Fibre Optic Sensor Assembly Using Temporary Stack
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Solution Overview
Problem
Existing fibre optic sensor manufacturing methods are complicated by the use of fused-fibre couplers, which cause signal loss and complicate the manufacturing process, particularly in high-volume applications like seismic surveying, where minimizing fibre fusion splices and couplers is desirable.
Innovation Solution
A method involving the assembly of a temporary stack of sensor elements using a compression device without through-going elements, allowing for the coiling of optical fibre onto completed accelerometer elements without fibre fusion splices, and subsequent disassembly and mounting of sensor units for simplified production and mechanical calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fused-fibre couplers are used to connect individual fibre-optic sensor units, then the sensors can be assembled and connected, but signal loss occurs and the manufacturing process becomes complicated
Solution Approach 1:
The patent removes the fused-fibre coupler component from the system entirely. Instead of using couplers to connect sensor units, the invention uses a continuous optical fibre that is coiled directly onto each sensor element within the stack, eliminating the need for intermediate coupling components and their associated signal losses.
Solution Approach 2:
The patent segments the sensor assembly into a stack of individual sensor elements that can be independently processed. Each sensor element is a complete functional unit that can be manufactured and tested separately before being assembled into the final sensor package, allowing for modular manufacturing and calibration.
2Ease of manufacture
If fused-fibre couplers are used to connect individual fibre-optic sensor units, then the sensors can be assembled, but the manufacturing process becomes complicated
Solution Approach 1:
The patent combines multiple operations into a single integrated process. The optical fibre is coiled onto multiple sensor elements in sequence during one continuous operation, rather than requiring separate coupling operations for each sensor connection. This merging of operations simplifies the overall manufacturing process.
Solution Approach 2:
The patent performs preliminary actions by pre-assembling the stack of sensor elements with their respective fibre coils before final integration. The continuous optical fibre is routed and coiled onto each sensor element in advance, allowing for pre-calibration and pre-assembly verification before the complete sensor package is finalized.
3Device complexity
If a continuous optical fibre is coiled onto sensor elements in a stack, then the use of couplers is eliminated, but the sensor elements must be assembled without through-going elements
Solution Approach 1:
The patent introduces a temporary stack assembly structure as an intermediary device. This temporary structure holds the sensor elements in place during the fibre coiling operation, allowing for precise fibre routing onto each element without requiring through-going mounting elements. The temporary stack can be removed after assembly, leaving the sensor elements properly positioned.
4Manufacturing precision
If sensor units are assembled before coiling the optical fibre, then mechanical calibration can be performed, but the assembly process requires temporary holding structures
Solution Approach 1:
The patent employs a temporary stack structure that is designed for single-use during the manufacturing process. This temporary assembly fixture holds the sensor elements in the correct configuration during fibre coiling and calibration, then is discarded or reused as a simple fixture. The temporary nature of this structure allows for easy modification and removal without affecting the final sensor product.
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
This method simplifies the manufacturing process, reduces signal loss, and allows for efficient assembly of multi-unit fibre optic sensors, enabling reliable and efficient production of fibre optic sensors for seismic applications.
Implementation Method 1
the stack is held together by compression using a compression device
Implementation Method 2
A continuous optical fibre is coiled onto the two or more sensor elements so as to form multiple sensor units
Data Source
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AI summary
There is provided a method for providing a fibre optic sensor (400). A temporary stack (100) including two or more sensor elements (10A-C) is assembled. A continuous optical fibre (6) is coiled onto the two or more sensor elements (10A-C) on the stack so as to form multiple sensor units (1A-C, 2A). The temporary stack (100) is disassembled to liberate the sensor units (1A-C, 2A) from the stack and to allow rearrangement of the sensor units (1A-C, 2A). The sensor units (1A-C, 2A) are subsequently mounted in a mounting structure (7) so as to provide a fibre optic sensor (400) including multiple sensor units (1A-C, 2A). A corresponding stack (100) is also provided.