Reference Pin Block for Head Suspension Alignment
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Solution Overview
Problem
Existing methods for aligning flexures and load beams in head suspensions, particularly those with very-thin flexures, face challenges in achieving high-precision positioning due to low rigidity, leading to inaccuracies in assembly.
Innovation Solution
A method involving the formation of positioning reference holes around a first welding spot on both the flexure and load beam, with corresponding reference pins used for alignment, ensures accurate positioning by laser-welding the flexure to the load beam at a predetermined load, utilizing a reference pin block with integral reference pins to minimize position errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If very-thin flexures are used to reduce weight and increase flexibility, then the head suspension becomes more adaptable, but the alignment precision between flexure and load beam deteriorates due to low rigidity
Solution Approach 1:
The patent introduces a reference pin block as an intermediary tool that provides stable reference pins for positioning. These reference pins insert into reference holes formed on both the flexure and load beam, creating a mediator that enables precise alignment even when the flexure itself has low rigidity. The reference pin block serves as the mediating device that transfers positioning accuracy from the rigid load beam to the flexible flexure.
Solution Approach 2:
The patent applies preliminary action by forming reference holes on both the flexure and load beam before the actual assembly and welding processes. The reference pin block with reference pins is prepared in advance to provide stable positioning references. This preliminary preparation of positioning features ensures that when assembly occurs, the alignment precision is already established, compensating for the low rigidity of the thin flexure during the welding process.
2Ease of manufacture
If traditional positioning methods are used for thin flexures, then the manufacturing process remains simple, but the alignment correctness between flexure and load beam deteriorates
Solution Approach 1:
The reference pin block acts as an intermediary positioning device that maintains process simplicity while improving precision. Instead of complicating the flexure design or requiring complex positioning mechanisms, the patent introduces this separate reference pin block that provides stable reference pins. These pins insert into pre-formed reference holes, creating a simple yet effective positioning system that enhances alignment correctness without significantly complicating the manufacturing process.
Solution Approach 2:
The patent segments the positioning function from the structural function of the flexure and load beam. By creating separate reference holes specifically for positioning purposes and using a dedicated reference pin block, the positioning function is segmented out. This allows the flexure to maintain its thin, flexible structure for its primary function while the segmented positioning features provide the necessary alignment precision independently.
3Stability of the object's composition
If reference holes are formed far from the welding spot to increase stability, then positioning stability improves, but the alignment precision at the welding location deteriorates
Solution Approach 1:
The patent applies local quality by forming reference holes at specific locations that are optimally positioned for both stability and welding precision. Rather than placing reference holes arbitrarily far from the welding spot for stability, or immediately at the welding spot for precision, the reference holes are strategically located in areas that provide both positioning stability and accurate alignment at the welding location. The reference pin block with its multiple reference pins distributed at different locations provides localized stability while ensuring the welding spot alignment precision.
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
This approach enhances alignment correctness and positioning precision between the flexure and load beam, even with low-rigidity flexures, by using the reference holes and pins to stabilize the mechanical characteristics and improve vibration characteristics of the head suspension.
Implementation Method 1
laser-welding the flexure to the load beam at a first welding spot so that the tongue is pressed against the projection under predetermined load
Data Source
AI summary
A reference block which is machined from a single body of material and is a single block with reference pins integral therewith is configured for use in a method of manufacturing a head suspension by laser-welding the flexure to the load beam at a first welding spot so that a tongue is pressed against a convex portion under predetermined load. The method includes steps of forming, before joining the flexure and load beam together, at least one positioning reference hole in each of the flexure and load beam within a circular range that is defined around the first welding spot with a radius equal to a distance between the first welding spot and the projection, laying the flexure and load beam one on another, inserting the reference pins of the reference pin block into the reference holes, and laser-welding the flexure and load beam to each other at the first welding spot.