By Dave Harris, trueCABLE Technical Specialist, BICSI INST1 Certified and Ben Hamlich, Director of Technical and Product Innovation, trueCABLE RCDD, FOI
Optical fiber Cables are a fundamental component of modern communications infrastructure, due to their high bandwidth, reliability, durability, and cost-effectiveness. During the installation of this infrastructure, many situations arise that require joining one optical fiber to another in a procedure called “splicing.” There are two main splicing methods: mechanical splicing and fusion splicing. This blog will delve into the nuances of each method, comparing their costs, labor efficiency, network performance, and more, to help you decide which splicing technology is best for your needs.
Why connect?
Fiber optic splice is used to connect two Fiber optics Optical fibers are connected together so that light energy can be transferred from one optical fiber to another optical fiber. A fiber splice is the permanent connection between two optical fibers. Once optical fibers are connected to a splice, they cannot be separated and put back together, as they can be if you connect them using connectors. Fiber splices are typically used for one of four reasons: to repair a damaged cable, to extend the length of a cable, to join two different types of cables, or to connect a braid. We’ll talk about fiber braids later in the article.
What is mechanical connection?
Many manufacturers offer mechanical splices. Mechanical splices like the one shown above are usually permanent; they align the split optical fibers and hold them in place. The index-matching gel inside the mechanical splice reduces or eliminates any Fresnel reflections or losses at the splice.
Mechanical splices can be used for both single-mode and multimode fiber cables. Mechanical splices are not superior to fusion splices. However, they can outperform pairs of mated connectors. The main advantage of a mechanical splice over a fusion splice is the lower cost of the equipment required to make the mechanical splice.
The assembly tool that holds the optical fiber and the mechanical splice is relatively inexpensive compared to the price of the fusion splice tool. However, the cost of the actual mechanical splice is much higher than the protective sheathing required for the fusion splice.
Steps for performing the mechanical connection process
Step 1: Prepare the fibers.Protective coatings, jackets, pipes, strength elements and other materials must be removed, leaving only bare fibers visible. The most important consideration is cleanliness.
Step 2: Clean the fibers: It’s time to clean the raw fibers after removing them from their shell. The glass can be kept clean by wiping it with fiber optic cleaner and lint-free wipes.
Step 3: Slit the fibers.This process is comparable to the fusion splicing process; however, the accuracy of the splicing is less important.
Step 4: Mechanically bond the fibers.This method does not use heat. Simply place the ends of the fibers into the mechanical splicer and bond them together. The index matching gel in the mechanical splicer will help the fibers easily connect from one end to the other.
Step 5: Fiber Protection: The final mechanical connection acts as a protection for its connection.
Advantages of mechanical connection
Mechanical connections do not require electricity.
With the exception of the fiber stripper and fiber splitter, many mechanical fiber splicer designs require no additional equipment.
Mechanical connection is useful in situations where fusion connection is not possible or practical. This makes it ideal for short-range connections.
Disadvantages of mechanical connection
Mechanical splices increase signal loss. The insertion loss is much higher. The normal insertion loss of a mechanical splice is about 0.2 dB, which is much higher than the 0.02 dB loss of a standard fusion splicer. Multimode fibers are usually mechanically splices.
Mechanical connectors have difficulty meeting the alignment requirements of single-mode fibers.
Mechanical connections are only used under relatively safe conditions, such as office buildings.
What is junctional fusion?
The fusion splicing process uses a high voltage electric arc between two electrodes to heat and melt the ends of the fibers together. This creates a permanent joint that is very fragile and must be protected from the outside environment and bending. This is typically accomplished using heat shrink tubing and a small metal rod commonly referred to as a sheath. Before the splicing is made, the optical fiber is passed through the center of the sheath, and the sheath is positioned so that it does not interfere with the fusion splicing process. After the fusion splicing process is successfully completed, the optical fiber is removed from the fusion splicer, and the sheath is placed directly over the splicing area. The sheath is then placed in an electric oven typically built into the fusion splicer. The oven heats the tube, causing it to shrink around the fusion splicer.
Image provided by 3SAE
Fusion splices are more expensive than the assemblies required for mechanical splices. However, they provide the lowest possible loss in the fiber connection. In addition, fusion splices do not produce Fresnel reflections. Fusion splices are the most accurate and robust method of joining optical fibers. After the optical fiber is stripped and slit, it is placed in a fusion splice, where the optical fiber is aligned between two electrodes. Depending on the fusion splice used, several alignment techniques are used to align the fiber optic cable.
The splicers available on the market today typically feature a display that allows you to view the optical fiber on two different axes. The cameras in the splicer magnify the optical fiber so that the ends can be lifted. Most splicers available today also have the ability to approximate the loss of the splicing after it is complete.
Steps to implement the fusion process
Step 1: Strip the fibers.You must first remove or peel off the protective polymer layer around the fiber optic cable before you can begin the splicing process. A mechanical stripper, similar to the pliers used in the splicing process, is typically used for this purpose. Remember to clean the stripping equipment before beginning the splicing process.
Step 2: Clean the fibers.It is time to clean the raw fibers after removing them from their shell. The glass can be kept clean by wiping it Fiber Optic Cleaner And lint-free wipes.
Step 3: Split the fibers.To make an effective joint, you need a proper knife. Instead of cutting the fibers, a cutting knife cuts, pulls or bends them to create a neat break, with the end face flat and perpendicular to the fiber axis.
Step 4: Integrate the fibers.After stripping and cutting the fibers, use a fusion splicer to splic them together. The ends of the fibers must first be aligned inside the splicer. Once they are properly aligned, melt the fibers with an electric arc, permanently fusing the ends together.
Step 5: Protect the fibers.The joint will not break during typical handling if the fibers are protected from bending and tensile loads. The joint is protected from weathering and breakage by a protective jacket placed in an electric oven usually built into the fusion joint. The oven heats the tube, causing it to shrink around the fusion joint.
Advantages of fusion bonding
Fusion splicing is a compact process with minimal insertion loss and back-reflection.
Lower signal loss means higher performance for optical fiber.
Fusion joint is permanent and has the highest mechanical strength.
The fusion bonding process can withstand a wide range of temperatures.
The fusion junction prevents dust and other contaminants from entering the optical path.
Disadvantages of fusion bonding
If too much heat is applied to melt the fiber optic cable for termination, the connection will become brittle and cannot be used for very long.
Integration leads to high upfront costs for connectivity and additional hardware.
Fusion joint cannot be used for temporary connections because it is a permanent connection.
Cost comparison
One of the most important differences between mechanical and fusion joints is the cost of the tooling and finishing parts required. In general, the tools and equipment required for fusion joints are much higher than those required for mechanical joints. However, the prices of consumables used in mechanical joints are typically higher than those used in fusion joints. The costs of each joint are lower in fusion joints, but the initial cost is much higher.
Mechanical fasteners
Mechanical splice systems are relatively inexpensive, costing around a few hundred dollars at the time of this writing. Most of the initial cost is the investment in a high-quality cleaver, although the quality of the fiber slit is more important in fusion splicing. Other than the cleaver, mechanical splice tools consist primarily of corrosion-resistant components such as cable strippers and Kevlar shears, which can be replaced as needed.
Fusion Bonding Tools
Fusion splicing systems are significantly more expensive, typically in the thousands of dollars range at the time of this writing. The higher cost is primarily due to the fusion splicer itself, which requires heating or welding the fiber strands. Additionally, fusion splicers require power, setup time, and regular maintenance. They also require a high-quality machete.
mechanical connectors
Mechanical systems use connectors and splices that can be installed on site to connect the cables. Many of these connectors use a cam lock system to secure the fibers without causing any damage. These connectors are much more expensive than pigtails and cannot be reconnected.
Fusion junction connectors
In order to join two pieces of fiber together using a splice, all that is required is a protective jacket, as well as the splice device itself. If a connector must be installed at the end of a strand of fiber, splice systems typically use “pigtail splices.” Pigtail splices are typically much less expensive than mechanical connectors.
Now, about the braids…
What is the thing that is connected to the strand or strands of a fiber optic cable? We call it Fiber optic braidA fiber optic tail is a portion of an optical fiber where one end terminates with a factory-installed connector and the other end is unterminated. As a result, the connector side can be connected to equipment, while the other side is fused in the case of a fusion splicer and mechanically attached to a fiber optic network cable. Fiber optic tails are used to connect fiber optic cables using a fusion splicer or mechanical splicer. We have more about fiber optic tails in our blog post, “What is fiber optic pigtail and what are its uses?“
TrueCABLE Pigtail Connection Solutions
Fiber optic patch cords are a versatile and cost-effective way to terminate bare fiber optic cable as well as connect devices and extend the reach of your network. They are easy to install, available in a variety of connector types and lengths, and made from high-quality materials. Fiber optic patch cords are used in a wide range of applications, including fiber optic network construction, testing and maintenance, data centers, telecommunications networks, and security systems. We offer A variety of single-position braids To meet your application needs.
conclusion
Both mechanical and fusion jointing have advantages and disadvantages. The choice of either jointing method should depend on your budget, the frequency of installations you will be performing, and the specific requirements of your projects. For small, occasional installations, mechanical jointing may be more cost-effective and convenient. However, for high-performance needs and large-scale projects, the higher quality and efficiency of fusion jointing may justify the higher initial investment.
Fusion splices remain the best performing option, and trueCABLE offers several fusion splice options when fusion splices are required in your fiber optic installation.
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