Alignment system and method for calibrating position of optical fiber bore ferrule

1. An alignment system for calibrating a position of an optical fiber in a bore of a ferrule, the optical fiber having light transmission path along a center axis of the optical fiber, the alignment system comprising:

an outer cylinder alignment element including a first end and a second end, wherein the first end receives a calibration ferrule that houses a fiber core alignment element having a fixed center axis and presenting a fixed fiber tip and wherein the second end receives a ferrule that houses an optical fiber, the optical fiber being unfixed within a bore of the ferrule and the optical fiber presenting a fiber tip opposite the fixed fiber tip;

an optical vision system that includes:

a first light source directed, in a first direction, towards the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element, wherein the first direction is perpendicular to the center axis of the optical fiber; and

a first imaging device positioned opposite the first light source, wherein the first imaging device produces a first image of the opposing fiber tip of the optical fiber and the fixed fiber tip within the outer cylinder alignment element based on light received from the first light source; and

a controlling and moving system that actively adjusts a position of the optical fiber in the bore of the ferrule to align the fiber tip and central axis of the optical fiber with the fixed fiber tip and central axis of the fiber core alignment element within the outer cylinder alignment element based on the detected first image.

2. The alignment system according to claim 1 , wherein the optical vision system further includes:

a second light source directed, in a second direction, towards the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element, wherein the second direction is perpendicular to the center axis of the optical fiber and is different from the first direction; and

a second imaging device positioned opposite the second light source, wherein the second imaging device produces a second image of the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element based on the light received from the second light source; and

wherein the controlling and moving system actively adjusts the position of the optical fiber in the bore of the ferrule to align the fiber tip and central axis of the optical fiber with the fixed fiber tip and central axis of the fiber core alignment element within the outer cylinder alignment element based on the detected second image.

3. The alignment system according to claim 2 , wherein the first light source is provided at one side of the outer cylinder alignment element in the first direction and wherein the first imaging device comprises a first camera provided at the other side of the outer cylinder alignment element in the first direction.

4. The alignment system according to claim 3 , wherein the second light source provided at one side of the outer cylinder alignment element in the second direction and wherein the second imaging device comprises a second camera provided at the other side of the outer cylinder alignment element in the second direction.

5. The alignment system according to claim 2 ,

further comprising an image processing system for processing the first image and the second image.

6. The alignment system according to claim 1 , wherein a gap exists between the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element.

7. The alignment system according to claim 2 ,

wherein a light transmission window is formed on a peripheral wall of the outer cylinder alignment element enabling transmission of light emitted from the first and second light sources there through.

8. The alignment system according to claim 2 ,

wherein an entirety of the outer cylinder alignment element is of transparent material enabling transmission of light emitted from the first and second light sources there through.

9. The alignment system according to claim 1 , wherein the controlling and moving system comprises:

a manipulator having a gripper that grips the optical fiber; and

a closed loop feedback control system that adjusts a position of the gripper until an error, detected by the optical vision system, of alignment of the fiber tip of the optical fiber relative to the fixed fiber tip of the fiber core alignment element is within a predetermined range.

10. The alignment system according to claim 9 , wherein the predetermined range is a range of −0.001 mm˜0.001 mm.

11. The alignment system according to claim 9 , wherein the predetermined range is a range of −0.3 μπι˜0.3 μπι.

12. A method of calibrating a position of an optical fiber in a bore of a ferrule, the optical fiber having a light transmission path along a center axis of the optical fiber, the method comprising:

inserting a calibration ferrule into a first end of an outer cylinder alignment element, wherein the calibration ferrule houses a fiber core alignment element presenting a fixed fiber tip having a fixed center axis;

inserting a ferrule into a second end of the outer cylinder alignment element, wherein the ferrule houses an optical fiber, the optical fiber being unfixed within a bore of the ferrule and the optical fiber presenting a fiber tip opposite the fixed fiber tip of the calibration ferrule;

directing light in a first direction towards the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element, wherein the first direction is perpendicular to the center axis of the optical fiber;

receiving the light directed in the first direction and generating a first image of the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element based on the received light; and

adjusting a position of the optical fiber in the bore of the ferrule to align the fiber tip and center axis of the optical fiber with the fixed fiber tip and central axis of the fiber core alignment element within the outer cylinder alignment element based on the generated first image.

13. The method according to claim 12 , further comprising:

directing light in a second direction towards the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element, wherein the second direction is perpendicular to the center axis of the optical fiber and the second direction is different from the first direction;

receiving the light directed in the second direction and generating a second image of the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element based on the received light of the second direction.

14. The method according to claim 13 , further comprising:

adjusting a position of the optical fiber in the bore of the ferrule to align the fiber tip and center axis of the optical fiber with the fixed fiber tip and central axis of the fiber core alignment element within the outer cylinder alignment element based on the generated image from the light directed in the second direction.

15. The method according to claim 12 , wherein a gap exists between the opposing fiber tip of the optical fiber and the fixed fiber tip of the fiber core alignment element within the outer cylinder alignment element.

16. The method according to claim 12 ,

wherein the position of the optical fiber in the bore of the ferrule is adjusted by:

gripping the optical fiber; and

moving the gripped fiber in response to an error feedback, the error feedback indicating an error of alignment of the fiber tip of the optical fiber relative to the fixed fiber tip of the fiber core alignment element.