1000 metres in a Single Blow: HFCL's Optibend Unitube Mini Cable for FTTx Connectivity
Case Study Highlights
- Designed for single-blow installations exceeding 1000 m
- 26 distinct Variants developed to meet diverse customer requirements
- Cables available from 2 fibers to 36 fibers
- The Optibend Unitube Mini Cable covers 1000 m in only 15 minutes*
- New S-Z shaped jetting test track engineered to simulate actual field conditions
Background
HFCL faced a significant challenge when a European customer requested a high-performance FTTx solution. The task was to develop a Unitube blown cable capable of reaching 1000 metres in an 8/5 mm microduct at 7 bar duct pressure. Although promising in early tests, the initial 24 fibers cable prototype underperformed in the field when faced with stringent field conditions. This setback motivated and provided an opportunity for HFCL to optimize its design. Through 26 iterations and extensive testing, HFCL collaborated with HTL Hosur to develop an Optibend Unitube Mini Cable with a low-friction outer jacket. Validated by rigorous simulations and field-like tests, the final design achieved outstanding performance, effectively meeting the customer's demands.
Customer’s Overview
HFCL was approached by a prominent European telecommunications leader known for its forward-thinking approach to infrastructure, seeking customized cable solutions. Operating in a highly competitive industry, they have consistently pushed the boundaries of technology to deliver superior connectivity solutions. Recently, they made headlines with their ambitious plans to expand high-speed internet access across rural and urban areas, demonstrating their commitment to advancing telecom services.
Despite their successes, the customer faced significant challenges in optimizing FTTx installations within smaller microducts. There were limitations during field installation due to approximately 7 bars of available duct pressure. The cable had to be blown through a distance of up to 1000 metres in a single attempt, navigating through turns, undulations, and changes in elevation along the route.
Recognizing the need for a more effective solution, they sought a partner known for innovation and reliability. They chose to collaborate with HFCL, driven by our proven track record in providing cutting-edge cable solutions and our commitment to customer-specific customization. Our expertise and state-of-the-art facilities promised a solution that would not only meet but exceed their performance expectations.
Challenges Faced
Material Innovation
Outer jacket compound required minimizing friction for maximum blowing distance. After extensive experimentation, we have devised 4 different jacket compounds, each combining different base resins and anti-slippage additives. Notably, the final one emerged as the top performer. This process of compound development was not without its challenges, spanning approximately six months to pinpoint the optimal composition for this specific application.
Engineering Complexity
Developing a unitube blown cable tailored for FTTx applications, intended for installation within 8/5 mm microducts spanning a distance of 1000 metres, while adhering to a strict maximum duct pressure limit of 7 bars.
Initial Performance Gap
Our cable design fell short during field testing, managing only 150 metres compared to a competitor's cable reaching 1000 metres effortlessly.
Iterative Design Process
Balancing cable stiffness was critical, too stiff hindered smooth navigation, while too flexible caused buckling.
HFCL’s Approach to the Challenges
Facing the challenge of optimizing FTTx installations in smaller microducts, HFCL approached the task with determination and innovation.
- Identification of Initial Solution
HFCL responded to the customer's demand with a recently developed 24 fibers cable, showcasing compatibility for blowing into the requested duct size. Despite initial promise, field testing revealed shortcomings, inspiring us to strive for improvement.
- Commitment to Improvement
Collaborating with the HTL Hosur team, we meticulously refined both the cable design and outer jacket material composition, testing almost 26 different variants to achieve the desired outcome.
- Thorough Testing and Validation
The cable underwent trials on the standard IEC Nx100 track, validating cable performance as per industry standards. Furthermore, we designed and constructed a new S-Z shaped test track to establish the most rigorous testing conditions possible, simulating real-world conditions and intentional bends in the test route.
- Focus on Design Optimization
Recognizing the importance of stiffness in navigating intricate bends, HFCL optimized the cable design to ensure smooth movement without compromising flexibility. This approach ensured efficient installation even in challenging FTTx topologies.
- Innovation in Material Development
Understanding the critical role of low-friction properties in blowing distance, HFCL's HTL Hosur renowned for their expertise in developing customised polymer material compounds developed an outer jacket compound with exceptional low-friction characteristics, enhancing the cable's performance significantly.
- Successful Qualification and Validation
Understanding the critical role of low-friction properties in blowing distance, HFCL's HTL Hosur renowned for their expertise in developing customised polymer material compounds developed an outer jacket compound with exceptional low-friction characteristics, enhancing the cable's performance significantly.
Success Metrics
Our optimized Optibend Unitube Mini Cable design resulted in a groundbreaking 1000 metres blowing distance, significantly surpassing initial field performance and demonstrating our ability to meet and exceed customer expectations.
Leveraging enhanced stiffness and low-friction outer jacket material, we achieved a remarkable 15-minute blowing time for the full 1000 metres, one-third of the time required by the competitor’s cable.
To achieve the final optimized design, we developed and tested 26 different variants, showcasing our commitment to innovation and customer-specific customization to deliver superior performance. We ensured that the cables maintained the same dimensions without compromising any mechanical and environmental performance.
Result
We proudly introduce the Optibend Unitube Mini Cables- the slimmest cabling solution available, ranging from 2 fibers to 12 fibers with a diameter of approximately 2.1 mm. Additionally, they are suitable for microduct air-blown installations and can accommodate up to 36 fibers with a diameter of approximately 2.4 mm.
"Thanks to HFCL's groundbreaking cable design, we achieved a remarkable 1000 metres blowing distance in just 15 minutes – a feat that surpassed our expectations threefold. This unparalleled performance has not only streamlined our FTTx installations but has also given us a competitive edge in the market.” - Our Customer
*Disclaimer: The observed test result at the customer site cannot be guaranteed for every route type.
