Bulk Feeding Disk Drives to Testing Systems
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Solution Overview
Problem
Current disk drive testing systems face challenges with vibration-induced errors and inefficiencies due to manual or serial feeding methods, which affect test accuracy and yield, especially with newer, more sensitive disk drives.
Innovation Solution
Implementing a bulk feeding system using disk drive totes and an automated transporter, such as a robotic arm or multi-axis linear actuator, to efficiently and accurately transfer multiple disk drives to test slots, reducing manual intervention and vibration-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or robotic arm feeding methods are used to individually supply disk drives to test slots, then the system can maintain simple structure and ease of operation, but the throughput is low and user intervention is required
Solution Approach 1:
The system divides the disk drive supply function into separate modular components: a tote carrier for bulk transport, individual disk drive carriers for precise positioning, and automated transporters for movement. This segmentation allows each component to be optimized independently while working together to achieve high throughput without excessive overall complexity
Solution Approach 2:
The patent introduces intermediary carriers (tote carriers and disk drive carriers) that mediate between the bulk storage location and the test slots. These intermediaries enable automated bulk transport while maintaining precise control over individual disk drive placement, resolving the contradiction between automation and precision
2Reliability
If individual disk drives are fed one by one using robotic arms, then vibration exposure is minimized for each drive, but the overall testing time increases due to sequential processing
Solution Approach 1:
Multiple disk drives are pre-loaded onto tote carriers in a controlled environment before being transported to the test slots. This preliminary action allows the actual testing to begin with multiple drives simultaneously rather than sequentially, reducing total testing time while maintaining low vibration exposure during the critical individual placement phase
Solution Approach 2:
The system enables continuous testing by maintaining multiple disk drives in different stages of the testing process simultaneously - some being loaded, others being tested, and others prepared for loading. This eliminates idle time between individual drive tests while maintaining the careful, low-vibration handling required for reliable testing
3Extent of automation
If automated transporters are used to retrieve and deliver disk drives, then user intervention is reduced and efficiency improves, but the complexity of the automated system increases
Solution Approach 1:
The tote carrier serves multiple functions: it acts as a bulk storage container, a transport unit, a positioning device, and a protective enclosure. The disk drive carrier similarly performs multiple functions including holding individual drives, providing precise positioning, and serving as a interface with the test slots. This multi-functionality reduces the need for separate specialized components, thereby reducing overall system complexity despite high automation
Solution Approach 2:
The automated transporters are designed to autonomously retrieve disk drives from tote carriers, position them in test slots, and handle the entire process without human intervention. The system includes self-contained error correction and positioning mechanisms that enable the transporters to operate independently, achieving high automation while keeping the control system manageable
4Productivity
If bulk feeding with totes is implemented, then throughput increases and testing time decreases, but the risk of vibration cross-talking between adjacent drives increases
Solution Approach 1:
The system provides localized vibration isolation for each disk drive carrier and test slot, rather than relying on global isolation for the entire bulk tote. Each individual drive position has its own vibration damping and isolation characteristics optimized for that specific location, allowing bulk handling while maintaining low vibration exposure for each drive during critical operations
Solution Approach 2:
The tote carriers and disk drive carriers are designed with built-in vibration damping and isolation features before the drives are loaded. These pre-installed cushioning mechanisms protect the drives during transport and handling phases, reducing the risk of vibration cross-talking before it can affect test accuracy
Data Source
AI summary
A method of supplying disk drives to a disk drive testing system includes placing a disk drive tote, carrying multiple disk drives, in a presentation position accessible to an automated transporter of the disk drive testing system. The method includes actuating the automated transporter to retrieve one of the disk drives from the disk drive tote, and actuating the automated transporter to deliver the retrieved disk drive to a test slot of the disk drive testing system and insert the disk drive in the test slot.