Applied Optical Systems Offers Plug & Play Portable Structures

By Ed Sullivan

Due to the growing need for hybrid, portable electric power and communications cabling, a new standard in advanced connection technology has emerged, making it simple and economical to couple fiber optic networking with an integral power source for truly flexible wireless access.

One of the more perplexing dilemmas facing enterprises today is that they have to be lean and robust at the same time. Not only do business strategies have to be agile, but so do operations, including the buildings and infrastructures that support them.

Among the foremost of those infrastructure requirements are low-voltage electric power and voice/data communications. Virtually every industry has a need to expand or relocate power and multi-channel communications conduits – cabling – on an ever-changing, as-needed basis: mining, manufacturing, military, oil platforms, broadcasting and even retail business.

With such a diverse range of industries that experience this re-location dynamic there is a need for hybrid communications (fiber optic/loop current) and low-voltage cabling that incorporates rugged design as well a easy connection, abundant bandwidth and the ability to pull power as well as communications over long distances with flexibility of access points.

A good example application is the subterranean mine, where the need for power and communications (including wireless and VOIP) access points is constantly changing locations in a very harsh environment.

Until recently the most popular solution for hybrid cables was CAT5 (Category 5 cable). Because of the copper twisted-pair wiring, applications using CAT5 (or 5e) were typically restricted to distances of 700-800 feet, and only 300 ft. when used as a network backbone. Also, the copper in CAT5 cable is problematic in some applications because copper is subject to interference from magnetic forces created in the presence of high-voltage lines. Such interference can cause corrupt data and cause sporadic performance.

To avoid those shortcomings and take advantage of the bandwidth, distance, superb system latency, and cost benefits R&D engineers began to look at fiber optics, which offered the choice of very high bandwidth (e.g. HDTV) and communication over miles.

Applied Optical Systems (Plano, TX) developed a long-distance hybrid system that carries both electrical and multi-channel fiber optics that accommodates both LAN and wireless LAN platforms. The "F-Link™" version of the Applied Optical Systems (AOS) line includes a family of products equipped with up to 34 fiber optic channels and a fiber optic backshell plus a complete line of connectors to provide that offer the flexibility and cost-effectiveness that are required by many applications.

The F-Link concept is more revolution than evolution. While some product lines are an adaptation of earlier technologies, this one was developed from the ground up as today's hybrid solution.

For example, the plug & play connectors and terminals are designed for use in harsh and rugged environments. Whereas most opto-electrical systems have connections that withstand only 20-30 lbs. of strain, this one has strain resistance of 250-400 lbs, depending on the quality of fiber or composite cable. Therefore it is idea for applications where high winds or rough handling may occur.

Designed to accommodate different configurations, the F-Link inter-connect concept takes advantage of precision injection molding techniques, keeping cost low while maintaining the highest precision in geometric cavity pattern layout.

Enhancing portability and affordability
An successful example of this re-location challenge is the portable classroom, used to support the changing facility requirements of an increasing number of school districts. These portable buildings are often used as temporary housing to accommodate student population overflow or new classroom construction projects.

The Albuquerque Public School District, one of the largest in the U.S., owns over 1,300 portable buildings. Each year 150 or more of these buildings, mostly used as temporary classrooms, are relocated. Every time a portable building is moved, there are substantial recurring costs resulting from hiring a contractor to disconnect and re-connect the data communications lines that integrated the building with the school.

"It cost tens of thousands of dollars every time we have to cable a group of portables," says Doug Ahlgrim, RCDD/NTS of contractor Sound & Signal Systems, Inc. of New Mexico. "That was much too wasteful, so we developed a ‘quick disconnect' plug & play design that would facilitate hooking up or unhooking a hybrid (fiber optic/electrical) plug and play design that would facilitate connecting or disconnecting all low voltage systems."

Tony Perry, Albuquerque Public Schools Technology Manager, was also involved in this design and implementation.

To ensure lasting performance and durability, Ahlgrim's team had to deal with harsh environment including New Mexico's seasonal temperature extremes and rough treatment that the connections received. Also, vandalism to the prior quick-disconnect the school district was using had been a reoccurring problem.

Researching a supplier of plug & play opto-electrical technology led us Ahlgrim to AOS, known for the design and manufacture of fiber optic inter-connect for harsh and rugged environments.

While AOS products include "tactical" fiber optic connectors conforming to U.S. military specifications, Ahlgrim was particularly interested in the "F-Link" series that includes versions designed for hybrid applications. Those are able to support port counts from two to 34 channels across 5 families of product.

"AOS tailored their F-Link platform to meet the Albuquerque Public School System in order to keep the cost down while also providing a system that is robust and rugged enough for the environments we're putting it in," Ahlgrim says. "Continuous vandalism of the previous "quick disconnect product lead the district to resolve the issue with the first installation of the F-Link inter-connect system. When used with Optical Cable Corporation (OCC) MX-Series Messenger Cable, the pull strength on the F-Link fiber optical solution exceeds 250 pounds and functions well in an outdoor environment.

Upon approval from the school district Sound & Signal Systems immediately replaced the previous broken connections with F-Link systems, on approximately 40 portable buildings. There has not been a single breakage problem since.

"Now we're talking about anywhere up to $2,000 per portable to get them connected on the network," Ahlgrim explains. "And every time they move it costs less than $1,000 to go unplug and then re-plug."

Ahlgrim adds that once the plug & play system is installed, overall costs have been reduced from tens of thousands of dollars down to just hundreds of dollars per relocation.

"We now have about 400-500 F-Link systems deployed within the district and it's growing every day," he says. "Though the district is not really seeing the huge savings yet, they'll start seeing it as they move from area to area and experience the savings based on the ease and simplicity of un-plug and re-plug, saving on labor, repair and replacement costs. Plus connector inventory is greatly simplified, and maintenance personnel can be trained on a single, easy system. So, there are even greater savings ahead."

The performance and savings are promising enough that the Albuquerque Public School System is considering standardizing on the F-Link connector.

In addition, the district has decided to use the same connector for the intercom, fire alarm, security, and phone systems throughout its school facilities.

Applied Optical Systems designs, develops, and manufactures fiber optic solutions through the efficient application of passive fiber optic components, cabling, systems, and leading fiber optic technologies for the mobile and fixed, military, governmental and industrial markets.

SOURCE: Applied Optical Systems, Inc.