Load Beam Controlled Droop via Rail Edge Coining
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Solution Overview
Problem
The manufacturing of double-delta configured load beams for disk drive suspensions often results in unwanted droop due to limited material length, leading to variability in pre-load force and affecting read/write performance, as existing methods either require forming gaps in rails or secondary bending operations that introduce additional variability.
Innovation Solution
A coining process is employed to increase the length of the rail edges before folding, using a punch with a shaped tip to form an indentation, which adjusts the angle between planes and maintains the load beam's planarity without gaps or reverse bending, thereby minimizing droop variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rails are folded using limited material length, then the load beam can be manufactured, but droop occurs due to insufficient material
Solution Approach 1:
The coining process is performed before the rail folding operation to pre-lengthen the rail edges. This preliminary action ensures that when the rails are subsequently folded, there is sufficient material length to achieve coplanarity between the first and second planes, eliminating droop while maintaining manufacturing simplicity
2Manufacturing precision
If gaps are formed in the rails to reduce droop, then droop variability decreases, but the rigidity of the load beam is reduced
Solution Approach 1:
The coining process applies localized deformation only at specific positions along the rail edges where material lengthening is needed. This localized quality change allows the rails to achieve coplanarity after folding without creating gaps, thereby maintaining the continuous structure and rigidity of the load beam while eliminating droop variability
3Manufacturing precision
If secondary bending operations are used to reverse droop, then planarity is improved, but additional variability is introduced to the pre-load
Solution Approach 1:
The coining operation is performed as a preliminary step before rail folding to pre-lengthen the material and establish the correct geometry. This eliminates the need for secondary bending operations that would otherwise be required to correct droop, thereby maintaining pre-load consistency and avoiding additional variability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coining process effectively reduces or eliminates droop in load beams, ensuring consistent pre-load force and improved disk drive performance by maintaining the load beam's planarity and rigidity, with adjustable droop angles achieved through precise punch tip design.
Implementation Method 1
coining the load beam at a location where the bend will occur in the rail
Implementation Method 2
forming the bent rail by folding the edge region of the load beam
Data Source
AI summary
A load beam having a bent rail, a suspension that includes the load beam, and a related method for manufacturing a load beam. The method includes providing the load beam before the bent rail is formed, and coining the load beam at a location where the bend will occur in the rail.