Producing high-quality fiber optic patch cords involves precise steps and procedures. This comprehensive guide will walk you through the entire process of making fiber optic patch cords. From cable cutting to connector assembly and testing, you will gain valuable insights into the production of these essential components in telecommunications and data transmission. So, let’s get started on your journey to mastering fiber optic patch cord production!

Prepare Tools and Consumables: Automatic Cable Cutting Machine, Scissors, Tape Measure, Cable Ties, Tape

STEP ONE

1） First check the optical cable according to the order requirements; then measure the length LCM required by the order and add the reserved length bCM to start cutting;

2) The length of the cutting cable is reserved according to the following requirements, and the error shall not exceed 3CM;

The reserved length of the pigtail of ø0.9mm is 5CM. If the ends are added on both sides, it is 10CM;

All fiber patch cords below 0.5 meters (including 0.5 meters) reserve 5CM;
10CM is reserved for all fiber patch cords from 0.5m to 20m;
15CM is reserved for fiber patch cords above 20 meters (including 20 meters) and below 50 meters;
20CM is reserved for all fiber patch cords from 50 meters (including 50 meters) to 100 meters;

3) Pigtail orders of 5 meters or less are required to be cut into fiber patch cords; More than 5 meters are directly cut into pigtails;

4) Roll the cut optical cable into a circle of 18±2CM, place a distance of 48±2CM on both sides and then fix it with a binding wire in the middle, requiring that the binding wire can slide gently on the optical cable；

5) Print the process card according to the length and quantity on order, and then bind the process card to the corresponding optical cable (the process card and the number of lines must be consistent).

Management Focus

  1) The quantity and length of the process card and the cutting length must be accurate (determined with the quality department in time);
  2) The optical cable cannot be misused (determined with the quality department in time);
  3) When coiling, the printed side of the cable faces outward, and the optical cable cannot be damaged when ordering the process card;
  4) For those below 5 meters, it is required to wind the tie wire on it, and the tie wire should not be too tight.

STEP TWO

1. Install the required optical cable model on the transmission shaft of the cutting machine and tighten the metal wheel.   

• Turn on the transmission power switch of the cable-cutting machine and the console power switch.

3. Wind the optical cable in an orderly manner according to the slot on the wheel, and then insert it into the channel of the cutting machine until the optical cable emerges from it.     

4. Open the work page, click the manual setting item, click the pressure wheel test, and press the optical cable.

Precautions

1. Note that the optical cable port should be above the wheel. When cutting the double-core optical cable, please pay attention to the direction of the cable printing and ensure that the printing on the reeled optical cable faces outward.
2. With the transmission direction switch facing up, select the positive direction of “obverse feed,” which corresponds to the winding side of the optical cable.
3. After the winding is completed, gently press the optical cable with the iron wire when inserting it into the channel of the cable-cutting machine.

STEP THREE

Instructions

1. Enter the working interface, click “Prepare to unload the cable,” then click “Automatic” of the cutting switch, take out a small section of the cut optical cable, and close the cable branch cover. 

2. Set the length and quantity of the optical cable on the operation interface. Note that the unit of length is MM. Set the transmission speed of the optical cable. The automatic cable-cutting machine fiber patch cord’s reserved length is 10cm, and the pigtail is uniformly reserved for 7cm.

3. After cutting the second optical cable, measure the actual length with a tape measure and correct the corresponding length on the automatic cable-cutting machine. After the correction, measure again until the error is within 2cm. 4. When changing the optical cable, the length of the optical cable needs to be reset, measured, and corrected.

Precautions

1. Ensure that the index of the barometer is at 5, and immediately turn the emergency stop switch when the optical cable does not automatically transmit or the machine alarms.
2. Before cutting the cable, confirm the optical cable’s type, color, and length and close the cable cover. Pay attention to the set speed, the transmission, and the cable tightness adjustment switch to ensure that the reel optical cable will not be too tight or loose.
3. When pulling out the optical cable, wait for the cable tray to stop and then quickly pull out the optical cable.
4. It is necessary to measure the actual length with a tape measure and make corrections to prevent batch errors.
5. If the machine fails and cannot be resolved, it must be reported immediately.

Glue Adjustment and Defoaming (by Hand and by Machine)

Prepare Tools and Consumables: Centrifugal Defoaming Machine, 353ND Epoxy, beaker

By Hand

1)Turn on the electronic scale and put a small beaker to reset it. Weigh the weight ratio of the Part A and Part B of the 353ND Epoxy at a ratio of 10:1; 
2) Take out the small beaker filled with 353ND glue and stir it in one direction with a bamboo stick until the color of the glue is uniform;
3) Put the stirred glue into a vacuum defoaming box to extract air. The defoaming time is about 10 minutes until the eyes can no longer see the bubbles;
4) Pour the de-bubbled glue into the syringe, and let the glue flow down the wall of the syringe naturally when pouring the glue; 

5) Turn the needle cylinder upside down, install the push rod to discharge the air in the needle tube;

6) Use special 353ND-T glue when making MTRJ and MPO;
7) The SMA connector must be glued with epoxy resin on the aluminum part to prevent the connector BOOT from falling off.

Note: The weighing must be accurate, and the amount of glue to be adjusted each time should be determined by the number of ferrules to be cured. (Generally, 3 grams of glue at a time is appropriate)

By Machine

1. Mix the glue in the beaker and pour it into the syringe. The amount of glue is less than 4.5ml, and the syringe’s needle should be completely closed.
2. Put the syringe evenly into the defoaming machine’s socket, fill it, pour 4-5ml of water into the test tube, and put it into the socket of the defoaming machine to prevent the defoaming machine from being in the process of defoaming shaking.                                                                                  3. The speed of the degassing machine is 3000 rpm, and the degassing time is 8 minutes to prevent incomplete degumming.    

4. After the defoaming machine is still, take out the syringe and check whether the defoaming is clean.

Precautions：

1. The glue in the beaker should be prepared evenly, and the syringe’s needle should be tightened and completely closed to prevent it from falling off (the needle must be ground in advance).
2. The jack in the degassing machine should be filled, and the test tube filled with water can be put into the jack.                                                                              3. The glue in the syringe can be put into production only after it has been degassed.                                  4. Keep the degassing machine and the desktop clean, and clean the items used in the degassing process.

• Sub Assembly

Prepare Tools and Consumables: Connector Kit, Ferrule, Cable Stripper, Kevlar Scissors

ST & SC & FC Sub Assembly

Operation Confirmation

1) The person in charge of the position carefully checks whether the order shows the customer’s special requirements or the temporary specification issued by the project before wearing the parts. If not, operate according to our company’s conventional standards;

2) Fan-out: the duplex cable is separated at a distance of 16cm from the top and wears a 2cm heat-shrinkable tube (regular requirements);

3) The number ring and BOOT threading method should be operated according to the requirements of the SOP worksheet for threading the boot. When threading the duplex type, thread the ST/SC/FC red BOOT on the printed end of the optical cable;

4) Pay attention to the directionality of the parts during the threading process. ST does not need to wear springs, and 3.0 optical cables need to wear rivets (1.6mm and 1.8mm, according to the order note);

4) Pay attention to the directionality of the parts during the threading process. The spring of the SC or FC 3.0mm optical cable is threaded after stripping the cable to press the Kevlar;

5) For the ST-MTRJ/DX type, the MTRJ end (including other types of connectors to the MTRJ type) does not require fan-out, heat shrinkable tubes, and number rings;

6) After the wearing is completed, it must be self-inspected and the first piece of quality IPQC must be confirmed before operation.

LC Sub Assembly

Operation Confirmation

1) The person in charge of the post carefully checks whether the order shows the customer’s special requirements or the temporary specification issued by the project before wearing the parts. If not, operate according to our company’s requirements；

2) Fan-out: the duplex cable is separated at 16cm from the top and wears the 2cm heat-shrinkable tube (regular requirements);

3) The method of threading the number ring and boot shall be operated according to the requirements of the SOP worksheet. When threading a 2.0mm optical cable, wear a yellow heat shrinkable tube at the printed end and a white heat shrinkable tube at the non-word end, and wear the yellow heat shrinkable tube at the 2.0mm SM/SX uniformly; 2.0mm MM/SX uniform wear white heat shrinkable tube, 3.0mm optical cable needs to wear rivets (rivet diameter 1.6mm or 1.8mm);

4) The aluminum parts, rivets, and stop rings of the 3.0mm optical cable LC are worn after the cable is stripped.

5) For the ST-MTRJ/DX type, the MTRJ end (including other types of connector to the MTRJ type) does not require fan-out, heat shrinkable tubes, and number rings;

6) After the wearing is completed, the first piece must be confirmed by self-inspection and quality IPQC before operation.

Precautions

1) When wearing parts, parts are mixed, missing, over-wearing, under-wearing, miss-wearing, and reverse-wearing;
2) The number ring is missed or reversed; the yellow and white heat shrinkable tube is worn on the wrong optical cable;
3) The 1.6mm and 1.8mm rivets are used incorrectly or missed, and the aluminum parts of LC and ST are mixed;
4) The distinction between single and duplex stop rings is unclear and mixed;
5) Does not distinguish the beginning and end of the cable printing, resulting in inconsistent products;
6) Bad parts are not selected, and the remaining parts are not cleaned up, resulting in mixed materials;
7) Direct operation without quality confirmation leads to abnormal batch quality.

LC Hybrid Patch Cord / Sub-Assembly

Operation Confirmation

1) Fan-out: the duplex cable is separated at 17cm from the top and wears the 2cm heat-shrinkable tube or according to the specific requirements of the order;
2) Putting on BOOT: When wearing the BOOT, operate according to the schematic diagram. During the process, uniformly pass the LC white heat shrinkable tube corresponding to the black BOOT to the printing end of the optical cable (the printing end of the cable jacket), and put the LC yellow heat shrinkable tube corresponding to the red BOOT through to the non-printed end of the optical cable (the non-printed end of the cable jacket) or according to the specific requirements of the order;
3) Number ring: LC-type hybrid patch cord (LC hybrid to other types of connectors), the yellow heat shrinkable tube at the LC end is uniformly worn with an “A” number ring (corresponding to the letter A of the jacket), and the corresponding connector boot end wear a “B” number ring on the end of the sleeve, or according to the specific requirements of the order;
4) Direction: When wearing the number ring, uniformly wear the number circle of the LC ends backward, and the connector corresponding to the LC is worn straight (the number circle will be reversed after the LC end is folded to the right) or according to the specific requirements of the order;
5) The MTRJ end does not need a fan-out, heat shrink tube, or number ring.

Management Focus

1) Pay attention to the order of wearing pieces; do not wear more, less, reverse, or leak loose pieces;
2) Whether the LC heat-shrinkable tube and the wire have printed or not must correspond, the number ring is worn in reverse, and the color of the heat-shrinkable tube cannot be wrong;
3) Wear the same color heat shrinkable tube on the same single-sided optical cable, and the number rings correspond to A and B (one end wears A and the other wears B).

SC/FC/ST Hybrid Patch Cord – Sub Assembly

Operation Confirmation

1) Fan-out: the duplex cable is separated at a distance of 17cm from the top and wears a 2cm heat-shrinkable tube or is produced according to the specific requirements of the order;

2) Putting on BOOT: Operating according to the diagram when wearing the BOOT. During the process, put the black BOOT on the black BOOT to the printing end of the optical cable (the cable jacket printing end), and put the red BOOT on the red BOOT to the Optical cable without the printing end (cable jacket without printing end), or produce according to the specific requirements of the order;
3) Number Ring

• Number Ring for SC-Type Hybrid Patch Cord (SC–to other types of connectors), the red BOOT at the SC end is uniformly worn with a “B” number ring (corresponding to the letter B of the jacket), and the corresponding connection Wear the “A” number ring on the end of the end sleeve or produce according to the specific requirements of the order;

• Number ring for ST-Type Hybrid Patch Cord (ST to other types of connectors), the red BOOT at the ST end wears an “A” number ring uniformly, and the corresponding connector boot end wears a “B” number ring. Or according to the specific requirements of the order;

• Number ring for FC-Type Hybrid Patch Cord (FC to other types of connectors), the red BOOT at the FC end wears an “A” number ring uniformly, and the corresponding connector boot end wears a “B” number ring. Or according to the specific requirements of the order;

4) Direction: When wearing the number ring, put the number ring of the SC/ST/FC end in reverse and wear the connector corresponding to the SC (the number ring will be reversed after the SC/ST/FC end is folded to the right), or produce according to the specific requirements of the order;
5) The MTRJ end does not need to fan out and wears a heat-shrinkable tube and a number ring.

Management Focus

1) Pay attention to the order of wearing pieces; do not wear more, less, reverse, or leak loose pieces;
2) The color of the BOOT must correspond to whether there is printing or not on the cable jacket, the number ring is worn front and back, and the correspondence with the color of the BOOT cannot be wrong;
3) Wear the BOOT of the same color on the same single-sided optical cable, and the number rings correspond to A and B (one end wears A and the other wears B).

Of course, the fan-out length and boot color are customized by the exact clients’ demand, or you can make your standard according to the regular demand in your market.

Prepare Tools and Consumables: Cable/Fiber Stripper, Kevlar Scissor, Hot Air Gun, Kimwipe, blades, and reference connector kits.

Cable & Fiber Stripping

Operation Confirmation

1) According to the connector type reference table, measure the length of the required stripped cable and fix it on the workbench;

Connector Type	Stripped Cable Length	0.9mm Exposed Length
LC ø2.0	32MM±2MM	32MM±2MM
LC ø3.0	34MM±2MM	34MM±2MM
SC ø2.0/ø3.0	27MM±2MM	27MM±2MM
MTRJ	30MM±2MM	30MM±2MM
ST ø2.0/ø3.0	35MM±2MM	35MM±2MM
FC ø2.0/ø3.0	29MM±2MM	29MM±2MM
FDDI/ESCON	5.5CM+2MM	5.5CM+2MM
MU	26MM+2MM	26MM+2MM

2) Select jaws according to different outer diameters of optical cables;

3) Hold the tail of the optical cable about 10CM away with your left hand, put the optical cable into the slot, and strip the cable;
4) After stripping the cable, fix the optical cable with wrapping tape to prevent the loose parts from falling.

Precautions

 1) Select the cable stripping length according to the flexibility of the optical cable. Choose the minimum tolerance to strip the cable when the flexibility is good.
2) The exposed length of the SMA connector refers to the exposed length of the armor,
3) Do not choose the wrong outer diameter when stripping the cable so as not to damage the optical cable;
5) When the 0.9 inner cores are one long and one short after the double-core optical cable is stripped, it is required to take the short one as the standard to measure the length;
6) When the cable is stripped, the cable exceeds 10cm, and the fiber is broken, it is necessary to re-measure the total length of the cable.

Fiber Stripping

Operation Confirmation

1) According to the type of connector, measure the stripped length, mark it, and fix it on the table;

No.	Connector Type	Stripping Length
1	FC/SC	13MM+1MM
2	LC	8MM+1MM
3	ST	15MM+1MM
4	SMA	5MM+1MM
5	MTRJ	8MM+1MM
6	E2000/LX.5	12MM+1MM
8	FDDI/ESCON	15MM+1MM
9	MU	8MM+1MM

2) Select fiber strippers and distinguish the front and back;
3) Hold the optical cable with one hand and hold the fiber stripping pliers with the other hand to form an angle of about 90 degrees with the 0.9 inner core of the optical fiber, and strip the required optical fiber;

4) After stripping, wipe off the coating on the optical fiber with a paper towel dipped in alcohol;

5) When the lengths of the two optical fibers differ, the shorter one should be used as the standard for re-stripping.

Precautions

 1) Before stripping, check whether the slots of the stripping pliers are clean to avoid easy stripping during stripping.
2) Before stripping, it is necessary to understand that different connectors require different stripping lengths;
3) The difference between the two optical cables should not exceed 2MM when the duplex optical cable is stripped;
4) When stripping the 1-meter patch cord, one end should be stripped and cured first, and the other should be stripped.

1. Curing

Prepare Tools and Consumables: Curing Oven, 353ND Epoxy, Epoxy, Kimwipe

STEP 1

Operation Confirmation

1) First, select the ferrule for glue injection according to the connector to be made; when injecting glue, do not drop the glue on the needle to other places, and wipe the excess glue on the needle with a paper towel to avoid glue on the ferrule.

2) Turn on the curing oven, preheat in advance, and set the corresponding temperature and time according to the data in the chart.

Curing Temperature Schedule
Ferrule Type	Curing Temperature (℃)	Curing Time (min)
LC/MU	95	30
SC/FC	100	20
ST	120	15
MTRJ	75	45
E2000	110	20
SMA	80	60

3) Before curing every day, measure the temperature of the curing furnace with a thermometer and make corrections to allow
It is allowed to adjust the range of ±5 according to the situation.

Precautions

1) The ferrule selection must be correct; the ferrules of SM and MM and the ferrules of PC and APC must be distinguished and cannot be mixed;

2) Before inserting the ferrule, check whether there are missing, excessive, reverse, and wrong threading parts and whether the length of the stripped fiber is correct. The distance between the two ferrules is required to be no more than 2mm for double cores. Recheck the previous processes to avoid mistakes;

3) When the ferrule is difficult to wear, the ferrule filled with glue can be heated at a temperature of 30-50°C, but the temperature should not be too high to prevent the glue in the ferrule from hardening;

4) If the customer has particular specifications, operate according to the customer’s rules.

STEP 2

Operation Confirmation

1) Put the stripped optical fiber into the ferrule filled with glue; the fiber should be exposed to 2-4mm from the end face, and then pull it back gently to test the fiber and see if the fiber is broken in the ferrule; The glue should be tapered and cannot be bent, there should be no glue on the ferrule, and the spilled glue should be wiped clean with paper towels.

2) The distance between the two ferrules must be lower than 2mm for the duplex cable. The cable and fiber must be stripped again when the distance between the ferrules exceeds 2mm.

3) Within 3-5 minutes of the oven for the connector, it is necessary to replenish the glue for the insufficient glue of the ferrule tail seat, and the glue at the tail should be appropriate to form a cone.

4) Remove the ferrule after the curing is completed, and use a fiber cutter to cut off the optical fiber emerging from the ferrule after the ferrule cools down.

Precautions

1. Do not test the fiber when threading the fiber, causing the solidification to break in the ferrule.
2. When curing the duplex optical cable, the ferrule length varies.
3. The ferrule tail is cured and bent, and the glue overflows to the metal flange.
4. The tail of the ferrule should not be tapered, and the tail is easy to break during the polishing process.
5. APC ferrule, PC ferrule, multi-mode ferrule, and single-mode ferrule are mixe

Prepare Tools and Consumables: Polish Machine, Polish Pad, Polish Film, Polish Jig, Polish Oil, Fiber Cutting Pen

Cutting Fiber

After removing the ferrule from the oven, use a fan to blow the ferrule to cool it down. After five minutes, remove the ferrule from the board, hold the connector in the left hand, align the fiber with the fiber cutter in the right-hand stroke, and then break;

Management Focus

1) Do not disassemble the baking plate when it is hot, as this will easily cause fiber breakage;
2) Pay attention to the force when cutting the fiber, and don’t break it all at once, which may easily cause blackheads;

Use of the Polish Machine

Instructions

1. Turn on the power and switch;
2. According to the type of patch cord or pigtail, adjust the speed, pressure, and time of the polish machine;

a. Prepare polishing jig, polishing pads, and polishing film according to the polishing process;

b. Specific Adjustment Method:

Pressure: Move the four-corner pressure column to reach the required pressure for polishing (in shutdown state).
Time: Toggle the timer to reach the time required for polishing (in shutdown state).
Speed: Press the start button, observe the speed display, turn the speed control knob, and lock the knob after the displayed speed reaches the requirement.

Precautions

1. Adjust the pressure, time, and speed before polishing. Otherwise, the polishing effect will not meet the requirements, and even the polishing film will be damaged.
2. If there is an emergency during polishing, you can press the emergency stop switch. If the polishing film is not fixed, the pressure is not adjusted, etc., the emergency stop switch should be reset by turning clockwise.

Polishing

Operation Confirmation

1. Put the polishing jig on the polish machine and press the polishing jig with two pressure columns;
2. Straighten out the optical cables to be ground and put the connectors into the polishing jig in turn;
3. Take off the polishing jig, turn it over, and press to check whether the connector ferrule is exposed and the length is consistent;
4. Put the polish pad on the polish machine, add polish oil or pure water according to the polishing process, then press the start switch of the polish machine and turn the pressure column to fix the polish jig;
5. After the polishing time is over and stops, turn the pressure column of the polish machine to loosen the polishing jig, turn over the polishing jig and clean the ferrule and polish film with a paper towel (30um degumming needs to be checked whether the degumming is clean), and then put it into the following polishing process for polishing;
6. After completing the polishing processes, remove the connector from the polishing jig and use an air gun to dry the remaining water vapor on the connector.

Precautions

1. When the polish machine is pressurized, it needs to be pressed symmetrically in pairs;
2. After APC polishing, it is necessary to check whether the angle is fully opened, and if the angle is not fully opened, it needs to be re-polished;
3. During the polishing process, if the polish film is not attached and running, you should immediately press to stop;
4. If the connector is not elastic or not exposed during the loading process, it is necessary to check whether the ferrule cylinder has glue and clean it;
5. The polishing time can be increased by 5-10 seconds by increasing the number of times.

FC/UPC, SC/UPC, ST/UPC Polishing Process

Polishing Step	Polishing Film	Time	Rotating Speed(r/m)	Polish Pad	Polishing Fluid	Polishing Film Life
1st Polishing	30um Polish Film	30s	100	70	Polish Oil	30 Times
2nd Polishing	9um Polish Film	28s	100	70	Polish Oil	30 Times
3rd Polishing	1um Polish Film	28s	100	80	Water	30 Times
4th Polishing	0.05um ADS	25s	100	70	Water	10 Times

LC/UPC, LC/APC Polishing Process

Polishing Step	Polishing Film	Time	Rotating Speed(r/m)	Polish Pad	Polishing Fluid	Polishing Film Life
1st Polishing	Emery Disc	20s	50	/	Polish Oil	30 Times
2nd Polishing	9um Polish Film	27s	50	80	Polish Oil	30 Times
3rd Polishing	1um Polish Film	27s	50	80	Water	30 Times
4th Polishing	0.05um ADS	15s	50	80	Water	10 Times

SC/APC, FC/APC Polishing Process

Polishing Step	Polishing Film	Time	Rotating Speed(r/m)	Polish Pad	Polishing Fluid	Polishing Film Life
1st Polishing	Emery Disc	30s	100	/	Polish Oil	30 Times
2nd Polishing	9um Polish Film	26s	100	70	Polish Oil	30 Times
3rd Polishing	1um Polish Film	26s	100	80	Water	30 Times
4th Polishing	0.05um ADS	20s	100	80	Water	10 Times

Precautions

1)The speed and pressure before polishing must be adjusted well, and the direction must be consistent;
2) When polishing different connectors, the polishing parameters must be set strictly according to the process;
3) During the polishing process, the speed and time can be adjusted according to the degree of damage to the polishing film, but the pressure and the polishing pad cannot be adjusted at will and must be set strictly according to the process;
4) Do a good job of polishing data statistics strictly according to the polishing situation statistics. The team leader or the engineer should be informed immediately if any abnormality is found;
5) Watching the machine involves paying attention to cleaning, and special attention should be paid to various details that are not conducive to cleaning.

• End Face Inspection

Note:
1: The size in the picture is the actual size of the entity seen on the monitor.
2: Area A refers to the part of the fiber within the range of 62.5um through the fiber.
3: Area B refers to the part of the optical fiber within the range of 125um outside the area of optical fiber A.
4: Area C refers to the part of the end face of the ferrule observed by the 400 times end face detector report outside 127um.

Note:
1: The black block or black spot on the rubber ring part of the end face is required to be depressed during 3D inspection.
2: When inspecting the end face, ensure that the ferrule and the end face of the optical fiber are clean and free of dirt (grinding fluid residue, wiping paper powder, glue), etc.
3: In Part B, the cumulative number of scratches and black and white spots cannot exceed 3, and the maximum number of scratches is 1.
4: The accumulative size of defects per unit of 5um in the C area cannot exceed 2.

Prepare Tools and Consumables: IL & RL Test Machine SM & MM, Standard Test Cable, Test Rod, Adapter, Kimwipe, Alcohol

Single Mode Insertion Loss Test

Operation Confirmation

1) Select the standard test cable and adapter according to the connector type and mode field of the fiber patch cord to be tested;
2) Connect the test cable after starting up, press the POWER button to switch to the insertion loss test, insert the test end into the test port, and then press and hold the POWER button for three seconds to reset;

3) Then clean the adapter and connect it to the test cable for testing;
4) All connectors should be tested; when the value of the tested terminal is greater than the test index, the tested connector, adapter, and test cable should be cleaned at the same time. if the measured value still does not meet the requirements, it should be repaired; if there is a large number of unqualified, it is necessary to test whether the test cable meets the basic requirements.

Management Focus

1) Clean the end face of the connector before testing;
2) Check whether the BOOT correspondence is correct;
3) Check the end face of the test cable every 30 minutes to prevent the end face from being polluted;
4) The identification of non-conforming products must be clear;
5) When testing the transfer fiber patch cord, replace the appropriate test port according to the connector type at the other end.

Multimode Insertion Loss Test

Instructions Manuel

1. Turn on the multi-mode light source, turn the multi-function knob to select the desired wavelength, press it again to enter the adjustment main menu screen, select to turn on the corresponding laser switch, and adjust the output power, (the initial value is displayed as 0.00 MW) Press Enter to enter, the font will become thicker, turn the multi-function knob clockwise to increase the power to 1-2mw, then exit the main menu and lock the button. The wavelength on the power meter should be consistent with the wavelength selected by the light source. The wavelength on the power meter can be modified using the wavelength selection and adjustment keys.                                          

2. Select a standard test cable and adapter according to the type of connector to be tested and the mode field.                                                 

3. Turn on the optical power switch, put one end of the test cable into the test port, and press the REF key to reset.
4. All connectors must be tested; when the test end’s value is greater than the test index, the tested connector, adapter, and test cable should be cleaned simultaneously. If the measured value still does not meet the requirements, it should be repaired; if there is a large number of unqualified, it is necessary to test whether the test cable meets the basic requirements.

Precautions
1. This operation manual only describes the range that our company needs to use. You can read the operation manual in detail if you need anything else.
2. During the whole operation process, the laser that needs to use the light source is in the “ON” state, and it takes a long time to adjust the output power, so patient adjustment is required.
3. Check the end face of the test cable every 30 minutes to prevent the end face from being scratched.  4. When testing the transfer fiber patch cord, replace the appropriate test port according to the connector type at the other end.

Return Loss Test

Operation Confirmation
1) Select the test cable and adapter according to the model of the fiber patch cord to be tested.
2) Power On: press the ON/OFF key to power on, and the LED window displays the value of “BR”; the normal value is above -70dB. after connecting the FC/APC connector test cable, the BR value should be between -14.7±0.3dB; The BR value of APC’s test cable should be above 60dB, otherwise the test cable and adapter should be cleaned.
3) Return Loss Storage: First, press the λ key to select the wavelength according to the customer’s requirements, press the BR key to perform the return loss test, and wrap 3-5 turns with a ø6 test rod at a distance of 10cm from the test connector until the BR value is stable and greater than (60dB) the desired value, press BR0 to store the return loss reference.

4) Return Loss Test: connect the test cable and the patch cable under test, wrap ø6 test rod for 3-5 turns at one end of the cable under test at 10 cm from the connector. When the BR value is stable, the value displayed by the LED is the return loss of the wound end value; when the value of the tested terminal is less than the required value, the tested connector, adapter, and test cable should be cleaned at the same time. If the return loss value still does not meet the requirements, it should be repaired; if a large number of unqualified when the product is in use, it is necessary to check whether the test cable meets the requirements.

Management Focus
1) When setting the return loss benchmark, first clean the test end and the adapter;
2) During the return loss test, the test end face and adapter should be cleaned frequently, and the end face of each connector should be cleaned before testing.

Final Section End Face Inspection

Operation Confirmation

1) Select the end face tester. Select the magnification and detection standard of the end face detector according to the customer’s end face requirements;
2. Select the port. Select the port according to the type of connector produced and install it on the end face detector. ø2.5 port for SC/FC/ST type, ø1.25 port for LC type, dedicated for MTRJ.
3. Wipe the connector to be detected on a paper towel, insert it into the detection port, adjust the end face to the clearest state, and judge whether the end face is qualified according to the end face detection standard;
4) Put on the corresponding dustproof caps of the finished products on the qualified connectors. (Note: Pick out all qualified cables for the packaging process, pick out the unqualified connectors, and let the polishing station repair them.

Precautions

1) The ferrule should be wiped clean before it can be put into the detection port.
2) To judge whether the end face is qualified, it must be carried out by the end face inspection standard.
3) Mark the defective products and send them to the repair station for repair in time.

Operation Confirmation
1) Check the appearance of the fiber patch cord that has passed the final terminal inspection:

a. Duplex Patch Cord and pigtails need to blow the heat-shrinkable tube at a distance of 18±1CM from the top of the connector;  b. Whether the optical cable and the connector are dirty or damaged; c. For duplex, check whether the length error of the two connectors is within 3MM (the error requirement for SC and LC connectors is 1MM); 

d. Whether the dust cap is worn as required;
e. Whether the jacket is worn correctly and whether there is any omission; patch cords that fail the visual inspection should be repaired immediately, and patch cords that cannot be repaired should be immediately removed from the area to be packed and marked for disposal.

2) Classify the patch cords according to the serial numbers on the patch cords, and pay attention not to mix the cables;
3) According to the order, coil the fiber patch cord or pigtail into a circle of about 18cm and put it into a 20*26cm PE bag, and stick the test reports in the middle of the bag or put them according to the client’s demand; the description of the label must be the same as that of the installed cable corresponding.

Management Focus

1) When inspecting the appearance, it must be inspected to pass the inspection before packaging; the heat-shrinkable tube should not be too tight;
2) Whether the jacket is worn correctly;
3) Labels and fiber patch cords cannot be mistaken; labels must be affixed straight and cannot be skewed;
4) Be careful not to mix cables.

We’ve now provided insights into all the production processes of crafting standard fiber optic patch cords. What other questions do you have? In our next installment, we’ll delve into the production process of MPO/MTP patch cords. We invite you to stay tuned, follow HOLIGHT, and expand your knowledge of product production.