Development of an automated fiber optic winding machine for gyroscope production

Fiber optic gyroscopes (FOGs) present an increasingly attractive solid-state alternative to the traditional spinning-mass gyroscopes. FOGs additionally present a potential cost benefit over ring laser gyroscopes (RLGs), as they require no inherently expensive mirrors or other mechanical components. However, the potential cost benefit has yet to be realized. At the heart of a FOG is a sensing coil comprised of several hundred meters of several kilometers of optical fiber, wound in one of several special patterns designed to improve gyroscopic performance. Winding a fiber optic sensing coil traditionally is performed on a semi-automated machine with the constant involvement of an operator. It is a complex process that can take as much as a week to complete. This paper describes the development of a fully automated fiber optic winding machine capable of accurately winding several different coil patterns, incorporates active tension control during winding, and includes a vision-based, automated error detection and correction system for improved reliability. The resulting machine can reduce winding times by as much as an order of magnitude.