High-Port Optical Cross Connect With Probe-Beam MEMS Alignment
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Solution Overview
Problem
Existing optical cross connect systems face challenges in scaling to high port counts due to limitations in modularity, redundancy, manufacturability, and high radix with low loss, as well as reliability concerns and high costs associated with deploying large devices at full capacity, which are not cost-effective and can become single points of failure.
Innovation Solution
A novel approach to active alignment using smaller arrays of elements with high mechanical stability perpendicular to light propagation, allowing for modular subcomponent design, independent manufacturing and assembly, and in-service servicing, with dedicated probe paths for real-time angular alignment compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If optical cross connect systems are scaled to high port counts using traditional optical bench technology, then the port count and switching capacity increase, but the device complexity, manufacturing difficulty, and cost increase significantly
Solution Approach 1:
The optical cross connect is divided into multiple independent subassemblies, each containing a subset of optical components (collimators, mirrors, detectors). These subassemblies can be manufactured separately and then integrated, reducing the complexity of manufacturing the entire system at once and enabling modular scaling to high port counts
Solution Approach 2:
The patent transitions from traditional two-dimensional optical bench mounting to a three-dimensional arrangement where subassemblies are stacked vertically with optical propagation regions between them. This vertical dimension enables high port count scaling without proportionally increasing the horizontal footprint and manages system complexity through layered modular architecture
2Quantity of substance
If large optical cross connect devices are deployed at full capacity, then the switching capacity is maximized, but the cost-effectiveness decreases and reliability concerns arise as single points of failure
Solution Approach 1:
By segmenting the optical cross connect into multiple subassemblies, the system eliminates the single point of failure problem. If one subassembly fails, the others continue to operate independently, maintaining partial switching capacity and improving overall system reliability while still achieving high total port count
Solution Approach 2:
The system enables dynamic scaling where subassemblies can be added or removed based on capacity requirements. This allows the system to start with fewer subassemblies and scale up incrementally, improving cost-effectiveness by deploying only the necessary capacity rather than building the full system at once
3Stability of the object's composition
If traditional optical bench designs are used, then mechanical stability is achieved in the direction of propagation, but the alignment complexity and manufacturing precision requirements increase
Solution Approach 1:
Each subassembly includes detectors that provide feedback on the alignment status of optical components. This feedback mechanism enables active alignment control, where misalignments are detected and corrected, reducing the stringency of initial manufacturing precision requirements while maintaining operational stability
Solution Approach 2:
The system performs self-alignment through the feedback from detectors within each subassembly. The alignment control is automated and does not require external intervention, allowing the system to compensate for manufacturing tolerances automatically and reducing the need for high-precision manual alignment during assembly
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 scalable, cost-effective, and reliable high port count optical cross connects by simplifying component design, supporting in-service maintenance, and ensuring signal integrity through active alignment, overcoming limitations of traditional optical bench technologies.
Implementation Method 1
an optical cross connect includes a plurality of subassemblies each including either an array of collimators and an array of adjustable mirrors
Implementation Method 2
an array of collimators and an array of adjustable mirrors, wherein the plurality of subassemblies are configured to modularly scale a size of the optical cross connect
Implementation Method 3
one or more probe ports configured to support an alignment signal for active alignment control
Data Source
Figure 1~2
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AI summary
An optical cross connect (20) includes a plurality of modular subassemblies (10) each including one or more of a fiber collimator array (50, 52) and a Micro-ElectroMechanical Systems (MEMS) mirror array (54, 56), arranged relative to one another with an optical propagation region (22) in between. At least one fiber collimator array (50, 52) comprises probe ports (16) configured to emit alignment beams. Detectors (120, 412), integrated within the MEMS mirror arrays (54, 56), receive the alignment beams and provide positional data for active alignment. Control circuitry performs bulk alignment by coarsely aligning each fiber collimator array (50, 52) to its corresponding MEMS mirror array (54, 56), and further performs MEMS-to-MEMS alignment by measuring angular offsets and applying tilt corrections. An end-to-end continuity check is optionally conducted by transmitting a test beam between collimator arrays (50, 52). The modular design supports scaling beyond 1000 ports, redundancy, and in-service real-time alignment.