US20220410334A1 - Method and assembly for polishing optical cables - Google Patents
Method and assembly for polishing optical cables Download PDFInfo
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- US20220410334A1 US20220410334A1 US17/801,500 US202117801500A US2022410334A1 US 20220410334 A1 US20220410334 A1 US 20220410334A1 US 202117801500 A US202117801500 A US 202117801500A US 2022410334 A1 US2022410334 A1 US 2022410334A1
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- Prior art keywords
- polishing
- platform
- cables
- fixture
- assembly
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/22—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground
- B24B19/226—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground of the ends of optical fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/22—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B29/00—Machines or devices for polishing surfaces on work by means of tools made of soft or flexible material with or without the application of solid or liquid polishing agents
- B24B29/02—Machines or devices for polishing surfaces on work by means of tools made of soft or flexible material with or without the application of solid or liquid polishing agents designed for particular workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
- B24B41/06—Work supports, e.g. adjustable steadies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
- B24B41/06—Work supports, e.g. adjustable steadies
- B24B41/067—Work supports, e.g. adjustable steadies radially supporting workpieces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/12—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation involving optical means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
- B24B49/16—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the load
Definitions
- the invention relates to methods and assemblies for polishing optical cables.
- Fiber optic cables are cables that contain several thousand optical fibers in a protective insulated jacket. These optical fibers are very thin strands of silica (e.g., glass) that transmit information in the form of light. Fiber optic cables are increasingly used in industries such as telecommunications, medical diagnostics, medical therapeutics (e.g. surgery and dentistry), automotive, lighting, mechanical inspection and analytical instrumentation, military, and aerospace.
- industries such as telecommunications, medical diagnostics, medical therapeutics (e.g. surgery and dentistry), automotive, lighting, mechanical inspection and analytical instrumentation, military, and aerospace.
- Fiber optic cables are polished after cleaving to remove scratches and other surface imperfections that promote signal loss.
- fiber optic cable polishers include a cable mount and a rotating polishing film that presses and rubs against the cable.
- important factors for consideration to achieve high precision polishing include the speed of the rotating film, the positioning of the cable and its applied pressure against the rotating film, and the duration of polishing.
- the invention provides improved methods, assemblies and devices for high precision polishing, which can be adjusted in a reactive manner due to inputs in real time from physical force data.
- a method of polishing optical cables which includes a polishing assembly loaded with a polishing film, the polishing assembly having a platform to which the polishing film is loaded, the platform configured to rotate according to a dual orbital motion and coupled to a force gauge that measures downward force applied against the platform, a mounting fixture configured to mount a plurality of optical cables, the mounting fixture attached to a movable arm that moves the mounting fixture towards and away from the platform.
- the method includes mounting a plurality of optical cables to the mounting fixture; pressing the optical cables against the rotating polishing film while simultaneously monitoring the downward force applied against the platform; and adjusting the downward force to remain within a prescribed tolerance.
- the fixture includes a plurality of clamps that clamp the plurality of optical cables in place.
- the clamps include a moveable tab that locks closed using magnetic force.
- the fixture and platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform.
- the adjustment dials are 4-way adjustment dials.
- the rotation speed of the platform preferably increases gradually.
- the arm presses the cables against the rotating polishing film gradually to polish the cables at a lower pressure followed by polishing the cables at a higher pressure.
- the higher pressure can vary but is typically about 0.5-1 lb. of pressure per cable.
- the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform.
- This downward force can be adjusted by a feedback mechanism that functionally couples the force gauge to the arm.
- the method can also include washing the polished optical cables in an ultrasonic bath, the bath optionally filled with deionized water and/or isopropyl alcohol. Moreover, the method can include optically inspecting a polished surface of the cables, and optionally repeating polishing and washing steps until the polished surface meets a final acceptable standard. During such a process a same or different polishing film can be used.
- the preferred approach for optical inspection includes inspection by camera.
- the camera may be configured to relay inspection footage to a computer, loaded with software that compares the polish to an intermediate or final standard. In some embodiments, the camera provides a live feed to a computer.
- a polishing assembly which includes a platform configured to receive a polishing film and configured to rotate according to a dual orbital motion; a force gauge functionally coupled to the platform and configured to measure downward force applied against the platform; a mounting fixture configured to mount a plurality of optical cables; and a movable arm configured to move the mounting fixture downwards to press mounted cables against the polishing film, upwards to pull the mounted cables away from the polishing film, and to rotate circularly along a continuous circular path.
- the fixture can include a plurality of clamps that clamp the plurality of optical cables in place.
- the clamps can include a moveable tab that locks closed using magnetic force.
- the fixture and platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform, the adjustment dials optionally being 4-way adjustment dials.
- the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform.
- the force gauge can communicate directly with the arm or with a computer that communicates with the arm.
- the polishing assembly can also include or be used in connection with an ultrasonic bath, the bath optionally filled with deionized water and/or isopropyl alcohol.
- the polishing assembly can also include or be used in connection with an optical inspection station, which includes a camera.
- the camera can relay inspection footage to a computer, optionally loaded with software that compares the polish to an intermediate or final standard. In some embodiments, the camera provides a live feed to a computer.
- a mounting fixture configured to mount a plurality of optical cables, which includes a planar surface having a plurality of apertures for receiving a plurality of optical cables; a plurality of arms that rock open and closed to release and lock the cables in place; and a plurality of magnets that magnetically lock the arms closed.
- FIGS. 1 A- 1 C are pictorial diagrams showing a polishing assembly 10 in accordance with one or more embodiments of the present disclosure.
- FIGS. 2 A- 2 F are pictorial diagrams showing an exemplary process of mounting optic cables 70 to a mounting fixture 50 in accordance with one or more embodiments of the present disclosure.
- FIG. 2 E is a pictorial diagram showing a cross-sectional perspective view of an exemplary clamp 54 in an open position taken along line 2 E- 2 E of FIG. 2 C in accordance with one or more embodiments of the present disclosure.
- FIG. 2 F is a pictorial diagram showing a perspective view of the clamp 54 in the closed position in accordance with one or more embodiments of the present disclosure.
- FIGS. 3 A- 3 B are pictorial diagrams showing movement of an arm 16 and the fixture 50 towards a polishing film 80 , which is positioned on the polishing platform 12 in accordance with one or more embodiments of the present disclosure.
- FIG. 4 is a pictorial diagram showing an exemplary cable path 22 over the polishing film 80 or platform 12 during dual orbital rotation in accordance with one or more embodiments of the present disclosure.
- FIG. 5 is a pictorial diagram showing an exemplary orbital gearing 24 to accomplish dual orbital rotation in accordance with one or more embodiments of the present disclosure.
- FIG. 6 is a pictorial diagram showing an exemplary ball bearing 26 configuration for improved dual orbital rotation in accordance with one or more embodiments of the present disclosure.
- FIG. 7 is a pictorial diagram showing a cross-sectional side view of the polishing assembly 10 along line 7 - 7 of FIG. 1 A in accordance with one or more embodiments of the present disclosure.
- FIG. 8 is a pictorial diagram showing an exemplary force gauge 20 in accordance with one or more embodiments of the present disclosure.
- FIG. 9 is a pictorial diagram showing the force gauge 20 in accordance with one or more embodiments of the present disclosure.
- FIGS. 10 A- 10 C are pictorial diagrams showing an exemplary mounting fixture 50 in accordance with one or more embodiments of the present disclosure.
- FIG. 10 D is a pictorial diagram showing a cross-sectional perspective view of the exemplary mounting fixture 50 taken along line 10 D- 10 D of FIG. 10 B in accordance with one or more embodiments of the present disclosure.
- FIG. 11 is a block diagram showing exemplary stations used during polishing and inspection processes of the polishing assembly 10 in accordance with one or more embodiments of the present disclosure.
- FIG. 12 is a flow chart showing an exemplary process of the assembly of polishing and inspecting optic cables 70 in accordance with one or more embodiments of the present disclosure.
- a polishing assembly and methods of polishing optical cables are disclosed here. More specifically, the polishing assembly may polish optical cables at a high precision, thereby, reducing signal loss when coupling ends of the optical cables to connectors or other devices.
- FIGS. 1 A- 1 C show a polishing assembly 10 in accordance with one or more embodiments of the present disclosure.
- High-precision polishing is accomplished by way of a polishing assembly 10 , which includes a base 48 and a mounting fixture 50 (also referred to herein as a “fixture”) selectively coupled to base 48 .
- base 48 may include a platform 12 , an arm 16 , and dial indicators 18 .
- Base 48 may also include a body 28 having a housing 30 that platform 12 extends therefrom.
- a motor 92 is disposed within housing 30 of body 28 (as shown in FIG. 7 ).
- platform 12 is configured to receive and secure a polishing film 80 (shown in FIGS. 3 A and 3 B ) and rotate about axis A of arm 16 (e.g., following a dual orbital motion).
- a force gauge 20 is functionally coupled to platform 12 (shown in FIG. 7 ) and configured to measure a force (e.g., a downward force that is along axis A of arm 16 and toward platform 12 ) applied against platform 12 .
- mounting fixture 50 is configured to receive and mount a plurality of optical cables 70 (shown in FIGS. 2 A and 2 B ), as discussed further herein.
- movable arm 16 is configured to move in multiple directions manually (e.g., using dials 38 ) or automatically.
- arm 16 may move in one or more directions to achieve various positions relative to platform 12 . In one or more embodiments, arm 16 may be moved to any desired position using, for example, dials 38 . In one or more embodiments, arm 16 may move mounting fixture 50 towards platform 12 and corresponding polishing film 80 (shown in FIGS. 3 A and 3 B ) to press mounted cables 70 (shown in FIGS. 2 A and 2 B ) against polishing film 80 . Similarly, arm 16 may move mounting fixture 50 away from polishing film 80 . For example, arm 16 may be moved upward away from platform 12 and along axis A.
- Arm 16 also rotates circularly about axis B of base 48 along a continuous circular path, which can be used to incorporate supplemental steps and stations, such as those for washing, quality inspection, and collection/mounting of cables, as discussed further herein.
- rotation permits the use of multiple movable arms 16 extending from a single axis (e.g., axis B) to polish multiple sets of optical cables 70 , where each movable arm 16 moves in series through any number of polishing, washing, and inspection steps.
- FIGS. 2 A- 2 F show an exemplary process of mounting optic cables 70 to mounting fixture 50 in accordance with one or more embodiments of the present disclosure.
- optical cables 70 are securely mounted to mounting fixture 50 , which is itself attached or attachable to arm 16 .
- mounting fixture 50 may be selectively coupled to arm 16 by inserting a protrusion 68 of arm 16 within a bore 14 of stem of mounting fixture 50 and fastening protrusion 68 within bore 14 using various attachment mechanism such as, for example, screws (as shown in FIG. 1 C ). While it is within the scope of the disclosure that mounting fixture 50 mount only one or only a few cables 70 , preferably, fixture 50 mounts a plurality of cables 70 to permit simultaneous and efficient polishing.
- fixture 50 mounts at least thirty or about thirty cables 70 .
- Cables 70 can be arranged according to a variety of patterns. For example, cables 70 may be equally spaced along a circular path about mounting fixture 50 . More specifically, cables 70 may be positioned and mounted about a circumference of pad 46 so that each cable 70 along the circumference is equidistant to axis A when mounting fixture 50 is attached to arm 16 .
- each clamp 54 may include at least a tab 56 , a spring 60 , and at least two magnets 58 (e.g., magnet 58 a of tab 56 and magnet 58 b of pad 46 ).
- each clamp 54 has at least two positions, namely, an open position (shown in FIGS. 2 A, 2 C, 2 D, and 2 E ) to permit cable 70 to slide in and out of aperture 52 , and a closed position (shown in FIGS. 2 B and 2 F ) that securely holds cable 70 in place during polishing, washing, and/or analysis.
- FIGS. 2 A- 2 F show a particularly preferred configuration, which uses magnetic attraction.
- a plurality of tabs 56 are shown that rock open and closed to either release or lock cables 70 in place, respectively.
- a plurality of magnets 58 are provided that magnetically hold rocking tabs 56 when in the closed position.
- a user may push tab 56 in a first direction (e.g., in a downward direction shown by directional arrow 11 ) toward pad 46 until magnet 58 a of tab 56 is abutting magnet 58 b of pad 46 .
- magnets 58 a,b results in clamp 54 maintaining the closed position by tab 56 continuously abutting pad 46 during operation of polishing assembly 10 .
- magnets 58 can be used to achieve the same affect, including ferrite, alnico, and rare earth magnets.
- a holding force of clamp 54 can be facilitated by a flat spring 60 , which presses against a boot 62 , through which cable 70 passes.
- magnetic attraction effectively maintains clamp 54 in a closed position and also provides an easy approach for releasing clamp 54 into the open position, namely, using one's finger to simply upwardly (e.g., in a direction opposite of directional arrow 11 ) flip a tongue portion 64 of tab 56 , which extends over the edge of pad 46 , to overcome the magnetic attraction between magnets 58 a,b .
- the open position may also be facilitated by a coiled spring 72 disposed beneath tab 56 that keeps tab 56 in the open position unless a user applies a downward force, compressing coiled spring 72 .
- fixture 50 is attached or attachable to mechanical arm 16 , and surface 82 fixture 50 is, preferably, aligned parallel to a surface 84 of platform 12 .
- the precise adjustment of the plane (e.g., surface 82 ) of fixture 50 can be performed through the use of dial indicators 18 on arm 16 and/or fixture 50 .
- four dial indicators 18 are used to provide complete control over the attachment of fixture 50 to mechanical arm 16 to ensure a precise alignment of planar fixture 50 . Since the parallel alignment between fixture 50 and polishing platform 12 is critical, in some embodiments, polishing platform 12 can be tilted, such as by dial indicators 18 to ensure parallel orientation with fixture 50 .
- FIGS. 3 A and 3 B show movement of arm 16 and fixture 50 towards polishing film 80 (e.g., as indicated by directional arrow 13 of FIG. 3 A ), which is positioned on polishing platform 12 in accordance with one or more embodiments of the present disclosure.
- fixture 50 is lowered towards the polishing film-loaded platform 12 for polishing (cables omitted for demonstration purposes).
- arm 16 slows as cables 70 (shown in FIG. 2 B ) reach polishing film 80 .
- a slow movement of arm 16 slowly builds pressure between cables 70 and polishing film 80 /platform 12 .
- polishing begins at a lower pressure, then the pressure is continued or increases over time during the polishing process.
- a typical force starts at about 0.5-1 lb, then increases up to about 20 lbs.
- the force may be as high as 30 lbs.
- the force applied to each cable 70 during polishing may be between 0.25-3 lbs.
- force gauge 20 (shown in FIGS. 7 - 9 ) measures the force applied to platform 12 , and a feedback mechanism communicatively coupled to force gauge 20 dictates movement of arm 16 to maintain the applied force within desired parameters.
- platform 12 may have a high speed of 100 rpm.
- FIG. 4 shows an exemplary cable path 22 over polishing film 80 during dual orbital rotation in accordance with one or more embodiments of the present disclosure.
- polishing may be performed by a way of singular orbital rotation.
- polishing is performed by way of dual orbital rotation of platform 12 , which is overlaid with polishing film 80 , such as a 3 ⁇ m-9 ⁇ m diamond film.
- dual orbital cable path 22 includes two concentric paths including an outer path 32 and an inner path 34 (e.g., two concentric epitrochoid paths).
- dual orbital rotation is that it prolongs the life of polishing film 80 because cable path 22 over film 80 does not repeat.
- twenty cables 70 may be positioned along an outer circumference of pad 46 , which follow outer path 32 during polishing, and ten cables 70 may be positioned along an inner circumference of pad 46 , which follow inner path 34 during polishing.
- FIGS. 5 and 6 show exemplary embodiments of orbital gearing 24 of platform 12 and a bearing 26 (e.g., a ball or roller bearing) of arm 16 used to accomplish the dual orbital rotation in accordance with one or more embodiments of the present disclosure.
- orbital gearing 24 is located beneath surface 84 of platform 12 and allows for rotation and lateral movement of platform 12 .
- bearing 26 allows for rotation of arm 16 about axis B.
- the force applied against platform 12 is preferably measured using force gauge 20 , which is positioned underneath polishing platform 12 (shown in FIG. 7 ).
- polishing assembly 10 also includes a strain gauge 96 .
- positioning force gauge 20 in physical force communication with platform 12 directly measures forces applied to platform 12 .
- force gauge 20 receives true pressure and, thus, provides true force data. As such, there is no need to further calculate or extrapolate pressure using equations or conversions that would be required in electronic or optical detection systems.
- force gauge 20 communicates directly with electronic circuitry in arm 16 to instruct upward or downward movement of arm 16 to achieve a desired force.
- force gauge 20 collects pressure readings and provides the data to a computer processing unit, which instructs movement of mechanical arm 16 and, optionally, rotational speed of polishing platform 12 in response to the provided pressure data.
- the dual orbital speed of polishing platform 12 and the contact force of cables 70 /mounting fixture 50 can be adjusted in response to pressure data provided by force gauge 20 .
- force gauge 20 provides data to ensure surface 82 of mounting fixture 50 is level with surface 84 of platform 12 so that pressure is evenly applied to each cable 70 .
- the computer processing unit may use an algorithm that compensates for nonlinearity and to prevent any undesired play or wiggle in arm 16 and mounting fixture 50 when not in use, which is often an inherent problem in stepper motors.
- the computer processing unit may also determine the lifetime of polishing film 80 .
- a timer of the computer processing unit may count the number of polishing cycles, the time of each polishing cycle, and/or the pressure of each polishing cycle to determine when a user should replace polishing film 80 .
- the computer processing unit may be any compatible electronic device (e.g., processor, smartphone, desktop computer, laptop, or tablet).
- computer processing unit may be loaded with a software (e.g., an application).
- computer processing unit may include an interface that allows for user input or display of collected or processed data.
- a system that measures force at the arm 16 requires substantially more compensation in that the measurement would also have to consider the weight of the fixture 50 , any connectors, optical cables 70 mounted to the fixture 50 , and arm 16 itself. Furthermore, it would also have to compensate for the downward force being applied by the arm 16 itself during polishing.
- the feedback mechanism controls the movement of arm 16 and, thus, the pressure applied from cables 70 against polishing platform 12 .
- This feedback mechanism can be by directly communicating force gauge 20 to a regulator that regulates downward movement of arm 16 .
- the regulator can be programmed to perform a stepwise progression through a preset array of pressures or can be adjusted manually by a user to perform a desired pressure.
- force gauge 20 is communicatively coupled to a computer with programming able to receive the pressure data and, in response, adjust movement of fixture 50 towards polishing platform 12 to meet program requirements.
- the computer is also communicatively coupled to motor 92 of polishing assembly 10 for controlling the speed of the dual orbital rotation of polishing platform 12 so that the rotational speed of polishing film 80 can progress according to real time measurements of the applied pressure.
- FIGS. 10 A- 10 D show another exemplary embodiment of mounting fixture 50 in accordance with one or more embodiments of the present disclosure.
- mounting fixture 50 may include an arrangement of cables 70 having two concentric circles.
- pad 46 may include an outer circular arrangement 172 of apertures 52 and an inner circular arrangement 174 of apertures 52 , where each clamp 54 may be mounted over each aperture 52 to mount cables 70 to fixture 50 .
- fixture 50 may also include outer bracket 142 and inner bracket 144 . Cables 70 may abut portions of brackets 142 , 144 that are directly above corresponding apertures 52 to provide alignment of cables 70 and secure opposing ends of cables 70 .
- apertures 52 may be empty (as shown in FIG. 2 E ).
- apertures 52 may have additional components disposed therein, such as a sleeve 188 , which cable 70 may traverse therethrough, and a pair of opposing notches 192 , which may further engage complementary surfaces of boot 62 to secure boot 62 to pad 46 .
- FIG. 11 is a block diagram showing polishing assembly in an exemplary use in accordance with one or more embodiments of the present disclosure.
- Polishing assembly 10 may be positioned at a polishing station 300 .
- Polishing assembly 10 may be in communication with a computer processing unit (e.g., electronic device 302 ) via a communication link 308 .
- Communication link 308 may be a wired or wireless communication.
- electronic device 302 may include a display and/or interface, allowing a user to input commands to electronic device 302 .
- Polishing assembly 10 may polish cables 70 at polishing station 300 using friction and by rubbing the ends of cables 70 , which are secured in fixture 50 , against polishing film 80 , which is secured to platform 12 .
- polishing assembly 10 includes or is used together with an ultrasonic bath (not shown).
- arm 16 of polishing assembly 10 may pivot about axis B toward a washing station 310 .
- Washing station 310 may include an ultrasonic bath 306 .
- Ultrasonic baths are liquid baths that use cavitation bubbles induced by high frequency to agitate the liquid. This agitation produces high forces on contaminants adhering to substrates, such as optical cables 70 .
- the method of polishing optical cables 70 can also include movement of arm 16 to move cables 70 away from platform 12 , rotation towards ultrasonic bath 306 , and lowering optical cables 70 into ultrasonic bath 306 to remove residual material away from optical cable 70 .
- ultrasonic bath 306 can include deionized water, isopropyl alcohol, or any combinations thereof.
- polishing assembly 10 may also include or be used together with an inspection station 320 .
- Inspection station 320 may include a camera 304 , which is in communication with electronic device 302 via communication link 312 .
- Communication link 312 may be a wired or wireless communication link.
- wired communication may be but not limited to, Ethernet, DSL, or cable.
- Wireless communication may be, but not limited to, use Bluetooth or Wi-Fi.
- Inspection station 320 may be used to inspect the surfaces of cables 70 before, during, or after polishing station 300 .
- arm 16 may pivot about axis B to inspection station 320 so the finish of cables 70 made be inspected by means discussed further herein.
- FIG. 12 is a flow chart showing an exemplary process 200 of polishing and inspecting cables 70 using polishing assembly 10 in accordance with one or more embodiments of the present disclosure.
- polishing assembly 10 includes or is used together with a quality control inspection step to ensure cable 70 is polished within required tolerances or percentage of yield) (e.g., inspection station 320 ).
- a quality control inspection step to ensure cable 70 is polished within required tolerances or percentage of yield (e.g., inspection station 320 ).
- cables 70 should be free of scratches and other surface imperfections that promote signal loss.
- a user or an automation may lower mounted cables 70 toward polishing platform 12 , which is loaded with a polishing film 80 , until cables 70 contact (e.g., are pressing against) polishing film 80 at a desired pressure.
- arm 16 may be lowered using dials 38 and one or more linear slides so that attached mounting fixture 50 is, consequently, lowered toward platform 12 , which has polishing film 80 secured thereto (e.g., secured to surface 84 of platform 12 ).
- the process may include monitoring the downward force applied against platform 12 using force gauge 20 .
- a user may begin the polishing process, allowing the process to proceed for a predetermined duration of time.
- the rotational speed of platform 12 may gradually increase once cables 70 are in contact with polishing film 80 to remove any imperfections on the surfaces of cables 70 .
- arm 16 may also increase pressure between cables 70 and platform 12 during the polishing process.
- the process may include adjusting the downward force to remain with a prescribed tolerance.
- arm 16 may rotate fixture 50 about axis A.
- the predetermined duration of time may be chosen by a user or may be determined, for example, by the computer processing unit.
- a user or computer processing unit may stop polishing so that the user or computer processing unit may analyze cables 70 .
- arm 16 may move fixture 50 over to inspection station 320 so that a user or electronic device 302 may analyze and determine the current status of the polish on each cable 70 .
- a user may do an optical inspection of cables 70 by referencing an exemplary image of a polished cable that is, for example, provided by electronic device 302 , as shown in block 208 . The user may then determine from the exemplary image whether or not cables 70 are within the desired tolerance or percentage of yield, as shown in block 212 .
- cables 70 may be scanned, for example, by camera 304 , which is communicatively coupled to the electronic device 302 so that electronic device 302 may determine the tolerance or percentage of yield of each cable 70 , as shown in block 210 .
- camera 304 may relay inspection footage to electronic device 302 , which is, optionally, loaded with software that compares the polish of cables 70 to an intermediate or final standard.
- camera 304 provides a live feed to electronic device 302 , which may be shown on a display of electronic device 302 .
- electronic device 302 may determine if the desired percentage of yield is achieved, as shown in block 212 .
- inspection is performed after washing cables 70 in ultrasonic bath 306 by instructing arm 16 to move fixture 50 with cables 70 away from ultrasonic bath 306 at washing station 310 and continue the rotational path to inspection station 320 , which itself may have one or more inspecting cameras, such as camera 304 .
- polishing assembly 10 may use a stepper motor and at least one bearing (e.g., a roller bearing), mounting fixture 50 may be moved in any direction to any position necessary for proper inspection.
- fixture 50 may rotate, pivot, or slide in any direction while camera 304 at inspection station 320 is scanning each cable 70 .
- electronic device 302 may provide data regarding the percentage of yield and, if applicable, the additional time required to achieve the desired percentage of yield.
- inspection can be performed by visual inspection under magnification, surface scattering approaches, or performed by a camera (e.g., camera 304 ) coupled to a computer or viewing monitor for surface analysis (e.g., electronic device 302 ), which eliminates any subjective aspect of inspection.
- a camera e.g., camera 304
- surface analysis e.g., electronic device 302
- inspection can result in a positive or negative response.
- a positive response demonstrates that the polished material is of suitable quality and, thus, passes inspection.
- a negative response demonstrates that the polished material is not of suitable quality and must be reworked.
- cables may be removed from mounting fixture 50 , as shown in block 214 . If the user or computer processing unit determines, that the desired percentage of yield has not been achieved, then the process may return to block 202 , continuing the polishing process until cables 70 are within the desired percentage of yield and are, thus, found to have an acceptable polish.
- mechanical arm 16 can move fixture 50 away from the inspection station 320 to a collection station (not shown) for collecting cables 70 .
- Collection may include releasing fixture 50 from mechanical arm 16 and/or opening clamps 54 to remove cables 70 .
- the positive response can also include releasing clamps 54 , whether by manually flipping tabs 56 upward (e.g., away from pad 46 ) or through automation, thereby allowing removal of polished cables 70 and, optionally, insertion of a next batch of cables for polishing.
- mechanical arm 16 can return fixture 50 to its polishing position at polishing station 300 for additional polishing.
- the negative response can also instruct polishing platform 12 to speed up, thereby saving processing time.
- the steps of polishing, washing, and inspection may be performed as a single cycle, as a series of cycles, or the steps be reordered over multiple cycles as desired.
- the method may perform two or more polishing and washing steps prior to the inspection step.
- polishing with different polishing films 80 such as progressing from 3 ⁇ m to 9 ⁇ m diamond films, may be performed prior to inspection.
- cables 70 are packaged using approaches known in the art for use in a variety of industries such as telecommunications, medical diagnostics, medical therapeutics (e.g. surgery and dentistry), automotive, lighting, mechanical inspection and analytical instrumentation, military and aerospace industries.
- the methods may also include a pretreatment step, where the cables 70 are pretreated with a solution prior to polishing.
- the pretreatment occurs by dipping the cables 70 in the ultrasonic bath.
- the specification may have presented the method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims.
Abstract
A polishing assembly and method for polishing optical cables, the polishing assembly having a platform configured to receive a polishing film and configured to rotate according to a dual orbital motion; a force gauge functionally coupled to the platform and configured to measure downward force applied against the platform; a mounting fixture configured to mount a plurality of optical cables; and a movable arm configured to move the mounting fixture downwards to press mounted cables against the polishing film, upwards to pull the mounted cables away from the polishing film, and to rotate circularly along a continuous circular path. The optical cables are pressed against the rotating polishing film while simultaneously monitoring the downward force applied against the platform so that downward force can be maintained within a prescribed tolerance throughout the polishing process.
Description
- This application claims benefit of priority to U.S. patent application No. 62/985,172, filed Mar. 4, 2020, the content of which is herein incorporated by reference in its entirety.
- The invention relates to methods and assemblies for polishing optical cables.
- Fiber optic cables are cables that contain several thousand optical fibers in a protective insulated jacket. These optical fibers are very thin strands of silica (e.g., glass) that transmit information in the form of light. Fiber optic cables are increasingly used in industries such as telecommunications, medical diagnostics, medical therapeutics (e.g. surgery and dentistry), automotive, lighting, mechanical inspection and analytical instrumentation, military, and aerospace.
- Fiber optic cables are polished after cleaving to remove scratches and other surface imperfections that promote signal loss. Typically, fiber optic cable polishers include a cable mount and a rotating polishing film that presses and rubs against the cable. Among the important factors for consideration to achieve high precision polishing include the speed of the rotating film, the positioning of the cable and its applied pressure against the rotating film, and the duration of polishing.
- The invention provides improved methods, assemblies and devices for high precision polishing, which can be adjusted in a reactive manner due to inputs in real time from physical force data. This is achieved in one aspect of the invention by a method of polishing optical cables, which includes a polishing assembly loaded with a polishing film, the polishing assembly having a platform to which the polishing film is loaded, the platform configured to rotate according to a dual orbital motion and coupled to a force gauge that measures downward force applied against the platform, a mounting fixture configured to mount a plurality of optical cables, the mounting fixture attached to a movable arm that moves the mounting fixture towards and away from the platform. The method includes mounting a plurality of optical cables to the mounting fixture; pressing the optical cables against the rotating polishing film while simultaneously monitoring the downward force applied against the platform; and adjusting the downward force to remain within a prescribed tolerance.
- In some embodiments, the fixture includes a plurality of clamps that clamp the plurality of optical cables in place. In further embodiments, the clamps include a moveable tab that locks closed using magnetic force.
- In preferred embodiments, the fixture and platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform. In some embodiments, the adjustment dials are 4-way adjustment dials.
- The rotation speed of the platform preferably increases gradually. Likewise, the arm presses the cables against the rotating polishing film gradually to polish the cables at a lower pressure followed by polishing the cables at a higher pressure. The higher pressure can vary but is typically about 0.5-1 lb. of pressure per cable.
- In preferred embodiments, the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform. This downward force can be adjusted by a feedback mechanism that functionally couples the force gauge to the arm.
- The method can also include washing the polished optical cables in an ultrasonic bath, the bath optionally filled with deionized water and/or isopropyl alcohol. Moreover, the method can include optically inspecting a polished surface of the cables, and optionally repeating polishing and washing steps until the polished surface meets a final acceptable standard. During such a process a same or different polishing film can be used. The preferred approach for optical inspection includes inspection by camera. The camera may be configured to relay inspection footage to a computer, loaded with software that compares the polish to an intermediate or final standard. In some embodiments, the camera provides a live feed to a computer.
- In a related aspect of the invention, a polishing assembly is provided, which includes a platform configured to receive a polishing film and configured to rotate according to a dual orbital motion; a force gauge functionally coupled to the platform and configured to measure downward force applied against the platform; a mounting fixture configured to mount a plurality of optical cables; and a movable arm configured to move the mounting fixture downwards to press mounted cables against the polishing film, upwards to pull the mounted cables away from the polishing film, and to rotate circularly along a continuous circular path.
- The fixture can include a plurality of clamps that clamp the plurality of optical cables in place. The clamps can include a moveable tab that locks closed using magnetic force.
- In some embodiments, the fixture and platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform, the adjustment dials optionally being 4-way adjustment dials.
- Preferably, the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform. The force gauge can communicate directly with the arm or with a computer that communicates with the arm.
- The polishing assembly can also include or be used in connection with an ultrasonic bath, the bath optionally filled with deionized water and/or isopropyl alcohol. The polishing assembly can also include or be used in connection with an optical inspection station, which includes a camera. The camera can relay inspection footage to a computer, optionally loaded with software that compares the polish to an intermediate or final standard. In some embodiments, the camera provides a live feed to a computer.
- In still another related aspect of the invention, a mounting fixture configured to mount a plurality of optical cables is provided, which includes a planar surface having a plurality of apertures for receiving a plurality of optical cables; a plurality of arms that rock open and closed to release and lock the cables in place; and a plurality of magnets that magnetically lock the arms closed.
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FIGS. 1A-1C are pictorial diagrams showing apolishing assembly 10 in accordance with one or more embodiments of the present disclosure. -
FIGS. 2A-2F are pictorial diagrams showing an exemplary process of mountingoptic cables 70 to amounting fixture 50 in accordance with one or more embodiments of the present disclosure. -
FIG. 2E is a pictorial diagram showing a cross-sectional perspective view of anexemplary clamp 54 in an open position taken alongline 2E-2E ofFIG. 2C in accordance with one or more embodiments of the present disclosure. -
FIG. 2F is a pictorial diagram showing a perspective view of theclamp 54 in the closed position in accordance with one or more embodiments of the present disclosure. -
FIGS. 3A-3B are pictorial diagrams showing movement of anarm 16 and thefixture 50 towards apolishing film 80, which is positioned on thepolishing platform 12 in accordance with one or more embodiments of the present disclosure. -
FIG. 4 is a pictorial diagram showing anexemplary cable path 22 over thepolishing film 80 orplatform 12 during dual orbital rotation in accordance with one or more embodiments of the present disclosure. -
FIG. 5 is a pictorial diagram showing an exemplaryorbital gearing 24 to accomplish dual orbital rotation in accordance with one or more embodiments of the present disclosure. -
FIG. 6 is a pictorial diagram showing an exemplary ball bearing 26 configuration for improved dual orbital rotation in accordance with one or more embodiments of the present disclosure. -
FIG. 7 is a pictorial diagram showing a cross-sectional side view of thepolishing assembly 10 along line 7-7 ofFIG. 1A in accordance with one or more embodiments of the present disclosure. -
FIG. 8 is a pictorial diagram showing anexemplary force gauge 20 in accordance with one or more embodiments of the present disclosure. -
FIG. 9 is a pictorial diagram showing theforce gauge 20 in accordance with one or more embodiments of the present disclosure. -
FIGS. 10A-10C are pictorial diagrams showing anexemplary mounting fixture 50 in accordance with one or more embodiments of the present disclosure. -
FIG. 10D is a pictorial diagram showing a cross-sectional perspective view of theexemplary mounting fixture 50 taken alongline 10D-10D ofFIG. 10B in accordance with one or more embodiments of the present disclosure. -
FIG. 11 is a block diagram showing exemplary stations used during polishing and inspection processes of the polishingassembly 10 in accordance with one or more embodiments of the present disclosure. -
FIG. 12 is a flow chart showing an exemplary process of the assembly of polishing and inspectingoptic cables 70 in accordance with one or more embodiments of the present disclosure. - Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.
- In accordance with various embodiments herein, a polishing assembly and methods of polishing optical cables are disclosed here. More specifically, the polishing assembly may polish optical cables at a high precision, thereby, reducing signal loss when coupling ends of the optical cables to connectors or other devices.
- In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustrative embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and mechanical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof. For completeness, the invention is discussed with respect to an “optical cable”, which is intended to encompass a fiber optic strand and a group of fiber optic strands as known in the fiber optic industry. However, the polishing assembly will also have use with other industries, where a high-precision polish of a silica substrate is desired.
- Referring now to the drawings,
FIGS. 1A-1C show a polishingassembly 10 in accordance with one or more embodiments of the present disclosure. High-precision polishing is accomplished by way of a polishingassembly 10, which includes abase 48 and a mounting fixture 50 (also referred to herein as a “fixture”) selectively coupled tobase 48. In one or more embodiments,base 48 may include aplatform 12, anarm 16, and dialindicators 18.Base 48 may also include abody 28 having ahousing 30 thatplatform 12 extends therefrom. In one or more embodiments, amotor 92 is disposed withinhousing 30 of body 28 (as shown inFIG. 7 ). In one or more embodiments,platform 12 is configured to receive and secure a polishing film 80 (shown inFIGS. 3A and 3B ) and rotate about axis A of arm 16 (e.g., following a dual orbital motion). In one or more embodiments, aforce gauge 20 is functionally coupled to platform 12 (shown inFIG. 7 ) and configured to measure a force (e.g., a downward force that is along axis A ofarm 16 and toward platform 12) applied againstplatform 12. In one or more embodiments, mountingfixture 50 is configured to receive and mount a plurality of optical cables 70 (shown inFIGS. 2A and 2B ), as discussed further herein. In one or more embodiments,movable arm 16 is configured to move in multiple directions manually (e.g., using dials 38) or automatically. - In one or more embodiments,
arm 16 may move in one or more directions to achieve various positions relative toplatform 12. In one or more embodiments,arm 16 may be moved to any desired position using, for example, dials 38. In one or more embodiments,arm 16 may move mountingfixture 50 towardsplatform 12 and corresponding polishing film 80 (shown inFIGS. 3A and 3B ) to press mounted cables 70 (shown inFIGS. 2A and 2B ) against polishingfilm 80. Similarly,arm 16 may move mountingfixture 50 away from polishingfilm 80. For example,arm 16 may be moved upward away fromplatform 12 and alongaxis A. Arm 16 also rotates circularly about axis B ofbase 48 along a continuous circular path, which can be used to incorporate supplemental steps and stations, such as those for washing, quality inspection, and collection/mounting of cables, as discussed further herein. Alternatively, or in addition, rotation permits the use of multiplemovable arms 16 extending from a single axis (e.g., axis B) to polish multiple sets ofoptical cables 70, where eachmovable arm 16 moves in series through any number of polishing, washing, and inspection steps. -
FIGS. 2A-2F show an exemplary process of mountingoptic cables 70 to mountingfixture 50 in accordance with one or more embodiments of the present disclosure. As shown inFIGS. 2A and 2B ,optical cables 70 are securely mounted to mountingfixture 50, which is itself attached or attachable toarm 16. For example, mountingfixture 50 may be selectively coupled toarm 16 by inserting aprotrusion 68 ofarm 16 within abore 14 of stem of mountingfixture 50 andfastening protrusion 68 withinbore 14 using various attachment mechanism such as, for example, screws (as shown inFIG. 1C ). While it is within the scope of the disclosure that mountingfixture 50 mount only one or only afew cables 70, preferably,fixture 50 mounts a plurality ofcables 70 to permit simultaneous and efficient polishing. In some embodiments,fixture 50 mounts at least thirty or about thirtycables 70.Cables 70 can be arranged according to a variety of patterns. For example,cables 70 may be equally spaced along a circular path about mountingfixture 50. More specifically,cables 70 may be positioned and mounted about a circumference ofpad 46 so that eachcable 70 along the circumference is equidistant to axis A when mountingfixture 50 is attached toarm 16. - By “mounted”, it is meant that
cables 70traverse mounting fixture 50 by passing throughpad 46 and are held in place. For example,cables 70 traverse through anaperture 52 ofpad 46 and are held in place such as by way of aclamp 54. In one or more embodiments, eachclamp 54 may include at least atab 56, aspring 60, and at least two magnets 58 (e.g.,magnet 58 a oftab 56 andmagnet 58 b of pad 46). In such embodiments, eachclamp 54 has at least two positions, namely, an open position (shown inFIGS. 2A, 2C, 2D, and 2E ) to permitcable 70 to slide in and out ofaperture 52, and a closed position (shown inFIGS. 2B and 2F ) that securely holdscable 70 in place during polishing, washing, and/or analysis. - Although there are different mechanisms available to the skilled artisan to reversibly clamp
cables 70,FIGS. 2A-2F show a particularly preferred configuration, which uses magnetic attraction. In particular, a plurality oftabs 56 are shown that rock open and closed to either release or lockcables 70 in place, respectively. Furthermore, a plurality ofmagnets 58 are provided that magneticallyhold rocking tabs 56 when in the closed position. For, example, a user may pushtab 56 in a first direction (e.g., in a downward direction shown by directional arrow 11) towardpad 46 untilmagnet 58 a oftab 56 is abuttingmagnet 58 b ofpad 46. The magnetic attraction betweenmagnets 58 a,b results inclamp 54 maintaining the closed position bytab 56 continuously abuttingpad 46 during operation of polishingassembly 10. The artisan will appreciate thatdifferent magnets 58 can be used to achieve the same affect, including ferrite, alnico, and rare earth magnets. Once magnetically closed, a holding force ofclamp 54 can be facilitated by aflat spring 60, which presses against aboot 62, through whichcable 70 passes. It has been found that magnetic attraction effectively maintainsclamp 54 in a closed position and also provides an easy approach for releasingclamp 54 into the open position, namely, using one's finger to simply upwardly (e.g., in a direction opposite of directional arrow 11) flip atongue portion 64 oftab 56, which extends over the edge ofpad 46, to overcome the magnetic attraction betweenmagnets 58 a,b. In one or more embodiments, the open position may also be facilitated by acoiled spring 72 disposed beneathtab 56 that keepstab 56 in the open position unless a user applies a downward force, compressing coiledspring 72. - Turning to
FIG. 3A andFIG. 3B ,fixture 50 is attached or attachable tomechanical arm 16, andsurface 82fixture 50 is, preferably, aligned parallel to asurface 84 ofplatform 12. The precise adjustment of the plane (e.g., surface 82) offixture 50 can be performed through the use ofdial indicators 18 onarm 16 and/orfixture 50. In preferred embodiments, fourdial indicators 18 are used to provide complete control over the attachment offixture 50 tomechanical arm 16 to ensure a precise alignment ofplanar fixture 50. Since the parallel alignment betweenfixture 50 and polishingplatform 12 is critical, in some embodiments, polishingplatform 12 can be tilted, such as bydial indicators 18 to ensure parallel orientation withfixture 50. -
FIGS. 3A and 3B show movement ofarm 16 andfixture 50 towards polishing film 80 (e.g., as indicated bydirectional arrow 13 ofFIG. 3A ), which is positioned on polishingplatform 12 in accordance with one or more embodiments of the present disclosure. In one or more embodiments,fixture 50 is lowered towards the polishing film-loadedplatform 12 for polishing (cables omitted for demonstration purposes). Typically, asarm 16 moves towards polishingfilm 80,arm 16 slows as cables 70 (shown inFIG. 2B ) reach polishingfilm 80. A slow movement ofarm 16 slowly builds pressure betweencables 70 and polishingfilm 80/platform 12. In one or more embodiments, polishing begins at a lower pressure, then the pressure is continued or increases over time during the polishing process. In an exemplary embodiment, when polishing a set of thirtycables 70, a typical force starts at about 0.5-1 lb, then increases up to about 20 lbs. In other embodiments, the force may be as high as 30 lbs. In one or more embodiments, the force applied to eachcable 70 during polishing may be between 0.25-3 lbs. As will be discussed in more detail in the paragraphs that follow, force gauge 20 (shown inFIGS. 7-9 ) measures the force applied toplatform 12, and a feedback mechanism communicatively coupled to forcegauge 20 dictates movement ofarm 16 to maintain the applied force within desired parameters. In one or more embodiments,platform 12 may have a high speed of 100 rpm. -
FIG. 4 shows anexemplary cable path 22 over polishingfilm 80 during dual orbital rotation in accordance with one or more embodiments of the present disclosure. In one or more embodiments, polishing may be performed by a way of singular orbital rotation. In one or more embodiments, polishing is performed by way of dual orbital rotation ofplatform 12, which is overlaid with polishingfilm 80, such as a 3 μm-9 μm diamond film. In one or more embodiments, dualorbital cable path 22 includes two concentric paths including anouter path 32 and an inner path 34 (e.g., two concentric epitrochoid paths). Among the benefits of dual orbital rotation is that it prolongs the life of polishingfilm 80 becausecable path 22 overfilm 80 does not repeat. In an exemplary embodiment, twentycables 70 may be positioned along an outer circumference ofpad 46, which followouter path 32 during polishing, and tencables 70 may be positioned along an inner circumference ofpad 46, which followinner path 34 during polishing. -
FIGS. 5 and 6 show exemplary embodiments oforbital gearing 24 ofplatform 12 and a bearing 26 (e.g., a ball or roller bearing) ofarm 16 used to accomplish the dual orbital rotation in accordance with one or more embodiments of the present disclosure. In one or more embodiments,orbital gearing 24 is located beneathsurface 84 ofplatform 12 and allows for rotation and lateral movement ofplatform 12. In one or more embodiments, bearing 26 allows for rotation ofarm 16 about axis B. - Proceeding to
FIGS. 7-9 , in preferred embodiments, the force applied againstplatform 12 is preferably measured usingforce gauge 20, which is positioned underneath polishing platform 12 (shown inFIG. 7 ). In one or more embodiments, polishingassembly 10 also includes astrain gauge 96. In particular, positioningforce gauge 20 in physical force communication withplatform 12 directly measures forces applied toplatform 12. The implication of this arrangement is thatforce gauge 20 receives true pressure and, thus, provides true force data. As such, there is no need to further calculate or extrapolate pressure using equations or conversions that would be required in electronic or optical detection systems. - In some embodiments,
force gauge 20 communicates directly with electronic circuitry inarm 16 to instruct upward or downward movement ofarm 16 to achieve a desired force. In other embodiments,force gauge 20 collects pressure readings and provides the data to a computer processing unit, which instructs movement ofmechanical arm 16 and, optionally, rotational speed of polishingplatform 12 in response to the provided pressure data. To this end, the dual orbital speed of polishingplatform 12 and the contact force ofcables 70/mountingfixture 50 can be adjusted in response to pressure data provided byforce gauge 20. In other embodiments,force gauge 20 provides data to ensuresurface 82 of mountingfixture 50 is level withsurface 84 ofplatform 12 so that pressure is evenly applied to eachcable 70. Furthermore, the computer processing unit may use an algorithm that compensates for nonlinearity and to prevent any undesired play or wiggle inarm 16 and mountingfixture 50 when not in use, which is often an inherent problem in stepper motors. In one or more embodiments, the computer processing unit may also determine the lifetime of polishingfilm 80. For example, a timer of the computer processing unit may count the number of polishing cycles, the time of each polishing cycle, and/or the pressure of each polishing cycle to determine when a user should replace polishingfilm 80. As understood by one skilled in the art, the computer processing unit may be any compatible electronic device (e.g., processor, smartphone, desktop computer, laptop, or tablet). In one or more embodiments, computer processing unit may be loaded with a software (e.g., an application). In one or more embodiments, computer processing unit may include an interface that allows for user input or display of collected or processed data. - The technical approach of coupling a
force gauge 20 to theplatform 12 rather than measuring an applied force through or at thearm 16 has many advantages. For example, a system that measures force at thearm 16 requires substantially more compensation in that the measurement would also have to consider the weight of thefixture 50, any connectors,optical cables 70 mounted to thefixture 50, andarm 16 itself. Furthermore, it would also have to compensate for the downward force being applied by thearm 16 itself during polishing. - As already introduced, the feedback mechanism controls the movement of
arm 16 and, thus, the pressure applied fromcables 70 against polishingplatform 12. This feedback mechanism can be by directly communicatingforce gauge 20 to a regulator that regulates downward movement ofarm 16. The regulator can be programmed to perform a stepwise progression through a preset array of pressures or can be adjusted manually by a user to perform a desired pressure. In other embodiments,force gauge 20 is communicatively coupled to a computer with programming able to receive the pressure data and, in response, adjust movement offixture 50 towards polishingplatform 12 to meet program requirements. Preferably, the computer is also communicatively coupled tomotor 92 of polishingassembly 10 for controlling the speed of the dual orbital rotation of polishingplatform 12 so that the rotational speed of polishingfilm 80 can progress according to real time measurements of the applied pressure. -
FIGS. 10A-10D show another exemplary embodiment of mountingfixture 50 in accordance with one or more embodiments of the present disclosure. As previously mentioned herein, a dual orbital rotation may be used to polishcables 70. Accordingly, mountingfixture 50 may include an arrangement ofcables 70 having two concentric circles. As shown inFIGS. 10A-10D ,pad 46 may include an outercircular arrangement 172 ofapertures 52 and an innercircular arrangement 174 ofapertures 52, where each clamp 54 may be mounted over eachaperture 52 to mountcables 70 tofixture 50. - In exemplary embodiments,
cables 70 mounted withinapertures 52 ofouter arrangement 172 may follow alongouter path 32 ofcable path 22 during the polishing process, andcables 70 mounted withinapertures 52 ofinner arrangement 174 may simultaneously follow alonginner path 34 ofcable path 22 during the polishing process (shown inFIG. 4 ). In one or more embodiments,fixture 50 may also includeouter bracket 142 andinner bracket 144.Cables 70 may abut portions ofbrackets apertures 52 to provide alignment ofcables 70 and secure opposing ends ofcables 70. In one or more embodiments,apertures 52 may be empty (as shown inFIG. 2E ). In other embodiments,apertures 52 may have additional components disposed therein, such as asleeve 188, whichcable 70 may traverse therethrough, and a pair of opposingnotches 192, which may further engage complementary surfaces ofboot 62 to secureboot 62 to pad 46. -
FIG. 11 is a block diagram showing polishing assembly in an exemplary use in accordance with one or more embodiments of the present disclosure.Polishing assembly 10 may be positioned at a polishingstation 300.Polishing assembly 10 may be in communication with a computer processing unit (e.g., electronic device 302) via acommunication link 308.Communication link 308 may be a wired or wireless communication. In one or more embodiments,electronic device 302 may include a display and/or interface, allowing a user to input commands toelectronic device 302.Polishing assembly 10 may polishcables 70 at polishingstation 300 using friction and by rubbing the ends ofcables 70, which are secured infixture 50, against polishingfilm 80, which is secured toplatform 12. - In one or more embodiments, polishing
assembly 10 includes or is used together with an ultrasonic bath (not shown). For example,arm 16 of polishingassembly 10 may pivot about axis B toward awashing station 310.Washing station 310 may include anultrasonic bath 306. Ultrasonic baths are liquid baths that use cavitation bubbles induced by high frequency to agitate the liquid. This agitation produces high forces on contaminants adhering to substrates, such asoptical cables 70. Accordingly, the method of polishingoptical cables 70 can also include movement ofarm 16 to movecables 70 away fromplatform 12, rotation towardsultrasonic bath 306, and loweringoptical cables 70 intoultrasonic bath 306 to remove residual material away fromoptical cable 70. Though non-limiting,ultrasonic bath 306 can include deionized water, isopropyl alcohol, or any combinations thereof. - In one or more embodiments, polishing
assembly 10 may also include or be used together with aninspection station 320.Inspection station 320 may include acamera 304, which is in communication withelectronic device 302 viacommunication link 312.Communication link 312 may be a wired or wireless communication link. For example, wired communication may be but not limited to, Ethernet, DSL, or cable. Wireless communication may be, but not limited to, use Bluetooth or Wi-Fi.Inspection station 320 may be used to inspect the surfaces ofcables 70 before, during, or after polishingstation 300. In an exemplary embodiment,arm 16 may pivot about axis B toinspection station 320 so the finish ofcables 70 made be inspected by means discussed further herein. -
FIG. 12 is a flow chart showing anexemplary process 200 of polishing and inspectingcables 70 using polishingassembly 10 in accordance with one or more embodiments of the present disclosure. In some embodiments, polishingassembly 10 includes or is used together with a quality control inspection step to ensurecable 70 is polished within required tolerances or percentage of yield) (e.g., inspection station 320). In particular,cables 70 should be free of scratches and other surface imperfections that promote signal loss. - In
block 202, after mountingcables 70 tofixture 50, a user or an automation may lower mountedcables 70 toward polishingplatform 12, which is loaded with a polishingfilm 80, untilcables 70 contact (e.g., are pressing against) polishingfilm 80 at a desired pressure. For example,arm 16 may be lowered usingdials 38 and one or more linear slides so that attached mountingfixture 50 is, consequently, lowered towardplatform 12, which has polishingfilm 80 secured thereto (e.g., secured to surface 84 of platform 12). Simultaneously, the process may include monitoring the downward force applied againstplatform 12 usingforce gauge 20. - In
block 204, a user may begin the polishing process, allowing the process to proceed for a predetermined duration of time. As mentioned herein, the rotational speed ofplatform 12 may gradually increase oncecables 70 are in contact with polishingfilm 80 to remove any imperfections on the surfaces ofcables 70. In one or more embodiments,arm 16 may also increase pressure betweencables 70 andplatform 12 during the polishing process. Thus, the process may include adjusting the downward force to remain with a prescribed tolerance. In one or more embodiments,arm 16 may rotatefixture 50 about axis A. In one or more embodiments, the predetermined duration of time may be chosen by a user or may be determined, for example, by the computer processing unit. - In
block 206, a user or computer processing unit (e.g., electronic device 302) may stop polishing so that the user or computer processing unit may analyzecables 70. For example,arm 16 may movefixture 50 over toinspection station 320 so that a user orelectronic device 302 may analyze and determine the current status of the polish on eachcable 70. For manual inspection, a user may do an optical inspection ofcables 70 by referencing an exemplary image of a polished cable that is, for example, provided byelectronic device 302, as shown inblock 208. The user may then determine from the exemplary image whether or notcables 70 are within the desired tolerance or percentage of yield, as shown inblock 212. For automated inspection,cables 70 may be scanned, for example, bycamera 304, which is communicatively coupled to theelectronic device 302 so thatelectronic device 302 may determine the tolerance or percentage of yield of eachcable 70, as shown inblock 210. For example,camera 304 may relay inspection footage toelectronic device 302, which is, optionally, loaded with software that compares the polish ofcables 70 to an intermediate or final standard. In one or more embodiments,camera 304 provides a live feed toelectronic device 302, which may be shown on a display ofelectronic device 302. After inspectingcables 70,electronic device 302 may determine if the desired percentage of yield is achieved, as shown inblock 212. - In one or more embodiments, inspection is performed after washing
cables 70 inultrasonic bath 306 by instructingarm 16 to movefixture 50 withcables 70 away fromultrasonic bath 306 atwashing station 310 and continue the rotational path toinspection station 320, which itself may have one or more inspecting cameras, such ascamera 304. Since polishingassembly 10 may use a stepper motor and at least one bearing (e.g., a roller bearing), mountingfixture 50 may be moved in any direction to any position necessary for proper inspection. For example,fixture 50 may rotate, pivot, or slide in any direction whilecamera 304 atinspection station 320 is scanning eachcable 70. After scanningcables 70,electronic device 302 may provide data regarding the percentage of yield and, if applicable, the additional time required to achieve the desired percentage of yield. - In one or more embodiments, inspection can be performed by visual inspection under magnification, surface scattering approaches, or performed by a camera (e.g., camera 304) coupled to a computer or viewing monitor for surface analysis (e.g., electronic device 302), which eliminates any subjective aspect of inspection. As shown in
block 212, inspection can result in a positive or negative response. A positive response demonstrates that the polished material is of suitable quality and, thus, passes inspection. A negative response demonstrates that the polished material is not of suitable quality and must be reworked. - If the user or computer processing unit determines the percentage of yield to be acceptable (e.g., within 90%), then cables may be removed from mounting
fixture 50, as shown inblock 214. If the user or computer processing unit determines, that the desired percentage of yield has not been achieved, then the process may return to block 202, continuing the polishing process untilcables 70 are within the desired percentage of yield and are, thus, found to have an acceptable polish. - In an exemplary embodiment, upon a positive response, optionally,
mechanical arm 16 can movefixture 50 away from theinspection station 320 to a collection station (not shown) for collectingcables 70. Collection may include releasingfixture 50 frommechanical arm 16 and/or opening clamps 54 to removecables 70. As such, the positive response can also include releasingclamps 54, whether by manually flippingtabs 56 upward (e.g., away from pad 46) or through automation, thereby allowing removal ofpolished cables 70 and, optionally, insertion of a next batch of cables for polishing. - On the other hand, upon a negative response,
mechanical arm 16 can returnfixture 50 to its polishing position at polishingstation 300 for additional polishing. Thus, the negative response can also instruct polishingplatform 12 to speed up, thereby saving processing time. - The skilled artisan will appreciate that the steps of polishing, washing, and inspection may be performed as a single cycle, as a series of cycles, or the steps be reordered over multiple cycles as desired. For instance, the method may perform two or more polishing and washing steps prior to the inspection step. In some instances, polishing with
different polishing films 80, such as progressing from 3 μm to 9 μm diamond films, may be performed prior to inspection. - After removal,
cables 70 are packaged using approaches known in the art for use in a variety of industries such as telecommunications, medical diagnostics, medical therapeutics (e.g. surgery and dentistry), automotive, lighting, mechanical inspection and analytical instrumentation, military and aerospace industries. - The foregoing disclosure of exemplary embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. As example, the methods may also include a pretreatment step, where the
cables 70 are pretreated with a solution prior to polishing. In some embodiments, the pretreatment occurs by dipping thecables 70 in the ultrasonic bath. - Further, in describing representative embodiments, the specification may have presented the method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims.
- While the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the scope of the appended claims.
Claims (24)
1. A method of polishing optical cables, the method comprising the steps of:
a) providing a polishing assembly loaded with a polishing film, the polishing assembly comprising a platform to which the polishing film is loaded, the platform configured to rotate according to a dual orbital motion and coupled to a force gauge that measures downward force applied against the platform, a mounting fixture configured to mount a plurality of optical cables, the mounting fixture attached to a movable arm that moves the mounting fixture towards and away from the platform;
b) mounting a plurality of optical cables to the mounting fixture;
c) pressing the optical cables against the rotating polishing film while simultaneously monitoring the downward force applied against the platform; and
d) adjusting the downward force to remain within a prescribed tolerance.
2. The method of claim 1 , wherein the fixture comprises a plurality of clamps that clamp the plurality of optical cables in place, wherein the plurality of clamps each comprise a moveable tab that locks closed using magnetic force.
3. (canceled)
4. The method of claim 1 , wherein the fixture and the platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform, the adjustment dials optionally being 4-way adjustment dials.
5. The method of claim 1 , wherein rotation of the polishing film increases gradually.
6. The method of claim 1 , wherein no one cable repeats its same position on the polishing film during polishing.
7. The method of claim 1 , wherein the arm presses the cables against the rotating polishing film gradually to polish the cables at a lower pressure followed by polishing the cables at a higher pressure.
8. The method of claim 7 , wherein the higher pressure is about 0.5-1 lb. of pressure per cable.
9. The method of claim 1 , wherein the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform.
10. The method of claim 1 , wherein the downward force is adjusted by a feedback mechanism that functionally couples the force gauge to the arm.
11. The method of claim 1 , further comprising washing the polished optical cables in an ultrasonic bath, the bath optionally comprising deionized water and/or isopropyl alcohol.
12. The method of claim 1 , further comprising optically inspecting a polished surface of the cables, and optionally repeating steps (c) and (d) until the polished surface meets a final acceptable standard, optionally using a series of different polishing films.
13. The method of claim 12 , wherein the optical inspection includes inspection by camera that the camera relays inspection footage to a computer, optionally loaded with software that compares the polish to an intermediate or final standard.
14-15. (canceled)
16. A polishing assembly comprising:
a) a platform configured to receive a polishing film and configured to rotate according to a dual orbital motion;
b) a force gauge functionally coupled to the platform and configured to measure downward force applied against the platform;
c) a mounting fixture configured to mount a plurality of optical cables; and
d) a movable arm configured to move the mounting fixture downwards to press mounted cables against the polishing film, upwards to pull the mounted cables away from the polishing film, and to rotate circularly along a continuous circular path.
17. The assembly of claim 16 , wherein the fixture comprises a plurality of clamps that clamp the plurality of optical cables in place, wherein the plurality of clamps each comprise a moveable tab that locks closed using magnetic force.
18. (canceled)
19. The assembly of claim 16 , wherein the fixture and the platform are adjustably aligned parallel to one another, preferably by way of adjustment dials that adjust the fixture and platform, the adjustment dials optionally being 4-way adjustment dials.
20. The assembly of claim 17 , wherein the force gauge is in physical-force communication with the platform, thereby measuring pressure directly applied to the platform.
21. The assembly of claim 20 , wherein the force gauge communicates with the arm or with a computer that communicates with the arm.
22. The assembly of claim 16 , further comprising an ultrasonic bath, the bath optionally comprising deionized water and/or isopropyl alcohol.
23. The assembly of claim 16 , further comprising an optical inspection station comprising a camera that relays inspection footage to a computer, optionally loaded with software that compares the polish to an intermediate or final standard.
24-26. (canceled)
27. A mounting fixture configured to mount a plurality of optical cables, the fixture comprising a planar surface comprising a plurality of apertures for receiving a plurality of optical cables; a plurality of arms that rock open and closed to release and lock the cables in place; a plurality of magnets that magnetically lock the arms closed; and a means for coupling the mounting fixture to a polishing assembly.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US17/801,500 US20220410334A1 (en) | 2020-03-04 | 2021-03-03 | Method and assembly for polishing optical cables |
Applications Claiming Priority (3)
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US202062985172P | 2020-03-04 | 2020-03-04 | |
PCT/US2021/020738 WO2021178584A1 (en) | 2020-03-04 | 2021-03-03 | Method and assembly for polishing optical cables |
US17/801,500 US20220410334A1 (en) | 2020-03-04 | 2021-03-03 | Method and assembly for polishing optical cables |
Publications (1)
Publication Number | Publication Date |
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US20220410334A1 true US20220410334A1 (en) | 2022-12-29 |
Family
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US17/801,500 Pending US20220410334A1 (en) | 2020-03-04 | 2021-03-03 | Method and assembly for polishing optical cables |
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US (1) | US20220410334A1 (en) |
WO (1) | WO2021178584A1 (en) |
Families Citing this family (1)
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CN114434271B (en) * | 2022-03-07 | 2022-11-22 | 江苏诺信光电科技有限公司 | Optical fiber jumper end face grinding equipment and method thereof |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US4693035A (en) * | 1985-10-30 | 1987-09-15 | Buehler Ltd. | Multiple optical fiber polishing apparatus |
DE69413589T2 (en) * | 1993-04-22 | 1999-04-08 | Nippon Telegraph & Telephone | Polishing disc for the end face of an optical fiber connection and polishing device |
US5459564A (en) * | 1994-02-18 | 1995-10-17 | Chivers; James T. | Apparatus and method for inspecting end faces of optical fibers and optical fiber connectors |
TW485863U (en) * | 2001-08-13 | 2002-05-01 | Hermosa Thin Film Co Ltd | Polishing equipment for end face of optical fiber |
JP2003329873A (en) * | 2001-12-27 | 2003-11-19 | Fujikura Ltd | Optical fiber holder with positioning mechanism, optical fiber adapter and optical fiber processing device |
ES2541704T3 (en) * | 2009-02-02 | 2015-07-23 | 3M Innovative Properties Company | Fiber optic polishing apparatus and method |
US9759872B1 (en) * | 2016-02-19 | 2017-09-12 | Domaille Engineering, Llc | Optical fiber polishing fixture |
-
2021
- 2021-03-03 WO PCT/US2021/020738 patent/WO2021178584A1/en active Application Filing
- 2021-03-03 US US17/801,500 patent/US20220410334A1/en active Pending
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