Modular Active Optical Cable for Harsh Environment Interconnects
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Solution Overview
Problem
Existing optical interconnect solutions fail to provide viable solutions for harsh environments in aerospace, military, and industrial applications, as they lack integration of multiple data types, electrical power distribution, and robust health monitoring capabilities, and are not suitable for field maintenance in contaminated environments.
Innovation Solution
An active optical cable apparatus with optoelectronic modules at each end, featuring optical and electrical connections, power regulation, and control electronics that enable simultaneous transmission of data and power, health monitoring, and firmware upgrades, using ruggedized connectors and shielding to withstand harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical cables are used for interconnects in harsh environments, then ruggedized connectors and flexibility in integrating different data types are achieved, but susceptibility to electromagnetic interference and large cable size occur
Solution Approach 1:
The cable is divided into separate electrical conductors and optical fibers, allowing each type of transmission medium to handle specific data types. This segmentation enables the system to leverage the immunity of optical fibers to electromagnetic interference while using electrical conductors for power distribution and certain data types that require electrical connections.
Solution Approach 2:
The hybrid cable assembly is designed to perform multiple functions simultaneously: optical data transmission, electrical power distribution, and electrical data transmission. This multi-functionality allows a single cable assembly to replace what would traditionally require multiple separate cables, achieving versatility in integrating different data types while maintaining immunity to electromagnetic interference for the optical portion.
2Use of energy by moving object
If electrical cables are used for interconnects, then the ability to distribute electrical power is achieved, but large cable size and weight occur
Solution Approach 1:
The cable assembly segments power distribution functionality into a dedicated electrical conductor portion, separate from the optical data transmission fibers. This allows the optical fibers (which are extremely lightweight) to handle data transmission while only the necessary electrical conductors are included for power distribution, reducing overall cable weight compared to using thick electrical cables for all functions.
Solution Approach 2:
The patent utilizes high-voltage, low-current electrical power transmission through the electrical conductors, which allows for more efficient power distribution with thinner conductors. This parameter change (from low-voltage/high-current to high-voltage/low-current) reduces the cross-sectional area and weight of the electrical conductors required for power distribution.
3Speed
If QSFP active optical cable is used, then high bandwidth data transmission is achieved, but lack of electrical power distribution and ruggedized connector compatibility occur
Solution Approach 1:
The hybrid cable assembly integrates QSFP-compatible optical interfaces for high-bandwidth data transmission while simultaneously incorporating electrical conductors for power distribution and electrical data transmission. The ruggedized connector design provides universal compatibility with military and industrial standards (such as M39012, M39029, M39030), allowing the same cable assembly to serve multiple functions and interface types.
Solution Approach 2:
The patent merges the QSFP optical interface with electrical power and data transmission capabilities into a single hybrid cable assembly. The ruggedized connector combines optical and electrical contacts in one interface, enabling simultaneous optical data transmission and electrical power distribution through the same physical connection point.
4Speed
If existing optical interconnect solutions are used, then high bandwidth transmission is achieved, but lack of health monitoring and built-in test capabilities occurs
Solution Approach 1:
The hybrid cable assembly incorporates monitor photodetectors that continuously monitor the optical signal quality and provide feedback on the health of the optical connection. These monitor photodetectors detect parameters such as optical power levels and signal integrity, providing real-time information about the condition of the optical link without interfering with the primary data transmission channels.
Solution Approach 2:
The electrical conductors in the hybrid cable assembly serve dual purposes: transmitting electrical data and providing health monitoring capabilities. The electrical interface includes built-in test functions that can detect connector integrity, contact resistance, and other electrical parameters, providing comprehensive health monitoring for both optical and electrical portions of the cable 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
The apparatus allows for reliable transmission of multiple data types and electrical power over independent channels, with built-in health monitoring and firmware upgrade capabilities, ensuring operation in harsh environments and facilitating field maintenance.
Implementation Method 1
The optical engine may have zero or more optical emitters; zero or more photodetectors; electronics for driving the optical emitters; electronics for receiving signals from the photodetectors
Implementation Method 2
zero or more photodetectors; electronics for receiving signals from the photodetectors
Data Source
AI summary
Apparatus enabling modular implementation of active optical cable (AOC) with multiple integrated functions including: integration of different types of data on the AOC via media conversion; distribution of electrical power over the AOC; electrical multiplexing data channels for optical fibers; integration of voltage regulators enabling AOC operation at different supply voltages; integration of voltage regulators to provide stable, low noise power source; ruggedized, blind-mateable electrical connectors; integration of electronics and optoelectronics inside a connector backshell; implementation of health monitoring and test channel enabling monitoring, test, and control of both ends of the AOC and monitoring and control of upstream systems and components; and enabling a form, fit, function replacement of existing electrical cables to improve SWaP, electromagnetic interference resiliency, length-bandwidth product, electromagnetic pulse resistance, signal integrity, system reliability, testability and maintenance. AOCs are customized for different connectors, pin-outs, electrical data combinations, power distribution and power supplies with minimal redesign/requalification.