Optical Fiber Bobbin Flange Design for Automated Winding
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Solution Overview
Problem
Existing bobbins for winding optical fibers face challenges in automating the winding process due to the generation of crossover wires, which affect transmission loss, and the formation of slits in main flange portions compromises their strength and rigidity, making high-speed winding and full automation difficult.
Innovation Solution
A bobbin design featuring a shallow cutout portion in the main flange portion and a continuous groove portion that guides the optical fiber from the auxiliary winding drum to the main winding drum, preventing crossover wires without deteriorating the strength or rigidity of the flange, allowing for automated winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple circular flange shape is used to start winding, then the structure is simple and easy to manufacture, but crossover wires are generated causing lateral pressure and bending in the optical fiber
Solution Approach 1:
The flange portion is segmented into multiple functional regions: a guide surface for directing the optical fiber, a cutout portion for the fiber to pass through, and a groove portion for guiding the fiber along a predetermined path. This segmentation eliminates crossover wires while maintaining manufacturing simplicity.
Solution Approach 2:
The groove portion acts as an intermediary structure that guides the optical fiber from the cutout portion to the winding drum surface along a predetermined path, preventing the fiber from crossing over and overlapping with itself.
2Object-generated harmful factors
If a slit is formed in the main flange portion to guide the optical fiber, then the fiber can be guided without crossover, but the strength and rigidity of the flange portion deteriorates
Solution Approach 1:
Instead of forming a complete slit through the entire flange, a shallow cutout portion is created with a depth that does not reach the outer peripheral surface of the winding drum. This local modification guides the fiber while preserving the overall strength and rigidity of the flange portion.
Solution Approach 2:
The cutout portion extends only partially through the flange thickness, providing sufficient guidance for the optical fiber while avoiding complete penetration that would compromise structural integrity. The groove portion is formed only in the inner surface where fiber guidance is needed.
3Object-generated harmful factors
If a slit is formed in the main flange portion, then fiber guidance is improved, but the rigidity decreases making high-speed winding difficult
Solution Approach 1:
The flange portion maintains its full thickness and rigidity in most areas, with only a shallow cutout and surface groove formed where fiber guidance is required. This localized modification preserves the overall structural stability for high-speed winding operations.
4Object-generated harmful factors
If manual work is used to reel and wind the optical fiber through a narrow hole, then crossover wires can be avoided, but full automation becomes difficult and work efficiency is limited
Solution Approach 1:
The groove portion and cutout portion are designed to automatically guide the optical fiber along a predetermined path without requiring manual intervention. The fiber self-aligns and self-guides through the cutout and along the groove, enabling full automation of the winding process.
Data Source
AI summary
A bobbin for winding an optical fiber includes a main winding drum having a cylindrical shape, an auxiliary flange portion that is provided on at least one of a first end and a second end of the main winding drum in an axis direction of the main winding drum, a first main flange portion that has a larger diameter than the external diameter of the auxiliary flange portion and that is provided on the main winding drum to face the auxiliary flange portion, a second main flange portion that is provided on the main winding drum to face the first main flange portion, and an auxiliary winding drum that is provided between the first main flange portion and the auxiliary flange portion.