Optical Module for Industrial Plug-in Connectors
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Solution Overview
Problem
Industrial fiber optic connectors are sensitive to environmental influences such as dirt, dust, shock, and vibration, and require precise alignment for effective signal transmission, which is challenging to maintain, especially in modular systems with larger tolerances.
Innovation Solution
A reversible module with a fiber optic connector and adapter system that uses spherical lenses for beam expansion and alignment, allowing for contact-free signal transmission through an air interface, and can accommodate different connector types like FC, LC, or ST, with a holding frame for secure fixation in the industrial connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber optic connectors are coupled with precise alignment, then signal transmission quality is improved, but device complexity and difficulty of assembly increase
Solution Approach 1:
The patent introduces an adapter as an intermediary component between fiber optic connectors. The adapter contains alignment features (alignment pins, alignment grooves) that mediate the coupling process, automatically aligning the fiber end faces without requiring manual precision alignment. This mediator absorbs the alignment complexity, allowing simple plug-and-connect operation while maintaining high signal transmission quality.
Solution Approach 2:
The connector design incorporates self-aligning features where the alignment pins and grooves automatically position the fiber end faces correctly when connectors are mated. The system performs its own alignment function without external intervention, eliminating the need for complex alignment tools or skilled assembly operations while ensuring precise end-face alignment for optimal signal transmission.
2Ease of repair
If fiber optic connectors are made reversible for replacement, then ease of repair is improved, but reliability under vibration and shock deteriorates
Solution Approach 1:
The patent employs a dynamic locking mechanism that adapts to environmental conditions. The reversible latch system maintains secure engagement during normal operation and under vibration/shock conditions, yet allows intentional release for replacement. The locking mechanism responds dynamically to insertion force and maintains constant engagement pressure, providing both stability during use and ease of replacement when needed.
Solution Approach 2:
The connector design incorporates pre-engineered locking features that provide beforehand security against vibration and shock. The reversible latch mechanism is designed with sufficient engagement strength to prevent accidental disconnection under environmental stress, while still allowing controlled release. This beforehand cushioning ensures reliable connection during operation without sacrificing replaceability.
3Ease of manufacture
If modular connector systems are used with larger tolerances, then ease of manufacture is improved, but alignment precision deteriorates
Solution Approach 1:
The adapter serves as a mediator that compensates for tolerance accumulation in modular assembly. It contains alignment features (pins, grooves, registration marks) that establish precise relative positioning between connectors regardless of individual component tolerances. This intermediary alignment system allows modules to be manufactured with larger tolerances while achieving precise end-face alignment when assembled.
Solution Approach 2:
The patent implements a universal connector design with standardized interfaces and alignment features that work across different module variations. The same adapter and alignment mechanism accommodate multiple connector types and tolerances, providing universal compatibility. This multi-functional approach simplifies manufacture by using common components while maintaining precise alignment through the standardized alignment feature system.
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 module ensures reliable signal transmission even under environmental stress and slight positional deviations, maintaining high light intensity and alignment without physical contact, and allows for easy replacement and maintenance of individual connectors.
Implementation Method 1
The light signal is widened and parallelized via a ball lens contained in the adapter (3)
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention relates to a module, which can be inserted into a housing of an industrial plug-in connector (5), wherein at least one optical fibre plug-in connector (2) can be inserted in the module (1), wherein at least one adapter (3) can be inserted in the module (1) and is connected to the optical fibre plug-in connector (2), wherein the adapter (3) contains an optical imaging element (11). In the plugged-in state, the optical elements (11, 11), for example the aforementioned spherical lenses, of two modules (1) are aligned towards each other such that the light signal that emerges from the optical element (11) of the module of the first industrial plug-in connector (5) couples into the optical element (11) of the module (1) of the second industrial plug-in connector (5).