Abstract:
An improved system and method for automated fiber polishing overcomes the limitations of conventional systems and methods. In particular, the present invention provides for continuous determination of the quality of the polish during a polishing procedure. An optical signal is transmitted to a fiber tip, and any back-reflected signal is detected and monitored to determine polish quality. In this manner, automated polishing quality assurance is provided in real time.

Description:
BACKGROUND OF THE INVENTION 
     In contemporary fiber optic systems, optimization of coupling efficiency between the optical fiber and active or passive devices is a key metric in system comparisons, such as the pumps used in fiber amplification systems. In a popular technique for improving coupling efficiency, an end of the optical fiber is polished to provide a lens shape at the end face. Hyperbolic-shaped end faces are among the most highly desired shapes, since they tend to provide the highest coupling efficiency. 
     A popular technique for fiber polishing involves the use of a motor-controlled jig to position the end face of a fiber in contact with a rotating abrasive wheel. Once in contact, the end face of the optical fiber is polished by the wheel to form a lens. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a system and method for fiber polishing that overcome the limitations of conventional systems and methods. In particular, the present invention provides for continuous and contemporaneous determination of the extent of the polish during a polishing procedure. An optical signal is transmitted to a fiber tip, and any back-reflected signal is detected and monitored to determine the polish. In this manner, an automated polishing quality assurance is provided in real-time, during the polishing operation. 
     According to a first embodiment, the present invention is directed to a system for polishing a tip of a fiber optic. The system includes a fiber tip polishing unit for positioning a fiber optic tip relative to a polishing surface. A control system controls the positioning of the fiber optic tip. A polishing feedback unit includes an optical source and an optical sensing unit. During a polishing operation, the optical source provides an optical monitoring signal in the fiber optic, and the optical sensing unit senses a portion of the monitoring signal inwardly reflected (i.e., back reflected) from the tip. 
     The fiber tip polishing unit preferably positions the fiber optic tip relative to the polishing surface in a plurality of degrees of freedom. In the present implementation, the tip is held in a silicon chuck. 
     The fiber tip polishing unit may further include a bearing along a longitudinal axis of the fiber tip for providing the fiber tip at the polishing surface at a controlled force. The bearing may comprise an air bearing. 
     The fiber tip polishing unit may further include a translation positioner along a longitudinal axis of the fiber tip, the translation positioner being coupled to the control system for controlling longitudinal positioning of the fiber tip with respect to the polishing surface. 
     The fiber tip polishing unit may further include a rotation positioner along a longitudinal axis of the fiber tip, the rotation positioner being coupled to the control system for controlling rotational positioning of the fiber tip about the longitudinal axis with respect to the polishing surface. 
     The fiber tip polishing unit may further include a lateral positioner coupled to the control system for controlling lateral positioning of the fiber tip with respect to the polishing surface. 
     The polishing surface may comprise a rotating polishing pad, and the fiber tip polishing unit may further include a pad motor coupled to the control system for controlling rotation rate of the polishing pad. An optional tilt positioner may be coupled to the control system for controlling tilt angle of the polishing surface with respect to the fiber tip. 
     The polishing feedback unit may further include an optical coupler, for example a 3 dB coupler, for dividing the monitoring signal generated at the optical source, such that a portion of the monitoring signal is delivered to the fiber optic tip in a first direction of propagation, and such that a portion of the monitoring signal inwardly reflected from the tip is delivered to the optical sensing unit in a second direction of propagation. An optional termination unit, for example an index-matching gel, substantially eliminates back reflection of a remaining portion of the monitoring signal propagating in the first direction. 
     The optical sensing unit may further generate a feedback signal based on the sensed portion of the monitoring signal for controlling the positioning of the fiber optic tip. 
     The control system preferably controls positioning of the fiber optic tip by controlling spatial positioning or force and orientation of the tip with respect to, and contact force with, the polishing surface. 
     According to a second embodiment, the present invention is directed to a method for polishing a tip of a fiber optic. The position of a fiber optic tip relative to a polishing surface is controlled. During a polishing operation, an optical monitoring signal is provided in the fiber optic, and a portion of the monitoring signal inwardly reflected from the tip is sensed. 
     In this manner, an apparatus and method are provided for automated fiber polishing by which the quality of the polish is monitored during the polishing operation, and, in response, a control system performs a real-time adjustment of the polishing apparatus. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other objects, features and advantages of the invention will be apparent from the more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
     FIG. 1 is a perspective view of a system for fiber optic polishing, in accordance with the present invention. 
     FIG. 2 is a block diagram of the optical back-reflection detection circuit for the system of FIG. 1, in accordance with the present invention. 
     FIG. 3A is a close-up perspective view of a fiber optic chuck having a silicon microbench, in accordance with the present invention. Inset FIG. 3B is a close-up perspective view of the silicon microbench of FIG.  3 A. 
     FIGS. 4A and 4B are plots of the distance measured by the encoder of FIG. 1 as a function of time for each side of the tip. FIGS. 4C and 4D are plots of distance measured as a function of time during constant-force mode. 
     FIGS. 5A and 5B are plots of back reflection levels detected by the photo detector  74  of FIG.  1 . FIGS. 5C and 5D are plots of back reflection levels detected during constant-force mode. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     With reference to FIG. 1 the fiber polishing apparatus  20  of the present invention comprises a fiber mount  22 , a platen mount  24  including polishing platen  44 , an optical signal back-detection circuit  78 , and a fiber polishing motion controller  76 . In combination, the components comprise a system for fiber polishing that provides enhanced efficiency and precision with continuous monitoring of the polishing operation during polishing. 
     The fiber mount  22  includes a motor mount  38  that supports a fiber rotation motor  36 , a translation motor  34 , rod mount  32 , translation rod  30 , and fiber chuck  26 . A fiber optic tip  28 , at the end of a fiber optic coil  66 , is mounted to the fiber chuck  26 , which in turn fixes the tip  28  in position relative to the chuck  26  during polishing. In one implementation, the end face is located 100 μm from the end of the chuck. 
     A close-up perspective view of the fiber chuck  26  is shown in FIG.  3 A. The chuck  26  includes first and second mating bodies  92  formed, for example, of a lightweight material such as aluminum. Each of the mating bodies preferably has a finished mating surface  84  that includes a V-groove  86 , and a recess at the distal end, shaped to support a precision grooved microbench  80  made, for example from, a hard, rigid, stable material such as silicon. The silicon microbench  80  preferably includes a V-groove  82  in alignment with the chuck upper-body V-groove  86 , and comprises a machined body of silicon for supporting the fiber tip  28  at its interface with the polishing platen  44 . As shown in inset FIG. 3B, the silicon microbench  80  may include a bevel  88  at its distal end to provide clearance for polishing of the tip  28  at steep angles, while retaining the tip  28  in close proximity to the end of the chuck  26  during polishing for enhanced precision. 
     While a first of the mating chuck bodies  92  is shown in FIG. 3, the second of the mating bodies (not shown) comprises a mirror image of body  92 , including a V-groove  86 , and silicon microbench  80  with V-groove  82 , to form a channel with the first body for securing the top surface of the fiber tip  28 . The upper and lower bodies are preferably hinged, or otherwise mated and clamped, so as to be fixed to each other during a polishing operation. 
     Returning to FIG. 1, the chuck  26  is mounted to a translation rod  30 , preferably formed of a lightweight and rigid material to reduce excessive moments imparted by the rod  30  and chuck  26  on the motor mount  38 . The translation rod  30  extends in a longitudinal direction to present the chuck  26  and fiber tip  28  to the platen  44 . 
     The rod  30  is coupled to the rod mount  32  through an air bearing  33 , which serves to create a low friction, low stiction, mechanical interface between the rod mount  32  and the rod, in the direction of the z-axis, yet rigid in the x-y plane. The chuck  26  and rod  30  are preferably rotationally fixed to each other. A translation (z-axis) motor  34  serves to extend and retract the chuck  26  and rod  30 , in the rod mount  32  on the air bearing  33  along a longitudinal direction indicated by arrow  58 . The translation motor  34  preferably comprises a closed-loop servomotor, for example a voice-coil-type motor, coupled to a controller  76 , for controlled translation of the optical fiber tip  28  during a polishing operation. 
     The translation motor  34 , air bearing  33 , rod mount  32 , translation rod  30 , and chuck  26  are collectively, in turn, coupled to a fiber rotation motor  36  mounted to the motor mount  38 . The fiber rotation motor  36  provides for collective rotation of the translation motor  34 , air bearing  33 , rod mount  32 , translation rod  30 , and chuck  26  in an angular direction indicated by arrow  60 . The translation motor  34  preferably comprises a closed-loop servomotor coupled to the controller  76 , for enhanced angular positioning of the optic  28  during a polishing operation. 
     The motor mount  38  is in turn coupled to a linear motor  40  for linear positioning of the fiber tip  28  relative to a centerline  94  of the platen  44  in a linear direction indicated by arrow  56  or x-axis direction. The linear motor  40  likewise preferably comprises a closed-loop servomotor coupled to the controller  76 , for enhanced linear positoning of the optic  28  during a polishing operation. 
     The platen mount comprises a platen chassis  42  to which first and second polishing platens  44  are rotatably mounted, for example on a low-friction bearing. The polishing platens  44  comprise, for example; polishing pads of different grit values (abrasive sizes) such that coarse and fine polishing is accomplished by first positioning the fiber optic chuck  26  to present the fiber end face to the coarse-grit platen wheel  44 A, followed by a linear shifting along a direction indicated by arrow  56  using the linear motor  40 , to then present the fiber end face to the fine-grit platen wheel  44 B. Alternatively, in other implementations, the platen wheels  44 A,  44 B comprise polishing pads of similar grit values, in order to double the service time period between pad replacements. Alternatively, a single platen wheel, or a plurality of platen wheels greater than two, may be provided, depending on the polishing application in the other implementations. 
     The platen wheels  44 A,  44 B are driven to rotate by a platen motor  48  mounted to the platen chassis  42 . The platen motor includes a drive shaft  50  for transferring the rotation of the motor  48  axle, to angular movement of the platen  44  in a direction indicated by arrow  62 . The platen motor  48  preferably comprises a closed-loop servomotor coupled to the controller  76 , to control the angular velocity of the platen  44  during a polishing operation. 
     During a polishing operation, the fiber tip  28  is caused to be translated across the surface of the platen  44  by the linear motor along a direction indicated by arrows  56 , so as to provide uniform wear of the polishing pads on the platen  44 . Since the linear velocity of the platen increases with radial distance from the center if the angular velocity is unchanged, the angular velocity of the platen  44  is preferably adjusted by the controller  76  as the axial position of the fiber changes to provide a constant linear velocity to ensure polishing consistency. Alternatively, variations in linear velocity are provided by the system of the present invention, for applications that require such a feature. 
     The platen wheels  44 A,  44 B are bisected by a chassis centerline  94 , along which, the fiber optic end face  28  is presented during a polishing operation. A platen tilt motor  52  is coupled to a platen tilt belt  54 , in turn driving the angular positioning of the platen chassis  42  and platen wheels  44 A,  44 B about the centerline  94 , along an angular direction indicated by arrow  64 . The platen tilt motor  52  preferably comprises a closed-loop servomotor coupled to the controller  76 , for enhanced control over the tilt of the platen wheels  44 A, 44 B during a polishing operation. Platen tilt controls the angle at which the fiber optic tip  28  is polished. functions to urge the fiber tip against the platen  44  at a constant force because of the low-friction/stiction rod/rod mount interface. The lightweight rod  30  and chuck  26 , in combination with the air bearing  33 , allow the system to react to changes in the platen surface relatively quickly. Without these features, any bump or warp of the surface of the platen  44  would cause a temporary increase in pressure, which may cause the fiber tip to crack, or gouge the pads. 
     For example a wedge-shaped lens or a spheric shape could be created with the machine described above. This is accomplished by executing four polishing steps in one implementation. During the first and second steps, the fiber&#39;s position is controlled using a z-axis position encoder  35  and motor  34  in a closed-loop control method. The fiber is driven to a proscribed position into the platen surface so that the amount of material removed is known to within the system&#39;s accuracy. Material is removed from opposite sides of the fiber during each of the first two steps respectively. The first two steps are typically performed with a coarse-grit lapping film in order to decrease the polishing time. 
     FIGS. 4A and 4B are plots of the distance measured by encoder  35  as a function of time for each of the side of the tip, respectively. As shown, during these position controlled steps, the distance is controlled in a linear fashion. 
     FIGS. 5A and 5B; are plots of the backreflection levels detected by the photodetector  74 . In the preferred embodiment, during these initial polishing steps, only cladding material is removed. Thus, back reflection levels are not affected. 
     During the third and fourth polishing steps, an open-loop control method on motor  34  is implemented in order to create a constant force between the lapping film and the fiber. A constant current is applied to the translation motor  34 , in order to apply a constant force to the fiber tip  28  by the fine-grit platen  44 B. The optical feedback system  78 , described below, is used to determine when the back reflected light intensity is 50% of its initial value in the third step. When the 50% point is reached, the fiber is retracted, rotated 180 degrees, and polished (fourth step) until the back reflection is negligible. In this manner, the wedge tip is assured to be centered relative to the fiber&#39;s core. The third and fourth steps are performed using a fine-grit lapping film to improve surface finish and control over polishing rates. 
     At any time during the polishing operation, the far-field emission pattern of light emitted from the fiber tip is visually inspected by positioning the tip  28  before camera  46 , installed on the platen chassis  42  to provide visual feedback to an operator or controller  76 . 
     During polishing, the present invention provides an enhanced automated feedback mechanism for analyzing the quality of the polish. The optical back-detection circuit  78  provides this function. The use of backreflection as a control signal during processing insulates the polishing process from concentricity variations and removes mode size variables when the backreflection light is the same wavelength as the operating wavelength of the final device. 
     With reference to both FIG.  1  and the block diagram of FIG. 2, the optical back-detection circuit  78  comprises a 3 dB coupler  68 , a light source  72 , a termination unit  70 , a photodetector  76 , and the controller  76 . During polishing, a light signal, preferably a single-mode light signal, is generated by the light source  72  and presented to the 3 dB coupler or circulator  68 . At the 3 dB coupler  68 , 50% of the signal is provided to the optic  66 , and 50% of the signal is provided to the termination unit  70 . The termination unit  70  may comprise an index-matching gel or other material or apparatus that substantially eliminates back-reflection of the signal back toward the 3 dB coupler. Such unit is not required if a circulator is used. 
     The portion of the probe light signal that is provided to the fiber optic  66  propagates down the fiber optic  66  to the tip  20  undergoing polishing. Most of that portion is emitted from the fiber tip  28 ; however, a certain amount, for example approximately 4%, is back-reflected through the fiber body  66  to the 3 dB coupler  68 . In an alternative implementation, the tip is coated prior to polishing to increase the level of back reflection. In one implementation the tip is metallized. At the coupler  68 , back-reflected light is split as above —50% being propagated back to the source  72 , and 50% being provided to a photo-detector  74 . The photo-detector  74  determines the intensity of the back-reflected light, and provides an intensity signal, or related control signal, back to the controller  76 . In response, the controller makes decisions with regard to position and orientation adjustments to the fiber tip  28  and the platen  44 , in order to optimize the polishing procedure in real time. 
     As an example, during polishing of a fiber, intensity of the back-reflected light is nearly constant until the core of the fiber tip  28  begins to undergo polishing. This is illustrated by FIGS. 5A and 5B as described previously. As the core becomes polished, as occurs in the third and fourth steps, light is reflected off the polished surface at a reduced angle, or the metal coating is removed, and therefore a higher percentage of light signal is output from the tip  28 . The back reflection from polishing to a wedge shape as shown in FIGS. 5C and 5D. Prior to polishing, a peak back-reflection level is initially recorded at time 0 in FIG.  5 C. The top half of the wedge is then polished until the back-reflection level reaches 50% of the peak, in the case of the metallized tip (see time 55 sec. in FIG.  5 C). This polishing into the core is preferably done under force control, such as the constant force mode. This is illustrated by FIG.  4 C. Distance slowly increases with time. Note the periodic oscillation resulting from pad wobble. The tip  28  is then rotated 180 degrees and the bottom half of the wedge is polished until the back-reflection level is reduced to substantially 0% as shown by FIG.  5 D. The constant force mode is shown by FIG.  4 D. In this manner, it is known that output coupling is optimized, while at the same time, a symmetric wedge shape is ensured. 
     The present invention is equally applicable to polishing of fiber tips to other shapes; however, analysis of the light signal is appropriately modified to in accordance with the light profile of the shape to be polished. 
     Following polishing, the optic tip  28  can be fused to cause the glass at the end of the tip  28  to become more rounded. An electric arc is applied across the tip, which causes the glass to melt. The surface tension of the glass and the intensity of the arc dictates the final, typically hyperbolic, shape of the glass tip. 
     While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made herein without departing from the spirit and scope of the invention as defined by the appended claims. 
     In one modification, the wavelength of the probe height is modulated to determine the shape of the tip. The longer wavelengths have a large mode size, which results in more of the power traveling in the cladding with typical Gaussian single mode distribution. Longer wavelengths are used to monitor cladding and cladding/core interface polishing, whereas shorter wavelengths are used to monitor polishing near the core center.