Optical Fiber Sorting Assemblies for Predetermined Sequence Transfer
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Solution Overview
Problem
The challenge is to automatically organize randomly sequenced optical fibers into a predetermined sequence for efficient fiber optic cable manufacturing, particularly for MPO connectors, which require precise and intricate termination processes.
Innovation Solution
A fiber sorting system comprising a first and second assembly, a computing system, and a control application that identifies key combinations to reorder fibers from a random sequence to a predetermined sequence using actuators and machine learning models to achieve precise alignment and organization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual fiber organization is used, then flexibility and adaptability are maintained, but time consumption and labor intensity increase significantly
Solution Approach 1:
The fiber organization system is divided into modular components: a first assembly for holding fibers in initial sequence, a second assembly for receiving organized fibers, and a computing system with control application. This segmentation allows automated high-speed fiber reorganization while maintaining system flexibility through independent modular units that can be configured for different fiber counts and arrangements.
Solution Approach 2:
The control application serves as an intermediary between the physical fiber assemblies and the control mechanisms. It receives images of fiber sequences, processes the data to determine reorganization steps, and sends commands to actuators. This software intermediary enables automated decision-making for fiber reorganization without requiring complex hardwired control logic.
2Loss of time
If automated fiber reorganization is implemented, then time and cost efficiency improve, but system complexity and initial investment increase
Solution Approach 1:
The system captures an image of the fiber sequence at the beginning of the organization process and determines the complete reorganization plan before physical manipulation begins. The control application pre-calculates all necessary actuator movements based on the initial fiber arrangement and the desired predetermined sequence, enabling efficient execution without continuous decision-making during the sorting process.
Solution Approach 2:
The system creates a digital representation (image) of the physical fiber arrangement and manipulates this copy through software algorithms to determine reorganization steps. This virtual modeling allows the system to plan and simulate fiber reorganization without physically moving fibers during the planning phase, reducing mechanical complexity while achieving precise control.
3Manufacturing precision
If precise fiber alignment is achieved, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
The system uses image capture to obtain feedback on the actual fiber sequence and positions. The control application compares the captured sequence against the predetermined sequence, identifies discrepancies, and automatically generates corrective movements. This closed-loop feedback ensures precise fiber alignment while keeping the control system relatively simple through software-based error correction rather than complex mechanical adjustment mechanisms.
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A method organizes fibers. A plurality of fibers is received into a first assembly. An initial sequence of the plurality of fibers in the first assembly is obtained. A set of key combinations is identified from the initial sequence and a predetermined sequence. A second assembly is slid across the first assembly. The set of key combinations is actuated to move the plurality of fibers from the first assembly to the second assembly and order the plurality of fibers in the second assembly in the predetermined sequence.