Fiber Routing Layouts Using Pre-Tested Optical Fibers
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Solution Overview
Problem
Existing fiber optic connector systems face inefficiencies in assembly and manufacturing due to the lack of pre-processed and pre-tested optical fibers, leading to increased costs and discarded devices.
Innovation Solution
Pre-manufacturing optical circuit layouts using pre-processed and pre-tested optical fibers, which are robotically routed on flexible substrates such as polymeric films, allowing for efficient assembly by aligning fiber ends with multi-dimensional connection locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical fibers are processed and tested after assembly in the optical connection device, then the assembly process is simpler, but manufacturing costs increase and devices are discarded due to failed optical performance
Solution Approach 1:
The patent applies preliminary action by pre-processing (connectorization, ferrulization, polishing, shaping) and pre-testing optical fibers before routing them on the substrate. This allows optical performance verification to occur prior to final assembly, enabling early detection of defective fibers and preventing waste of entire optical connection devices. The pre-processed fiber ends are then staged in multi-dimensional arrangements that correspond to connection locations, maintaining assembly simplicity while reducing manufacturing costs and device discard rates.
2Productivity
If optical fibers are pre-routed and pre-positioned on substrates, then assembly efficiency improves, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into distinct stages: pre-processing of optical fibers, routing on flexible substrates using robotic devices guided by digital maps, and final assembly. This segmentation allows complex pre-positioning operations to be performed separately using automation, improving assembly efficiency while managing manufacturing complexity through process breakdown and specialized equipment for each stage.
Solution Approach 2:
The patent replaces manual mechanical routing and positioning operations with robotic devices controlled by digital maps. This substitution automates the complex task of routing optical fibers along precise paths and positioning pre-processed ends in multi-dimensional arrangements, significantly improving assembly efficiency while the digital mapping system manages and simplifies the overall manufacturing process complexity.
3Device complexity
If manual assembly methods are used for optical fibers, then equipment costs are lower, but assembly time and labor intensity increase
Solution Approach 1:
The patent implements self-service by having the robotic device automatically route optical fibers and position them according to digital maps without requiring complex manual intervention. The system serves itself by using pre-processed fibers that are ready for routing, eliminating the need for complex alignment and processing equipment during assembly, thus reducing equipment complexity while maintaining high assembly speed and low labor intensity.
Data Source
AI summary
The present disclosure relates to fiber management systems and methods for facilitating assembling fiber optic devices in an efficient manner by allowing pre-processed and tested optical fibers to be pre-routed on a substrate prior to installation in their corresponding fiber optic devices.