Fiber End Inspection Optics for Full Connector Face Contamination Detection
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Solution Overview
Problem
Existing fiber optic connector inspection systems struggle to efficiently inspect multiple fibers and alignment pins in a single image, leading to slow inspection processes, potential errors, and inability to detect contamination outside the fiber region, which can degrade connector performance over time.
Innovation Solution
A visual inspection module with a tunable lens, adjustable focal length, and optimized illumination system that captures a wide field of view of the connector end face, including all fibers and alignment pins, using a single image sensor and adjustable illumination pattern to maintain image quality and detect contaminants effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high magnification is used to obtain good image quality on fiber, then image quality is improved, but field of view is limited to only one or a couple of fibers
Solution Approach 1:
The inspection process is segmented into multiple sequential inspections. The mechanical moving system divides the inspection of 12 fibers into at least 3 positions, with each position inspecting a subset of fibers (e.g., 4 fibers simultaneously). This segmentation allows the system to maintain high magnification for good image quality while covering the entire connector end face through multiple staged observations.
2Reliability
If mechanical moving system is used to shift field of view to inspect all fibers, then all fibers can be inspected, but inspection process becomes slow and tedious
Solution Approach 1:
The system employs a dynamic mechanical moving system that automatically shifts the microscope's field of view between multiple positions. Rather than manual shifting, the system dynamically transitions through at least 3 positions to capture images of all 12 fibers. This automated dynamic movement maintains inspection completeness while significantly improving speed and reducing operator burden compared to manual methods.
3Extent of automation
If moving scanning system is used to automatically control microscope movement, then automation is improved, but position and order of fibers may be incorrect causing inspection errors
Solution Approach 1:
The moving scanning system incorporates feedback mechanisms to verify and correct the position and order of fibers during automatic movement. The system captures images at multiple positions and uses this visual feedback to confirm proper alignment and ordering of fibers before completing the inspection. This feedback loop prevents errors that would otherwise occur from misplaced or misordered fiber inspection.
4Extent of automation
If microscope angle is changed to continuously move for inspecting all fibers, then automation is improved, but illumination condition becomes non-repeatable resulting in inconsistent image quality
Solution Approach 1:
The system uses periodic action by returning the microscope to standardized, repeatable illumination conditions at each inspection position. Rather than continuously changing angles without reset, the system periodically re-establishes consistent illumination parameters when transitioning between fiber groups. This periodic reset of illumination conditions ensures that image quality remains consistent and comparable across all 12 fibers, even though the microscope moves between multiple positions.
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 rapid, accurate inspection of all fibers and alignment pins in a single image, reducing errors and ensuring consistent image quality while detecting contaminants across the entire connector end face, thereby improving network installation reliability.
Implementation Method 1
The apparatus includes an illuminator, a lens, and an image sensor. The illuminator directs light onto the connector end face, and the lens focuses the reflected light to form an image on the image sensor.
Implementation Method 2
a lens configured to focus light reflected from the connector end face onto the image sensor
Data Source
AI summary
A visual inspection device and apparatus is disclosed for inspecting fiber ends of a connector by capturing an image of the connector end face, and implementing an image analysis tool for detecting contamination from the captured image. The visual inspection tool includes components for providing a larger field of view to capture the entire connector end face in a single image, and the image analysis tool is able to accurately and efficiently detect contamination from the captured image.