View
58
Download
4
Category
Tags:
Preview:
DESCRIPTION
Laser Cleaving of Optical Connectors. Didi Hachnochi VP Engineering & R&D Duane Dinkel President Sagitta Incorporated 655-H Fairview Road Simpsonville, SC 29680. Introduction. The Problems Mechanical cleaving – operator and tool-dependent quality (hand-scribe, sand-blasting, etc.) - PowerPoint PPT Presentation
Citation preview
Laser Cleaving of Optical Laser Cleaving of Optical ConnectorsConnectors
Didi Hachnochi
VP Engineering & R&D
Duane Dinkel
President
Sagitta Incorporated
655-H Fairview Road
Simpsonville, SC 29680
IntroductionIntroduction
• The Problems Mechanical cleaving – operator and tool-dependent quality (hand-
scribe, sand-blasting, etc.)
Epoxy Bead size – operator and process-dependent quality
Polishing – sub-optimal initial conditions (overuse of consumables;
costly)
Connector/Fiber-specific challenges – MT, Large OD fiber, SMA’s, etc.
Compromised First Pass Yield, Throughput, Quality, and Cost!
• The Solution Laser Cleaving (integrated denubbing and epoxy removal)
• Results
• Future Technologies
• Conclusion
Connector Termination ProcessConnector Termination Process
Cut toLength
Strip & Clean
AssemblyI
InsertionInto ferrule
EpoxyApplication
EpoxyCure
FiberCleave
Air Polish“Denub”
EpoxyRemoval
PolishSequence
AssemblyII
CleanEndface
VisualInspection
GeometryInspection
OpticalInspection
LabelAnd Pack
Uncleaved Connector TipUncleaved Connector Tip
CeramicFerrule
Fiber“Stinger”
EpoxyBead
5.0 – 15.0mm
CeramicFerrule
Fiber“Stinger”
EpoxyBead
5-15 mm
300-1200um
Manual Cleave ProcessManual Cleave Process
Epoxy Bead
Before After
Ferrule
Fiber
Hand Scribing ToolApply Torsion
Epoxy Bead
Before After
Ferrule
Fiber
Hand Scribing ToolApply Torsion
Mechanical techniques represent > 90% of the industryMechanical techniques represent > 90% of the industry
Hand Polish Process – “Denubbing”Hand Polish Process – “Denubbing”
Hand polishing can consume up to 30 sec per end Hand polishing can consume up to 30 sec per end
After
Fiber Stub & Epoxy Bead
Before
Coarse Hand Polishing Material
– 1000um300 –
Fiber Stub & Epoxy Bead
Coarse Hand Polishing Material
300 – 1200 um 300 – 500 um
Manual Cleave – The ProblemsManual Cleave – The Problems
• Variable Epoxy Bead Size Polishing process variable
Requires hand polish to remove
• Variable “Stinger” Length Extra polishing step
Epoxy Bead Size RangeHeight: 300 - 1200umVolume: 0.02 – 0.05 mm3
Cleaved Fiber Range300 – 500um
• Poor Cleave = Bad Endface
Yield (and quality) problem ⇨ reworks!
Core cracks
Endface chips
Laser Cleaver AnimationLaser Cleaver Animation
Laser Cleaving PrincipalLaser Cleaving Principal
CeramicFerrule
Fiber“Stinger”
EpoxyBead
300 – 1200um
5.0 – 15.0mm
From Curing
80 – 120um
Into Polishing
Focused CO2 beam spot passes thru fiber and epoxy
Combines Cleaving + Denubbing + Epoxy RemovalCombines Cleaving + Denubbing + Epoxy Removal
Simplex Connector Before/After CleaveSimplex Connector Before/After Cleave
Small epoxy
bead
Large epoxy bead
Before Cleave
Hand Cleave Bellow epoxy!
Laser CleaveFiber stub & residual epoxy <
100μ
After Laser
Cleave
Cleave Height Control
-30
-20
-10
0
10
20
30
0 20 40 60 80 100
Sample #
Pro
tru
sio
n V
aria
tio
n,
um
Field Performance - SimplexField Performance - Simplex
USL
TGT
LSL
Cleave Height Reproducibility
Limits must be sufficient to eliminate polishing steps Limits must be sufficient to eliminate polishing steps
MT Connector Cleaving ProgressMT Connector Cleaving Progress
FerruleEpoxy
12 Fibers
Before
After 4 cycles
After 2 cycles
Field Performance - MTPField Performance - MTP
Maximum fiber variation < 20um
Demonstrated ability to remove 20mm3 (5mm x 2mm x 2mm) of epoxy
bead
Cleave height adjustable from 50um
Only constraint is in molded ferrule tolerance (specified at +/- 50um)
Laser Cleaving ImplementationLaser Cleaving Implementation
• Laser safety compliance
• Ergonomics
• Ferrule size (1.25mm vs. 2.5mm vs. MT, etc.)
• Fiber type – SM vs. MM
• Process flow
• Violation of intellectual property
Quality Benefits of Laser CleavingQuality Benefits of Laser Cleaving
• Eliminates operator and tool dependent cleave quality
• Simplifies the polishing process & removes interdependencies
• Eliminates cleave related multimode fiber “core cracking”
• Improves connector reliability - laser “tempers/anneals” fiber endface relieving inherent fiber stresses
Removes up-stream variability
“Levels the process playing field”Removes up-stream variability
“Levels the process playing field”
Cost Benefits of Laser CleavingCost Benefits of Laser Cleaving
• Reduces consumable costs Minimizes abrasive consumable cost (1-2 polishing
operations eliminated)
Eliminates scribe blade wear-out
• Higher yields • Reduces headcount (or increases throughput)
Combines scribing + denubbing + epoxy removalCombines scribing + denubbing + epoxy removal
Cost Benefits of Laser CleavingCost Benefits of Laser Cleaving
Labor ⇩
Cost of Consumables ⇩(abrasive films, scribes, etc.)
Yields ⇧
COGS reduces by 5 – 10%
(Shaving $50M annually out of industry costs)COGS reduces by 5 – 10%
(Shaving $50M annually out of industry costs)
Manual Laser Cleaving
BOM CoC L&O Total BOM CoC L&O Total Savings, $/end
SM Low-Volume
US (325K ends) $1.13 $0.13 $1.85 $3.17 $1.13 $0.11 $1.51 $2.83 $0.33
MX (650K ends) $1.13 $0.13 $0.46 $1.75 $1.13 $0.11 $0.37 $1.65 $0.10
China (950K ends) $1.06 $0.11 $0.18 $1.36 $1.06 $0.10 $0.14 $1.32 $0.04
MM Mid-Volume
US (650K ends) $0.98 $0.07 $1.44 $2.54 $0.98 $0.05 $1.16 $2.26 $0.28
MX (1300K ends) $0.93 $0.07 $0.36 $1.38 $0.93 $0.05 $0.28 $1.30 $0.08
China (1900K ends) $0.83 $0.06 $0.14 $1.05 $0.83 $0.05 $0.11 $1.01 $0.04
Enabling Benefits of Laser CleavingEnabling Benefits of Laser Cleaving
• Cleaves fiber types that are not readily
mechanically cleaved
• Accommodates large OD and specialty fibers
• Suitable for MTP production
Field DataField Data
Assessment SC (MM) LC (MM)
(Laser) (Manual) (Laser) (Manual)
Total Connectors Evaluated > 50K - > 25K -
First Pass Yield 95% 85% 98% 85%
Cracks 1% 5% 1% 5%
Chips 4% 10% 1% 10%
Average Throughput, UPH 360 150 450 200
Average Cleave Height, um 95 400 60 300
Cleave Height Variability*, +/- um 20 300 20 300
Field Observations and Comments Laser cleaving removes operator dependence – excellent repeatability between shifts,
minimizes training Laser cleaving removes upstream epoxy bead variability – reduces polishing steps Laser cleaving decreases manufacturing costs – 2x throughput, improves yield
Field Observations and Comments Laser cleaving removes operator dependence – excellent repeatability between shifts,
minimizes training Laser cleaving removes upstream epoxy bead variability – reduces polishing steps Laser cleaving decreases manufacturing costs – 2x throughput, improves yield
Image Acquisition & ProcessingImage Acquisition & ProcessingExtending the CapabilityExtending the Capability
1 .Raw data
image
2. Image processing – Edge
3. Image processing – Best fit to edge
4. Best edge fit on original image
Enables automating the laser cleaving processEnables automating the laser cleaving process
• Field Module
• Single Step Polishing Support Module
• Fully automated platform
Extensions of Laser Cleaving TechnologyExtensions of Laser Cleaving Technology
Cleaving + Polishing + Cleaning + InspectionCleaving + Polishing + Cleaning + Inspection
ConclusionConclusion
• Advantages of Laser Cleaving Increased Quality & FPY
Faster – eliminate polishing process steps
Cheaper – lower process cost, less rework
Reliable – no detrimental impact
Field scalable
Enables Single Step Polishing
• Disadvantages None, of course
Thank You!Thank You!
Recommended