U.S. patent application number 10/082810 was filed with the patent office on 2003-07-10 for fiber trim method and apparatus for an integrated optical fiber processing system.
Invention is credited to Proscia, David, Sommer, Phillip R..
Application Number | 20030128964 10/082810 |
Document ID | / |
Family ID | 21898056 |
Filed Date | 2003-07-10 |
United States Patent
Application |
20030128964 |
Kind Code |
A1 |
Sommer, Phillip R. ; et
al. |
July 10, 2003 |
Fiber trim method and apparatus for an integrated optical fiber
processing system
Abstract
Embodiments of the invention generally provide a fiber trim
apparatus and method. The apparatus and method are generally
configured to trim an exposed fiber optic cable segment protruding
from at least one optical interface being processed within a
multi-stage integrated optical component processing system. The
fiber trim apparatus generally includes a laser cutting tool
adapted to direct at least one laser beam to the optical interface
to trim at least some of an excess of fiber optic cladding and core
extending from the at least one optical interface, and a trim
positioning apparatus adapted to position the excess fiber optic
cladding and core extending from the at least one optical interface
between a pre-processing and processing position with respect to
the laser cutting tool.
Inventors: |
Sommer, Phillip R.; (Newark,
CA) ; Proscia, David; (San Ramon, CA) |
Correspondence
Address: |
MOSER, PATTERSON & SHERIDAN, L.L.P.
Suite 1500
3040 Post Oak Blvd.
Houston
TX
77056
US
|
Family ID: |
21898056 |
Appl. No.: |
10/082810 |
Filed: |
February 25, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10082810 |
Feb 25, 2002 |
|
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|
10038093 |
Jan 4, 2002 |
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Current U.S.
Class: |
385/147 ;
385/134 |
Current CPC
Class: |
B24B 19/226 20130101;
G02B 6/25 20130101; G02B 6/3863 20130101; B24B 41/067 20130101;
G02B 6/245 20130101; G02B 6/4226 20130101 |
Class at
Publication: |
385/147 ;
385/134 |
International
Class: |
G02B 006/00 |
Claims
1. A fiber trim apparatus adapted to trim an exposed fiber optic
cable segment protruding from at least one optical interface being
processed within a multi-stage integrated optical component
processing system, comprising: a laser cutting tool adapted to
direct at least one laser beam to the optical interface to trim at
least some of an excess of fiber optic cladding and core extending
from the at least one optical interface; and a trim positioning
apparatus adapted to position the excess fiber optic cladding and
core extending from the at least one optical interface between a
preprocessing and processing position with respect to the laser
cutting tool.
2. The apparatus of claim 1, wherein the laser cutting tool
comprises a laser source adapted to provide one or more laser beams
configured to cut the excess fiber and fiber optic cladding.
3. The apparatus of claim 2, wherein the laser cutting tool further
comprises a beam splitter having a first laser transmission path
coupled on a first end to the laser source and on a second end to
the laser beam splitter assembly.
4. The apparatus of claim 1, wherein the laser cutting tool
comprises a laser beam splitter assembly adapted to direct one or
more laser beams onto the excess fiber optic cladding and core
extending from the optical interface.
5. The apparatus of claim 4, wherein the laser beam splitter
assembly comprises a first laser beam transmission path wherein the
first laser transmission path directs at least a portion of a first
laser beam generally orthogonal to a longitudinal axis of the fiber
optic cable.
6. The apparatus of claim 4, wherein the laser beam splitter
assembly further comprises a second laser beam transmission path,
wherein the second laser transmission path directs at least a
portion of a second laser beam generally parallel to a longitudinal
axis of the fiber optic cable.
7. The apparatus of claim 4, wherein the laser beam splitter
assembly further comprises a first and a second laser beam
transmission paths, the first laser beam transmission path
directing at least a portion of a first laser beam generally
orthogonal to a longitudinal axis of the excess fiber optic
cladding and core extending from the optical interface, and wherein
the second laser transmission path directs at least a portion of a
second laser beam about parallel to the excess fiber optic cladding
and core extending from the optical interface.
8. The apparatus of claim 1, wherein the trim positioning apparatus
comprises a trim pincher adapted to hold the optical interface.
9. The apparatus of claim 8, wherein the trim positioning apparatus
comprises a horizontal trim motor and a vertical trim motor adapted
to position a component interface terminated to the fiber optic
cable between the pre-processing position and processing
position.
10. An optical fiber trim apparatus adapted to trim an exposed
segment of a fiber optic cable protruding from at least one optical
interface being processed within a multi-stage integrated optical
component processing system, comprising: a laser cutting tool
coupled on an input to at least one laser beam source adapted to
burn the excess cladding and core of the exposed segment of a fiber
extending from the at least one optical interface; and a laser beam
splitter assembly coupled on an output of the laser cutting tool,
wherein the laser beam splitter assembly is configured to direct at
least a first laser beam and a second laser beam to the exposed
segment of the fiber optic cable protruding from the at least one
optical interface to burn at least some of a fiber optic cable
cladding and core therefrom.
11. The apparatus of claim 10, wherein the laser beam splitter
assembly comprises a first laser beam positioning member adapted to
position the first and second laser beams on the fiber optic
cladding and core.
12. The apparatus of claim 11, wherein the first laser beam
positioning member comprises a first and a second laser beam
transmission paths, wherein the first laser beam transmission path
directs at least a portion of the first laser beam generally
orthogonal to a longitudinal axis of the excess fiber optic
cladding and core extending from the optical interface, and wherein
the second laser transmission path directs at least a portion of
the second laser beam generally parallel to the excess fiber optic
cladding and core extending from the optical interface.
13. The apparatus of claim 10, further comprising a trim
positioning apparatus moveably disposed on a frame member, the
optical interface being held by a trim pincher disposed on the trim
positioning apparatus.
14. The apparatus of claim 13, wherein the trim positioning
apparatus includes a horizontal trim motor and a vertical trim
motor adapted to cooperatively move the trim pincher between a
component loading and a processing position.
15. A method for trimming an excess fiber optic cladding and core
material extending from an optical interface, comprising:
positioning the excess fiber optic cladding and core material
extending from the optical interface within a portion of a laser
beam split into two or more laser beams, wherein the two or more
laser beams are adapted to trim the excess fiber optic cladding and
core extending from the optical interface; positioning the two or
more laser beams at one or more incidence angles with respect to
the longitudinal axis of the excess fiber optic cladding and core
extending from the optical interface; and trimming the excess fiber
optic cladding and core extending from the optical interface.
16. The method of claim 15, wherein positioning the two or more
laser beams comprises directing at least some of the first laser
beam about orthogonal on to the excess fiber optic cladding and
core extending from the optical interface.
17. The method of claim 15, wherein trimming comprises directing at
least some of the second laser beam about parallel on to the excess
fiber optic cladding and core extending from the optical
interface.
18. The method of claim 15, wherein trimming comprises burning the
excess fiber optic cladding and core extending from the optical
interface using at least one of the first and second laser
beams.
19. The method of claim 15, wherein splitting at least some of
laser beam into at least the first laser beam and the second laser
beam comprises directing some of the laser beam along a first laser
path and some of the laser beam along a second laser path, wherein
the first and second laser paths are about orthogonal.
20. The method of claim 19, further comprising prior to trimming
directing at least some of the first and second laser beams onto
the excess fiber optic cladding and core extending from the optical
interface.
21. A fiber trim apparatus adapted to trim at least a portion of an
exposed fiber optic cable segment protruding from an optical
interface, comprising: a frame supporting a laser-cutting tool
having a laser source and a laser splitter assembly adapted to
split one or more laser beams into at least a first and second
beams, wherein the laser splitter assembly includes at least a
first laser transmission path coupled on one end to the laser
source and on another end to the splitter assembly, wherein the
splitter assembly further defines a first split transmission path
and a second split transmission path for guiding the first and
second beams; a laser light positioning member coupled to the
splitter assembly and adapted to position the first and second
beams onto the exposed fiber optic cable segment; and a trim
positioning apparatus moveably disposed on the frame and adapted to
hold and position the optical interface for processing.
22. The apparatus of claim 21, wherein the laser light positioning
member is adapted to align the first split laser beam orthogonal to
the exposed fiber optic cable segment.
23. The apparatus of claim 21, wherein the laser light positioning
member is adapted to align the second beam axially with respect to
the longitudinal axis of the exposed fiber optic cable segment.
24. The apparatus of claim 21, wherein the first beam and the
second beam are about simultaneously directed on the exposed fiber
optic cable segment.
25. The apparatus of claim 21, wherein the first beam and the
second beam are sequentially directed on the exposed fiber optic
cable segment.
26. The apparatus of claim 21, wherein the trim positioning
apparatus comprises a trim pincher apparatus adapted to hold and
position the optical interface between a plurality of processing
positions adjacent the laser light positioning member.
27. The apparatus of claim 26, wherein the trim positioning
apparatus comprises a horizontal trim motor and a vertical trim
motor adapted to move the trim pincher apparatus vertically and
horizontally between the plurality of processing positions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application under 37
C.F.R. .sctn.1.53(b) of U.S. patent application Ser. No.
10/038,093, filed Jan. 4, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention generally relates to a method and apparatus
for assembling optical subsystems or optical interconnections.
[0004] 2. Background of the Related Art
[0005] In the manufacture of fiber optic communication systems,
optical interconnects and other components are assembled to form
various interconnected optical subsystems. Typically, optical
components are integrated into optical subsystems that collectively
create, for example, an optical switch. As the communication
industry's need for optical communication bandwidth has increased,
the ability for interconnect surfaces to provide a precise
connection between optical subsystems is becoming critical,
especially with regard to optical transmission modes that use
multiple wavelengths of light to transmit information, such as
Dense Wavelength Division Multiplexing (DWDM), for example. DWDM is
a fiber-optic transmission technique that employs multiple light
wavelengths to transmit data in a parallel-by-bit or
serial-by-character format. DWDM is a major component of most
optical networks that allows the transmission of e-mail, video,
multimedia, data, voice--carried in Internet protocol (IP),
asynchronous transfer mode (ATM), and synchronous optical
network/synchronous digital hierarchy (SONET/SDH), respectively,
over fiber optic communication systems.
[0006] Generally, fiber optic interconnections include two
individual optical terminations mated together to provide a unitary
and continuous optical path therethrough. Conventionally, to form
an optical interconnect interface, fiber optic cables are
terminated into an optical interconnection called a ferrule that is
adapted to connect or mate the optical cables together. Ideally,
optical interconnects, such as ferrules, are manufactured with
precisely polished and dimensionally optimized interconnect
surfaces to provide low insertion loss and to prevent reflected
transmission. Generally, optical interconnects are assembled in
stages as subassemblies using a combination of a robotic assembly
(e.g., pick and place robotics) and/or by hand. Generally, as each
assembly stage is finished, the subassemblies are stored as work in
process (WIP) elements and/or pieces in a processing storage bin,
awaiting the next process step. Unfortunately, optical components
are often mishandled by assembly personnel and are often left in
the process bin unprotected. Therefore, the conventional assembly
processes often lead to incorrectly assembled or damaged optical
components, which may lead to optical system performance and/or
optical system interconnection issues. For example, a damaged or
improperly assembled optical component may cause mechanical
interface difficulties, poor specification repeatability, poor
reliability, and undesirable interface aberrations, such as
improper radius of curvature and apex offset, for example, which
often affect insertion loss, light polarization, extinction ratio,
return loss performance, etc. Moreover, staged subassembly
processing systems are often inefficient, as the subassemblies
often must wait long periods for the next process step requiring a
larger than necessary WIP to maintain and adequate throughput.
[0007] Typically, interconnection inefficiencies are overcome by
additional equipment, such as repeaters. Generally, repeaters
amplify the optical signal to overcome insertion loss and signal
attenuation, thereby extending the optical signal broadcast range.
Additionally, testing equipment such as an interferometer may be
used to precisely test, for example, the radius of curvature and
apex offset. The radius of curvature is the radius of the
interconnect surface, and is critical for proper mating of
interconnect surfaces. The apex offset is the measure of the
interconnect optical path alignment and is critical for the proper
alignment of the optical paths between two optical interconnect
surfaces. Unfortunately, as the optical subassemblies are
assembled, the damage caused by the assembly processes must be
accounted for and tested. Moreover, testing each interconnection
and subassembly for parameters such as radius of curvature and apex
offset increases the manufacturing time, and thus, the cost of the
optical subassemblies. Further, for large fiber optic communication
systems employing thousands of optical interconnections, using
equipment such as repeaters designed to overcome the interconnect
inefficiencies may lead to an overall increase in the cost of the
fiber optic communication system. Thus, having damaged or
improperly assembled optical components affects the transmission of
light, which affects information flow, reduces the system
bandwidth, reduces the system efficiency, increases equipment
costs, and generally increases the cost of the communication
system.
[0008] Therefore, there is a need for a method and apparatus to
provide a system for assembling optical components and
subassemblies in a simple, repeatable, efficient, and cost
effective manner.
SUMMARY OF THE INVENTION
[0009] Embodiments of the invention generally provide a method and
apparatus for assembling optical components used in interconnecting
optical subassemblies. In one embodiment, the invention provides
one or more optical component processing stages for processing
optical subassemblies, wherein the stages may include a component
installation stage adapted to assemble a plurality of components on
a plurality of fiber optic cables, a fiber preparation stage
adapted to remove the outer coating of a fiber optic cable to
expose a fiber optic cladding and core, and a component attachment
stage adapted to attach at least one optical component on the
cladding and the core. Additionally, a fiber trim stage adapted to
trim an excess of cladding and core material from an optical
interface, an optical surface polishing stage adapted to polish an
optical interface surface, and at least one movable optical
component carrier adapted to transport the plurality of fiber optic
cables and the plurality of components between the one or more
optical component processing stages may be provided.
[0010] Embodiments of the invention further provide a fiber trim
apparatus adapted to trim an exposed fiber optic cable segment
protruding from at least one optical interface being processed
within a multi-stage integrated optical component processing
system. The fiber trim apparatus generally includes a laser cutting
tool adapted to direct at least one laser beam to the optical
interface to trim at least some of an excess of fiber optic
cladding and core extending from the at least one optical
interface, and a trim positioning apparatus adapted to position the
excess fiber optic cladding and core extending from the at least
one optical interface between a pre-processing and processing
position with respect to the laser cutting tool.
[0011] Embodiments of the invention further provide an optical
fiber trim apparatus adapted to trim an exposed segment of a fiber
optic cable protruding from at least one optical interface being
processed within a multi-stage integrated optical component
processing system. The trim apparatus generally includes a laser
cutting tool coupled on an input to at least one laser beam source
adapted to burn the excess cladding and core of the exposed segment
of a fiber extending from the at least one optical interface, and a
laser beam splitter assembly coupled on an output of the laser
cutting tool, wherein the laser beam splitter assembly is
configured to direct at least a first laser beam and a second laser
beam to the exposed segment of the fiber optic cable protruding
from the at least one optical interface to burn at least some of a
fiber optic cable cladding and core therefrom.
[0012] Embodiments of the invention further provide a method for
trimming an excess fiber optic cladding and core material extending
from an optical interface. The method generally includes
positioning the excess fiber optic cladding and core material
extending from the optical interface within a portion of a laser
beam split into two or more laser beams, wherein the two or more
laser beams are adapted to trim the excess fiber optic cladding and
core extending from the optical interface. Additionally, the method
may include positioning the two or more laser beams at one or more
incidence angles with respect to the longitudinal axis of the
excess fiber optic cladding and core extending from the optical
interface, and trimming the excess fiber optic cladding and core
extending from the optical interface.
[0013] Embodiments of the invention further provide a fiber trim
apparatus adapted to trim at least a portion of an exposed fiber
optic cable segment protruding from an optical interface. The fiber
trim apparatus generally includes a frame supporting a
laser-cutting tool having a laser source and a laser splitter
assembly adapted to split one or more laser beams into at least a
first and second beams, wherein the laser splitter assembly
includes at least a first laser transmission path coupled on one
end to the laser source and on another end to the splitter
assembly, wherein the splitter assembly further defines a first
split transmission path and a second split transmission path for
guiding the first and second beams. Additionally, the fiber trim
apparatus may include a laser light positioning member coupled to
the splitter assembly and adapted to position the first and second
beams onto the exposed fiber optic cable segment, and a trim
positioning apparatus moveably disposed on the frame and adapted to
hold and position the optical interface for processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] So that the manner in which the above recited features of
the invention are obtained can be understood in detail, a more
particular description of the invention, briefly summarized above,
may be had by reference to the embodiments thereof, which are
illustrated in the appended drawings. It is to be noted, however,
that the appended drawings illustrate only typical embodiments of
this invention, and are therefore, not to be considered limiting of
its scope, for the invention may admit to other equally effective
embodiments.
[0015] FIG. 1 illustrates an exemplary simplified plan view of one
embodiment of a staged optical component processing system of the
invention.
[0016] FIG. 2 illustrates a perspective view of an exemplary
embodiment of an optical component carrier of the invention.
[0017] FIG. 3 illustrates a magnified perspective view of the
exemplary optical component carrier illustrated in FIG. 2.
[0018] FIG. 4 illustrates a perspective view of an exemplary
component storage apparatus of the invention.
[0019] FIG. 5 illustrates a plan view of an exemplary embodiment of
an optical component attachment stage and an optical assembly
transport system of FIG. 1.
[0020] FIG. 6 illustrates a side view of an exemplary embodiment of
an optical component attachment assembly of FIG. 5.
[0021] FIG. 7 illustrates a front view of an exemplary embodiment
of the component dispensing tube of FIG. 5.
[0022] FIGS. 8A and 8B illustrate top and side views of an
exemplary embodiment of a component feeder assembly of FIG. 5.
[0023] FIG. 9 illustrates a side view of an exemplary embodiment of
component feeder assembly, and a sectional view of the lower end of
the component dispensing tube assembly of FIG. 5.
[0024] FIGS. 10A-10J illustrate partial sectional views of the
operation of the component installation stage of FIG. 5.
[0025] FIG. 11 illustrates a perspective view of an exemplary
embodiment of a fiber preparation stage of FIG. 1.
[0026] FIG. 12 illustrates a side view of the exemplary fiber
preparation stage of FIG. 11.
[0027] FIGS. 13A and 13B illustrate diagrammatic views of an
exemplary embodiment of a stripping tool of FIG. 11.
[0028] FIGS. 14A-F illustrate diagrammatic views of the operation
of the fiber preparation stage of FIG. 11.
[0029] FIG. 15 illustrates a partial perspective view of an
exemplary embodiment of a component attachment stage of FIG. 1.
[0030] FIGS. 16-25 illustrate a top and side views of an exemplary
embodiment of the component attachment stage of FIG. 15 during a
component attachment sequence.
[0031] FIG. 26 illustrates a perspective view of an exemplary
embodiment of an optical fiber trim stage and a polishing stage of
FIG. 1.
[0032] FIGS. 27 and 28 illustrate a perspective view and a side
view, respectively, of the optic fiber trim stage of FIG. 26.
[0033] FIG. 29 illustrates a top view of the staged
optical-subsystem polishing system of FIG. 26.
[0034] FIG. 30 illustrates a side view of an optical-subsystem
polishing tool of FIG. 26.
[0035] FIG. 31 illustrates cut away perspective view of one
embodiment of an optical-subsystem polishing tool of FIG. 30.
[0036] FIG. 32 illustrates a cut away side view of the
optical-subsystem polishing tool of FIG. 30.
[0037] FIG. 33 illustrates a cut away side view of the
optical-subsystem polishing tool of FIG. 30 illustrating an optical
component in a processing position.
[0038] FIG. 34 illustrates a top view of an exemplary embodiment of
an optical-component testing stage of FIG. 1.
[0039] FIG. 35 illustrates a side view of the optical-component
testing stage of FIG. 34.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Aspects of the invention generally provide a method and
apparatus for assembling optical components and optical
subassemblies used in interconnecting optical systems. The term
optical component herein generally refers to any component,
assembly, or subassembly used in the manufacture of optical
interconnects and optical subassembly. FIG. 1 is a simplified plan
view of one embodiment of a staged optical component processing
system 100 of the invention. The staged optical component
processing system 100 is a self-contained system having the
necessary processing utilities supported on a system frame 101 that
can be easily installed, and which provides a quick start up for
operation. The optical component processing system 100 includes an
optical component installation stage (CI) 102 adapted to install a
plurality of optical components, e.g., ferrules, onto a fiber optic
cable. The term ferrule is used herein to denote a fiber-optic
cable connector as is known in the art. Ferrules generally have
three parts: a flange portion usually made of a rigid material,
e.g., stainless steel, to allow the ferrule to be mechanically
coupled to an optical subassembly; a body; and a fiber optic cable
receiving end having a small center opening used to receive a fiber
optic cable (i.e., pigtail) and an optical transmission portion to
receive the cladding and core of the fiber optic cable. The body is
typically made of materials such as zirconia, alumina, and
materials similar thereto that may be adapted to support a fiber
optic cable. Ferrule connectors are generally available in several
different light transmission modes, such as single mode, which is
used to transmit one signal per fiber, or multimode, which is used
to transmit many signals per fiber, depending on the number of
wavelengths contained within the transmission. The optical
component processing system 100 also includes an optical fiber
preparation stage (FP) 104 adapted to remove an outer protective
coating from a fiber optic cable to expose a fiber optic cladding
layer surrounding a fiber optic core. The term core is used herein
to describe the light transmission portion of a fiber optic cable,
which is generally surrounded by the fiber optic cladding. The
optical component processing system 100 further includes a
component attachment stage (CA) 106, adapted to attach (i.e.,
terminate) a component, e.g., a ferrule, onto an exposed cladding
and core portion of a fiber optic cable. To finish the component
attachment and optical interface, the optical component processing
system 100 may further include a fiber optic trim stage (FT) 108
adapted to cut and trim a fiber optic cladding and core length
protruding from an optical component optical interface. The optical
component processing system 100 may also includes an optical
component interface polishing stage (POL) 110 configured to polish
the optical interface. The optical component interface polishing
stage (POL) 110 may include three polishing stages adapted to
grind, polish, and finish the optical interface surface of the
component in order to provide an exemplar optical interface
connection. In one aspect, the optical component processing system
100 further includes an optical component testing stage (TEST)
adapted to power (i.e., bias), stimulate, and test optical
component subassemblies for proper operation.
[0041] The optical component processing system 100 may further
include an optical assembly transport system 114 configured to
transport an optical component carrier 116 containing a plurality
of optical components to be processed between optical component
processing stages 102-111. The optical assembly transport system
114 may be adapted to support one or more optical component
carriers 116 to allow for an efficient assembly process. For
example, one optical component carrier 116 may be stationed
adjacent the component installation stage 102 to receive optical
components therein, while another optical component carrier 116 may
be stationed adjacent the fiber preparation module 104 for fiber
optic cable preparation. The optical component processing system
100 may also include a utility module 112, which houses the support
utilities needed for operation of the optical component processing
system 100, such as compressed air used to power portions of the
optical component processing system 100, de-ionized water and/or
CO.sub.2 used for cleaning, vacuum, and electrical power
distribution components.
[0042] In one aspect of the invention, the optical component
processing system 100 further includes a process controller 118.
The process controller 118 is coupled to the optical component
processing system 100 via an input/output (I/O) cable 90. In
general, the processing system controller 118 may include a
controller, such as programmable logic controller (PLC), computer,
or other microprocessor-based controller. The process controller
118 may include a central processing unit (CPU) in electrical
communication with a memory, wherein the memory may contain an
optical component assembly control program that, when executed by
the CPU, provides support for controlling the optical component
processing system 100. In another aspect of the invention, the
processing system controller 118 may provide control signals for
the processing of the subassemblies at each processing stage
102-111, movement of the optical component carrier 116 on the
optical assembly transport system 114, and optical component
testing protocols at the testing stage 111. The processing system
controller 118 may also be adapted to receive signals, such as
processing status, test data, and the other signals from each of
the processing stages 102-111, as well as the optical assembly
transport system 114 to provide control of the component
processing. The optical component assembly control program may
conform to any one of a number of different programming languages.
For example, the program code can be written in PLC code (e.g.,
ladder logic), C, C++, BASIC, Pascal, or a number of other
languages.
[0043] Optical Component Carrier
[0044] FIGS. 2-3 illustrate perspective views of one embodiment of
an optical component carrier 116. The optical component carrier 116
is adapted to hold a plurality of fiber optic cables and optical
components therein. The optical component carrier 116 includes a
top 206 (e.g., a lid), a bottom 214, a back wall 224, a front wall
210, and sidewalls 222 that define a storage region 200 therein. In
one aspect, for ease of component loading and unloading, the lid
206 may be removable from, or hinged, to any of the sidewalls 222,
the bottom 214, and/or the front wall 210. The optical component
carrier 116 includes a front member 208 parallel to and disposed
adjacent the front wall 210. The optical component carrier 116 also
includes a mid member 209 generally orthogonal to the sidewall 222
and the bottom 214 and disposed between the front wall 210 and back
wall 224. The mid member 209, sidewalls 222, and back wall 224,
define an assembly holding region 226 configured to hold a
plurality of component storage apparatuses 202 therein. The
component storage apparatuses 202 may be adapted to hold a fiber
optic cable and/or a plurality of components therein. The mid
member 209 and front member 208 are separated by a plurality of
partitions 218. The partitions 218 are generally parallel and
spaced sufficiently from each other to hold a fiber or component
therebetween. The partitions 218 are generally parallel to the
sidewalls 222, and orthogonal to the front wall 210 and the bottom
214. The front member 208, the partitions 218, and the mid member
209 may be adapted to form individual component assembly slots 204
configured to hold a plurality of optical components and at least
one fiber optic cable therein.
[0045] FIG. 3 illustrates a magnified perspective view of the front
member 208 and front wall 210, which are adapted to form a
plurality of v-shaped notches 229, each of which may hold and
position a fiber optic cable and/or optical component in a
processing position. The front member 208 and front wall 210 are
generally spaced apart to allow a clamp apparatus 230 to move
freely in a vertical manner therebetween. The clamp apparatus 230
is generally adapted to hold a fiber optic cable or component,
e.g., ferrule, within the v-shaped notch 229. The clamp apparatus
230 includes a sliding member 232 that is slidably disposed between
the front member 208 and front wall 210. The sliding member 232
includes a clamp member 236 that is adapted, when positioned
against a component or fiber optic cable, to force the fiber optic
cable or component into the v-shaped notch 229. The clamp apparatus
230 further includes an engaging member 234 coupled to the sliding
member 232 to position the clamp member 236 toward or away from a
fiber optic cable or component positioned within the v-shaped notch
229. The engaging member 234 is disposed within, and in sliding
engagement with a slot 226 of the front wall 210. The slot 226 is
adapted to allow a desired vertical travel of the sliding member
232 to release or engage the fiber optic cable or component within
the v-shaped slot 229. While normally the weight of the clamp
member 236 may be sufficient to supply a component holding force
when a component is held between the v-shaped notch 229 and the
clamp member 236, in one aspect, the clamp apparatus 230 may be
biased, i.e., spring loaded, in order to provide a clamping force
to the clamp member 236 to assist in positioning and holding the
fiber optic cable or component within the v-shaped notch 229. In
operation, a lifting tool or other engaging apparatus may activate
the engaging member 234 to slide the sliding member 232 within the
slot 226 to hold or release a fiber optic cable or component from
the v-shaped notch 229. For example, as illustrated in FIG. 3, an
first engaging member 234' is positioned in a lower position in the
first slot 226' to position the first sliding member 232' and first
clamp member 236' to hold a first fiber optic cable 237 within a
first v-shaped notch 229'.
[0046] FIG. 4 illustrates a perspective view of one embodiment of a
component storage apparatus 202. Each component storage apparatus
202 may include a c-shaped spool 247 adapted to support a fiber
optic cable 237 thereon, and provide egress and ingress for a fiber
optic cable portion therein for processing. The c-shaped spool 247
is generally adapted to dispense the fiber optic cable 237 from a
spool opening 241 thereon. The c-shaped spool 247 may be made of a
rigid material, such as metal, plastic, or other materials that are
sufficiently strong and adapted to provide a suitable resilience
for the fiber optic cable 237 wrapped thereon. The component
storage apparatus 202 may further include two outer rings 242A-B
that include outer walls 244A-B, respectively, to form a first
cover 248A and a second cover 248B, respectively. The outer rings
242A-B may be made of any flexible material such as foam, rubber,
and the like, adapted to provide resilience when compressed. In one
aspect, the covers 248A-B, when placed in axial alignment and
abutted, define an inner component void 245 and a fiber-dispensing
slot 246 whereby the fiber optic cable 237 internal to the c-shaped
spool 247 is clamped frictionally within the fiber-dispensing slot
246. In another aspect, the fiber optic cable 237 may be positioned
within the inner void 245 in one or more loops to provide a strain
relief as the fiber optic cable 237 is pulled in and out of the
spool opening 241.
[0047] Component Installation
[0048] FIGS. 5 and 6 are a plan view and a side view respectively
of one embodiment of the optical assembly transport system 114 and
the component installation stage 102. The optical assembly
transport system 114 includes a plurality of rollers 302A-B. The
rollers 302A-B are spaced and disposed along the longitudinal axis
of the optical assembly transport system 114 to support the optical
component carrier 116 and allow for ease of movement of the optical
component carrier 116 between the processing stages 102-111. Each
of the rollers 302A-B are rotatably mounted to the frame 101 and
are generally disposed orthogonal to the travel direction of the
optical component carrier 116. In one aspect of the invention, the
optical assembly transport system 114 may include a conveyor drive
304 adapted to spin at least one set of the rollers 302A-B to
engage the bottom 214 of the optical component carrier 116, and
urge the optical component carrier 116 upstream or downstream along
a process path defined by the optical assembly transport system
114. In one aspect, as illustrated in FIG. 2, the conveyor drive
304 may include a conveyor motor 316 to drive a roller drive system
324 to rotate the rollers 302A-B. In another aspect, the optical
assembly transport system 114 includes a carrier positioning
apparatus 322 adapted to receive and position the optical component
carrier 116 for processing. The carrier positioning apparatus 322
includes a shaft 325 coupled to a pedestal 323 adapted to support
the optical component carrier 116. The pedestal 323 and shaft 325
extend through an opening 311 of the floor 319 of the optical
assembly transport system 114 to engage the bottom 214 of the
optical component carrier 116. The carrier positioning apparatus
322 may be adapted to move the shaft 325 and pedestal 323 generally
in three dimensions, i.e., parallel, vertical, and orthogonal, with
respect to the longitudinal axis of the optical assembly transport
system 114, i.e., along the axis of rollers 302. In another aspect,
the carrier positioning apparatus 322 may be coupled to the I/O
cable 90 and responsive to the process controller 118 to position
the optical component carrier 116 into a plurality of processing
positions.
[0049] In operation, the optical component carrier 116 may be moved
on the rollers 302A-B upstream or downstream along the optical
assembly transport system 114. When the optical component carrier
116 is disposed about adjacent the position apparatus 322 the
optical component carrier 116 may be stopped by at least two stop
pins 308A and 308B. The carrier positioning apparatus 322 may raise
the pedestal 323 upward to contact the bottom 214 of the optical
component carrier 116 and then lift the optical component carrier
116 off the rollers 302A-B to stop the optical component carrier
116 from moving to the next processing stage 102-111 and to
position the optical component carrier 116 in a plurality of
processing positions with respect to the component installation
stage 102. Subsequently, the carrier positioning apparatus 322 may
move the pedestal 323 and optical component carrier 116 to a
desired processing position with respect to the component
installation stage 102.
[0050] As illustrated in FIGS. 2-3, the component installation
stage 102 may be mounted to the system frame 101 adjacent the
optical assembly transport system 114 and may be adapted to insert
components on fiber optic cables disposed within the optical
component carrier 116. The component installation stage 102
generally includes a robot 310 adapted to retrieve and place
components on a plurality of fiber optic cables disposed within the
optical component carrier 116. A plurality of dispensing tube
assemblies 320A-E (five are shown) are disposed on a table top 317
attached to frame 101, and are adapted to hold optical components
and assembly components, such as retainers, springs, and other
components, to be dispensed. The robot 310 is positioned at about
the center of the component installation stage 102 and is adapted
to retrieve the components from the dispensing tube assemblies
320A-E, and place the components on a fiber optic cable disposed
within the carrier 116. In one aspect, the robot 310 includes a
first arm 312 coupled at one end to an axial member 318 and a
second end to a second arm 314 via a joint 316. The robot 310
includes a component transfer tool 331 rotatably mounted to a
distal end of the second arm 314. The robot 310 and component
transfer tool 331 are adapted to transport components from the
dispensing tube assemblies 320A-E to the optical component carrier
116, and then install the components on one or more of the fiber
optic cables therein. Once the components have been installed on
the one or more of fiber optic cables, the optical component
carrier 116 may be lowered by the carrier positioning apparatus 322
onto rollers 302A-B, which, in response to the conveyor drive 304
and rollers 302A-B (when activated), transports the optical
component carrier 116 upstream or downstream to another processing
stage 102-111.
[0051] FIG. 7 illustrates one embodiment of a component dispensing
tube assembly 320A. The component dispensing tube assembly 320A
includes a plurality of component tubes 307. Each component tube
307 generally contains a plurality of vertically stacked components
or subassemblies of the same type. For example, the component tubes
307 may contain stacked o-rings. While, the component tubes 307 are
generally vertically aligned to facilitate the dispensing of the
components through a dispensing orifice 309 using gravity, other
alignments are contemplated. Alternatively, the component tubes may
be placed configured to be spring biased in order to dispense
components. The component tubes 307 are mounted to a component
feeder assembly 330 adapted to facilitate the dispensing of
components from the dispensing tubes 307.
[0052] FIGS. 8A and 8B are side and top views, respectively, of one
embodiment of a component feeder assembly 330. The component feeder
assembly 330 generally includes a nest plate 332 adapted to support
the dispensing tube assemblies 320A-E, and component tubes 307. The
component feeder assembly 330 may include a separator air actuator
334 adapted to move the nest plate 332 in a generally horizontal
plane, and a pneumatic thruster 346 adapted to raise and lower the
nest plate 332 to facilitate component dispensing. FIG. 9 is a side
view of the nest plate 332, the component transfer tool 331,
including a component holding arm 337 and a sectional view of a
lower end of the component dispensing tube assembly 320A. FIG. 9
illustrates the pneumatic thruster 346 in a lowered position
relative to the component dispensing tube assembly 320A and the
component transfer tool 331 in a component holding position. The
component transfer tool 331 includes on a distal end of the
component holding arm 337, a component holding shaft 339 adapted to
hold a plurality of components stacked in an axial position
thereon. Illustratively, a plurality of components are shown
stacked on the component holding shaft 339. In one aspect, the
component transfer tool 331 may rotate the component holding shaft
339 between about a vertical component loading position and about a
horizontal component dispensing position in about axial alignment
with the longitudinal axis of the fiber optic cable to dispense
components thereon. A dispensing tool 340 is disposed adjacent and
in sliding engagement with the component feeder assembly 330. The
dispensing tool 340 is used to regulate the dispensing of the
components through the dispensing orifice 309 and is actuated by a
dispensing actuator 341.
[0053] FIGS. 10A through 10J are partial sectional views
illustrating the operation of the nest plate 332, and component
feeder assembly 330, dispensing components from the component tubes
307 onto the component holding shaft 339. FIG. 10A illustrates a
partial view of the component feeder assembly 330 in component
acquisition position where the dispensing tool 340 and a separator
355 are shown in a retracted position relative a component 351A. To
receive components therein, the nest plate 332 is disposed adjacent
the dispensing orifice 309. FIG. 10B illustrates a component groove
354 of the nest plate 332 having the component 351A dispensed
therein. FIG. 10C illustrates the separator 355 in a component
separating position overlaying the component 351A. FIG. 10D
illustrates the dispensing tool 340 in a component holding position
adjacent the next component 351B to hold the next component within
the component tubes 307. FIG. 10E illustrates the nest plate 332 in
a lowered position. FIG. 10F illustrates the holding shaft 339
extending through the nest plate 332 into an axial opening of the
component 351A, to slide the component 351A thereon. FIG. 10G
illustrates the separator 355 in a open position to allow removal
of the component 351A from the component groove 354. FIG. 10H
illustrates an empty nest plate 332 after the component has been
removed by the component transfer tool 331. In one aspect, the
component 351A is removed by the rotation of the component transfer
tool 331 in a horizontal plane generally parallel the component
groove 354. FIG. 101 illustrates the nest plate 332 raised to a
component loading position adjacent the dispensing orifice 309.
FIG. 10J illustrates the dispensing tool 340 and separator 355 in a
retracted position to allow the loading of next component 351B into
the component groove 354.
[0054] Fiber Preparation
[0055] FIGS. 11-12 are a perspective view and side view,
respectively, of one embodiment of a fiber preparation stage 104 of
FIG. 1. FIGS. 11-12 illustrate the optical component carrier 116 in
a pre-processing position. The fiber preparation stage 104 is
disposed adjacent the optical assembly transport system 114 to
receive a carrier 116 in a processing position. The fiber
preparation stage 104 includes a fiber preparation tool 400. The
fiber preparation tool 400 includes fiber strip/cut assembly 405,
which includes an upper positioning member 414. The upper
positioning member 414 includes a cutting tool 402 adapted to cut a
fiber optic cable 237 and a stripping tool 404 adapted to strip the
outer protective coating of the fiber optic cable 237 to expose the
fiber optic cladding and core. The upper positioning member 414
further includes an upper positioning motor 418 adapted to move the
cutting tool 402 to and from a cutting operation and the stripping
tool 404 to and from a stripping operation. In one aspect, the
upper positioning member 414 and upper positioning motor 418 may be
controlled by the process controller 118 to position the cutting
tool 402 and/or stripping tool 404 into a plurality of processing
positions. The fiber preparation tool 400 further includes a lower
positioning member 415 that includes a first gripper 416, and a
second gripper 417. The first and second grippers 416,417 are
adapted to hold the fiber optic cable 237 during a striping process
or cutting processing step. The lower positioning member 415
includes a lower positioning motor 419 adapted to move the first
and second grippers 416,417 between a plurality of processing
positions. In one aspect, the lower positioning member 415 may be
controlled by the process controller 118 to position the first
gripper 416 and/or second gripper 417 into their respective
processing positions.
[0056] In one embodiment, as illustrated in FIGS. 11-12, the
optical assembly transport system 114 is configured as an indexing
transport system 114'. The indexing transport system 114' includes
a carrier support member 144 adapted to lift and hold an optical
component carrier 116 between a component transport position and a
component processing position. As illustrated in FIG. 12, the
indexing transport system 114' may also include a lifting apparatus
142 having a shaft member 147 in sliding engagement with the frame
101 via bearings 146. The shaft member 147 includes a rolling end
151 distal a support end coupled to the carrier support member 144.
The rolling end 151 is in rotatable contact with a cam member 150
disposed on a camshaft 149. When rotated by a camshaft motor (not
shown) the cam member 150 is adapted to raise and lower the shaft
member 147 in a vertical direction from a lower cam position to an
upper cam position, to urge the carrier support 144 into contact
with the optical component carrier 116. In one aspect, as
illustrated in FIG. 11, the indexing transport system 114' includes
indexing stops 147A-C, adapted to index the optical component
carrier 116 sequentially between a plurality processing positions
with respect to the slots 204 therein. For example, if the optical
component carrier includes ten slots 204, the indexing stops 147A-C
may be adapted to sequentially position the optical component
carrier 116 to ten processing positions corresponding to each slot
204. In operation, the indexing transport system 114' receives one
of a plurality of optical component carriers 116 moving along the
rollers 320A-B into a processing position relative the fiber
preparation stage 104. A first stop 147B is raised vertically to
contact recesses (not shown) in the bottom 214 of the optical
component carrier 116, while the other two stops 147A and 147C are
held in a lower release position. The first stop 147B contacts the
optical component carrier 116, stopping the optical component
carrier 116 in a first processing position. Subsequently, the
camshaft 149 rotates to move the cam member 150 from a lower
transport position to a raised processing position. In the raised
processing position, the carrier support 144 lifts the optical
component carrier 116 off the rollers 302A-B, and into a processing
position. In one aspect, as illustrated in FIG. 12, the carrier
support 144 includes two support rails 152A-B where the support
rail 152B includes a plurality of buttons 154 thereon, adapted to
support a recessed portion (not shown) of the optical component
carrier 116 bottom 214. In another aspect, a bottom gripper tool
153 is used to pull the bottom 214 of the optical component carrier
116 onto the buttons 154 to secure the optical component carrier
116 for processing.
[0057] When processing is finished at the first processing
position, the carrier support member 144 is lowered into a release
position, allowing the rollers 302A-B to contact the bottom 214 of
the optical component carrier 116 thereby urging the optical
component carrier 116 toward the next slot 204. Subsequently, the
first stop pin 247B is lowered to a release position, and the outer
two stops 247A, 247C are raised to a contact position with
respective recesses (not shown) in the bottom 214 that correspond
to the next slot 204 and second processing position. In one aspect,
the fist stop 247B, and outer two stops 247A and 247C, alternate
during processing to index the optical component carrier 116 along
the optical transport system 114 in a sequential fashion. In
another aspect of the invention, as illustrated in FIG. 11, the
indexing transport system 114' includes an engaging tube 145 and an
engaging tool 156 that are adapted to operate the engaging member
234 (see FIG. 3) of the optical component carrier 116. Operational
aspects of the fiber preparation tool 400 is described below with
respect to FIGS. 13A-13B, and FIGS. 14A-14F.
[0058] FIGS. 13A and 13B illustrate one embodiment of a fiber
stripping tool 404 in different operational positions. The fiber
stripping tool 404 includes a body 421 having a first clamping
member 422 juxtaposed to a second clamping member 423. The first
and second clamping members 422-423 are disposed on, and in
slidable engagement with a rail member 424 adapted to allow the
first and second clamping members 422-423 to move between a
plurality of fiber clamping positions. The first and second
clamping members 422-423 are activated by a clamp drive 425 adapted
to move the first and second clamp members 422-423 along the rail
member 424. The stripping tool 404 further includes a first heating
element 410A disposed on the first clamp member 422 and opposite a
second heating element 410B disposed on the second clamp member
423. The first and second heating elements 410A-B are positioned to
clamp a fiber optic cable 237 therebetween. The heating elements
410A-B may be of any conventional type, such as resistive heaters
coupled to a power supply (not shown), that are adapted to heat,
melt, and remove the outer protective coating from the fiber optic
cable 237 to expose the cladding and core. FIG. 13A illustrates the
first and second clamp members in a non-clamping position about a
fiber optic cable 237. FIG. 13B illustrates the first and second
clamp members 422-423 in a clamping position about the fiber optic
cable 237. In one aspect, in order to maintain an even pressure
along the clamped portion of the fiber optic cable 237, a first pin
427A and second pin 427B may be disposed along, distal the rail
member 424, and in slideable engagement with a respective outer
surface 426A-B of the first and second clamp members 422-423. In
another aspect, to limit the travel of the clamp members 422-423
toward each other and establish a maximum clamping force, a third
pin 428A and a fourth pin 428B may be disposed between and in
slideable engagement with a respective inner surface 429A-B of the
clamping members 422-423.
[0059] FIGS. 14A through 14F diagrammatic views illustrating one
embodiment of a fiber preparation process for the fiber preparation
stage 104 of FIGS. 11-12. FIG. 14A illustrates the first gripper
416 in position to pull the end of a fiber optic cable 237 from the
optical component carrier 116. The first gripper 416 is positioned
adjacent the optical component carrier 116 and a fiber optical
cable 237 is illustrated protruding from the optical component
carrier 116 and griped by the first gripper 416. FIG. 14B
illustrates the first gripper 416 gripping one end of the fiber
optic cable 237 and the lower positioning member 415 moving the
first gripper 416 about orthogonal away from the optical component
carrier 116 to expose a portion of the fiber optic cable 237 for
processing. FIG. 14C illustrates the second gripper 417 holding the
end of the fiber optic cable 237 to allow the first gripper 416 to
reposition along the exposed fiber optic cable 237 toward the
carrier 116 to expose a portion of the fiber optic cable 237 for
processing therebetween. Subsequently, as illustrated in FIG. 14D,
the first gripper 416 moves to a second processing position where
it grips the fiber optic cable 237 at a point along the exposed
length of the fiber optic cable and the stripping tool 404
positions the first and second clamp members 422-423 about the
exposed portion of the fiber optic cable 237. Subsequently, the
first and second clamp members 422-423 and heating elements 410A-B
are clamped around the fiber optic cable 237. Once the first and
second clamp members 422-423 have clamped the fiber optic cable
237, the second gripper 417 moves away to a neutral position. As
illustrated in FIG. 14E, once the outer protective coating has been
heated sufficiently to melt and be removed, the stripping tool 404
is moved laterally along the fiber optic cable 237 to remove the
outer coating of the fiber optic cable 237 exposing the fiber optic
core and cladding. Once the outer protective coating has been
removed, the cutting tool 402 is positioned adjacent the first
gripper 416 and cuts the fiber optic cable core. After cutting, the
cutting tool 402 moves to neutral position as illustrated in FIG.
14F. Although in one aspect, a first stripping process removes
about 900 microns of fiber coating and a second stripping process
removes about 400 micron or about 250 microns of outer protective
coating, depending upon the coating thickness, the processes need
not be done at the same process step. For example, the a first
layer of the outer protective coating may be removed first, the
fiber optic core cut by cutting tool 402 and then a second layer
may be removed.
[0060] Component Attachment
[0061] FIG. 15 is partial perspective view of one embodiment of a
component attachment stage 106 adjacent the optical assembly
transport system 114 wherein a plurality of components 538 have
been attached to at least one of a plurality of fiber optic cables
237 extending from an optical component carrier 116. FIGS. 16-25
are a top and side views, respectively, of one embodiment of the
component attachment stage 106, illustrating a component attachment
sequence. As illustrated in FIG. 15, the component attachment stage
106 may include a component attachment assembly 500 adapted to
attach (e.g., terminate) a component 538 onto a fiber optic cable.
The component attachment assembly 500 includes a fiber gripper
assembly 505 having a plurality of attachment pinchers 506 thereon.
As illustrated in FIGS. 16-23, the component attachment assembly
500 may include an attachment robot 507 rotatably mounted to a
robot platform 508. The attachment robot 507 may include an
attachment gripper 503 thereon adapted to grab and move one or more
fiber optic cables from the optical component carrier 116 into a
processing position within each attachment pincher 506. As
illustrated in FIG. 15, the component attachment assembly 500 may
further include a component attachment tool 510 that is adapted to
hold one or more components 538, e.g., ferrules, for attachment on
the fiber optic cable. The component attachment tool 510 is
rotatably mounted to a movable attachment assembly 512 that moves
the component attachment tool 510 between a plurality of component
loading and a component attachment positions. The moveable
attachment assembly 512 may be driven by an attachment motor 522,
such as a linear motor or stepper motor. In one aspect, the
component attachment tool 510 may be rotated by a rotation motor
523, such as a linear motor or stepper motor, such that a plurality
of component holding recesses 514 are positioned in a component
loading position to accept components 538 therein. In another
aspect, when loaded with components for an attachment process, the
component attachment tool 510 may rotate to align a fiber-receiving
end of the components 538 in an axial attachment position with
respect to a longitudinal axis of the mating fiber optic cable
237.
[0062] In operation, as illustrated in FIGS. 16-25, the attachment
robot 507 moves at least one of a plurality of fiber optic cables
237 from the optical component carrier 116 into an attachment
orientation with respect to a fiber-receiving end of a mating
optical component 538. Subsequently, the attachment assembly 500
attaches at least one of a plurality of mating optical components
538 on one of the plurality of mating optical fibers 237. For
example, as illustrated by FIGS. 16 and 17, optical fibers 237 are
positioned by the attachment robot 507 into the fiber gripper
assembly 505 within a respective attachment pincher 506 so that a
length of the fiber optic cables 237 extend from a respective
attachment pincher 506 (ten are shown). In one aspect, the optical
fibers 237 are positioned so that an exposed fiber optic cladding
and core length extends from the pinchers 506. In another aspect,
as components 538 may have different axial insertion (i.e.,
attachment) depths, therefore, the exposed fiber optic cladding and
core length may extend according to the axial insertion depth.
Thus, when inserted on the exposed fiber optic cladding and core
length, a flange member of the components 538 are generally in
axial alignment and may abut a respective pincher 506. FIGS. 18 and
19 illustrate the component attachment tool 510 including a first
set of the plurality of components 538 after laterally moving into
an attachment position with the fiber optic cable 237. The
component attachment tool 510 is rotated to align the individual
components 538 into about axial alignment with the exposed core of
a mating fiber optic cable 237. In one aspect, the component
attachment tool 510 includes a component rotation assembly 525
adapted to individually rotate the components 538 about their
longitudinal axis to allow the optical fibers 237 to be more easily
inserted.
[0063] In another aspect, the components 538 and/or the fiber optic
cable 237 include epoxy therein to bond the fiber optic cable 237
to the mating component 538. FIGS. 20 and 21 illustrate the
component attachment tool 510 moved into an attachment position by
the movable attachment assembly 512. FIGS. 22 and 23 illustrate the
components 538 after attachment. In one aspect, when epoxy is used,
an epoxy curing apparatus 528 may be used to cure the epoxy. In
another aspect, the epoxy curing apparatus 528 heats the attached
components 538 and fibers 237 to cure the epoxy therebetween. FIGS.
15, 24, and 25 illustrate one type of epoxy curing apparatus 528
positioned by a positioning apparatus (not shown) in an
epoxy-curing position including the components 538 therein. To
facilitate a uniform epoxy heat-curing process, the epoxy curing
apparatus 528 may be adapted to clamp around the components 538 to
impart heat more evenly.
[0064] As illustrated in FIGS. 15-25, to increase throughput, the
component attachment tool 510, when rotated in an attachment
position, may include an alternative component loading position
where a plurality of secondary component holding recesses 514' are
positioned vertically to accept components for a subsequent
attachment process. Thus, when the attachment process is complete
the component attachment tool 510 rotates to align the next set of
components 538' for a subsequent attachment step.
[0065] Fiber Trim
[0066] FIG. 26 is a perspective view of one embodiment of an
optical fiber trim stage 108 and a polishing stage 110 of FIG. 1.
FIGS. 27 and 28 are a perspective view and a side view,
respectively, of one embodiment of the optic fiber trim stage 108
adjacent the optical component transport system 114. The fiber trim
stage 108 includes a laser-cutting tool 600 adapted to trim and cut
the excess core and cladding of an exposed portion of a fiber optic
cable extending from an optical component, e.g., a ferrule, to
develop a generally smooth optical interconnect surface. The
laser-cutting tool 600 generally includes a laser source 602 and a
laser splitter assembly 604 adapted to position one or more laser
beams on a fiber optic cable. In one aspect, the laser source 602
may be any coherent laser light source adapted to burn away the
fiber optic cable protruding from and adjacent an optical interface
portion of the optical component. As illustrated in FIG. 28, the
laser splitter assembly 604 includes a first laser transmission
path 605 coupled on one end to the laser source 602, and on another
end to a splitter 606. The splitter 606 includes a first split
transmission path 608 and a second transmission path 609 for
guiding a first and second split laser beam 620 and 621 therein,
respectively. The first and second split transmission paths 608-609
are coupled on a distal end to a first laser light positioning
member 610. The laser light positioning member 610 is adapted to
position the first and second split laser beams 620-621. In one
aspect, the laser light positioning member 610 aligns one laser
beam 620 about orthogonal to a protruding fiber optic cable and/or
exposed cladding and core. In another aspect, the laser light
positioning member 610 aligns the other laser beam 621 about
axially with respect to the longitudinal axis of the fiber optic
cable and/or exposed cladding and core.
[0067] The laser-cutting tool 600 may further include a trim
positioning apparatus 614 moveably disposed on a frame member 611
and being adapted to hold and position a component 538 for
processing. In one aspect, the component 538 is held by a trim
pincher 616 disposed on the trim positioning apparatus 614. The
trim positioning apparatus 614 may include a horizontal trim motor
618 and a vertical trim motor 619 adapted to move the trim pincher
616 vertically and horizontally between a plurality of processing
positions. In operation, the trim positioning apparatus 614 moves a
component 538 attached to a fiber optic cladding and core, from the
optical component carrier 116, between a pre-process position to a
trim process position. Subsequently, a protruding length of the
fiber optic cladding and core extending from the surface of the
component is trimmed (e.g., burned) away from the surface of the
optical component 538 by using the first and/or second laser beam
620-621.
[0068] Component Interface Polish
[0069] FIGS. 29-33 illustrate an exemplary embodiment of the staged
optical-subsystem polishing system 110 of FIG. 1, adjacent the
optical assembly transport system 114. FIG. 29 is a top view the
staged optical-subsystem polishing system 110. The exemplary
optical component polishing system 110 may generally include three
polishing apparatuses 708 that provide three optical component
polishing stages, which may be a coarse polishing stage 702 where
optical components are given an initial coarse polish, a fine
polishing stage 704 where optical components are given a finer
polish than the initial coarse polish, and a finish polishing stage
706 where optical components are given a finish polish. The optical
components are generally polished at each stage using a web of
polishing material having a polishing surface thereon, that may be
manufactured from materials such as silicon-carbide, diamonds,
silicon-dioxide, and other polishing materials. In one aspect,
after the coarse and fine polishing stages, the component is
cleaned with de-ionized water. Subsequently, an inert pressurized
gas, such as CO.sub.2, for example, may be used as a cleaning agent
to remove any fine residue adhering to the optical surfaces
produced during the polishing process. The polishing apparatus 708
may be used to polish the optical interconnect surfaces of optical
components, e.g., ferrules.
[0070] FIGS. 30-31 illustrate a side and perspective view,
respectively, of a polishing apparatus 708 that may include a body
712, a support 718, and a mounting plate 715. FIG. 29 may be
referenced with the discussion of FIGS. 30-31. In one aspect, the
body 712, support 718, frame 101, and mounting plate 715 are
mounted to each other using conventional fasteners such as screws,
bolts, nuts, and the like, and in another aspect may be a single
component. While in another aspect, the support 718 is vertically
mounted on the mounting plate 715 to define a vertical polishing
position for an orbital assembly 720 to help in the removal of
polishing debris, it is contemplated that the orbital assembly 720
may mounted in any position to perform the same polishing function.
In one aspect, a collection tray 760 is disposed under the orbital
assembly 720 to collect debris and fluids during processing. The
tray 760 is coupled to a drain 761 that is fluidly coupled to a
waste collection system or container (not shown).
[0071] As illustrated in FIGS. 29-30, the orbital assembly 720
includes a polishing assembly 730 and a spacer 732 flexibly coupled
to the polishing assembly 730 and rigidly mounted to the support
718. The polishing assembly 730 is positioned to allow the optical
component to be polished at generally an orthogonal direction
relative the support 718. The polishing assembly 730 includes a
right and left side plate 734,736, respectively, adapted to support
a polishing table 738, a polishing material supply apparatus 740,
and a polishing material receiver 742. In one aspect, the polishing
table 738 is formed from a rigid material having a low coefficient
of friction, such as Teflon .RTM. impregnated aluminum, stainless
steel, or other materials having a low friction surface thereon. In
another aspect, the low friction surface may be applied to the
polishing table 738 as a coating thereon. The polishing table 738
also includes a polishing surface recess 739 formed therein. In
operation, a web of polishing material 765 is disposed over the
polishing table 738 proximate the recess 739 and between the
polishing material supplier 740 and polishing material receiver
742. Generally, the polishing table 738 is adapted to orbitally
rotate within the polishing assembly 730 to polish optical
component optical interfaces.
[0072] As illustrated in FIG. 31, in one aspect, the polishing
material supply apparatus 740 includes a brake 752 and is adapted
to support a roll of polishing material 765 thereon (see FIG. 30).
The brake 752 applies a frictional force to the polishing material
supply apparatus 740, which keeps the roll of polishing material
765 taught. The polishing material supply apparatus 740 further
includes a supply clutch 754 to control the dispensing of the
polishing material 765 from the polishing material supply apparatus
740. As illustrated in FIG. 31, the polishing material receiver 742
is coupled to a receiver clutch 764 mounted to the left side plate
736. The receiver clutch 764 constrains the web of polishing
material movement to only one direction from the polishing material
supply apparatus 740 to the polishing material receiver 742. The
polishing material receiver 742 is rotated by a drive apparatus 743
(see FIG. 29) to take up and thereby advance the polishing material
765 across the polishing table 738. In one aspect, the supply
clutch 754, drive apparatus 743, and brake 752 are operated
together to control the advancement of the web of polishing
material 765 while maintaining a taught web of polishing material
765 across the polishing table 738. As such, the polishing material
765 contacting optical components may be refreshed as needed via
advancement of the polishing material from the supply apparatus 740
to the receiver 742.
[0073] FIGS. 32-33 are a partial cut away side view and side view
respectively of one embodiment of the polishing assembly 730. FIGS.
29-31 may be referenced with the discussion of FIGS. 32-33. In one
aspect, the polishing assembly 730 is coupled to an orbital
actuator 770 to move the polishing table 738 in an orbital motion
about a polishing plane that is generally orthogonal to the surface
of the optical component being polished. The orbital actuator 770
includes a drive frame 780 supporting a motor 774 coupled to an
eccentric shaft 776 extending generally perpendicular through the
support 718. One end of the eccentric shaft 776 is rotatably
coupled to the polishing table 738 via a bearing 772. One or more
counter balances 778 are disposed on the eccentric shaft 776 to
offset the centrifugal and centripetal forces developed by the
non-uniform mass distribution of the polishing table 738 during
operation, thereby minimizing vibration.
[0074] As the eccentric shaft 776 axially spins, it orbitally
rotates about a motor shaft center 785. As the bearing 772
generally provides some rotational friction, the polishing table
738 is rotationally urged about the shaft 776 in the direction of
the shaft rotation. To rotationally constrain the polishing table
738, while allowing the polishing table 738 to simultaneously move
with the orbital rotation of the eccentric shaft 776, four flexible
supports 750A-D are rotatably mounted on one end to the spacer 732
and on an opposite end to the polishing table 738. Thus, in
operation, the polishing table 738 moves in an orbital fashion
about the shaft 776 while maintaining a generally parallel position
with respect to the support 718. In one aspect, to minimize the
tension and allow for flexure of the polishing material and 765
during processing, a pair of rotatable strain relief members 783A
and 783B are in rotatable engagement with the polishing material
765.
[0075] As illustrated in FIG. 32, a component support 782, used to
support optical components during processing, is mounted by a
support 775 to a polishing force apparatus 744. The polishing force
apparatus 744 is used to position and force optical components held
by the component support 782 against the polishing material 765
(see FIG. 33). The polishing force apparatus 744 may be any
apparatus such as a motor driven actuator adapted to move the
component support 782 generally perpendicular toward and away from
the polishing table 738, and as needed, during a polishing
operation, maintains pressure of the optical component against the
polishing material 765. The polishing force apparatus 744 may be
slidably mounted to a polishing position apparatus 746 which may be
mounted to an upper end 722 of a secondary support 718 prime. The
polishing position apparatus 746 may be any apparatus such as a
motor driven actuator adapted to laterally move the component
support 782 generally parallel to the polishing table 738 and
across the surface of the polishing material 765. In one aspect, as
illustrated in FIG. 31, the component support 782 is independently
secured to a secondary support 718' mounted to the frame 101 to
provide vibration isolation from the polishing assembly 730. In
another aspect, the polishing force apparatus 744 and polishing
position apparatus 746 are mounted to the support 718, 718' via
flexible mounting fasteners such as rubber, vinyl, plastic, nylon,
and the like, adapted to provide vibration damping
therebetween.
[0076] In one aspect, (see FIG. 30) an air inlet/outlet 747 is
disposed on the right side plate 734, in communication with the
polishing table 738, and coupled to air conduction channels -(not
shown) that extend through the polishing table 738. The air
conduction channels are coupled to a plurality of holes 751 (see
FIG. 32) disposed around the recess 739 within a groove 758. A
vacuum pressure may be provided to the groove 758 via the air
inlet/outlet 747 through the holes 751 to hold the web of polishing
material 765 to the polishing table 738 during a polish process. In
one aspect, the holes 751 may be distributed throughout the recess
739 and/or the groove 758 to allow the recess 739 under vacuum to
hold the web of polishing material 765 to the polishing table 738.
In another aspect, air pressure may be provided from the air
inlet/outlet 747 to the holes 751 during a polish material
cleaning/renewing process to force the polishing material 765 away
from the polishing table 738 releasing debris and/or allowing the
polishing material 765 to be dispensed from the polishing material
supply apparatus 740 to the polishing material receiver 742.
[0077] In one aspect, the component support 782 further includes a
sensor assembly 788, adapted to measure the polishing pressure of
the optical component against the polishing material 765 during a
polishing process and provide a signal to the process controller
118 indicative of the polishing pressure. In operation, the
polishing force apparatus 744, sensor assembly 788, and process
controller 118 form a polishing pressure feedback system to
maintain a generally constant pressure between the optical
component, polishing material 765, and the polishing table 738
throughout the polishing process.
[0078] In another aspect, as illustrated in FIG. 32, a sub-pad 756
typically composed of a flexible material such as rubber, vinyl,
resin, plastic, and other suitable flexible material, that provides
a flexible, but firm, polishing surface, may be disposed in the
recess 739. The sub-pad 756 is also adapted to provide a desired
amount of flexure and resistance under the polishing material 765
against the component to form a desired radius of curvature for the
optical surface being polished. In one aspect, the sub-pad 756 is
adapted to form a radius of curvature dependant upon the pressure
developed between the surfaces being polished, polishing material
765, and the sub-pad 756. For example, a lighter pressure between
an optical component being polished, polishing material 765, and
the sub-pad 756 provides for a flatter (i.e., smaller) radius of
curvature whereas a greater pressure provides for a rounder (i.e.,
larger) radius of curvature. In another aspect, to provide for a
greater polishing pressure to form a desired radius of curvature
while decreasing the polishing time required, the sub-pad 756
includes a firmer surface having more flexure resistance thereon.
It is contemplated that the compliance and resilience of the
sub-pad 756 may be selected to provide any desired radius of
curvature, flexure, and processing time.
[0079] Component Testing
[0080] FIGS. 34 and 35 are a simplified plan view and a side view,
respectively, of one embodiment of the optical assembly testing
stage 111. The optical assembly testing stage 111 is disposed
adjacent the optical carrier transportation system 114 to
facilitate the automatic testing of a plurality of assembled
optical components. The optical assembly testing stage 111 may
include a number of different optical component testing tools 800
(one is shown). The optical component carriers 116 move along the
optical carrier transportation system 114 and are positioned
adjacent the optical component testing tool 800 that includes at
least one powered component testing stage 802 interfaced to a
optical testing equipment module 812. The powered component testing
stage 802 may generally include a test robot 804 that has a test
pincher 806 adapted to move one or more of terminated fiber optic
assemblies to a processing position. In one aspect, the powered
component testing stage 802 includes a component stimulation tool
808 that is adapted to provide power and signals to the components
within the optical component carrier 116. The powered component
testing stage 802 may also include an optical interface front end
812 adapted to receive an optical component, e.g., a ferrule. In
one aspect, the component stimulation tool 808 may be adapted to
mate with the optical component carrier 116 such that the
stimulation signals and power (e.g., bias) from the component
stimulation tool 808 are transmitted to the components within the
optical component carrier 116. For example, an attenuation module
may be located within the optical component carrier 116. The
component stimulation tool 808 provides the electrical power and
the signals necessary to operate the attenuation module. The
component end of the cable 237 may be inserted into the component
interface front end 812. Test signals from the component interface
812 may then be transmitted to the component testing system 820 for
analysis. In another aspect, the testing system 820 is adapted to
verify if the optical interface and or optical component is
defective. In another aspect, the process controller 118 controls
the testing process and equipment.
[0081] Although various embodiments which incorporate the teachings
of the invention have been shown and described in detail herein,
those skilled in the art can readily devise many other varied
embodiments within the scope of the invention. For example, it is
contemplated that the staged optical component processing system
100 may be configured to simultaneously process a plurality of
different types of optical components and components either
serially or in parallel. For example, a fiber optic switch
including a plurality of pigtail fiber optic cables may be
processed simultaneously with a fiber optic amplifier having a
single fiber optic pigtail. Therefore, while foregoing is directed
to exemplary embodiments of the invention, other and further
embodiments of the invention may be devised without departing from
the basic scope thereof, and the scope thereof is determined by the
claims that follow.
* * * * *