Fiber Optic Ferrule Offset Measurement Without Test Ferrule Rotation
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Solution Overview
Problem
Existing methods for determining core-to-ferrule offsets in fiber optic connectors require physical rotation of the connector, which is costly, complex, and time-consuming, making them unsuitable for high-throughput manufacturing environments.
Innovation Solution
A non-contact imaging method using a reference ferrule as an optical gauge block to align and measure the core-to-ferrule offset without rotating the test ferrule, employing profile imaging modules and a core imager to capture and analyze images from multiple angles, allowing precise determination of the offset vector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical rotation of the connector is used to determine core-to-ferrule offsets, then measurement accuracy can be achieved, but measurement time and system complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical rotation system with an optical imaging system. Instead of physically rotating the connector to multiple positions, the invention uses profile imaging modules to capture images of the ferrule from multiple angular positions simultaneously, and uses image processing to calculate the offset. This substitution of mechanical motion with optical measurement achieves the same measurement accuracy without the time penalty of physical rotation.
Solution Approach 2:
The invention creates optical copies (images) of the ferrule profile at multiple angular positions and processes these copies to determine the offset. By capturing and analyzing multiple images rather than physically moving the component through multiple measurement positions, the system achieves accurate offset determination while eliminating the time-consuming mechanical rotation process.
2Measurement precision
If physical rotation of the connector is used to determine core-to-ferrule offsets, then measurement accuracy can be achieved, but system complexity and cost increase
Solution Approach 1:
The patent eliminates complex mechanical rotation mechanisms by substituting them with a stationary optical imaging system. The profile imaging modules remain fixed while using optical methods to capture ferrule profiles from multiple effective angles, thereby reducing mechanical complexity while maintaining measurement accuracy through image processing algorithms.
Solution Approach 2:
The invention introduces image processing algorithms as an intermediary between the optical capture and the offset determination. These computational methods process the captured images to extract precise ferrule profile information and calculate offsets, replacing the need for complex mechanical positioning systems and simplifying the overall measurement apparatus.
3Measurement precision
If physical rotation of the connector is used to determine core-to-ferrule offsets, then comprehensive measurement data can be obtained, but throughput decreases
Solution Approach 1:
By replacing sequential mechanical rotation with simultaneous optical imaging from multiple angles, the system captures all necessary measurement data in a single measurement cycle rather than requiring multiple sequential rotations. This dramatically increases throughput while maintaining the ability to determine complete offset vectors through image processing.
Solution Approach 2:
The system performs preliminary capture of all necessary profile images simultaneously before any processing occurs. By having all angular position data captured at once rather than sequentially during rotation, the measurement process is decoupled from mechanical motion, enabling high-speed operation that maintains measurement completeness while increasing productivity.
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 accurate and efficient measurement of core-to-ferrule offsets with sub-nanometer precision without physical rotation, reducing measurement time and cost while maintaining high throughput.
Implementation Method 1
capturing a plurality of images of a reference ferrule including a first core image and a first plurality of profile images... wherein the first plurality of profile images are capture by profile imaging modules
Implementation Method 2
each profile image of the first plurality of profile images including a second image element corresponding to the cylindrical shaped outer surface of the reference ferrule
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A method, system, and computer program product for determining a core-to- ferrule offset of a ferrule for a fiber optic connector, A reference ferrule is physically aligned with a core imager by positioning the reference ferrule so that edges of the reference ferrule in a plurality of profile images are aligned with fiducial markers in the images. The reference ferrule is incrementally rotated about its longitudinal center access, a core image captured at each rotational angle, and a reference core-to-ferrule offset determined based on the core images. A test ferrule is physically aligned with the core imager by positioning the test ferrule so that edges of the test ferule are aligned with the edges of the reference ferrule in a plurality of profile images. The core-to-ferrule offset of the test ferrule is then determined based on an offset between the test and reference cores in a composite core image.