Patent Application
20090153993
This disclosure relates to disk drive testing.
Disk drive manufacturers typically test manufactured disk drives for compliance with a collection of requirements. Test equipment and techniques exist for testing large numbers of disk drives serially or in parallel. Manufacturers tend to test large numbers of disk drives simultaneously in batches. Disk drive testing systems typically include one or more racks having multiple test slots that receive disk drives for testing.
The testing environment immediately around the disk drive is closely regulated. Minimum temperature fluctuations in the testing environment are critical for accurate test conditions and for safety of the disk drives. The latest generations of disk drives, which have higher capacities, faster rotational speeds and smaller head clearance, are more sensitive to vibration. Excess vibration can affect the reliability of test results and the integrity of electrical connections. Under test conditions, the drives themselves can propagate vibrations through supporting structures or fixtures to adjacent units. This vibration “cross-talking,” together with external sources of vibration, contributes to bump errors, head slap and non-repetitive run-out (NRRO), which may result in lower test yields and increased manufacturing costs.
Current disk drive testing systems employ automation and structural support systems that contribute to excess vibrations in the system and/or require large footprints. Current disk drive testing systems also use an operator or conveyer belt to individually feed disk drives to the testing system for testing.
In one aspect, a disk drive testing system includes at least one robotic arm defining a first axis substantially normal to a floor surface. The robotic arm is operable to rotate through a predetermined arc (e.g. 360°) about, and to extend radially from, the first axis. Multiple racks are arranged around the robotic arm for servicing by the robotic arm. Each rack houses multiple test slots that are each configured to receive a disk drive transporter configured to carry a disk drive for testing. A transfer station is arranged for servicing by the robotic arm. The transfer station includes multiple tote receptacles that are each configured to receive a disk drive tote.
Implementations of the disclosure may include one or more of the following features. In some implementations, the robotic arm includes a manipulator configured to engage the disk drive transporter of one of the test slots. The robotic arm is operable to carrying a disk drive in the disk drive transporter to the test slot for testing. The robotic arm defines a substantially cylindrical working envelope volume, and the racks and the transfer station are arranged within the working envelope volume for servicing by the robotic arm. In some examples, the racks and the transfer station are arranged in at least a partially closed polygon about the first axis of the robotic arm. The racks may be arranged equidistantly radially away from the first axis of the robotic arm or at different distances.
In some implementations, the transfer station is operable to rotate about a longitudinal axis defined by the transfer station substantially normal to a floor surface. The transfer station includes a transfer station housing that defines first and second opposite facing tote receptacles. In some examples, the transfer station includes a station housing defining a longitudinal axis, and multiple tote receivers rotatably mounted to rotate about the longitudinal axis. Each tote receiver is independently rotatable of the other and defines first and second opposite facing tote receptacles. In some examples, the tote receivers are rotatably mounted on a spindle extending upwardly substantially normal from a station base.
The robotic arm may independently service each test slot by transferring a disk drive between a received disk drive tote of the transfer station and the test slot. In some implementations, the disk drive tote includes a tote body defining multiple disk drive receptacles configured to each house a disk drive. Each disk drive receptacle defines a disk drive support configured to support a central portion of a received disk drive to allow manipulation of the disk drive along non-central portions. In some examples, the disk drive tote includes a tote body defining multiple column cavities and multiple cantilevered disk drive supports disposed in each column cavity (e.g. off a rear wall of the cavity column), dividing the column cavity into multiple disk drive receptacles that are each configured to receive a disk drive. Each disk drive support is configured to support a central portion of a received disk drive to allow manipulation of the disk drive along non-central portions.
In some implementations, the disk drive testing system includes at least one computer in communication with the test slots. A power system supplies power to the disk drive testing system and may be configured to monitor and/or regulate power to the received disk drive in the test slot. A temperature control system controls the temperature of each test slot. The temperature control system may include an air mover (e.g. a fan) operable to circulate air over and/or through the test slot. A vibration control system controls rack vibrations (e.g. via passive dampening). A data interface is in communication with each test slot and is configured to communicate with a disk drive in the disk drive transporter received by the test slot.
Each rack may include at least one self-testing system in communication with at least one test slot. The self-testing system includes a cluster controller, a connection interface circuit in electrical communication with a disk drive received in the test slot, and a block interface circuit in electrical communication with the connection interface circuit. The block interface circuit is configured to control power and temperature of the test slot. The connection interface circuit and the block interface circuit are configured to test the functionality of at least one component of the disk drive testing system (e.g. test the functionality of the test slot while empty or while housing a disk drive held by a disk drive transporter).
In some implementations, each rack includes at least one functional testing system in communication with at least one test slot. The functional testing system includes a cluster controller, at least one functional interface circuit in electrical communication with the cluster controller, and a connection interface circuit in electrical communication with a disk drive received in the test slot and the functional interface circuit. The functional interface circuit is configured to communicate a functional test routine to the disk drive. In some examples, the functional testing system includes an Ethernet switch for providing electrical communication between the cluster controller and the at least one functional interface circuit.
The disk drive testing system sometimes includes a vision system disposed on the robotic arm to aiding guidance of the robotic arm while transporting a disk drive. In particular, the vision system may used to guide a manipulator on the robotic arm that holds the disk drive transporter to insert the disk drive transporter safely into one of the test slots or a disk drive tote. The vision system calibrates the robotic arm by aligning the robotic arm to a fiducial mark on the rack, test slot, transfer station, and/or disk drive tote.
In another aspect, a disk drive tote includes a tote body defining multiple disk drive receptacles configured to each house a disk drive. Each disk drive receptacle defines a disk drive support configured to support a central portion of a received disk drive to allow manipulation of the disk drive along non-central portions.
In yet another aspect, a disk drive tote includes a tote body defining multiple column cavities and multiple cantilevered disk drive supports disposed in each column cavity (e.g. off a rear wall of the column cavity), dividing the column cavity into multiple disk drive receptacles that are each configured to receive a disk drive. Each disk drive support is configured to support a central portion of the received disk drive to allow manipulation of the disk drive along non-central portions.
In another aspect, a method of performing disk drive testing includes loading multiple disk drives into disk drive receptacles defined by a disk drive tote, and loading the disk drive tote into a tote receptacle defined by a transfer station. The method includes actuating a robotic arm to retrieve a disk drive transporter from a test slot housed in a rack, and actuating the robotic arm to retrieve one of the disk drives from the transfer station and carry the disk drive in the disk drive transporter. The robotic arm is operable to rotate through a predetermined arc about, and to extend radially from, a first axis defined by the robotic arm substantially normal to a floor surface. The method includes actuating the robotic arm to deliver the disk drive transporter carrying a disk drive to the test slot, and performing a functionality test on the disk drive housed by the received disk drive transporter and the test slot. The method then includes actuating the robotic arm to retrieve the disk drive transporter carrying the tested disk drive from the test slot and deliver the tested disk drive back to the transfer station.
In some examples, the method includes actuating the robotic arm to deposit the disk drive transporter in the test slot (e.g. after depositing the tested disk drive in a disk drive receptacle of the disk drive tote). In some examples, delivering the disk drive transporter to the test slot includes inserting the disk drive transporter carrying the disk drive into the test slot in the rack, establishing an electric connection between the disk drive and the rack.
The method may include rotating the received disk drive tote in the transfer station between a servicing position (e.g. a position accessible by an operator) and a testing position accessible by the robotic arm. The transfer station sometimes includes a transfer station housing that defines first and second opposite facing tote receptacles, each configured to receive a disk drive tote.
In some examples, the robotic arm selectively delivers the tested disk drive to a return tote housed by the transfer station. The robotic arm delivers the tested disk drive to a disk drive receptacle of a passed return tote when the tested disk drive successfully passed the functionality testing, and the robotic arm delivers the tested disk drive to a disk drive receptacle of a failed return tote when the tested disk drive failed the functionality testing.
In some implementations, performing a functionality test on the received disk drive includes regulating the temperature of the test slot while operating the disk drive. Also, operating the received disk drive may include performing reading and writing of data to the disk drive. In some examples, the method includes one or more of circulating air over and/or through the test slot to control the temperature of the test slot, monitoring and/or regulating power delivered to the received disk drive, and performing a self-test on the test slot with a self-testing system housed by the rack to verify the functionality of the test slot.
The method may include communicating with a vision system disposed on the robotic arm to aid guidance of the robotic arm while transporting the disk drive. The method may also include calibrating the robotic arm by aligning the robotic arm to a fiducial mark on the rack, test slot, transfer station, and/or disk drive tote recognized by the vision system.
The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
Referring to
The robotic arm 200 may be configured to independently service each test slot 310 to provide a continuous flow of disk drives 500 through the testing system 100. A continuous flow of individual disk drives 500 through the testing system 100 allows random start and stop times for each disk drive 500, whereas systems that require batches of disk drives 500 to be run at once must all have the same start and end times. Therefore, with continuous flow, disk drives 500 of different capacities can be run at the same time and serviced (loaded/unloaded) as needed.
Isolation of the free standing robotic arm 200 from the racks 300 aids vibration control of the racks 300, which only shares the floor surface 10 (see e.g.
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In some implementations, the disk drive testing system 100 includes a transfer station 400, as shown in
The transfer station 400, in some examples, includes a station housing 410 that defines a longitudinal axis 415. One or more tote receivers 420 are rotatably mounted in the station housing 410, for example on a spindle 412 extending along the longitudinal axis 415. Each tote receiver 420 may rotate on an individual respective spindle 412 or on a common spindle 412. Each tote receiver 420 defines first and second opposite facing tote receptacles 430A and 430B. In the example shown, the transfer station 400 includes three tote receivers 420 stacked on the spindle 412. Each tote receiver 420 is independently rotatable from the other and may rotate a received disk drive tote 450 between a servicing position (e.g. accessible by an operator) and a testing position accessible by the robotic arm 200. In the example shown, each tote receiver 420 is rotatable between a first position (e.g. servicing position) and a second position (testing position). While in the first position, an operator is provided access to the first tote receptacle 430A, and the robotic arm 200 is provided access on the opposite side to the second tote receptacle 430B. While in the second position the robotic arm 200 is provided access the first tote receptacle 430A, and an operator is provided access on the opposite side to the second tote receptacles 430B. As a result, an operator may service the transfer station 400 by loading/unloading totes 450 into tote receptacles 430 on one side of the transfer station 400, while the robotic arm 200 has access to totes 450 housed in tote receptacles 430 on an opposite side of the transfer station 400 for loading/unloading disk drives 500.
The transfer station 400 provides a service point for delivering and retrieving disk drives 500 to and from the disk drive testing system 100. The totes 450 allow an operator to deliver and retrieve a batch of disk drives 500 to and from the transfer station 400. In the example shown in
A housing door 416 is pivotally or slidably attached to the transfer station housing 410 and configured to provide operator access to one or more tote receptacles 430. An operator opens the housing door 416 associated with a particular tote receiver 420 to load/unload a tote 450 into the respective tote receptacle 430. The transfer station 400 may be configured to hold the respective tote receiver 420 stationary while the associated housing door 416 is open.
In some examples, the transfer station 400 includes a station indicator 418 which provides visual, audible, or other recognizable indications of one or more states of the transfer station 400. In one example, the station indicator 418 includes lights (e.g. LED's) that indicate when one or more tote receivers 420 need servicing (e.g. to load/unload totes 450 from particular tote receives 420). In another example, the station indicator 418 includes one or more audio devices to provide one or more audible signals (e.g. chirps, clacks, etc.) to signal an operator to service the transfer station 400. The station indicator 418 may be disposed along the longitudinal axis 415, as shown, or on some other portion of the station housing 410.
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With the disk drive 500 in place within the frame 560 of the disk drive transporter 550, the disk drive transporter 550 and the disk drive 500 together can be moved by the robotic arm 200 for placement within one of the test slots 310, as shown in
The disk drives 500 can be sensitive to vibrations. Fitting multiple disk drives 500 in a single test rack 310 and running the disk drives 500 (e.g., during testing), as well as the insertion and removal of the disk drive transporters 550, each optionally carrying a disk drive 500, from the various test slots 310 in the test rack 300 can be sources of undesirable vibration. In some cases, for example, one of the disk drives 500 may be operating under test within one of the test slots 310, while others are being removed and inserted into adjacent test slots 310 in the same test rack 300. Clamping the disk drive transporter 550 to the test slot 310 after the disk drive transporter 550 is fully inserted into the test slot 310, as described above, can help to reduce or limit vibrations by limiting the contact and scraping between the disk drive transporters 550 and the test slots 310 during insertion and removal of the disk drive transporters 550.
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Each rack 300, in some examples, includes at least one functional testing system 650 in communication with at least one test slot 310. The functional testing system 650 tests whether a received disk drive 500, held and/or supported in the test slot 310 by the disk drive transporter 550, is functioning properly. A functionality test may include testing the amount of power received by the disk drive 500, the operating temperature, the ability to read and write data, and the ability to read and write data at different temperatures (e.g. read while hot and write while cold, or vice versa). The functionality test may test every memory sector of the disk drive 500 or only random samplings. The functionality test may test an operating temperature of the disk drive 500 and also the data integrity of communications with the disk drive 500. The functional testing system 650 includes a cluster controller 610 and at least one functional interface circuit 660 in electrical communication with the cluster controller 610. A connection interface circuit 620 is in electrical communication with a disk drive 500 received in the test slot 310 and the functional interface circuit 660. The functional interface circuit 660 is configured to communicate a functional test routine to the disk drive 500. The functional testing system 650 may include a communication switch 670 (e.g. Gigabit Ethernet) to provide electrical communication between the cluster controller 610 and the one or more functional interface circuits 660. Preferably, the computer 320, communication switch 670, cluster controller 610, and functional interface circuit 660 communicate on an Ethernet network. However, other forms of communication may be used. The functional interface circuit 660 may communicate to the connection interface circuit 620 via Parallel AT Attachment (a hard disk interface also known as IDE, ATA, ATAPI, UDMA and PATA), SATA, or SAS (Serial Attached SCSI).
A method of performing disk drive testing includes loading multiple disk drives 500 into a transfer station 400 (e.g. as by loading the disk drives 500 into disk drive receptacles 454 defined by a disk drive tote 450, and loading the disk drive tote 450 into a tote receptacle 430 defined by the transfer station 400). The method includes actuating a robotic arm 200 to retrieve a disk drive transporter 550 from a test slot 310 housed in a rack 300, and actuating the robotic arm 200 to retrieve one of the disk drives 500 from the transfer station 400 and carry the disk drive 500 in the disk drive transporter 550. The robotic arm 200 is operable to rotate through a predetermined arc about, and to extend radially from, a first axis 205 defined by the robotic arm 200 substantially normal to a floor surface 10. The method includes actuating the robotic arm 200 to deliver the disk drive transporter 550 carrying the disk drive 500 to the test slot 310, and performing a functionality test on the disk drive 500 housed by the received disk drive transporter 550 and the test slot 310. The method then includes actuating the robotic arm 200 to retrieve the disk drive transporter 550 carrying the tested disk drive 500 from the test slot 310 and deliver the tested disk drive 500 back to the transfer station 400. In some implementations, the rack 300 and two or more associated test slots 310 are configured to move disk drives 500 internally from one test slot 310 to another test slot 310, in case the test slots 310 are provisioned for different kinds of tests.
In some examples, the method includes actuating the robotic arm 200 to deposit the disk drive transporter 550 in the test slot 310 after depositing the tested disk drive 500 in a disk drive receptacle 454 of the disk drive tote 450, or repeating the method by retrieving another disk drive 500 for testing from another disk drive receptacle 454 of the disk drive tote 450. In some examples, delivering the disk drive transporter 550 to the test slot 310 includes inserting the disk drive transporter 550 carrying the disk drive 500 into the test slot 310 in the rack 300, establishing an electric connection between the disk drive 500 and the rack 300.
In some implementations, the method includes performing a functionality test on the received disk drive 500 that includes regulating the temperature of the test slot 310 while operating the disk drive 500. Operation of the received disk drive 500 includes performing reading and writing of data to the disk drive 500. The method may also include circulating air over and/or through the test slot 310 to control the temperature of the test slot 310, and monitoring and/or regulating power delivered to the disk drive 500.
In some examples, the method includes performing a ‘disk drive’ type and/or ‘test slot only’ type of self-test on the test slot 320 with the self-testing system 600 housed by the rack 300 to verify the functionality of the test slot 310. The ‘disk drive’ type self-test tests the functionality of the disk drive testing system with a received disk drive 500, held and/or supported in the test slot 310 by the disk drive transporter 550. The ‘test slot only’ type of self-test tests the functionality of the test slot 310 while empty.
In some examples, the method includes communicating with the vision system 270 disposed on the robotic arm 200 to aid guidance of the robotic arm 200 while transporting the disk drive 500, which may be carried by a disk drive transporter 550. The method includes calibrating the robotic arm 200 by aligning the robotic arm 200 to a fiducial mark 314 on the rack 300, test slot 310, transfer station 400 and/or tote 450 recognized by the vision system 270.
Other details and features combinable with those described herein may be found in the following U.S. patent applications filed concurrently herewith, entitled “DISK DRIVE TESTING”, with attorney docket number: 18523-062001, inventors: Edward Garcia et al., and having assigned Ser. No. ______, the entire contents of the aforementioned applications are hereby incorporated by reference.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.
