2. Related Art A fiber guide, called a pizza cutter, is the closest related art known. While winding a fiber coil, the fiber must be guided to make contact with the side walls (flanges) of a spool or coil form or bobbin comprising a spindle on which the coil is wound and in most cases at least one flange. The fiber guide, used to control the point of deposit of the fiber onto the surface of the coil, must be made as thin as practical so it can lay fiber close to the flanges. Minimum size of the fiber guide is determined by the radius of the spindle upon which the fiber is being wound plus the flange extending beyond the spindle.

Stated another way, the fiber guide radius plus the spindle radius must exceed the spindle flange radius. The rotational axis of the fiber guide must be located outside

of the flange circumference. Larger diameter fiber optic coils will require large spool diameters and even larger associated guide wheel diameters. As the diameter of a pizza cutter wheel type guide is allowed to increase, the diameter of the guide wheel and the continuing requirement for the thickness of the wheel to be thin, so as to be able to approach the flanges, combine to cause the wheel to deflect or deform slightly resulting in a loss of precision in the deposition of the fiber forming the coil.

It is difficult to fabricate a wheel of large diameter because as the diameter is increased, maintaining the wheels flatness under load becomes very difficult. As flatness is lost, the wheel will start to wobble and interfere with the precise deposition of optical fiber onto the top layer of fiber on the coil being fabricated.

The present invention is not limited by the diameter of the side walls or the flanges and is capable of being used to manufacture large diameter fiber optic coils. In addition, the present invention is more robust in comparison to the prior art. It can tolerate impacts against the spool flange without damage due to compliance of the wire strands where the prior art would deform or become dented or out-of-flat.

Additionally, the fiber often tends to"pop-out"of the pizza cutter style prior art guide wheel during use.

This condition is eliminated with the present invention.

Summary of the Invention The invention comprises a fiber guide for spooling fiber optic or glass fiber from an automatic coil winding machine onto a target rotating spool. This invention fiber guide may find employment in other applications in which other forms of fiber, filament or wire, such as magnet wire, must be accurately guided onto a rotating flanged spool.

A first embodiment of the invention fiber guide comprises in combination; a rigid body. The rigid body, more particularly referred to as a pay guide assembly, is comprised of two parts with a gap between the parts. The parts are referred to as a left and right pay guide arm coupled together in opposing relation to form a mouth or receiving aperture shaped as an arc. Two parallel strands of wire are tightly stretched across the receiving aperture of the arc and anchored. The are spaced apart along the length of the pay guide assembly or opening of the mouth or receiving aperture. A spool for receiving the glass fiber is mounted or positioned so that it extends into the arc or aperture formed by the pay guide assembly and approaches the wire strands.

A guide pulley is carried or mounted in the pay guide assembly. The pulley operates to guide the fiber between the wire strands and onto a spool or fiber optic coil that is being fabricated for use in a fiber optic gyro or a hydrophone for use as an interferometer sensor in an acoustic application such as a towed array or a planar array.

The guide pulley is rotatably mounted on a guide pulley shaft. The guide pulley shaft is carried by the body or pay guide assembly. The guide pulley rotates on

the shaft to guide the fiber from the winding machine onto the spool via the space between said wire strands. A guide pulley bearing means is positioned on the shaft for rotatably supporting the guide pulley. An adhesive means is used to fix the bearing means in a predetermined position to locate the pulley guide to direct the fiber between the strands. The adhesive means is typically a cyanoacrylic adhesive.

The predetermined position of the bearing means is a manually adjusted position to preload the bearing means to be substantially free of wobble, the preload being adjusted to a level at which a first slight deceleration is observed subsequent to and in response to manually spinning the guide pulley.

A method is provided for preloading a fiber guide pulley bearing means having a spaced apart right and left pay guide arm carrying a pulley shaft where the pulley shaft has right and left spaced apart bearings.

In this embodiment, the left and right parallel strands or guide wires are in the alternative, formed from piano or music wire.

In a first embodiment, a spacer washer or shim is fixed between the wires to fix the spacing of the wires to a predetermined width in the first embodiment. In a second embodiment, the gap between the left and right pay guide arms is established by a spacer washer interposed between the wires at least a top or bottom of the opposing hands plus the thickness of each of the wire strands, and any additional spacers that may be interposed between the wires and opposing surfaces of the respective pay guide arms.

Each of the embodiments have a means for anchoring the wire strands to the pay guide assembly, and a wire tensioning means carried by the pay guide assembly to tension the wire strands.

In each of the embodiments, the gap at the top and bottom of the pay guide assembly forms a top and bottom throat which is either open or closed to allow or stop insertion of fiber. It should be understood that at least one end must remain open, i. e. the space in the throat must be sufficiently unobstructed as to allow the passage of a fiber. With one end open, it is possible to pass the central portion of a fiber that is stored on two feed bobbins so that a winding machine can wind the fiber onto the fiber coil in alternate layers starting from the mid point of the length of continuous fiber. Quadrapole winding is done in this manner and the guide must have at least one end open for loading.

However, some applications, such as winding a mandrel on a hydrophone are wound starting at one end of a continuous fiber. In those applications, where the coil is wound from a first end of the fiber source, the fiber can be threaded through the wire strands or wire guides making it possible to have a fiber guide with both throats obstructed or closed.

Each respective throat has a respective first and second side separated by a predetermined distance. Each respective wire strand is contact with a corresponding top and bottom side via direct contact or via a spacer or shim.

Additional washers or spacers outboard of the wires and between the wires and sides of the throat may be used to protect the opposing surfaces of the throat or body.

The pay guide arm has a hole to receive a threaded end of a hollow threaded standoff. The standoff has a cross hole through the body orthogonal to the axis of the body.

A wire strand is passed through the hole and a rubber plug followed by a set screw is inserted into the hollow end of the standoff and screwed into the hole until the rubber plug engages the wire strand passing through the cross hole preventing further movement of the wire. The wire strands are subjected to a predetermined preload to place them in tension before the set screw is tightened. The preloading step in combination with a standoff or other anchoring means combine to form a tensioning means.

In an alternative embodiment of the tensioning means a box or pair of pivot plates forming a box is pivotally connected to the pay guide assembly and to the left and right parallel strands or guide wires. A spring is connected between the plate and the pay guide assembly for drawing the wire into a tensioned condition. A threaded screw adjustably holds the spring to the box or plates forming a box. The threaded screw engages the box at a distance from the pivotal connection between the box and the pay guide assembly so as to apply a torque to the box as the distance between the box and the spring is shortened by operation of the threaded screw.

In each embodiment, the fiber guide is comprising a pivotal connection from an automatic coil winding machine and the body or pay guide assembly. A pay guide arm serves as a means for connecting the pivotal means on the winding machine and said body.

In each of the embodiments of the fiber guide, the spool or fiber optic coil onto which optical fiber is being wound, has a spool rotation axis and a predetermined window, similar in its characterization to the winding window formed by the bobbins or coil forms used by magnetic component production, for receiving fiber. The window is formed by the flanges at the ends of a coil form or spindle. The spindle has a surface that is typically cylindrical. A left and right flange each have an inner surface of predetermined height that extend above the spindle surface.

In each embodiment, the coil winding machine further comprises a servo means for moving the fiber guide parallel to the spool rotation axis as the spool or coil form is rotated. A guide pulley guides the fiber between the wire strands or wire guides onto an outer surface of a fiber coil being formed on the spool.

In yet another embodiment of the fiber guide, the wire strands are electrically insulated from the automatic coil winding machine. In addition, the automatic winding machine provides a means for electrically sensing and teaching the servo means where the limits of linear travel exist for the wire strands parallel to the rotation axis of said spool rotation axis. The limits exist where the outer surface of wire strands electrically contacts a corresponding left or right flange inner surface. A tool is shown for transferring the location and position between spaced apart pair of non-conductive inner flange surfaces to an external space bordered by conductive surfaces for teaching the linear servo where the limits of travel should be set.

Brief Description of the Drainas Figs. 1 and 2 are side elevational and top plan views of prior art pizza cutter type fiber guides; Fig. 3 is an elevational view of the present invention fiber guide; Fig. 4 is an end view of Fig. 3 showing a toggle plate tensioner; Fig. 5 shows the new fiber guide pivotally mounted from an automatic winding machine; Fig. 6 illustrates quadrupole winding employing the subject new fiber guide; Fig. 7 shows the pay guide assembly with guide wheel guiding optical fiber; Fig. 8 shows a top elevation view of the left and right pay guide arms, the guide wheel being omitted; Fig. 9 is an exploded top elevation view of the left and right pay guide arms and the guide wheel; Fig. 10 is an exploded bottom elevation view of the left and right pay guide arms and the guide wheel; Fig. 11 is an exploded top plan view showing the pay guide assembly attached to the guide arm, the guide arm being insulated from the pay guide assembly by a kapton insulator; Fig. 12 is a schematic end view of the music wires with a fiber passing between them, the music wires being moored by standoffs at both top and bottom of the right and left guide arms; Fig. 13 is an exploded side elevation of the drilled standoff, the o-ring or rubber plug insert and the set screw; Fig. 14 is a schematic end view of the music wires with a fiber passing between them, the music wires being moored by standoffs at the bottom end and clamping between a separator washer against outer washer surfaces between the upper registration surfaces of the left and right pay

guide arms; Fig. 15 is a schematic partial section of the guide wheel supported by a shaft between the left and right pay guide arms.

Fig. 16 is a schematic sectional view of a tool used to provide a conductive surface that is co-planar with a spool's non-conductive left and right inner flange surfaces; and Fig. 17 is schematic end view of the tool of Fig. 16 draped over the spindle of a non-conductive spool or bobbin.

Fig. 18 is a side elevation view of a fiber guide in which the two parallel strands or guides 38,39 are separated by a spacer washer; Fig. 19 is a front elevation of the fiber guide of Figure 18 showing the dual clamps for griping and holding the fiber, the fiber passing between the rollers and out of the page, as an alternative for the guide pulley of Figs. 3 and 17; Fig. 20 is a top elevation view of Fig. 18 showing the left and right strands separated by a very thin spacer and clamped by two Fig. 21 is a schematic partial section of Figure 20.

Figure 22 is a schematic irregular section of Figure 18 taken through each rotational axis; Figure 23 is a partial schematic top view of an alternative embodiment of Figure 18 modified to show one open throat; Figure 24 is a side elevation view of Figure 23 showing the open throat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Figs. 1 and 2 show an earlier pizza cutter style fiber guide 11 with its guide wheel 12 portrayed as thin as possible. Optical fiber 13 is carried in the grooved circumferential outer edge 14 of the guide wheel 12. The guide wheel 12 rotates on its guide wheel shaft 16.

In operation, the guide wheel 12 is mounted on a coil winding machine (not shown) and is translated by a linear servo motor drive (not shown) parallel to the rotational axis 18 of spool or coil form 20. The guide wheel 12 feeds fiber onto the rotating outer layer or outer surface 21 of the fiber coil 22 that is being formed on the rotating spindle 24 of the spool or coil form 20. The space on a plane passing through the axis of the coil form or bobbin 20 and bordered by the spindle surface 25 of the spindle 24 and the inner walls 27 of spool flange 28 forms a winding window.

Figure 2 schematically shows the fiber guide 11 driven by linear servo motor drive (not shown) moved to the right or upward in the figure until the top surface 29 of the guide wheel 12 deposits the last fiber coil on the outer or top layer 21 of the fiber coil 22 and contacts the right spool flange 28 inner surface 27. As shown in Fig. 1, fiber guide 11 is translated in and out of the page, as the spool 20 rotates on its axis 18.

As shown in Figures 1 and 2, the minimum size of the guide wheel radius C is determined by radii A (of the spindle 24) and flange radius B, of the spool or coil form 20. The guide wheel shaft 16 must always be located outside the spool's flange radius"B". From Fig. 2, it can be seen that the sum of the guide wheel radius C and the spindle radius A must be greater than the radius of the

spool flange B or (C+A >B).

Figs. 3 and 4 show a first embodiment of the present invention fiber guide 10 having a rigid body comprising pay guide assembly or pay guide assembly 30 and pivot arm 32.

The pay guide assembly 30 forms an arcuate body, comprising two parts or similar sections, i. e. a left and right pay guide arm 34,35 with a gap between the parts. A left or bottom gap or throat 36 is shown in Fig. 4. A right or top gap or top throat 37 is located by reference number 37 in Fig. 3. Each gap or throat, has a respective first and second side separated by a predetermined distance.

Referring to Figures 3 and 4, a continuous length of music wire is first draped over the large dowel pin 53 and then wrapped around dowel pins 44 to pass through the first throat at the left of pay guide assembly 30 to form the left and right parallel strands 38,39 as they pass to the second throat at the right of pay guide assembly 30.

The two parallel wire strands of music wire 38,39 are tightly stretched across the receiving aperture or cord of the arc, longitudinally of the pay guide assembly, and are anchored at one end (the right end), and extend to a wire tensioner at the other end (the left end). Each respective wire strand is in contact with a corresponding pay guide arm top and bottom side.

Wire tensioner 42 to pivots in response to the tension in spring 55, in a clockwise direction around pivot pin 56 to maintain tension in wire strands 38,39 by urging pivotal plate or block 43 to raise the large pin 53 thus tensioning the wire strand around dowel pin 44.

Spring 55 is fixed to pay guide assembly 30 by pin 51 and extends between parallel plates 43 or through tensioner

or block 42 to engage tension adjusting screw 58 to force the plate 43 or block to the right, thereby maintaining the left and right parallel strands or guides 38,39 taut.

Tension is adjusted as required by rotating a nut shown on the left end of adjusting screw 58.

Each pay guide arm 34,35 has an upper and lower end.

Each upper and lower end has a respective registration face. Opposing registration faces form a gap or throat 36, 37. The pay guide arms are held together and dimensioned to create a slight gap e. g. 0.016 inches between opposing pairs of upper and lower registration faces 36,37.

A pair of aluminum dowel pins 44 and a pair of hexagonal standoffs 56a, 56b, the second being hidden by the first, are similarly disposed at the right end of the pay guide arm. The standoffs serve to anchor the respective wire strands as tension is adjusted by rotating the above hexagonal hollow standoff bodies 46a, 46b of the characterized standoffs 56a, 56b or by other preferable alternative means.

The pay guide assembly 30 has an open receiving aperture to receive spool or coil form flange 28. Glass or fiber optical fiber 13 bends around a 1 inch guide pulley 47 carried by the arcuate body or pay guide assembly 30 for guiding the fiber between parallel spaced apart wire strands or wire guides 38,39 onto the spool 20 which guide it very closely to the last layer of fiber laid down on fiber optic coil 22. The parallel wire strands or guides 38,39 are formed from piano or music wire or other filament having high tensile strength such as glass fiber or steel wire.

The guide pulley 47 is carried by the pay guide

assembly 30 for guiding the fiber between the wire strands 38,39 and onto the spool 20 or more particularly onto the rotating outer surface 21 of the fiber coil 22.

Spool 20 is turned on axis 18 (Fig. 3) to draw the fiber 13 onto the fiber coil 22. Pivot arm 32 may be pivoted to maintain the proximity of optical fiber 13, wire strands 38,39 and the rotating outer surface 21 of fiber coil 22 on spool 20 receiving optical fiber 13.

Figure 13 shows a disassembled hexagonal standoff 57a having a threaded hollow standoff body 46a, a transverse receiving hole 48a drilled therein to receive ends of the left and right parallel strands or guides 38,39 and in combination with rubber plug 61 and screw 63 form a means for anchoring the left and right parallel strands to the pay guide assembly or pay guide arms 34,35. As discussed later in connection with Figure 14 and 18-23, an alternative means is provided by a washer fixed between the wires by a screw or bolt or adhesive to fix the spacing of the wires to a predetermined width.

Figure 14 schematically shows an arrangement in which a bolt 49 is used to clamp the pay guide arms 35,36 together with the left and right parallel strands 38,39 held or clamped therebetween separated by a spacer washer 40, the thickness of which sets the separation of the left and right parallel strands. Spacers or shims or washers 52a, 52b protect the opposing registration faces 41a, 41b.

It should be understood that alternative methods of clamping might be used such as an external clip or a welded bridge to join the left and right side pay guide arms 35, 36. The use of spacer 40 results in closing the end of the receiving aperture at which it is used. Spacers may be used at both ends of the receiving aperture or at both ends

of the pay guide assembly 30 for applications not requiring that the fiber be wound from the midpoint of a single strand. Such applications include fiber optic mandrels which are wound from the starting end of a fiber and not from the middle.

Figure 14 shows how the second throat at the top of the figure uses a spacer washer and bolt to lock the left and right pay guide arms 34,35 together.

In the tensioning process, the pay guide assembly 30 is orientated such that the guide wires 38,39 or wire strands point downward. A predetermined weight characterized to provide a proper level of tension or preload is then coupled to each of the wire strands 38,39 as the bolt is tightened to prevent relaxation of the tension and strain in the wire strands.

The combination of the pay guide arms and the clamping action of the bolt 49 and washer and the anchor provided by the large pin thereby form a wire tensioning means. The procedure of draping the wire strand over the large pin insures an equal level of tension in each wire strand using a single weight coupled to both ends of the wire strand exiting the second throat.

As an alternative tensioning means, a bolt 49 and spacer washer 40 could be used at the throat of each end of the pay guide assembly or pay guide as an anchor or mooring means. One end of the guide would be clamped thus securing the wire strands spaced by a washer in a first throat.

The same procedure as characterized above would then be used to space and clamp the wire strands as they exit the second throat concurrent with being preloaded to obtain

the proper tension. This procedure eliminates the need for the large pin 53 but requires the use of a separate weight simultaneously applied to each of the wire strands exiting the second throat.

The other ends of the strands are each anchored to the pay guide assembly 30 by standoffs 46, screwed into body 30, cross-drilled hole at 59 with the wire strands penetrating the standoffs 46 and being wrapped around the dowel pin 44. Each end of the pay guide assembly 30 is drilled to provide a hole which is then threaded to receive the external threaded end of a standoff 46. Four standoffs are used in Figs. 3. The standoffs are hex #6-32 internally threaded to receive rubber plug 61 and #6-32 set screw 63. The wire strands are first placed over large pin 53, and around dowel pins 44 and brought to the other end of body 30 and anchored.

In Fig. 5, another schematic, the pay guide assembly 30 is mounted offset from the automatic machines 67a by pivot arm 32. The preferred layout of the pivot arm 32 is 10 degrees below the horizon, (in the figure) the ends of the pay guide assembly 30 are on a phantom circle having a diameter of 3.93 inches (just slightly larger than the O. D. of the spool flange 25). Optical fiber 13 is shown leaving a fiber source spool 106 or half transfer spool, passing under the guide pulley 47 and between the wire strands 38, 39. The wire strands are depicted as almost touching the outer layer 21 of coil 22.

In Fig. 6, is a schematic layout to show how quadupole winding is accomplished by the present invention with two fiber guides each being sourced with fiber from a respective half transfer spool 73. The fiber guide at the lower right is in its stored position. The fiber guide at

the upper left is also in a stored position; however, the same guide is depicted in phantom in its registered position above the coil form. The use of two fiber guides permits alternated ends of the fiber to be controlled and fed in alternated layers between the spool 23 flanges.

U. S. Patents 4,856,900 to Ivancevic, 5,371,593 to Cordova et al and 5,405,485 to Henderson, all incorporated herein by reference, explain the details of quadrupole winding and how an automatic winding machine is made and operates to make coils for fiber optic rotation sensors.

Fig. 6 shows the automatic machines as blocks 67 and 67'and the two half transfer spool sources of fiber 71 & 73 used to alternately lay down layers of fiber on spool 23.

Fig. 7 is a schematic plan view showing the pay guide assembly 30 with pivot arm 32 attached. The guide pulley 47 is supported by a shaft and bearing means and is depicted as guiding optical fiber 13. A pivotal connection (not shown) from the winding machine holds the pay guide assembly in proper position and orients the pay guide. As shown in Fig. 5, a declination angle of 10 degrees from level leading to the coil spindle has been found to be best for operation.

Figure 8 is an exploded forward view of the pay guide arm showing a left and right pay guide arms 34,35 that comprise the pay guide. As the hands are joined, in the central region, it can be seen that a hole or recess for receiving the guide pulley 47 is provided. The throat gap for the left and right throat can be seen to be approximately equal to dimension G where G = D- (E + F)

Fig. 9 is an exploded plan view of the top view of the left and right pay guide arms and the guide pulley 47. The insert phantom circle figure is a schematic depicting the optical fiber 13 residing in a circumferential groove in the guide pulley 47. Left and right dowel pins 44 and left and right standoffs are also shown with the wire strands wound thereon and passing down into the top throat.

Fig. 10 is an exploded plan view of the bottom view of the left and right pay guide arms and the guide pulley which would be obscured if the left and right hands are brought together. Use of the standoffs shown will depend on the tensioning means selected.

Figure 11 is a top plan view of the pay guide assembly 30 with the left and right pay guide arms 34,35 clamped together by a contact bolt 77. The contact bolt also electrically connects a signal source via a terminal and conductor 80 to the right pay guide arm 35.

The pivot arm is shown as an exploded assembly comprising a pivot arm adaptor 76 coupled to the left pay guide arm, a pivot arm extension coupled to the pivot arm adapter and to the winding machine (not shown). An insulator, such as a kapton insulator 78 is interposed between the pivot arm extension and the pivot arm adaptor for insulating the pay guide assembly 30 from the pivot arm extension. Non-conductive screws couple the pivot arm adapter to the pivot arm extension. A phantom pivot arm extension is shown at the left of the pivot arm.

In this arrangement, wire strands 38,39 (not shown) are electrically insulated from the automatic coil winding machine. The position of the pivot arm extension relative to the adapter would be switched to the phantom position

for use in a the second fiber guide on an automatic winding machine.

The use of the kapton insulator and an electrical signal source represents a means for electrically sensing and teaching the servo means (not shown) the limits of travel parallel to the rotation axis of the spool rotation axis necessary to bring each respective strand to a corresponding left and right flange inner surface 27.

When a bobbin is used having conductive flanges, the contact of the electrically excited music wire with the flange produces an electrical response that is detected by an a sensor that signals the location of the linear motor servo into a memory for storage. The electrical contact surface on the inner wall of the bobbin is in fixed relation with the winding machine frame.

The detected signal is used to signal the lateral drive servo and computer control moving the fiber guide to stop or reverse its direction each time the guide reaches the end of a layer of fiber coils. The encoder readout for the position of the guide at the point of electrical contact is stored and thenceforth used as the learned drive limit for lateral movement of the fiber guide carried by the servo drive assembly on the winding machine.

Figure 12 is a schematic end view of the wire strands, the top and bottom throats, and the fiber 13 passing between the wire strands. Standoffs 46 are shown along with dowel pins 44 at the top and bottom pay guide arms.

The fiber 13 is shown passing around the dowel pins 44 and entering the receiving hole in each of the standoffs 46.

This figure shows the spaced apart piano wires 38,39 guiding the glass or optical fiber 13 therebetween. The

diameter of the wire may be 0.004 inches and the spacing between the wires 0.008 inches. The glass fiber, in this example, has a diameter that is typically in the range of 0.0031 inches to 0.0049 inches.

WIRE CONTROLLED FIBER GUIDE WIRE INSTALLATION PROCEDURE Figure 12 is a schematic view of the ends of the left and right pay guide arms. The steps for installing the music wire into to tensioner proceeds as follows: 1. Install the hex standoffs 46 (item 1) into the tapped holes of the left and right pay guide arms. Torque until standoffs 46 make light contact with Fiber Guide body.

2. Using. 004"diameter music wire, cut off an approximate 12 inch length.

3. Referring to Figures 12 and 13, thread one end of wire through a cross-drilled hole in a standoff 46.

4. Install the o-ring segment into the threaded hole of the standoff 46.

5. Install the set-screw into the same threaded hole following the o-ring segment. Torque the set-screw sufficiently such that the wire is restrained in the hole.

Apply 1 to 3 full wraps of wire around standoff prior to routing around. 125" die dowel pin 44 (see figure 1).

Wire Installation,"Top End" (left hand view, figure 1): 6. Route wire around. 125" die dowel pin 44 (see figure 1) followed by 1 to 3 full wraps (CCW) around standoff (item 1). Next, thread the end of the wire through the cross-drilled hole in the standoff 46 for the lower end of the pay guide arm.

7. Install o-ring segment and set-screw per steps 4 and 5.

8. Lightly tension the wire by rotating the standoff.

9. Using a dowel, gently push both wires in and out, at each end of Fiber Guide, attempting to make them parallel when viewed from the side of the Fiber Guide. From this

view, only one wire should be visible.

10. Repeat steps 2 through 8 using the other length of wire.

Final Tension Adiustment: 11. Using a gram force gage at the wire mid-span, check the lateral deflection force of each wire for a deflection of . 004" at mid-span. Note that. 004"can be estimated when wires are viewed under a microscope:. 004"= 1 wire diameter.

12. Adjust the"Top End"standoff (item 1) to obtain 3.0 to 4.0 grams deflection force for 004"lateral deflection.

12. Check wire separation gap at both ends of Fiber Guide.

Verify that gaps are within. 0075"to. 0085". If necessary, fiber guide mating surfaces can be shimmed to achieve the correct spacing.

Figure 13 is a more detailed exploded view of the standoff 46. Rubber plug 61 and #6-32 set screw 63 are also shown with a drill hole in the side of standoff 46.

The music wire is draw through the cross drilled hole and locked in place by the rubber plug as the rubber plug is driven into the axial hole by the #6-32 screw. Once the music wire, extending through the cross drilled hole, is locked in place by the rubber plug, the tension of the music wire is adjusted by turning the standoff.

Figure 14 is a preferred alternative embodiment. It shows a schematic end view of the wire stands, the top and bottom throats, and the fiber 13 passing between the wire strands. Previous fiber guides used grooved wheels to guide the fiber. The wheels allowed the fiber to escape if there was any slack during the wind and the wheels were very delicate and easily damaged. The previous fiber guides, such as those in Figures 1,3,4, and 7-10 were very complicated and difficult to setup. The tension was

set by deflection of the wire after types and required multiple trial and error steps to achieve the desired tension. The spacing between the wires was established by two parallel arms permanently spaced and could only be changed by complete tear-down and the addition of shims or machining. Standoffs had to be adjusted.

The embodiment of Figure 14 retains the notion of using left and right parallel strands as guides but eliminates standoffs along with dowel pins 44 at the top and bottom pay guide arms. This figure shows the spaced apart piano wires 38,39 guiding the glass or optical fiber 13 therebetween. As in the discussion of Figure 12, the diameter of the wire may be 0.004 inches and the spacing between the wires 0.008 inches. The glass fiber, in this example, has a diameter that is typically in the range of 0.0031 inches to 0.0049 inches. Alternative views are presented in Figures 18-24.

Figure 15 is a partial section schematic view of the guide pulley 47 having a guide pulley wheel having a left and right face 12a, 12b and an axle hole 50. The guide wheel 12 is carried by the pay guide assembly 30 to guide the glass fiber 13 to and between the left and right parallel strands 38,39 of music wire for deposit onto the coil on spool 20. The guide pulley is mounted on guide wheel shaft 16 using a right and a left ball bearing 100a, 100b. Each respective bearing has an inner 102a, 102b race and outer race 104a, 104b. Each respective race has a respective inner and outer surface.

Prior to mounting the bearings, the dimensions of the wheel 12a, 12b, pay guide arms, and the guide wheel shaft 16 length are analyzed and the shaft 16 is marked to permit precise location of the outer surface of the inner race of

the right bearing at a predetermined distance from the end of the shaft 16. The shaft length, the pay guide wall thicknesses, the wheel thicknesses and bearing shoulder thickness are analyzed and characterized to position the center of the wheel on a line to pass the optical fiber precisely between the left and right parallel strands 38, 39.

The right bearing 100a is then positioned on the shaft and moved to align the outer surface of the inner race with the mark. Once positioned, the right bearing's inner race 102a is secured with a cynoacrylic adhesive (crazy glue).

The shaft is then inserted into a receiving hole through the right pay guide arm 35 and pressed in until the end of the shaft 16 is flush with the outer surface of the right pay guide.

The mark is positioned on the shaft at a location from the shaft's end, based on the analysis, to locate the bearing so that a predetermined clearance would exist between t'r. e-nner surface __ the r-ght pay guide arm and the outer surface of the outer race of the right bearing 10Oa.

The guide pulley 12a, 12b is then positioned onto the right bearing. The left bearing is then positioned onto the shaft with its outer race inserted into the axle hole in the wheel. A force is then applied to the inner race 102b of the left bearing 100b as the wheel is spun and released. The force is adjusted to the point at which the wheel rotates wobble free and for which a very slight deceleration in the wheel is perceived. At that point, the bearing is secured on the shaft, with the same force applied, with cyanoacrylic adhesive. A small amount of cyanoacrylic adhesive is also applied to the joint between

the left surface of the wheel and the shoulder of the outer race of the left bearing 100b.

Figure 16 shows a schematic sectional view of a coil form 20 mounted on a mandrel 82 prior to use for winding a coil. If the coil form 20 is of non-conductive material, the inner walls of the coil form flanges 27 can not be used for electrically signaling when the wire strands reach the limit of lateral travel. The tool 81 shown is draped over the coil form. Lower left and right registration walls 83, 84 are co-planar with the upper inner registration walls 85,86. The tool is typically of aluminum. Upper and lower guide pins 87,88 allow the left and right halves to extend and contract with near perfect orthogonality.

Top and bottom springs 89,90 restore the halves to engage and retain contact with the inner walls of the flanges. The left and right upper inner registration walls 85,86 are conductive and co-planar with the inner walls of the flange. The inner registration walls 85,86 are electrically contacted by the left and right parallel strands 38,39 to signal the servo 80 and teach the servo where the limits of travel are in relation to the inner walls of the spool flange inner surface 27.

In this embodiment, lateral travel limits are detected by use of the conductive flanges on the aluminum tool of Figure 16 and 17 that is positioned over the spool. The tool is machined to precisely register on the spool and carry the location of the spool flange inner surfaces 27a, 27b radially outward into the path of the left and right parallel strands 38,39 in their lateral travel.

In operation, the fiber guide is moved by a linear motor, laterally under encoder and servo 79 control by a computer near the surface of the fiber coil 22. At the limit of travel, one of the left or right parallel strands 38,39 electrically contacts the inner surface of the tool outer flange 85,86 which is co-planar with the inner surface of the bobbin flange 27a, 27b at which point, the servo 79 stops lateral motion in preparation for starting the next layer of winding.

Figure 17 shows the tool 81 of Figure 16 draped on the mandrel containing a non-conductive coil form or bobbin.

The inner periphery 92 of the tool's outer flange is close to the outer periphery 94 of the bobbin chuck 96.

Figures 18-24 shows an alternative embodiment of the invention fiber guide. The fiber guide consists of a'C' shaped or left pay guide arm 34 with wire attachment points at each extreme end of the pay guide arm. The attachment points consist of a calibrated and hardened spacer 40, such as that shown in Figure 14, to set the distance between the left and right parallel strands 38,39. Two hardened washers 52a, 52b to clamp the left and right parallel strands formed from two. 004 diameter steel wires or guides into position to guide the fiber and two shoulder screws 49 for retaining and clamping the washers. It also has two rollers mounted in the middle of the arm to pre- align the optical fiber before it passes through the alignment wires.

Fig. 18 is a side elevation view of fiber guide 10 in which the two parallel strands or guides 38,39 are separated by a spacer washer 40, (not shown). The embodiment of figure 18 eliminates or simplifies the setup process by the use of simple spacers to set the wire gap,

straight line wire position allows the use of a simple weight to set tension and overlapping ball bearings to pre- align the fiber and prevent accidental disengagement from a pre-aligned position.

Fig. 19 is a front elevation of the fiber guide of Figure 18 showing the dual clamps for griping and holding the fiber, the fiber passing between the upper flanged roller 110, and a lower roller 112 and out of the page. The rollers are spaced by 0.012 to 0.015 inches. As shown, the fiber is maintained in tension against the lower surface of the upper flanged roller 110. While tension is retained the fiber can move left and is stopped by the bearing wall and to the right where it is stopped by the flange.

Fig. 20 is a top elevation view of the fiber guide of Fig. 18 showing the left and right strands 38,39 separated by a very thin spacer 40 between the parallel strands and clamped by a fastener 49 as in Figure 14. The left and right parallel strands are between shims or washers 52a, 52b to protect the opposing registration faces 41a, 41b and to grip the left and right parallel strands 38,39 against spacer 40.

Figure 21 is a schematic sectional view of Figure 20 taken on section line 21,21 to expand the view of the spacer 40 separating the left and right parallel strands 38,39, the shims 52a and 52b and the fastener 49.

Figure 22 is an irregular sectional view of Figure 18 taken on a line passing through each of four bearing centers. The upper flanged roller bearing 110 and the lower roller bearing 112 are shown. A first bearing spacer 116 is positioned under the upper flanged roller bearing 110 and a second bearing spacer is shown positioned below the

lower roller bearing 112. The spacers are machined to thickness for setting the height of the inner surface of the flange and two modified shoulder screws 120,122 are for retaining and preloading the bearings.

Figure 23 is a schematic top view of a portion of a fiber guide assembly as it would appear if one throat had to remain open as might be made necessary if coils were to be wound starting from the mid point of a roll of fiber stored on two equal bobbins such as quadrapole wound coils for fiber optic gyros.

The fiber guide of Figures 18-22 are for applications such as mandrels for fiber optic acoustic interferometers which may be wound with fiber from the end of a coil of fiber. In operation, the pay guide arm of Figures 23-24 assembly 30 is mounted to the hydrophone winding machine and guides the optical fiber onto the acoustic mandrels in such a way as to align the fibers next to each other for the sensing portion of the mandrel and also routes the fiber through spiral groove at each end of the mandrel.

The alternate design of Figure 23 and 24 is suitable for quadrapole wound fiber optic coils. In this alternative design for quadrapole winding, one side of the pay guide parallel wires is open to allow insertion of unbroken fiber. Figure 23 and Figure 24 show that one end of the'C'shaped pay guide arm is separated into a left pay guide arm 34 and a right pay guide arm 35 with simple cap screws 124a, 124b to hold the arms together.

Figure 23 is a front elevation of the schematic of Figure 22. Cap screws 126a, 126b retain the left and right parallel strands 38,39. The other end of the arm is closed as is previously described for the embodiment of Figures 18-21.

While the invention has been explained in connection with a single embodiment, it is intended that only the appended claims be used to limit the scope of this patent.