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Fiber Optics Dispensing Sees the Future through Automation
December 31, 1969 |Estimated reading time: 3 minutes
Many dispensing applications involved in fiber optics component manufacturing benefit from automation. Benefits include reduced labor, lower adhesive usage, less scrap and rework, and increased production efficiency.
By Mike Fornes
Automating dispensing applications provides accuracy and precision of adhesive volume and placement, and is becoming a fiber optics industry standard. This automation is being driven by customer demands, such as increased product quality and reduced manufacturing costs. There are a wide range of dispensing tools and levels of automation to match fiber optics manufacturers' specific needs. These tools and automation levels accommodate a broad range of adhesives and manufacturing processes, allowing customized application.
From the R&D BenchFiber optics dispensing historically was a labor-intensive function developed as an extension of research and development (R&D). The manual techniques that engineers developed in the R&D phase were duplicated on the manufacturing floor. This met the immediate need to get the job done but required extensive labor, led to adhesive waste and resulted in varying product quality.
The First StepThe first step in automation involves precisely controlling dispensed adhesive volume. This initial automation stage involves using a syringe. When manually manipulated, syringes allow deposition control by using a needle chosen for the task, accommodate one or two component materials, and can be filled automatically.
Syringes are produced with the filling adhesive in mind. A standard clear barrel serves typical adhesives; an amber barrel, UV-cure fluids; and an opaque black, light-cure fluid.
Both syringe pistons and tips can be customized. Additionally, dispense tips can be specified in numerous ways to meet manufacturing requirements. Fluid application also can be controlled by carefully selecting the diameter and dispense tip length.
Syringes are served by various fill systems that can be specified based on volume of material per application and fluid viscosity. Fill systems allow materials to be purchased in bulk, lowering the material cost.
With regulated air pressure, an automated shot time provides excellent shot-to-shot repeatability, reducing excess adhesive and polishing time.
Other applications call for a positive displacement auger dispenser with a closed loop drive system. With a closed loop drive system, as viscosities change, a consistent flow rate is maintained. An auger gun with an easily removable auger is best for two-component materials. For thicker materials, the positive displacement auger eliminates a tail effect.
Tabletop AutomationBecause tabletop automation is ideal for low- to medium-volume production or lean manufacturing operations, it can be a final solution or building block to a fully automated assembly line.
Tabletop system benefits include increased throughput and improved process control. These systems integrate with various dispensing systems and other automation.
Fully Integrated SystemsWork cells combine system integration with flexibility for multiple operations. Splicing applications require nano automation for fiber alignment before dispensing. There are many versions of nanostage automation used in fiber alignment at varying costs. In addition to XYZ movement, it is important to investigate and understand the advantages of pitch, yaw and rotation control, and active feedback. Return on investment for these features can be realized through reduced scrap, improved product quality and increased margins through end-product differentiation.
A fully automated fiber optics production line evolves from multiple integrated, conveyorized work cells, each dedicated to a specific manufacturing function.
System SelectionIn selecting systems for fiber optics automation, it is important to assess performance needs, such as throughput, cycle time and yield, as well as machine features. Hardware and software flexibility must be understood. The machine's ability to be upgraded or integrated into a larger automation process also is a factor.
Training needs and the required skill level of operators are both critical features. How quickly a machine can be used fully as well as the system's reliability also are key.
The equipment supplier's experience with fiber optics automation and dispensing is critical. The supplier's infrastructure must provide necessary support for specifying, installing and troubleshooting equipment, in addition to operator training and ongoing field support.
Michael Fornes, market manager, may be contacted at Nordson Corp. Product Assembly Group, 11475 Lakefield Drive, Duluth, GA 30097; (770) 497-3700; E-mail: mfornes@nordson.com.