual feedback signals, allowing the system to self-regulate and compensate for adhesive loss without manual intervention, thereby increasing productivity
2Manufacturing precision
If manual adhesive injection is used, then device complexity is low, but manufacturing precision of adhesive amount is inaccurate
Solution Approach 1:
The system incorporates visual feedback mechanisms where the injection amount is determined based on visual feedback signals. This feedback loop enables precise control of adhesive injection by automatically adjusting the injection parameters, significantly improving manufacturing precision while the automated control handles the complexity
Solution Approach 2:
The first adhesive injection station performs preliminary action by filling the bores with adhesive before optical fiber insertion. This preliminary adhesive application ensures that sufficient adhesive is present initially, and the system is prepared to compensate for any loss during the subsequent fiber insertion process
3Manufacturing precision
If single station adhesive injection is used, then device complexity is low, but manufacturing precision of full filling is insufficient
Solution Approach 1:
The injection process is divided into two sequential stations: the first station performs initial filling of the bores, and the second station provides compensatory injection after optical fiber insertion. This segmentation ensures complete filling by addressing both initial placement and subsequent compensation needs, improving manufacturing precision
Solution Approach 2:
The first adhesive injection station performs preliminary action by filling the bores with adhesive before optical fiber insertion. This preliminary adhesive application ensures that sufficient adhesive is present initially, and the system is prepared to compensate for any loss during the subsequent fiber insertion process
Data Source
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AI summary
An automatic injection system includes: an injector adapted to inject an adhesive into a multi-bore ferrule; a first clamp configured to clamp the multi-bore ferrule so as to hold the multi-bore ferrule at a first adhesive injection station; and a second clamp configured to clamp the multi-bore ferrule so as to hold the multi-bore ferrule at a second adhesive injection station. At the first adhesive injection station, optical fibers are not inserted into the bores of the multi-bore ferrule, and the injector injects the adhesive into the multi-bore ferrule until the bores are fully filled with the adhesive; and at the second adhesive injection station, the optical fibers are inserted into the bores of the ferule, and the injector injects the adhesive into the multi-bore ferrule again so as to compensate the loss of adhesive during inserting the optical fibers. The adhesive may be automatically injected into the bores of the multi-bore ferrule by using the automatic injection system, thereby increasing the efficiency of injecting the adhesive and improves the quality of the ferrule assembly.