Media noise low-fly height test for a disc drive

Abstract

Method and apparatus for characterizing the flight characteristics of a read/write head. A disc is accelerated to a selected rotational velocity sufficient to aerodynamically support the head. The head is positioned over a portion of the disc non-accessible to customer data and a magnetoresistive element of the read/write is biased using a suitable voltage or current. A media noise landing signature obtained as the element transduces white noise from the surface identifies the head as a low-flying head.

Description

FIELD OF THE INVENTION

[0002] This invention relates generally to the field of magnetic data storage devices, and more particularly, but not by way of limitation, to identifying a low-flying read/write head of a disc drive based on a media noise landing signature.

BACKGROUND

[0003] Disc drives are used for data storage in modern electronic products ranging from digital cameras to computers and network systems. Typically a disc drive includes a mechanical portion and an electronics portion in the form of a printed circuit board assembly that controls functions of the mechanical portion while providing a communication interface to a host being serviced by the disc drive.

[0004] Typically, the mechanical portion, or head-disc assembly, has a disc with a recording surface rotated at a constant speed by a spindle motor assembly and an actuator assembly positionably controlled by a closed loop servo system for use in accessing the stored data. The actuator assembly commonly supports a magnetoresistive read/write head that writes data to and reads data from the recording surface. Normally, the magnetoresistive read/write head uses an inductive element, or writer, to write data to and a magnetoresistive element, or reader, to read data from the recording surface.

[0005] The disc drive market continues to place pressure on the industry for disc drives with increased capacities, higher data rates and lower costs. A key aspect of achieving lower costs is an identification of marginal components as early as practical in the manufacturing process to preclude needless accrual of additional manufacturing costs and costly rework operations in subsequent processes. Additionally, an ability to identify, remove and replace marginal components from a disc drive prior to shipment is an aid in reduction of field failure and warranty expense.

[0006] A critical component of a disc drive is the magnetoresistive read/write head. As each read/write head passes through manufacturing processes in preparation for use in a disc drive, costs associated with those processes accrue and contribute to the overall cost of the disc drive. By measuring characteristics of the read/write head throughout the manufacturing process, defective and marginal read/write heads can be culled from the process before additional costs are needlessly applied.

[0007] Fly height of a read/write head is an important operating characteristic of the read/write head for proper operation of the disc drive. A read/write head with a fly height greater than a specified nominal fly height will typically display poor data transfer characteristics and is generally replaced. However, a read/write head with a fly height less than the specified nominal fly height will typically display good data transfer characteristics and, unless detected, is generally not replaced. An undetected low-fly head within a disc drive poses an increased risk to subsequent failure of the disc drive over the useful life of the disc drive.

[0008] As such, challenges remain and a need persists for effective techniques for determining a low-flying read/write head within a disc drive throughout the disc drive manufacturing process. It is to this and other features and advantages set forth herein that embodiments of the present invention are directed.

SUMMARY OF THE INVENTION

[0009] As exemplified herein, embodiments of the present invention are directed to categorization of a fly height status of a read/write head of a disc drive as either a low-flying read/write head or as a non low-flying read/write head.

[0010] Categorization of the fly height status of the read/write head is based on detection of an occurrence of a media noise landing signature prior to encountering a predetermined rotational velocity threshold. The media noise landing signature is preferably determined from a readback response of the head to white noise (i.e., a readback signal obtained from a nonrecorded region of the disc).

[0011] During a landing procedure, the media noise landing signature is provided by a readback signal generated from white noise present in a magnetic recording surface of a disc of the disc drive. The readback of the white noise present in the recording surface occurs as a disc decelerates from a nominal operating rotational velocity to a stationary state during the landing procedure. The media noise landing signature is formed just prior to the read/write head landing on the disc.

[0012] These and various other features and advantages, which characterize the present invention, will be apparent from a reading of the following detailed description and a review of the associated drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a top plan view of a disc drive that incorporates a read/write head screened for low-fly height.

[0014] FIG. 2 is a functional block diagram of a circuit for controlling operation of the disc drive of FIG. 1 and in determining a fly height status of the read/write head of FIG. 1.

[0015] FIG. 3 is a graphical representation of a typical media noise landing signature of the white noise present in the recording surface read by the read/write head prior to landing on a disc.

[0016] FIG. 4 is a flow chart of a characterization process for characterizing the fly height status of a read/write head of the disc drive of FIG. 1.

[0017] FIG. 5 provides a functional block diagram of a system configured to carry out the routine of FIG. 4 in accordance with preferred embodiments of the present invention.

DETAILED DESCRIPTION

[0018] Referring to the drawings in general, and more particularly to FIG. 1, shown therein is a top view of a disc drive 100, also referred to herein as a data storage device, constructed in accordance with preferred embodiments of the present invention.

[0019] The disc drive 100 includes a basedeck 102 supporting various data storage device components including a spindle motor assembly 104 that supports one or more axially aligned rotatable discs 106 forming a disc stack 108, each disc 106 having at least one, and usually two, recording surfaces 109.

[0020] Adjacent the disc stack 108 is a head stack assembly 110 (also referred to as an actuator assembly) that pivots about a bearing assembly 112 in a rotary fashion. The actuator assembly 110 includes an actuator arm 114 that supports a load arm 116, which in turn supports a read/write head 118 corresponding to the rotatable recording surface 109. The recording surface 109 is divided into concentric information tracks 120 (only one depicted) over which the read/write head 118 is positionably located. The information tracks 120 accommodate head position control information written to embedded servo sectors (not separately depicted).

[0021] Between the embedded servo sectors are data sectors used for storing data in the form of bit patterns. The read/write head 118 includes a reader element (not separately shown) offset radially and laterally from a writer element (not separately shown). The writer element writes data to the concentric information tracks 120 while the reader element controls the positioning of the read/write head 118 relative to the concentric information tracks 120 during write operations. During read operations the reader element reads data from the concentric information tracks 120 for passage to a host (not shown) serviced by the disc drive 100 and for use by a servo control system.

[0022] The term “servoing,” or “position-controlling,” as used herein, means maintaining control of the read/write head 118 relative to the rotating recording surface 109 during operation of the disc drive 100. When servoing to or servoing on a selected information track 120, the actuator assembly 110 is controllably positioned by a voice coil motor assembly 122. The voice coil motor assembly 122 includes an actuator coil 124 immersed in a magnetic field generated by a magnet assembly 126. A pair of steel plates 128 (pole pieces) mounted above and below the actuator coil 124 provides a magnetically permeable flux path for a magnetic circuit of the voice coil motor 122.

[0023] During operation of the disc drive 100, current passes through the actuator coil 124 forming an electromagnetic field, which interacts with the magnetic circuit of the voice coil motor 122, causing the actuator coil 124 to move relative to the magnet assembly 126. As the actuator coil 124 moves, the actuator assembly 110 pivots about the bearing assembly 112, causing the read/write head 118 to move over the rotatable recording surface 109, thereby allowing the read/write head 118 to interact with the information tracks 120 of the recording surface 109.

[0024] To provide the requisite electrical conduction paths between the read/write head 118 and read/write circuitry of the disc drive (not shown), read/write head wires (not shown) affixed to the read/write head 118 are attached to a read/write flex circuit 130. The read/write flex circuit 130 is routed from the load arm 116 along the actuator arm 114 and into a flex circuit containment channel 132 and secured to a flex connector body 134.

[0025] The flex connector body 134 supports the flex circuit 130 during passage through the basedeck 102 and into electrical communication with a printed circuit board assembly (PCBA), (not shown) typically mounted to the underside of the basedeck 102.

[0026] The flex circuit containment channel 132 also supports read/write signal circuitry including a preamplifier/driver (preamp) 136 that conditions read/write signals passed between the read/write circuitry and the read/write head 118. The printed circuit board assembly mounted to the underside of basedeck 102 provides the data storage device read/write circuitry that controls the operation of the read/write head 118, as well as other interface and control circuitry for the disc drive 100.

[0027] Turning to FIG. 2, position-controlling of the read/write head 118 is provided by the positioning mechanism (not separately shown) operating under the control of a servo control circuit 142 programmed with servo control code, which forms a servo control loop.

[0028] The servo control circuit 142 includes a micro-processor controller 144 (also referred to herein as controller 144), a volatile memory or random access memory (VM) 145, a demodulator (DEMOD) 146, an application specific integrated circuit (ASIC) hardware-based servo controller (“servo engine”) 148, a digital to analog converter (DAC) 150 and a motor driver circuit 152. Optionally, the controller 144, the random access memory 145, and the servo engine 148 are portions of an application specific integrated circuit 154.

[0029] Typically, a portion of the random access memory 145 is used as a cache for data read from the information track 120 awaiting transfer to a host connected to the disc drive 100 and for data transferred from the host to the disc drive 100 to be written to the information track 120. The components of the servo control circuit 142 are utilized to facilitate track following algorithms for the actuator assembly 110 (of FIG. 1) and more specifically for controlling the voice coil motor 122 in position-controlling the read/write head 118 relative to the selected information track 120 (of FIG. 1).

[0030] The demodulator 146 conditions head position control information transduced from the information track 120 of the rotatable recording surface 109 to provide position information of the read/write head 118 relative to the information track 120. The servo engine 148 generates servo control loop values used by the controller 144 in generating command signals such as seek signals used by voice coil motor 122 in executing seek commands. Control loop values are also used to maintain a predetermined position of the actuator assembly 110 during data transfer operations.

[0031] The command signals generated by the controller 144 and passed by the servo engine 148 are converted by the digital to analog converter 150 to analog control signals. The analog control signals are used by the motor driver circuit 152 in position-controlling the read/write head 118 relative to the selected information track 120, during track following, and relative to the rotatable recording surface 109 during seek functions.

[0032] In addition to the servo control code program of the application specific integrated circuit 154, control code is also programmed into the application specific integrated circuit 154 for use in executing and controlling data transfer functions between a host 156 and the disc drive 100. Read/write channel electronics 158, operating under control of the controller 144 executing the control code, passes data received from the host 156 to the read/write head 118 for storage on the disc 106 and passes data read by the read/write head 118 from the disc 106 back to the host 156.

[0033] The read/write channel electronics 158 includes a servo variable gain amplifier (SVGA) 160, which amplifies an amplitude of a head position control signal read from the information track 120. The amplified amplitude of the head position control signal, provided by the servo variable gain amplifier 160, is stored in a servo variable gain amplifier register 162 for subsequent release to, and processing by, the servo engine 148.

[0034] It will be recognized that the height (distance) that a given read/write head 118 flies above an associated disc surface will generally depend upon the rotational speed of the discs 106 and the particular characteristics of the head. While all of the heads 118 in a particular disc drive are designed to nominally fly at the same height for a selected rotational speed of the discs 106 (i.e., a nominal operational fly height), some amount of manufacturing variations will tend to be present in a given population of heads.

[0035] Thus, in a given disc drive 100, some heads will tend to fly at a slightly higher than nominal operational fly height while other heads will tend to fly at a slightly lower than nominal operational fly height. The lowest flying head 118 in a disc drive 100 will typically land (i.e., contact the associated disc surface) before the other heads 118 in the drive as the discs 106 are decelerated to rest.

[0036] A particularly low flying head can accordingly pose a long term reliability risk for the drive. Drive manufacturers have employed a number of different methodologies in an attempt to screen for low flying heads during disc drive manufacturing operations.

[0037] The present invention (as embodied herein and as claimed below) provides a novel approach to characterizing the fly height characteristics of a selected head 118 through evaluation of the readback response of the head 118 to white noise (i.e., a readback signal obtained from a nonrecorded region of the associated disc 106).

[0038] As will be recognized, an amplitude of a readback signal obtained from a selected head 118 will generally increase as the head 118 comes into closer proximity to the disc 106. It has been found that a peak amplitude of a readback signal obtained from white noise on the disc 106 will reach a maximum value just prior to the head 118 landing on the disc surface. Thus, monitoring the readback response of a head to white noise provides a distinct media landing noise signature that can be used to accurately determine the fly height characteristics of the head.

[0039] FIG. 3 provides a graphical representation of a readback signal 170 obtained from a selected head 118 of the disc drive 100 in accordance with preferred embodiments of the present invention. The signal 170 is plotted against a disc speed x-axis (in decreasing revolutions per minute, rpm) and a signal amplitude y-axis.

[0040] The signal 170 was obtained as the head 118 was flown over the landing zone (120, FIG. 1). The head 118 had not been previously used to write data to this portion of the disc 106; rather, the white noise exhibited in the signal 170 arose from the existing, substantially randomly directed magnetization of the particles in the magnetic recording layer of the disc 106. The signal 170 was obtained while the head 118 flew in an ambient environment (for example, air) while the disc speed was gradually reduced.

[0041] It will be noted from FIG. 3 that portion 172 of the readback signal 170 represents the response of the head 118 while the head was supported adjacent the disc surface. As the head 118 came into close proximity with the disc 106, an increase in signal amplitude was encountered, culminating in a peak amplitude at point 174. The head then subsequently came into substantially constant contact with the disc 106 at point 176 (and, due to friction forces, the disc 106 decelerated quickly to a full stop). It has been determined that this characteristic media landing noise signature (as shown in FIG. 3) can be used as a reliable and repeatable indicator of the landing characteristics of the head 118.

[0042] Generally, it has been found that higher flying heads tend to land at a lower rpm and lower flying heads tend to land at a higher rpm. By applying a threshold value suitable for the environment in which the discs 106 are rotated, heads that exhibit the peak amplitude above said threshold value can be characterized as insufficiently low flying heads and removed from the manufacturing operation.

[0043] FIG. 4 provides a flow chart for a head flight characterization routine 200, generally illustrative of steps carried out in accordance with preferred embodiments of the present invention. The routine is preferably carried out during manufacturing using a test stand or other suitable test equipment for a population of heads (such as 118). The routine can also be carried out within the confines of a disc drive (such as 100), as desired. Also, the routine can be carried out using an ambient environment or a reduced density environment. The reduced density environment may be obtained by replacing a portion of the ambient atmosphere with an inert gas such as helium. The first head to be tested is selected at step 202, and the associated disc (such as 106) is accelerated at step 204 to a nominal rotational velocity. This results in the generation of an air bearing sufficient to fly the head 118 adjacent the disc surface, as indicated by step 206. The head 118 is moved at step 208 to a position adjacent a region of the disc surface inaccessible for storage of customer data (such as the landing zone 120).

[0044] An appropriate biasing of the head 118 (such as through application of a low level read bias current) is applied at step 210 to enable the head 118 to output a readback signal in response to the white noise of the random magnetization of the disc surface. Monitoring of the readback response of the head is initiated at step 212. At this point, the head 118 will generally provide a baseline response such as shown at portion 172 of signal 170 in FIG. 3.

[0045] The disc surface is next decelerated beginning at step 214 and continuous speed measurements are obtained as the disc surface decelerates to rest. As the head 118 comes closer to the disc surface, a peak amplitude of the media landing noise signature (such as point 174, FIG. 3) will be determined, step 216. This can be carried out by monitoring the output of a digital oscilloscope configured to display the readback response. The peak amplitude can also be determined through sample averaging of adjacent values in the readback signature.

[0046] The associated disc speed S1 corresponding to the peak amplitude is next identified at step 218, and this disc speed is compared to a preselected threshold value ST at step 220. As shown by decision step 222, when the disc speed S1 is found to be greater than the threshold value ST, the head is determined to have unsuitably low flying characteristics and the flow passes to step 224 where the head is replaced or otherwise rejected from the manufacturing operation.

[0047] On the other hand, when the disc speed S1 is less than the threshold value ST, the head is accepted for further operations. The routine then passes to decision step 226 which inquires whether additional heads remain to be tested. If so, the next head is selected at step 228 and the routine is repeated for the next selected head. Finally, when all heads have been tested in turn, the routine ends at step 230.

[0048] In an alternate embodiment, each of the plurality of disc drives (such as 100) are placed in an altitude chamber, the rotational velocity of the disc (such as 106) is maintained at the nominal operating rotational velocity and a white noise present in a recording surface (such as 106) of the disc is read while increasing the effective altitude experienced by the disc drive.

[0049] Upon encountering the media noise landing signature, the effective altitude experienced by the disc drive concurrent with the occurrence of the media noise landing signature is logged for each of the plurality of disc drives of the particular configuration being evaluated. The data are reviewed and a determination is made, taking into consideration any additional margin of safety thought appropriate, regarding an effective altitude threshold, and an effective altitude threshold is set.

[0050] In an additional alternate embodiment, an ambient atmosphere within each of the plurality of disc drives (such as 100) is displaced with a lower density atmosphere, such as helium, at a predetermined rate; rotational velocity of the disc (such as 106) is maintained at substantially the nominal operating rotational velocity; and a white noise present in the recording surface (such as 109) of the disc is read while the ambient atmosphere is displaced. Displacement of the ambient atmosphere with a lower density atmosphere decreases the fly height of the read/write head (such as 118).

[0051] Upon encountering the media noise landing signature, the rate dependent elapse time of the atmosphere displacement procedure is logged for each of the plurality of disc drives of the particular configuration being evaluated. The data are reviewed and a determination is made, taking into consideration any additional margin of safety thought appropriate, and an effective rate dependent elapse time threshold is set.

[0052] FIG. 5 provides a system 300 configured to carry out the routine of FIG. 4 in accordance with preferred embodiments of the present invention. The system 300 includes several components discussed above including the disc 106, head 118, preamp 136 and read/write channel 158 shown in FIG. 2. The system further preferably includes a housing 302 in which at least the head 118 and the disc 106 are disposed, a motor 304 used to rotate the disc 106 at a desired rotational speed, a control circuit 306 which provides overall control of the system 300, and an analysis and display module 308.

[0053] In a preferred embodiment, the system 300 is incorporated into a spin-stand in which multiple discs 106 and heads 118 are supported. In such case the heads 118 are preferably evaluated as part of a servo track writing operation in which the aforementioned servo information is written to the disc surfaces 109. The control circuit 306 in this configuration can comprise a host computer alone or in conjunction with selected circuitry from FIG. 2 configured to carry out the routine of FIG. 4. The module 308 can comprise a monitor of the computer or a separate data acquisition device (such as a digital oscilloscope).

[0054] In an alternative embodiment, the system 300 is embodied within the disc drive 100 so that the housing 302 corresponds to the housing formed by the base deck 102 and top cover 103, the motor 304 corresponds to the spindle motor 104 (FIG. 1) and the control circuit 306 corresponds to the controller 144 (FIG. 2).

[0055] The module 308 can comprise a separate data acquisition device (such as a digital oscilloscope) with test probes placed in electrical communication with appropriate test points on the disc drive printed circuit board assembly to obtain data as shown in FIG. 3. The display module 306 can also be incorporated into the circuitry of FIG. 2 such as by using suitable programming of the controller 144 so that the signature is detected in relation to baseline and peak values from the readback signals obtained from the head 118.

[0056] Accordingly, embodiments of the present invention are generally directed to categorization of a read/write head (such as 118) of a disc drive (such as 100) as a low-flying read/write head or a non low-flying read/write head. The categorization is based on an occurrence of a media noise landing signature (such as 170) occurring prior to an encountering of a predetermined threshold. The media noise landing signature is based on a readback of a white noise present in a recording surface (such as 109) located within a region of the disc inaccessible for storage of customer data. The readback of the white noise present in the recording surface preferably occurs while a disc (such as 106) decelerates from a nominal operating rotational velocity to a stationary state during a landing procedure.

[0057] For purposes of the appended claims, it will be understood that the disclosed structure corresponding to the recited first means comprises the circuitry shown in FIG. 5.

[0058] It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed in the appended claims.

Claims

1. A method for detecting a low-flying read/write head in a disc drive comprising: aerodynamically supporting the head above a magnetic recording surface; biasing a magnetoresistive element of the head; and monitoring for an occurrence of a media noise landing signature response from the biased magnetoresistive element as the head transduces white noise from the magnetic recording surface.

2. The method of claim 1, further comprising decelerating the magnetic recording surface to cause the head to land onto the magnetic recording surface, wherein the media noise landing signature response occurs just prior to said landing of the head onto the magnetic recording surface.

3. The method of claim 1, further comprising: accelerating the disc attached to a spindle of the disc drive to substantially an operating rotational velocity; moving the read/write head to a region of the disc inaccessible for storage of customer data; and detecting the white noise within the region of the disc inaccessible for storage of customer data.

4. The method of claim 3, further comprising steps of: determining the rotational velocity of the disc concurrent with the occurrence of the media noise landing signature; and comparing the determined rotational velocity of the disc concurrent with the occurrence of the media noise landing signature to a predetermined rotational velocity threshold.

5. The method of claim 1, wherein the aerodynamically supporting, biasing and monitoring steps are carried out in an ambient atmosphere.

6. The method of claim 1, further comprising providing placing the head in a reduced density atmosphere having a density less than a density of an ambient atmosphere so that the aerodynamically supporting, biasing and monitoring steps are carried out in said reduced density atmosphere.

7. A method for characterizing fly height of a read/write head in a disc drive by steps comprising: accelerating a disc attached to a spindle of the disc drive to an operating rotational velocity; biasing a magnetoresistive element of the read/write head; reading a white noise response from the head present in a recording surface of the disc; and monitoring for an occurrence of a media noise landing signature response from the biased magnetoresistive element.

8. The method of claim 7, in which the read/write head flies adjacent the disc rotating at substantially the operating rotational velocity, and in which the media noise landing signature is formed prior to the read/write head landing on the disc.

9. The method of claim 7, in which the white noise present in the recording surface is detected by steps comprising: accelerating the disc attached to the spindle of the disc drive to substantially the operating rotational velocity of the disc; developing an air bearing between the read/write head and the rotating disc; moving the read/write head to a region of the disc inaccessible for storage of customer data; and detecting an amplitude of the white noise present in the recording surface within the region of the disc inaccessible for storage of customer data.

10. The method of claim 7, further comprising steps of: decelerating the disc by progressively decreasing rotational velocity increments; identifying the occurrence of the media noise landing signature; determining the rotational velocity of the disc concurrent with the occurrence of the media noise landing signature; and comparing the determined rotational velocity of the disc concurrent with the occurrence of the media noise landing signature to a predetermined rotational velocity threshold to characterize the read/write head as a low-flying read/write head.

11. The method of claim 7, further comprising steps of: decelerating the disc by progressively decreasing rotational velocity increments; and identifying an absence of an occurrence of the media noise landing signature while the rotational velocity of the disc is progressively decreased to a predetermined rotational velocity threshold to characterize the read/write head as a non low-flying read/write head.

12. The method of claim 8, further comprising steps of: decelerating the disc by progressively decreasing rotational velocity increments; monitoring the amplitude of the white noise present in the recording surface within the region of the disc inaccessible for storage of customer data; identifying an occurrence of the media noise landing signature; determining the rotational velocity of the disc concurrent with the occurrence of the media noise landing signature; and comparing the determined rotational velocity of the disc concurrent with the occurrence of the media noise landing signature with a predetermined rotational velocity threshold to characterize the read/write head as a low-flying read/write head.

13. The method of claim 8, further comprising steps of: decelerating the disc by progressively decreasing rotational velocity increments; monitoring the amplitude of the white noise present in the recording surface within the region of the disc inaccessible for storage of customer data; and identifying an absence of an occurrence of the media noise landing signature while the rotational velocity of the disc is progressively decreased to a predetermined rotational velocity threshold to characterize the read/write head as a non low-flying read/write head.

14. A system which detects a low-flying read/write head, comprising: a rotatable magnetic recording surface which establishes fluidic currents during rotation sufficient to aerodynamically support the head adjacent the surface; and first means for determining whether the head operably flies below a predetermined fly height at a selected rotational speed of the surface in relation to a media noise landing signature obtained as the head transduces white noise from the surface.

15. The system of claim 14, wherein the first means further decelerates the surface to cause the head to land onto the magnetic recording surface, and wherein the media noise landing signature response occurs just prior to said landing of the head onto the magnetic recording surface.

16. The system of claim 14, wherein the first means further operates to accelerate the surface to substantially an operating rotational velocity, move the head to a region of the surface inaccessible for storage of customer data, and detect the white noise within the region of the disc inaccessible for storage of customer data.

17. The system of claim 14, further comprising a housing in which the head and the surface are disposed, the housing enclosing an ambient atmosphere so that the head is aerodynamically supported by the ambient atmosphere.

18. The system of claim 14, further comprising a housing in which the head and the surface are disposed, the housing enclosing a reduced density atmosphere having a density less than a density of an ambient atmosphere so that the head is aerodynamically supported by the reduced density atmosphere.