Optical Fiber Splice-On Connector Subunit Mass Production
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Solution Overview
Problem
Mass production of subunits for mechanical splice-on (SC, FC, LC) APC connectors requires precise control over the radial orientation and length of fiber stubs, which is challenging with existing methods, especially in achieving consistent results within acceptable tolerances.
Innovation Solution
An apparatus and method involving a magazine with slots, a cleaver, and a fiber holder that allows for sequential and precise cleaving and pulling of fiber stubs within the subunits without altering their radial orientation, followed by epoxy curing and polishing, ensuring uniformity in the subunits produced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass production of subunits is implemented, then productivity increases, but manufacturing precision of fiber stub orientation and length deteriorates
Solution Approach 1:
The production process is segmented into discrete steps (cleaving, pulling, positioning) that can be individually controlled and optimized. The magazine is segmented into multiple slots that can be processed sequentially, allowing mass production while maintaining precision through standardized repeatable operations in each segment.
Solution Approach 2:
The apparatus uses self-aligning features where the fiber stub automatically positions itself during the cleaving and pulling process. The cleaver and fiber holder are designed to work together in a fixed geometric relationship that inherently maintains radial orientation without requiring active control or measurement during operation.
2Manufacturing precision
If precise control of fiber stub radial orientation is achieved, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The complex active control systems for maintaining radial orientation are extracted from the mass production process. Instead, a simple fixed geometric relationship between the cleaver and fiber holder is used, where precision is achieved through the inherent stability of the mechanical setup rather than complex active control mechanisms.
Solution Approach 2:
Instead of using complex mechanisms to actively maintain radial orientation during processing, the invention inverts the approach by designing the cleaver and fiber holder in a fixed geometric relationship where precision is achieved through the stability and repeatability of the fixed setup rather than active control.
3Manufacturing precision
If precise control of fiber stub length is achieved, then manufacturing precision improves, but production time increases
Solution Approach 1:
The fiber stub is pre-positioned and pre-aligned before the pulling operation begins. The cleaver is positioned in advance at the exact location where the stub needs to be cleaved, and the fiber holder is pre-positioned to grasp the stub at the correct point. This preliminary setup eliminates the need for measurement and adjustment during the actual pulling operation, achieving precision without time loss.
Solution Approach 2:
The cleaving and pulling operations are performed in continuous sequence without interruption or repositioning. The magazine is designed to present multiple subunits in succession, allowing the apparatus to maintain continuous operation with each subunit processed in a single uninterrupted cycle, thereby achieving high precision length control without increasing production time.
Data Source
AI summary
The invention provides and apparatus and method for mass producing a plurality of fiber optic mechanical splice-on connector subunits. The apparatus utilizes a magazine detachably mounted on a frame and containing a plurality of slots. The slots contain a plurality of subunits, each of which includes a ferrule assembly carrying a fiber stub coated in uncured epoxy. The slots are moved through a cleaving zone on the apparatus defined by the area between a cleaver and fiber holder, wherein the fiber stubs are cleaved and then pulled so the portion of the fiber stub extending from the ferrule assembly to the cleaved end has a specified length. After cleaving and pulling all the fiber stubs in the magazine, the magazine is detached from the apparatus and moved to an oven wherein the epoxy is cured. After cooling, the subunits and removed from the magazine to provide a plurality of subunits, each containing a cleaved fiber stub securely oriented therein.