The FFS-2000 is a complete workstation with all fusion splicing procedures logically integrated into a single, system that can be used to produce consistent splices quickly and efficiently. This third generation Fusion Splicing Workstation uses Vytran's proven filament fusion technology to provide a convenient, reliable method of making high strength, low-loss splices. New to the FFS-2000 is Vytran's True Core Imaging™ technology, a high-magnification, high-resolution optical imaging system capable of detecting and displaying the inner core structure of a fiber.  This technology provides for fast, accurate core alignment and splice loss calculation. This system also incorporates a new Windows-based user interface for greater programming flexibility and networking capabilities. With its complete workstation design, enhanced imaging capabilities and increased programming flexibility, the FFS-2000 is an ideal platform for production and R&D applications.

Standard Features

• Fiber coating soaking station 
• Thermal coating removal station
• Ultrasonic fiber cleaning station 
• Fiber cleaving station
• True Core Imaging™ for automatic fiber alignment and accurate splice loss determination
• Automatic 4-axis positioning system for PM rotation (optional)
• Filament fusion splicing station with automatic post-fusion fire polishing for strength enhancement
• Recoat station for acrylate buffer restoration
• Built-in proof tester/tension tester (optional) 
• Personal computer
  

The Process for Precisions Splicing

The FFS-2000 incorporates all components and procedures to prepare the fiber for splicing: 

• A coating soaking station is incorporated for specific fibers that require a solvent pre-soak 
  to soften the coating prior to stripping. 
  
• A Thermal Mechanical Stripping (TMS) station provides a fast, single-step process for safely 
  removing acrylate coatings while maintaining fiber strength. 
  
• Ultrasonic fiber cleaning removes any coating particles or residue left on the glass surface 
  which could reduce splice strength. 
  
• An automatic fiber cleaver produces a low end angle cleave, important for achieving low loss 
  splices. 
  
• Uniquely designed Fiber Holding Blocks and a Transfer Jig minimize fiber handling by 
  precisely positioning the fiber for each process.
  

Automatic Alignment

The FFS-2000 uses Vytran’s True Core Imaging™ technology which is a high-magnification, high-resolution optical imaging system that detects and displays a fiber’s inner core structure. This technology is used in conjunction with 0.01mm resolution stepper motor controlled X-Y positioners to provide a fully automated system capable fast and accurate alignment. In addition to the vision-based alignment system, the FFS-2000 can also be interfaced to external test and measurement equipment such as power meters, spectrum analyzers and polarimeters, to create a fully automated optical assembly station for production and R&D applications.

PM Rotation (Optional)

The FFS-2000 offers an optional 4-axis positioning system for fully automated alignment of polarization-maintaining fiber. Rotary fiber holding fixtures are stepper motor driven for absolute positioning of the fiber to .01° . This system also offers the choice of active splicing with external feedback or fully automated blind splicing using Vytran’s End-View Alignment™ technology.
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End-View Alignment

Filament Fusion

Vytran's unique filament fusion technology provides a consistent, reliable method of making high-strength low-loss splices. Precise control of the fusion process is achieved by purging the splice region with an inert gas and using a tungsten filament to supply the thermal input necessary for fiber fusion. Because the fusion heat source is isolated from the environment, filament fusion splicing is not dependent upon ambient conditions. A controlled environment in combination with constant power control circuitry ensures repeatable performance splice after splice.



Fire Polishing

Vytran's patented fire polishing process significantly increases splice strength through a rapid post-fusion heat treatment of the splice region. When a fusion splice is made, silica will evaporate off of the hot center region of the splice and condense on either side of the joint where the fiber is cooler. The condensed silica deposits act as a surface flaw, lowering splice strength. The fire polishing process removes or minimizes the deposits, thereby improving splice strength. In addition, the fire polishing process provides core diffusion capabilities that can be used to adiabatically expand the mode field diameter of a fiber. Through this thermally expanded core (TEC) process, extremely low-loss fusion splices between markedly dissimilar fibers, such as those typically used in WDM applications, can be achieved.
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Splice Loss Determination

Vytran’s True Core Imaging™ technology is used not only for precise core alignment prior to splicing, but also for splice loss determination after splicing. Because Vytran's True Core Imaging™ technology provides a true clear view of a fiber’s inner core, an accurate estimation of splice loss can be achieved based on an analysis of the finished splice. Vytran has developed a proprietary algorithm that accurately calculates loss for splicing a variety of similar or dissimilar fiber types. 

Recoating

The FFS-2000 includes an optical fiber recoater to restore the protective polymer coating over the fusion splice. The combination of high-strength filament fusion splicing and UV acrylate recoating provides a more reliable alternative to standard heat shrink protection sleeves. The recoat process maintains a near original fiber diameter and delivers a smooth, flexible fusion splice that can be handled or tightly coiled as if no splice were present.

Proof Testing (optional)

The optional built-in proof tester/tension test provides a convenient way to ensure the long-tem reliability of every fusion splice. The completed splice is clamped between two mandrels and load is automatically applied to the fiber by rotation of one of the mandrels. The load can be taken up to a pre-determined level and released (proof test mode), or can be continually increased to determine breaking strength (tensile test mode). By selecting a proof test level approximately three times higher than the applied service load on the splice, the long term reliability of the splice can be assured.

FFS-2000 SPECIFICATIONS

Overall

Size: 17.0" x 13.9" x 5.0" (432 X 353 X 127 mm).
Weight: 26 lbs (11.8 kg).
Power: 12V DC. External power supply provided with universal AC input.
Operating System: PC-based with Windows® interface.

Fiber Prep

Soaking Station: Solvent pre-soak station available for "hard" coatings.
Coating Stripper: Thermal mechanical stripping process for high-strength coating removal.
Fiber Cleaner: Ultrasonic cleaning that maintains fiber strength.
Fiber Cleaver: Tension and scribe method with automated diamond cleaving wheel.

Splicing

Fusion Method: Filament Fusion.
Fusion Temperature: Constant power control for consistent fusion process.
Alignment Method: Fully automated by True Core Imaging™ or external feedback
X-Y Fiber Positioning: Stepper motor controlled (0.01mm resolution)
Z Fiber Feed: Stepper motor controlled (0.125mm resolution)
Fiber Viewing: Real time image processing system viewed directly on computer monitor.
Strength Enhancement: Automated post-fusion fire polish step for high strength splicing.
Loss Estimation: True Core Imaging™technology for accurate loss calculation.

Recoating

Recoat Mold: Quartz.
Recoat Diameter: 260mmstandard; custom sizes available.
UV Source: Four (4) tungsten halogen lamps.
Cure Time: 15 seconds typical.
Recoat Material: Ultraviolet curable acrylate.

Proof Testing

Maximum Tension: 20 pounds (9.1kg)
Mandrel Size: 2" diameter (51 mm).
Accuracy: +/- 2%

PM Rotation Option

Rotation Alignment: Fully automated by End-View Alignment technology or external feedback.
Rotation Drive: Stepper motor controller (0.01° resolution).
Rotation Travel: 190° left and right sides.

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