Slider Flatness Inspection via Interferometric Segmentation
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Solution Overview
Problem
Existing slider fabrication methods face challenges in accurately measuring the flatness of multiple sliders simultaneously, leading to inefficiencies and potential imperfections in hard-disk drive components due to non-uniform surface features and surface roughness.
Innovation Solution
A method utilizing a large-aperture interferometer to capture images of entire slider bars, segmenting the images into individual slider surface maps, and employing pattern recognition of slider poles for precise alignment and cropping, allowing for high-throughput and accurate measurement of flatness across multiple sliders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to measure slider flatness, then measurement can be performed, but analysis time is excessive and sampling cannot reach 100%
Solution Approach 1:
The patent combines multiple slider measurements into a single interferometric image capture. By imaging an entire slider bar containing multiple sliders simultaneously, the system merges what would otherwise require multiple sequential measurements into one operation, dramatically increasing throughput and eliminating time losses between measurements
Solution Approach 2:
The patent segments the captured interferometric image into individual slider surface maps using automated image processing. This segmentation allows each slider to be analyzed independently from a single composite image, enabling 100% sampling of all sliders without requiring separate measurement operations for each one
2Measurement precision
If manual or sequential measurement methods are used, then individual slider flatness can be assessed, but manufacturing efficiency decreases and yield losses increase
Solution Approach 1:
The patent replaces manual or sequential mechanical measurement processes with an automated optical interferometric system. The interferometer captures surface topography data optically, and automated image processing algorithms perform the segmentation and analysis, eliminating manual intervention and sequential operations while maintaining measurement precision
Solution Approach 2:
The patent creates digital copies of slider surfaces through interferometric imaging. These digital surface maps serve as accurate representations of the physical slider surfaces, allowing multiple analyses and measurements to be performed on the digital copies without requiring repeated physical measurements of the actual sliders
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 significantly reduces analysis time and error, enabling 100% sampling of slider flatness in a reduced time frame, improving manufacturing efficiency and reducing yield losses by ensuring uniformity and precision in slider surfaces.
Implementation Method 1
receiving an image of a surface of the slider bar from an interferometer
Data Source
AI summary
A method includes receiving an image of a surface of a slider bar from an interferometer, where the slider bar includes at least two sliders, and where the image includes image data according to at least two image data channels for a slider bar surface and the at least two sliders. The method also includes generating a slider bar map of the surface of the slider bar based upon the image data of the image, where the slider bar map includes at least two data channels and ascertaining a plurality of individual slider surface maps based on a number of sliders included on the slider bar, where the ascertaining is also based upon the slider bar map having the at least two data channels. The method also includes segmenting the slider bar map according to the plurality of individual slider surface maps.