Disk Drive Self-Diagnosis for Manufacturing Rack Failure Detection
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Solution Overview
Problem
Existing manufacturing processes for disk devices face challenges in accurately diagnosing failures in constituent units, leading to potential production of defective devices and increased costs due to manual checks and additional equipment needs.
Innovation Solution
A failure diagnosis method is implemented in the manufacturing process, where disk devices acquire and analyze data on power supply levels and spindle motor rotation periods to determine if constituent units are within allowable ranges, preventing faulty manufacturing by identifying and stopping processes with abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual checks and additional equipment are used to diagnose failures in constituent units, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The disk device performs self-diagnosis by acquiring its own operational data (power supply level, spindle motor rotation period) and determining whether constituent units are within allowable ranges. This eliminates the need for external diagnostic equipment and manual checks, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The invention monitors specific operational parameters (power supply level, spindle motor rotation period) to diagnose failures. By changing from manual visual inspection to automated parameter-based diagnosis using existing sensors, measurement precision improves without adding complex diagnostic equipment.
2Reliability
If manual checks are performed to identify failures, then reliability is improved, but productivity decreases due to increased inspection time
Solution Approach 1:
The disk device automatically performs failure diagnosis by acquiring operational data and determining constituent unit status without manual intervention. This maintains high reliability through continuous monitoring while improving productivity by eliminating time-consuming manual inspection processes.
Solution Approach 2:
The system continuously monitors operational parameters (power supply level, spindle motor rotation period) and provides real-time feedback on constituent unit health. This automated feedback loop ensures high reliability while maintaining manufacturing efficiency by immediately identifying failures without stopping the production flow.
3Measurement precision
If additional diagnostic equipment is acquired to improve failure detection, then measurement precision is improved, but loss of substance increases due to additional capital investment
Solution Approach 1:
The disk device uses its own built-in sensors and control units to perform failure diagnosis, eliminating the need for external diagnostic equipment. This maintains measurement precision while avoiding additional capital investment and associated costs.
Solution Approach 2:
Existing components in the disk device (control unit, sensors for power supply and motor rotation) are made multi-functional by using them for both normal operation and failure diagnosis. This eliminates the need for dedicated diagnostic equipment, reducing manufacturing costs while maintaining detection accuracy.
Data Source
AI summary
According to an embodiment, there is provided a failure diagnosis method. The failure diagnosis method includes installing a disk device in a manufacturing rack. The failure diagnosis method acquiring, by the disk device, data on a state of a predetermined constituent unit in the manufacturing rack with the disk device being installed in the manufacturing rack. The failure diagnosis method includes determining, by the disk device, whether or not the state of the predetermined constituent unit falls within an allowable range by using the data acquired.