Actuator – Focal Plate Integration Round 1

2011-03-02Silber / Bebek

Back Insertion

FOCALPLATE(FP)

ACTUATORS

CLAMPS

FIBERS(alsopower)

Z-STOP(optional)

Z-STOP(optional)

Front Insertion

FOCALPLATE(FP)

ACTUATORS

CLAMPS

FIBERS(alsopower)

Z-STOP(optional)

Z-STOP(optional)

CONNECTOR

“Wedge”

FOCALPLATE(FP)

ACTUATORS

CLAMPS

FIBERS(alsopower)

CONNECTOR

MOUNTINGPLATE

HEXAPODorKINEMATICCLAMP

Z-STOP(optional)

Z-STOP(optional)

• 28 actuators per wedge

• Combine into a single 32-fiber connector (and single power connector)

Fiberbot

Ztip

2xVACUUMCLAMP(holdactuator)

CONTACTPROBE(locateZfp)

MICROSCOPE(x,y)or(θ,φ)RAILS

Coupled Integration Issues (1 of 2)Issue Options Tightly coupled with…

Insertion Direction FrontBack

Fiber GroupingFiber Handling During InstallFiber Threading Thru ActuatorFocal Plate FormReplacement of Actuators / Fibers

Fiber Grouping Connector per fiberBlock connector (28-32x fibers) after FP integrationBlock connector (28-32x fibers) before FP integration

Insertion DirectionPower / Electronics GroupingFiber Threading Thru ActuatorFiber Handling During InstallFocal Plate FormReplacement of Actuators / Fibers

Power Cables / Buses Grouping Dangling cable per actuatorCable grouping (28-32x cables)

Fiber GroupingReplacement of Actuators / Fibers

Electronics Grouping Board per actuatorBoard per group of actuators (28-32x)

Ferrule Z Positioning Ferrule z-stopMicroscope and clamp

Z Tolerance StackupIntegration ToolingPre- / Post-integration MetrologyReplacement of Actuators / FibersActuator Z Positioning Actuator z-stop

Actuator z-stop with shimsMicroscope and clamp

Fiber Handling During Install Bend / twist protection deviceTrust the techs…Extra length (for easier handling)Less length (for less to “trip over”)

Insertion DirectionFiber GroupingFiber Threading Thru ActuatorIntegration ToolingReplacement of Actuators / Fibers

Fiber Threading Thru Actuator Before FP integrationAfter FP integrationDuring FP integrationDuring FP integration + final actuator assembly step

Insertion DirectionFiber GroupingFiber Handling During InstallReplacement of Actuators / Fibers

Coupled Integration Issues (2 of 2)

Issue Options Tightly coupled with…

Z Tol. Stackup, FP to Fiber Tip Ferrule z-stop + Actuator z-stopFerrule z-stop + Actuator z-stop + Graded ShimsMicroscope AdjustmentMicroscope Adjustment + “Wedge” Mounting

Ferrule Z PositioningActuator Z PositioningFocal Plate FormPre- / Post-integration Metrology

Focal Plate Form FlatSphericalFlat Subdivided (wedges)Spherical Subdivided (wedges)

Insertion DirectionFiber / Power / Electronics GroupingZ Tolerance StackupIntegration ToolingPre- / Post-integration MetrologyReplacement of Actuators / Fibers

Integration Tooling Manual insertion + manual z-adjustmentRobot insertion + manual z-adjustmentRobot insertion + robot z-adjustment

Ferrule / Actuator Z PositioningFiber Handling During InstallFocal Plate Form

Pre-integration Metrology CMM of FPCMM of FP + “gauge blocking” of every actuatorCMM of FP + statistical sample of some actuators

Ferrule / Actuator Z PositioningZ Tolerance StackupFocal Plate FormFerrule / Actuator Z PositioningZ Tolerance StackupFocal Plate Form

Post-integration Metrology CMM of feature on ferrules possible?Robot with microscope on fiber tips?

Replacement of Actuators During integration“One year later”

Insertion DirectionFiber / Power / Electronics GroupingFerrule / Actuator Z PositioningFiber Handling During InstallFiber Threading Thru ActuatorFocal Plate FormPost-integration Metrology

Replacement of Fibers During integration“One year later”

Best method for mapping out various plausible configurations?

Configuration Options Implications

Insertion Direction

Fiber Grouping

Electronics Grouping etc. Estimated Z

Tol. Stackup Risks

Front 1 1 … 1µm Connector density, …

Front 28 1 … 0.3µm Connector groupalizing, …

Front 28 28 … 100µm Bigfoot, Godzilla, …

Back 28 1 … 1mm …

Back 28 28 … 0.231Mm …

etc… … … … … …