How To Fusion Splicing Fiber Optic Composite Cables

Fusion splicing is a critical process for joining two optical fibers in fiber optic composite cables to ensure low signal loss and high reliability. Below is a step-by-step guide on how to perform fusion splicing for fiber optic composite cables:

1. Preparation

Tools and Equipment Needed:

• Fusion splicer

• Fiber cleaver

• Stripping tools (for removing cable jackets and coatings)

• Isopropyl alcohol and lint-free wipes

• Heat shrink tubing (for protecting the splice)

• Fiber holder or tray

• Safety glasses and gloves

Safety Precautions:

• Wear safety glasses to protect your eyes from fiber shards.

• Handle fibers carefully to avoid breakage or injury.

  
  

2. Strip the Cable

• Remove the Outer Jacket:

• Use a cable stripper to carefully remove the outer jacket of the photoelectric composite cable.

• Be cautious not to damage the internal optical fibers or power lines.

• Separate the Components:

• Identify and separate the optical fibers from the power lines.

• Use a fiber stripping tool to remove the protective coating from the optical fibers, exposing the bare glass fiber.

3. Prepare the Optical Fibers

• Use a fiber cleaver to make a clean, perpendicular cut on the fiber ends.

• A proper cleave is essential for a successful fusion splice.

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• Use lint-free wipes and isopropyl alcohol to clean the stripped fibers thoroughly.

• Ensure no dirt or residue remains on the fiber surface.

• Clean the Fibers:

• Cleave the Fibers:

4. Fusion Splicing the Optical Fibers

1. Set Up the Fusion Splicer:

• Turn on the fusion splicer and select the appropriate program for the type of fiber being spliced (e.g., single-mode or multi-mode).

2. Load the Fibers:

• Place the cleaved fibers into the fusion splicer's fiber holders.

• Ensure the fibers are properly aligned in the V-grooves.

3. Perform the Splice:

• Start the fusion splicing process. The splicer will automatically align the fibers, perform the fusion, and assess the quality of the splice.

• The splicer will display the estimated splice loss (typically < 0.1 dB for a good splice).

5. Protect the Fiber Splice

1. Slide Heat Shrink Tubing:

• Before splicing, slide a piece of heat shrink tubing (splice protector) onto one of the fibers.

• After splicing, move the tubing over the splice point.

2. Heat the Tubing:

• Use a heat gun or the splicer's built-in heater to shrink the tubing, securing and protecting the splice.

6. Connect the Power Lines

1. Strip the Power Lines:

• Use wire strippers to remove the insulation from the power lines, exposing the conductive metal.

2. Twist or Solder the Wires:

• For a secure connection, twist the exposed wires together or solder them.

• Use heat shrink tubing or electrical tape to insulate the connection.

3. Test the Connection:

• Use a multimeter to ensure the power lines are properly connected and there is no short circuit.

7. Organize and Secure the Cable

1. Place the Splice in a Tray:

• Use a fiber holder or splice tray to organize and protect the spliced fibers.

• Avoid bending the fibers beyond their minimum bend radius.

2. Reassemble the Cable:

• Recover the cable with protective sleeves or enclosures, ensuring the power lines are properly insulated and secured.

8. Test the Splice and Connection

1. Test the Optical Fibers:

• Use an OTDR (Optical Time-Domain Reflectometer) or power meter to measure the splice loss and ensure it meets the required specifications.

2. Test the Power Lines:

• Use a multimeter to verify the continuity and proper connection of the power lines.

Tips for Successful Welding

• Work in a Clean Environment: Avoid dust and debris, as they can affect the splice quality.

• Calibrate Equipment: Regularly calibrate the fusion splicer and cleaver for optimal performance.

• Handle Fibers Gently: Avoid excessive bending or pulling of the fibers.

Summary of Steps

1. Prepare the cable: Strip the outer jacket and separate the fibers and power lines.

2. Prepare the fibers: Clean, cleave, and splice the optical fibers using a fusion splicer.

3. Protect the splice: Use heat shrink tubing to secure the fiber splice.

4. Connect the power lines: Strip, twist/solder, and insulate the power lines.

5. Organize and secure: Place the splice in a tray and reassemble the cable.

6. Test: Verify the splice quality and power line connection.

By following these steps carefully, you can successfully weld (fusion splice) photoelectric composite cables, ensuring reliable performance for both optical and electrical transmission.