Optical Element Cleaver Using Image Recognition for Splice-Accurate Positioning
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Solution Overview
Problem
Existing methods for cleaving and splicing optical fibers are often manual, inaccurate, and irreproducible, requiring manual alignment and transfer of optical elements, which leads to loss of reference alignment and inaccurate positioning of cleaves and splices.
Innovation Solution
An automated apparatus using image recognition and digital signal processing to accurately position a cleave unit relative to a splice or other reference feature in an optical assembly, allowing for precise and reproducible cleaving and splicing without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning and alignment methods are used for cleaving and splicing optical fibers, then the process can be performed with simple equipment, but the accuracy and reproducibility of cleave positioning relative to splice locations deteriorates
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated system that uses image recognition to locate splice positions and a translation unit with motor control to automatically position the cleave blade at the desired distance from the splice, eliminating manual alignment errors
Solution Approach 2:
The system performs self-alignment by automatically capturing images, processing them to locate splice positions, calculating the required translation distance, and executing the positioning without operator intervention, making the process reproducible and accurate
2Manufacturing precision
If manual transfer of optical elements between cleaver and splicer is performed, then the apparatus can be simpler and separate, but the reference alignment is lost and positioning accuracy deteriorates
Solution Approach 1:
The patent combines the cleaver, splicer, and translation unit into a single integrated apparatus, allowing the optical element to remain in position while the cleave blade is translated to the correct location, thereby maintaining reference alignment throughout the process
Solution Approach 2:
The translation unit acts as an intermediary mechanism that moves the cleave blade relative to the optical element without requiring manual handling or transfer of the element itself, preserving the established reference alignment
3Manufacturing precision
If automated image recognition and translation control are implemented, then the positioning accuracy and reproducibility improve, but the device complexity and cost increase
Solution Approach 1:
The patent replaces complex manual alignment procedures with automated image recognition and motor-controlled translation, using software-based positioning calculations that simplify the control system while maintaining high precision
Solution Approach 2:
The system creates a digital representation of the optical element through image capture, processes this copy to locate splice positions, and uses the information from this digital model to control the physical cleave positioning, separating the measurement and control functions from the physical manipulation
Data Source
AI summary
Apparatus and methods are described herein for cleaving an optical element at a defined distance from a splice (or other reference point/feature) of the optical element within a desired precision and/or accuracy. In some embodiments, a method includes receiving an indication of a location of a feature in an intermediate optical assembly visible within an image of the intermediate optical assembly. The feature can be for example, a splice. A position of the intermediate optical assembly is translated relative to a cleave unit based on the indication. After translating, the intermediate optical assembly, the intermediate optical assembly is cleaved to form an optical assembly that has an end face at a location disposed at a non-zero distance from the location of the feature. In some embodiments, the location of the feature can be determined with an image recognition system.