Helix Adjustment for Connector Positioning on Tapered Assemblies

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Solution Overview

Problem

The precise placement of connectorized ends in optical fiber cables is challenging due to deviations in component dimensions, leading to significant positional errors over long cable lengths, requiring labor-intensive field splicing and potential environmental exposure.

Innovation Solution

A method and system for preparing bundled optical fiber cables by monitoring the dimensions of subunits and central members to adjust the winding rate, ensuring accurate positioning of connectorized ends without altering the line speed, using a payoff reel, strander, and monitoring system to account for deviations in helical length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If subunits are wound around a central member to form a bundled cable, then the cable structure is formed and production is enabled, but deviations in component dimensions cause significant positional errors in connectorized ends over long cable lengths

Engineering Contradiction:

Improveproduction rateVSAvoidpositioning accuracy of connectorized ends

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by measuring the actual dimensions of subunits and central members before winding, and pre-calculating the adjusted winding rate to compensate for dimensional deviations. This allows the connectorized ends to be positioned accurately at desired locations along the cable before production begins, eliminating the need for field splicing while maintaining production efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by using a monitoring system to measure actual dimensions of components during production, then using this measured data to dynamically adjust the winding rate. This closed-loop control ensures that despite variations in component dimensions, the connectorized ends are positioned with high accuracy at predetermined locations along the cable length.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If field splicing is performed to correct connectorized end positions, then positioning accuracy is improved, but labor intensity increases and environmental exposure risks arise

Engineering Contradiction:

Improvepositioning accuracy of connectorized endsVSAvoidlabor intensity and operational complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent eliminates field splicing by performing preliminary positioning calculations and adjustments during the manufacturing process itself. The winding rate is adjusted based on measured component dimensions to ensure connectorized ends are positioned accurately at desired locations before the cable leaves the factory, removing the need for subsequent field interventions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing system performs self-correction by automatically measuring component dimensions and adjusting winding parameters without requiring manual field splicing operations. The system serves itself by detecting dimensional variations and compensating through automated winding rate adjustment, eliminating labor-intensive corrective operations.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If the winding rate is adjusted to compensate for dimensional deviations, then positioning accuracy is improved, but the complexity of the production system increases

Engineering Contradiction:

Improvepositioning accuracy of connectorized endsVSAvoidcomplexity of monitoring and control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a feedback-based control system where a monitoring system measures actual dimensions of subunits and central members, then feeds this information to a controller that adjusts the winding rate accordingly. This automated feedback loop achieves high positioning accuracy while keeping the system relatively simple by using direct measurement and proportional adjustment rather than complex multi-variable control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex mechanical adjustment mechanisms with a monitoring and control system that uses measurements and automated winding rate adjustment. Instead of requiring complex mechanical devices to physically adjust component dimensions or positions, the system uses sensing and control to achieve the same positioning accuracy through software-based winding rate modification.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11662534B2Online helix adjustment to control connector location on preconnectorized tapered assemblies

Publication Date: 2023.05.30 CORNING RES & DEV CORP

AI summary

Embodiments of the disclosure relate to a method of preparing a bundled cable. In the method, a plurality of subunits is wound around a central member in one or more layers of subunits to form the bundled cable. For a section of the central member, each layer of subunits has a pitch over which a subunit of the layer of subunits makes one revolution around the section of the central member and a length of the subunit required to make the one revolution. The subunits are configured to have a nominal helical length equal to the ratio of a nominal length to a nominal pitch. Further, in the method, a measurement of the bundled cable is monitored, and a winding rate of the plurality of subunits is adjusted based on the measurement in order to account for deviations from the nominal helical length.