Optimization and development of the welding system for fiber-optic duct joints

Abstract: At present, the fiber optic ducts are connected by a mechanical type of joint. In this method, two ducts cut in the right angle are pushed in from both sides of the joint, and takes approximately one second to joint ducts together. The problem with the existing joint technology is that if there is water inside of the joint, it will be damaged when the water freezes into ice, and then may cause leakage. There is a risk of explosion when compressed air to blow the fiber. Thus, a joint protection device (silicone rubber sleeve) was developed to seal the joint for protection utterly. However, this will cause the larger size of the entire joint and limit the number of single-duct joints next to each other in a multi-duct joint. Fiber optic ducts are made of High-Density Polyethylene, which is the best plastic for remelting and can be welded by using the electro-fusion welding method. Based on the thermoplasticity of this material, this thesis developed a plastic joint with a built-in conductive metal wire inside. The applied voltage will heat the wire, then remelt the duct surfaces to weld them together through the joint. The welding system uses a portable battery operating system, so there is no need to connect it to the grid. To prevent the battery from being damaged by supplying too much current, a capacitor bank is used to store high energy for the preheating joints. The system uses a microcontroller to control and monitor current and voltage to ensure uniform heating of the metal wire. Theemphasisof this thesis isplacedon the implementation of basic experiments to run the welding system. Multiple welding experiments show that the welding system can manually set parameters to control the welding current of different joints, thereby ensuring the welding quality. Using a 2.5Ω joint to weld ducts will approximately consume 120J from the battery, so a fully charged 42V, 4.4AH rechargeable battery can perform almost 5600 times of welding. The suitable range of joint resistance will decrease as the required energy consumption increases/ the welding time decreases.