Granted Patent B2

US 9,720,185 · App. 14/718,850 · Granted Aug 1, 2017

Abstract

Claims (85)

1. A processing system to connectorize optical cables, the processing system comprising:

a table arrangement on which a plurality of processing stations are disposed;

a track arrangement that is disposed above the table arrangement and from which coils of the optical cables to be connectorized are hung;

wherein the processing stations include:

a strip-clean-cleave station configured to process optical fibers at the end of the optical cables to create a prepared end of the optical fiber;

a splice station configured to fusion splice the prepared ends of the optical fibers to prepared ends of stub fibers at a splice location, each stub fiber being held by a respective ferrule;

an overmold station configured to injection mold a hub around each splice location;

a UV cure station at which UV light is directed towards the hubs to cure the injection mold;

a heat cure station including an oven configured to receive the ends of the optical cables to finish curing the injection mold; and

a connector assembly station at which an optical connector is assembled around each hub and respective ferrule; and

a second strip-clean-cleave station disposed at a separate location from the table arrangement, the second strip-clean-cleave station configured to prepare an end of a fiber stub extending from a ferrule.

2. The processing system of claim 1 , wherein the processing stations also include a non-contact testing station including a receptacle to receive each assembled optical connector, and a light source to direct light into the assembled connector to determine coupling loss of the optical cable.

3. The processing system of claim 1 , wherein the table arrangement includes a main table and a separate table, wherein the strip-clean-cleave station is disposed at the main table, and wherein the splice station is disposed at the separate table.

4. The processing system of claim 1 , wherein the table arrangement includes a first processing line and a second processing line, wherein the first processing line includes the splice station, the overmold station, the UV cure station, the heat cure station, and the connector assembly station, and wherein the second processing line includes a second splice station, a second overmold station, a second UV cure station, a second heat cure station, and a second connector assembly station.

5. The processing system of claim 4 , wherein the first and second processing lines share the strip-clean-cleave station.

6. The processing system of claim 4 , wherein the first processing line includes the non-contact testing station and the second processing line includes a second non-contact testing station.

7. The processing system of claim 4 , wherein the table arrangement is U-shaped including two arm sections extending from a base section, wherein the strip-clean-cleave station is located at the base section, and wherein each of the processing lines extends along part of the base section and along a separate one of the arm sections.

8. The processing system of claim 4 , wherein the track arrangement includes a first track disposed over the first processing line and a second track disposed over the second processing line.

9. The processing system of claim 1 , further comprising a carrier configured to transport a plurality of processed fiber stubs from the second strip-clean-cleave station to the table arrangement, the carrier inhibiting contamination of the processed fiber stubs.

10. The processing system of claim 9 , wherein the carrier defines a plurality of cavities in which the processed fiber stubs can be loaded, the carrier being configured to retain the ferrules holding the processed fiber stubs and to not contact bare glass of the processed fiber stubs.

11. The processing system of claim 10 , wherein the carrier is configured to receive the processed stub fibers with dust caps mounted over the ferrules.

12. The processing system of claim 11 , wherein the carrier is configured to transport at least fifty processed stub fibers.

13. The processing system of claim 1 , wherein the overmold station also performs tensile testing on the splice location.

14. The processing system of claim 1 , wherein the UV cure station includes a chamber recessed within the table arrangement.

15. A strip-clean-cleave arrangement configured to prepare an end of an optical fiber that is retained by a holder, the strip-clean-cleave arrangement comprising:

a body at which a plurality of sub-stations are disposed, the body having an input end and an output end;

a walking beam configured to automatically transport the optical fiber between the sub-stations from the input end to the output end using the holder; and

a control unit configured to automatically operate the sub-stations and the walking beam during an operation cycle;

wherein the plurality of sub-stations includes:

a load sub-station at the input end of the body;

a strip sub-station at which a coating is removed from the optical fiber;

a clean sub-station at which remnants of the coating are removed from the optical fiber by an ultrasonic bath;

a cleave sub-station at which an end of the optical fiber is severed to form a prepared end of the optical fiber; and

an unload sub-station at the output end of the body, wherein the load and unload sub-stations are configured to move between inner and outer positions, wherein the load and unload sub-stations are in range of the walking beam when in the respective inner positions, and wherein the load and unload sub-stations are accessible to a user when in the respective outer position.

16. The strip-clean-cleave arrangement of claim 15 , wherein the cleave-substation includes a tension cleaver to sever the end of the optical fiber.

17. The strip-clean-cleave arrangement of claim 15 , wherein the clean sub-station includes two docks at each of which a separate optical fiber can be received at the ultrasonic bath.

18. The strip-clean-cleave arrangement of claim 17 , wherein each of the docks is configured to angle the optical fiber relative to a vibrating floor of the ultrasonic bath.

19. The strip-clean-cleave arrangement of claim 15 , wherein the clean sub-station is structured so that the end of the optical fiber touches a vibrating floor of the ultrasonic bath during operation of the clean-substation.

20. The strip-clean-cleave arrangement of claim 15 , wherein the clean sub-station includes a leveler arrangement that maintains a level of cleaning fluid within the ultrasonic bath.

21. The strip-clean-cleave arrangement of claim 20 , wherein the leveler arrangement includes a leveler tank that drains to a supply tank, a siphon that extends between the leveler tank and the ultrasonic bath, and a piston that pumps water into the leveler tank.

22. The strip-clean-cleave arrangement of claim 15 , further comprising a guard arrangement coupled to the body to at least partially surround the sub-stations, the guard arrangement defining apertures through which the load and unload stations are accessible.

23. The strip-clean-cleave arrangement of claim 22 , wherein the guard arrangement includes a light curtain extending across the apertures, wherein breaking the light curtain triggers the control unit to pause operation of the walking beam.

24. The strip-clean-cleave arrangement of claim 15 , wherein at least one of the sub-stations includes a presence sensor for the holder, and wherein the at least one of the sub-stations operates during the operation cycle of the strip-clean-cleave arrangement only if a presence of the holder is detected by the presence sensor.

25. The strip-clean-cleave arrangement of claim 15 , wherein the load sub-station also includes a heating unit configured to straighten a jacket disposed around the optical fiber.

26. A processing system to connectorize optical cables, the processing system comprising:

a table arrangement on which a plurality of processing stations are disposed, the table arrangement including a first processing line of the processing stations and a second processing line of the processing stations, wherein the table arrangement is U-shaped including two arm sections extending from a base section, and wherein each of the processing lines extends along part of the base section and along a separate one of the arm sections;

a track arrangement that is disposed above the table arrangement and from which coils of the optical cables to be connectorized are hung;

wherein the processing stations of the first processing line include:

a strip-clean-cleave station located at the base section, the strip-clean-cleave station being configured to process optical fibers at the end of the optical cables to create a prepared end of the optical fiber;

a splice station configured to fusion splice the prepared ends of the optical fibers to prepared ends of stub fibers at a splice location, each stub fiber being held by a respective ferrule;

an overmold station configured to injection mold a hub around each splice location;

a UV cure station at which UV light is directed towards the hubs to cure the injection mold;

a heat cure station including an oven configured to receive the ends of the optical cables to finish curing the injection mold; and

a connector assembly station at which an optical connector is assembled around each hub and respective ferrule;

wherein the processing stations of the second processing line include a second splice station, a second overmold station, a second UV cure station, a second heat cure station, and a second connector assembly station.

27. A processing system to connectorize optical cables, the processing system comprising:

a table arrangement on which a plurality of processing stations are disposed;

a track arrangement that is disposed above the table arrangement and from which coils of the optical cables to be connectorized are hung;

wherein the processing stations include:

a strip-clean-cleave station configured to process optical fibers at the end of the optical cables to create a prepared end of the optical fiber;

a splice station configured to fusion splice the prepared ends of the optical fibers to prepared ends of stub fibers at a splice location, each stub fiber being held by a respective ferrule;

an overmold station configured to injection mold a hub around each splice location;

a UV cure station at which UV light is directed towards the hubs to cure the injection mold, wherein the UV cure station includes a chamber recessed within the table arrangement;

a heat cure station including an oven configured to receive the ends of the optical cables to finish curing the injection mold; and

a connector assembly station at which an optical connector is assembled around each hub and respective ferrule.

28. A strip-clean-cleave arrangement configured to prepare an end of an optical fiber that is retained by a holder, the strip-clean-cleave arrangement comprising:

a body at which a plurality of sub-stations are disposed, the body having an input end and an output end;

a walking beam configured to automatically transport the optical fiber between the sub-stations from the input end to the output end using the holder; and

a control unit configured to automatically operate the sub-stations and the walking beam during an operation cycle;

wherein the plurality of sub-stations includes:

a load sub-station at the input end of the body;

a strip sub-station at which a coating is removed from the optical fiber;

a clean sub-station at which remnants of the coating are removed from the optical fiber by an ultrasonic bath, wherein the clean sub-station is structured so that the end of the optical fiber touches a vibrating floor of the ultrasonic bath during operation of the clean-substation;

a cleave sub-station at which an end of the optical fiber is severed to form a prepared end of the optical fiber; and

an unload sub-station at the output end of the body.

29. A strip-clean-cleave arrangement configured to prepare an end of an optical fiber that is retained by a holder, the strip-clean-cleave arrangement comprising:

a body at which a plurality of sub-stations are disposed, the body having an input end and an output end;

a walking beam configured to automatically transport the optical fiber between the sub-stations from the input end to the output end using the holder; and

a control unit configured to automatically operate the sub-stations and the walking beam during an operation cycle;

wherein the plurality of sub-stations includes:

a load sub-station at the input end of the body;

a strip sub-station at which a coating is removed from the optical fiber;

a clean sub-station at which remnants of the coating are removed from the optical fiber by an ultrasonic bath, wherein the clean sub-station includes a leveler arrangement that maintains a level of cleaning fluid within the ultrasonic bath, wherein the leveler arrangement includes a leveler tank that drains to a supply tank, a siphon that extends between the leveler tank and the ultrasonic bath, and a piston that pumps water into the leveler tank;

a cleave sub-station at which an end of the optical fiber is severed to form a prepared end of the optical fiber; and

an unload sub-station at the output end of the body.

Assignments (22)