Fiber Optic Design Solutions

Winchester Electronics engineers use highly advanced, best-in-class software tools, equipment, and technologies during the design, development, and verification/validation phases of their projects. Parts are first designed in a 3D CAD environment and then simulated to obtain an optimum performance given a specific set of parameters and requirements, based on the application. Finally, the simulation results are correlated and validated to actual measurements, reducing repeated design iterations and redundant prototypes.

Optical Simulation

The two types of broadly used fiber optic interconnects can be characterized as ferrule-based or free space. For ferrule-based connectors, it is critical to maintain appropriate compressive forces on the fiber interface in addition to appropriate mechanical tolerances on the ferrules and alignment sleeves so that physical contact is maintained between the end faces of the optical fibers. For free space interconnects and devices, optical simulation of the light beam behavior in free space is the key requirement. Winchester Electronics has fiber optic interconnect design and simulation tools to cover both interconnect scenarios. This allows design of predictable insertion and return losses over changes in temperature and under conditions of shock and vibration. Design is done through advanced modeling of the interface using the interface before physical samples are created.

Fiber Interface Modeling & Simulation Tools

• 3D Solid Modeling using Solidworks®.
• Early Design cycle simulation using Ansys Multiphysics® to simulate mechanical forces
• Optical simulation of any free-space beams and optical surfaces and coatings using Photon Inc. FRED software. Gaussian beam decomposition is used for single and multimode beams, while ray tracing capabilities are also available for large core fiber applications.
• Characterization and verification of prototypes using physical testing. 
• Environmental testing of finished connector to verify optical performance

Mechanical Analysis of the Fiber Optic Connector

• Spring and latching forces are calculated to ensure the system will maintain appropriate pressure at the optical interfaces.

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Free Space Optical Analysis

• Photon Inc. FRED software uses advanced modeling techniques beyond ray tracing to simulate coherent sources and calculate single-mode or multi-mode fiber insertion losses.
• Standard lens catalogs and custom designed lenses and coatings are used within the system to duplicate the optical arrangement within the connector or device interface

• Sensitivity analysis accurately predicts required machining and assembly tolerances

• Insertion loss calculations show where losses are occurring and the design can be optimized to eliminate any unnecessary beam scattering.

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Optical Testing

Winchester Electronics Optical Lab includes a variety of test equipment for optical measurement and evaluation. This includes JDS insertion and return loss test equipment with standard 850, 1310 and 1550nm, in addition to custom wavelength multimode and single mode light sources for testing at virtually any wavelength, launch condition and fiber type. Reference leads are stocked for all major single and multi-fiber optical connectors including non-standard military ferrule sizes, MT multi-fiber ferrules, and free space lens to fiber coupling. Interferometric physical inspection is available to characterize the fiber end face.

Environmental chamber linked to JDS multi fiber test equipment allows optical insertion and return loss testing while under environmental stress.

Support

Our engineers are always available to personally meet and discuss how best to assist you in achieving your design objectives. We will provide drawings, 3D models, and design recommendations as well as detailed testing and simulation analysis reports.

Our approach is to provide not just a connector, but a complete solution to the entire passive interconnect system or platform. We will work with you to develop appropriate fiber types, ferrule choices, or available standard connectors that may meet your need.

Winchester's EL Series™ Fiber Optic Video Jack was recently named Winner of the IABM Peter Wayne Award & Winner of the TV Technology-Europe STAR Award for excellence in innovation! For more information about this product and other fiber optic offerings, please visit our Fiber Optic Product catalog page.