CHAPTER - 9
HOW THE OPTICAL FIBER IS FUSED USING FUSION SPLICER ?
Fusion splicing is a technique used to join optical fibers by melting or fusing their ends
together using an electric arc. This process creates a permanent and low-loss connection
between the fibers. Fusion splicing is typically performed using a specialized piece of
equipment called a fusion splicer.
FUSION SPLICER:
A fusion splicer is a specialized tool used in the field of telecommunications and fiber optics.
It's used to join or "splice" optical fibers together by melting or fusing them at their ends,
creating a continuous connection that allows light to pass through with minimal loss. This
process is crucial for creating reliable and high-performance optical networks.
Fusion splicers typically work by aligning the fiber ends precisely using a combination of
microscopic cameras, then applying heat to melt the fibers together. The resulting splice is
typically stronger and has lower optical loss compared to mechanical splicing methods.
Fusion splicers come in various types, including core alignment splicers and cladding
alignment splicers. Core alignment splicers are more advanced and typically provide lower
splice losses by aligning the cores of the fibers, whereas cladding alignment splicers align the
outer layers of the fibers.
These devices are used extensively in telecommunications, data centers, cable TV networks,
and other industries where high-speed, high-bandwidth communication is essential. Proper
training and expertise are required to operate fusion splicers effectively due to the precision
involved in aligning and splicing the fibers.
Here's an overview of the process of fusion splicing using a fusion splicer:
Place the protective sleeve
Remove the plastic coating of the fibres
Clean the fibres with isopropyl alcohol
Cutting the optical fibers
Run the splicing in the optical fusion splicer
Using the sleeve to protect the fusion
1. PLACE THE PROTECTIVE SLEEVE
Before starting to splice the two fiber optic cables, put inside the protective sleeve one of
them, so it will prevent cables detach.
2. REMOVE THE PLASTIC COATING OF THE FIBRES
Optical fiber is shielded by several plastic layers that have to be removed. For this purpose,
the optical fiber stripper supplies different diameter holes to rid off the plastic protection to
achieve the optical fiber exposed.
To do that, this step has to be repeated for every single layer.
Hold the optical fiber stripper with one hand. With the other hand take the outside of one of
the optical fiber and introduce it into the proper fiber stripper hole. Then, simply stretch out
the plastic shield and get rid off it. 3 cm approx. of optical fiber will be enough.
3. CLEAN THE FIBRES WITH ISOPROPYL ALCOHOL
Removing the plastic coating will leave residues to be cleaned otherwise they will have an
impact on the quality of the fusion splicing. An isopropyl alcohol wipe is used because this
kind of alcohol evaporates very quickly without leaving residue.
4. CUTTING THE OPTICAL FIBERS
In this process we are using a precision cutter that performs a perfect 90 degrees cutting
angle, which could not be achieved using other tools such as scissors. Set and secure one of
the fibers so that when cutting it you have from 12 to 17 mm of exposed fiber (0.5 to 0.7
inch) after the plastic coating (step 1). This measurement is subject to the specifications of the
fusion splicing machine used in the next step.
Lower the cover (step 2) and spread the blade to cut the fiber (step 3). Then, repeat this
process with the other fiber.
5. RUN THE SPLICING IN THE OPTICAL FUSION SPLICER
All you have to do is put in place the ends of both fibers in their corresponding guides in the
optical fusion splicer. The ends of the fibers must be:
Aligned with each other.
Centered on the electrodes.
We should Avoid any physical contact between neither fibers nor electrodes. At this point,
we must lower the cover of the fiber optic splicer and press the fusion key. The fiber optic
splicer is a highly automated device that evaluates and aligns the fibers before proceeding to
“burn” the ends using an electrical shock so that they finish up by being physically joined as
if they were a single wire.
If the fusion splicer has interrupted the process, it may be because one of the following
problems:
Bad arrangement of the wires on their guides.
The fibers are not cut at a 90 degree angle.
There are remains of the plastic cover on the end of the fiber.
It the fusion has been OK, the device itself will estimate the fusion losses. Otherwise, check
the proper execution of the steps above.
6. USING THE SLEEVE TO PROTECT THE FUSION
At this point the two fibers have become one. Extract the fibers from the guides of the splicer
and cover the fusion point with the protective sleeve. Then, insert the whole assembly into
the fusion oven built into the splicer and press the proper key of the machine.
The oven will apply heat for a few seconds and the heat shrink plastic will shrink up to cover,
encapsulate and thus protect the fiber.
From now on it is possible to work with the optical fiber cable having no fear it may break up
by the point of fusion.
