A 50-Second Skimmer into Fusion Splicing Process

Here’s a quick snapshot at the process of Fusion splicing. All it will take you is 50-seconds.

Fusion splicing definition
Fusion splicing is done for two ends of the fibre optic cables. It is similar to the welding process. The only difference in fusion splicing is that the materials involved are glass bunches and not metals. Like welding, the splicing is done by using localized heat. It could either be an electric arc or a laser shot.

Types of Fusion splicing
Depending on the splicing environment and the industrial application, fibre optic cable splicer machines are classified as:
-    Field Splicing Kit
-    Factory Fusion Splicer
-    Laboratory Splicer machine

There is another set of classification depending on the medium where splicing is done.
 For example, Marine fusion splicer machines are used for under-sea deployment submarines. Aerial fusion splice tools are used for space ships and aeroplanes.

Principle involved in Fusion splicing of Fibre optic cables
Before moving ahead with the fusion splicing, get familiar with the principals of:
-    Optical Wave Guide Theory
-    Heat Transfer
-    Glass property
-    Material Science
-    Fluid Mechanics
-    Static Dynamics
-    Stress Strain Energy Transformation
-    Mechanical Engineering
-    LASER

Features of Fusion Splicing
Fusion splicing used on fibre optic cables is a permanent alliance. Unlike the use of fibre optic connectors, the fused cables can’t be detached. The features associated with the fusion splicing are:
-    Quick operation that takes less than 30 minutes
-    Easy alignment if fusion splicer machine is used
-    It saves resources and cost-effective
-    Loss through the fusion spliced fibre optic cables is measured at less than 0.2 decibels across a length of   124 miles.
-    The strength of the fused site is impeccable.

Position of the Fusion splicing technique in the industry
In the digital age, it goes without saying that fibre optic cables form the connectivity face of the IT industry. In optical network, the precision of fusion splicing process can make or break business. Poor quality fusion splicing at the fibre optic cable ends could result in significant loss of data and interference during transmission. Loss of data or corruption means loss of revenue.
This is the exact reason why the best in the industry prefer to go with the fusion splicer machines. The fusion splicer machines are preferred over mechanical splicer for two reasons:
1.    Fusion splicer machines involve use of precision cleaving and alignment models
2.    The automatic dusting and removal of dirt and moisture is taken care by the fusion splicer machine

Objective of the Fusion splicing technique
The primary objective of the fibre optic fusion splicer technique is to achieve the same quality of physical and data transmission properties as the original cables. Closer the resemblance, higher will be the efficiency of the spliced cables.

Fusion splicing is done to achieve:
-    Impeccable physical strength without compromising on the quality of signal transmission
-    Elongation of the fibre optic cables without involving any fibre optic connectors
-    Long-term reliability in terms of signal transmission across a variable medium
-    Zero maintenance as far as replacement of fibre optic cables are concerned

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5 Unassailable Pointers of a successful Fibre Optic cable Fusion Splicing

Did you know that the process of fusion splicing is just as old as the television? Why suddenly has it caught the interest of the IT leaders and Cloud technology providers? Well, the answer lies in the mega bandwidth demands and the dwindling copper resources. The age of connectivity and smart resource planning has prompted the companies to adopt fibre optic cables as their new go-to layout. From in-house architecture to outside plan applications, fibre optic cables are ruling the roost. And the fibre optic fusion splicing process is what stamps the seal of authority on the final architecture. How and why? We tell you in 5 quick ways.

- Permanent Fusion: Bend it around
Fusion splicer machines give the fibre optic cables the much needed flexibility that it lacks initially. Once the splicing is done, the two fibre optic cables are fused permanently. It does not break or crack even when passed around a corner. The flexibility of using a fusion splicer site eliminates the use of an additional kit of connectors.
 

With splicing in place, the fibre optic cables can be twisted, bent and even looped around.
 

- Elongate the Layout without Compromising on Bandwidth
Modern-day fibre optic cables carry signals at a bandwidth of more than 2.5 GBPS. This incredible capacity requires additional lengths. In most cases, a connector will suffice. It is economical to use a fibre optical cable bunch from the same family. It serves two purposes:
 

-    Increase the length of the wire to any desired magnitude
-    Strengthen the structural ability of the cable to sustain pressure in out-of-plant applications.

- Single Mode Splicing: Enhanced data centre capacity
If you are serving your clients with LAN service across long-haul OSP, the fusion splicer technique to connect two or more fibre optic cables becomes evident. It is usually done for the single-mode fibres as they have fewer glass-cores in bunch. At data centres, where the emphasis is on resource density and performance, the fibre optic cables are fused together using the fusion splicer machines.
 

- Simple Localized heating: No High-end resource tools
Fusion splicer machines are economical as far as pricing and effectiveness are concerned. Two fibre optic cables are joined using localized heat. The only care that has to be taken is with respect to the removal and re-covering of the outer shell around the glass core.

 

The fusion splicing is said to be 100 per cent effective if there is no hint of scratch, lips or grooves on the glass sheath. Moreover, the tube should be completely free from moisture and dust.
 

From angle of cleavage to alignment degree, the fusion splicer machine ensures that the two ends of the fibre optic cables are properly spliced to prevent any loss of signal at the site.
 

- Excepted loss tolerance: Less than 0.2 Decibels
A fusion splicing process is said to be a success if the resultant loss of data is found to be less than 0.2 decibels. It should be free from any moisture and dust. Two fibre optic cables can be fused at the cost of data loss.

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Smart Guide - Install fibre optic cables into connectors in 12 Steps

Depending on the length and quality of the optic fibre cables, you can opt for a simple attachment method to connect the fibres. The mode of attachment between two optic fibre cables varies according to the type of connectors used. If you ask any expert on optic fibre connector installation, they all suggest a series of procedures that every installation model will have. 

 

Installation Method: A general guider
 

Step 1:
Always start by cutting an optic cable couple of inches longer than desired length. It will save you the hassle of double attachment in the end, in case your original length falls short.
 

Step 2:
 Soak the optic fibre cables in paint thinner solution.
 

Step 3:
Remove the optic glass fibre cables from the liquid medium and dry it off completely. Always use linen cloth for drying purposes.
 

Step 4:
Once dry, remove the outer jacket of the fibre using magnifying glass. Ensure that the fibre glass is not nicked. Use a rubberised stripper for a better grip while removing the outer jacket.
 

Step 5:
While cutting the fibre coating, ensure that you have also removed the strength members. If not, it would create blocks once the connector is ready for installation.
 

Step 6:
Clean the bared optic fibre cable with a linen cloth dipped in spirit solution. For best results, propan-ol or its isomeric alcohol version is used. Ensure that the alcohol does not come in direct contact with the glass of the fibre optic cables.
 

Step 7:
You can now start the connection of the fibre optic cables using the fibre optic connectors. It is done by applying epoxy medium or by making a crimp.
 

Step 8:
Form a beaded structure at the tip of the connector before inserting the fibre optic cables into the connector.
 

Step 9:
After inserting the cable into the fibre optic connector, anchor the strength members for a permanent fixing. Don’t put too much pressure on the cable as it is very delicate at the connector site initially.
 

Step 10:
Hold the connector with care. The anchors of the strength members ensure that the fibre optics remains shielded from the physical stress.
 

Step 11:
Slowly slide the connector bracket into over the cable till it no longer moves beyond the site. Lock the connector to its brace.
 

Step 12:
Once fixed with the connector, clean and polish the fibre optic cables. 

 

Precautions to be taken in the domestic installation :

• Always prepare the ends of the fibre optic cables to be connected with connectors. It requires elaborate smoothening to correct spots, lips and fractures.

• While chipping away the older outer jacket, ensure that you are using light force. Fibre optic cables are susceptible to extensive damage during the removal process.

• Use only industrial quality of epoxy and propan-ol for cleaning and removal purposes. The local varieties are dilute versions and may not be effective in the connection process.

• Take extra care during cleaving if you wish to have a mirror-like finish.

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6 Important components of a Fusion Splicing Machine

Fusion splicing is not carried out by hands. The operators use sophisticated hand-held tools and automatic machines to achieve flawless joint connectivity. The conventional components of the automatic fusion splicing machine used to join cables consist of more than 5000 distinct parts and tools. They are adjusted depending on the fusion process for single mod and multimode fibre optic cables. A brief overview is provided on some of the important components as below.

1    Optical Core or Profile Alignment Systems
Also known as the PAS module, the Optical Core Alignment System helps in aligning the fibre optic cables at a particular gradient. The alignment model is set at 90 degrees once the fibre optic cables are sufficiently illuminated. The PAS uses video camera surveillance to recognize the core of the fibres that could be used for fusion splicing.

2    PAS Software
The automatic alignment of the PAS fusion splicing module is installed with updated software that helps in estimation of the splicing loss. The PAS software keeps the loss of material and energy to a minimum.

3    Automatic Fibre Alignment Panel
The fusion splicing process is a dynamic technique. While the splicing is being carried out, the fibre optic cables are continuously on the move. This is particularly true of splicing models that cater to voluminous amount of cables. The Automatic Fibre Alignment system aligns the fibre optic cables exactly at places where the splicing is to be done. 

4    LID system
Local Injection and Detection System is a key component of the Fibre Fusion splicing machine. It detects the edges where the light bends or is reflected back. The LID system works on the principle of micro-bending that helps in establishing the amount of light passing through the spliced junction.

5    Actuators
LID Core alignment uses actuators to measure the light coupled through the fibre optic cables fused using splicing. The actuators ensure that at the fusion splicing technique produces the best transmission channel with optimal alignment. The LID and actuators help in retaining high-quality transmission of data with minimum splice loss.
 

6    Fibre strippers
The basic tool to begin fusion splicing of the fibre optic cables is the Fibre Stripper and cleaver. The set consists of cable preparation apparatus. The Fibre Strippers can handle all types of fibre optic cables. The automated Fusion Splicing Plants are suitable for:
-    Loose tube cables
-    Gel-filled cables
-    Dry water-blocked cables

They are also compatible with various styles of jackets and the armour shields used over the fibre optic cables.
Common types of strippers installed over the Fusion Splicing machine are:
-    Miller Stripper
-    Micro-strip tool
-    No-Nik Stripper
These are all Left Alignment Strippers.
Tips to be followed before and after using the Strippers
Strippers require careful cleaning after subsequent use. The process of fusion splicing may lead to significant wear and tear. Strippers need to be adjusted for the right-sized stripping every time. The automatic machines need to be adjusted correctly so that the stripper don’t knick the internal core.

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5 Performance Boosting Cleaning tips for Fibre Optic cables

Fibre optic cables last a lifetime but still require regular cleaning. This cleaning regime is not as simple as you think. It is more than dusting and rubbing the outer jacket. Cleaning and maintenance of fibre optic cables is also about keeping the cables away from direct sunlight, moisture and rodent attacks. Since they are made of glasses, they are relatively delicate. The outer jacket keeps the external agents from damaging the optic cables but you need extra preparation to handle the life more efficiently. Here’s a list of 5 things you must do to keep the optic fibre cables retain their “desired” operational efficiency.

 

1    Verify the Performance rating of cable before and after Cleaning
Always test the rating of the fibre cable before cleaning. Verify whether the cable is functioning at the level at which it is supposed to work. Moisture and blockage in the internal reflection can create barriers in transmission. Signal loss can be prevented if you calibrate the cable volume before and after every maintenance routine.
 

2    Check for Loops and knots
Due to poor handling of the fibre optic cables, they tend to get tangled. The tangling usually occurs at places where there is movement. Check for the knot over ceilings and in false wall facade. Though the knots may not have any impact on the performance of the cables, they definitely tend to shorten the overall cable layout. When you would think of expanding your cable layout, the tangled optic fibre cable would pose lot of unnecessary issues. You may either cut the tangled part or use fusion splicing to rejoin them.
 

3    Never place a heavy furniture over the cables
Fibre optic cables are not built for rugged handling. Though the manufacturers would promise a rough handling won’t create problem, refrain from making such an attempt. Handle the fibre optic cable just like a high-end electronic gadget. Never place your feet or tap it with your heels. Keep the fibres away from heavy furniture, especially the ones made of metal and wood.
 

4    Use dryer to clean the core
Use a blow dryer at least rpm speed to clear the dust and moistures. Use dry air to ensure highest degree of cleaning. Use gloves to avoid leaving fingerprint marks on the body. Never use the blow dry to clean the inside of the fibre optic cable. If you have recently performed fusion splicing you won’t require the dry blowing option. The automatic fusion splicing machine has special apparatus to clear the moistures and dust. If you are using connectors, be extra careful about using dryers at high rpm. You might disturb the alignment altogether.
 

5    Avoid disturbing the light source panel
Light source adjustment can be done only by expert fibre optic engineers or manufacturers. A disturbed source will lead to poor attenuation and kill the signals beyond a certain frequency. Always rely on the services of a certified technician. A technical cleaning service will cost anywhere between USD 200 to USD 4500 depending on the expanse of the layout and components involved.

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5 Trendy Upgrades in the Fibre Optic Cable Splicing Machines

Fusion splicing of the fibre optic cables requires sophisticated technology with reliable tools. There are automatic splicing machines available in the market but they require skilled operators with years of technical expertise behind them. Contemporary technologies for fusion splicing have proven to be a reliable mechanism in producing long length connections. Most upgrades are made in the design and accuracy of the Profile Alignment System or PAS. Let’s study the various superior technologies that have been introduced recently in the fusion splicing of the fibre optic cables.
 

PAS with Dual Axis Camera Monitoring:
 

Fibre optic cable connections are very hard to deal with especially when you have long lengths to handle. Whenever there is slight interference in the connection due to bending or breakage of the fibre optic cables, it requires immediate fusion splicing. The recent introduction of the Fusion Splicer with an advanced PAS monitoring system allows the operator to make nicks with accuracy.
 

Advantages:
 

 o    The operator can handle multiple ribbon splicing. The fusion splicing machine with Dual Axis camera monitoring comes with a high resolution that accommodates up to 24-fibre ribbons.
o    The fusion splicer with camera vision allow the operator to clean and dust away the moisture and other impurities before splicing the fibre optic cables. It ensures highest accuracy of fusion.
o    The cost of installation is recovered in short period of time owing to higher quality of finished connections over the cables.
o    It ensures minimum loss of splices and prevents wastage. 

  

Automatic Arc Calibration:
 

Most operators find it hard to control the splicing over the arc of the fibre optic cable. The Automatic Arc Calibration technology prevents the slip of the fusion arc in smaller fibres. They can not only detect the ruggedness of the surface but also check if there is any groove. The splicing finish is judged using the Automatic Arc Measurement screen. It is often the final fusioning process and acknowledged as the industrial standard of finest smoothness achievable.
 

Auto-Start Spicing with Tube Heating:
 

The feed is controlled using the automatic start and stop command. The length of the fibre optic cable required to be spliced is fed in to the monitor. The software makes the adjustment in the clamp and splicer tips to accommodate the desired spicing length. The tube heating keeps the moisture away. The fusion splicing efficiency is measured in terms of amount of moisture present inside the glass surface and on the outer jacket or sleeve. 

Positioning in Zero-degree:

Some operations require the positioning of the fibre optic cables at zero degrees. This is particularly true of cases with the fibre optic connectors are used. In order to prevent the slipping of the connector and the funnel over the fibre cable core, the Zero-Degree Fibre Positioning kit is used. The PAS system is linked to the Zero Degree holder for more accurate operation. 

  

Software Updates:
 

The latest upgrades in the software are made using Internet firmware. These updates are offered by the fusion splicing machine manufacturers based on the membership.

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Top Industrial Fusion Splicer Models

Fibre Optic cables are prone to breakage just like any other wiring hardware but the act of joining them back together is relatively easy too. The process of joining two ends of different fibre optic cables using heat is called as Fusion splicing. The apparatus used to do the splicing is known as a fusion splicer. The fusion splicer connects two fibre optic cables end-to-end in such a manner that the light passing through the connection is not scattered or reflected back at the location where splicing is done. Fusion splicer is an important tool in the fibre optic cable manufacturing industry. The primary purpose of using the fusion splicer is to ensure that the broken cable or the spliced unit is just as strong as the original fibre.


Industrial Models

There are many types of fusion splicer tools available in the market but the most common of them are the mass fusion splicer and the dual-heater fusion splicer machines. The components of fusion splicer are:
-    Splice protection unit
-    Heat shrink sleeve
-    Jacket remover

The fusion splicer innovations are moving rapidly towards non-electric arc set-ups used as a heating apparatus. Laser-backed heating arcs could be the new technology driving the innovations backed by the new-age fusion splicer tools and designs. The Quantum fusion splicer is the latest innovation to hit the market. The fusion splicer used for industrial purposes are all ROHS compliant and built to deliver high-grade precision and unswerving performance. The reliability of the fusion splicer machines come with warranty and extended replacement programs.

Best models available in the commercial Fusion splicer segment

•    Q 101 Core Alignment Fusion Splicer
The core alignment model of the Fusion splicer uses the advanced Quantum core technology. It is the very fast in its performance. It reduces the heater shrink time from 28 seconds to 14 seconds. The performance of the Quantum core fusion splicer used in the industry is further strengthened by the use if dual independent ovens. These ovens are patented by the respective manufacturing companies.

•    Hand held Fusion Splicer

The Fusion splicer from the handheld category uses the standard FTTx technology. The splicer has one of the smallest footprint designs in the industry. The splicing time is 11 seconds. The fusion splicer is laced with advanced tech specifications like full HD navigational Touch screen for a reliable interfacing with the operator. The fusion splicer also has an in-built training video demonstration model with automatic software updates. The USB port is also present that makes it easy to connect with other high-end software gadgets. The Fibre holder system and the top-end Lithium-ion battery casing make the fusion splicer light and sturdy.

•    Groove Fusion Splicer

The industrial Groove fusion splicer has a fully navigational LCD touch screen. The optimized splicing model also boasts of internet interface and automatic software update. The SD Port and USB port adds up to its enticing fusion splicer specification making it one of the most economical industrial apparatuses to be used in the fusion splicing segment for Fibre optic cables.

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