Data storage device screening heads by verifying defects after defect scan

Description

BACKGROUND

Data storage devices such as disk drives comprise a disk and a head connected to a distal end of an actuator arm which is rotated about a pivot by a voice coil motor (VCM) to position the head radially over the disk. The disk comprises a plurality of radially spaced, concentric tracks for recording user data sectors and servo sectors. The servo sectors comprise head positioning information (e.g., a track address) which is read by the head and processed by a servo control system to control the actuator arm as it seeks from track to track.

FIG. 1 shows a prior art disk format 2 as comprising a number of servo tracks 4 defined by servo sectors 6₀-6_N recorded around the circumference of each servo track. Each servo sector 6_i comprises a preamble 8 for storing a periodic pattern, which allows proper gain adjustment and timing synchronization of the read signal, and a sync mark 10 for storing a special pattern used to symbol synchronize to a servo data field 12. The servo data field 12 stores coarse head positioning information, such as a servo track address, used to position the head over a target data track during a seek operation. Each servo sector 6_i further comprises groups of servo bursts 14 (e.g., N and Q servo bursts), which are recorded with a predetermined phase relative to one another and relative to the servo track centerlines. The phase based servo bursts 14 provide fine head position information used for centerline tracking while accessing a data track during write/read operations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a prior art disk format comprising a plurality of servo tracks defined by servo sectors.

FIG. 2A shows a data storage device in the form of a disk drive according to an embodiment comprising a head actuated over a disk.

FIG. 2B is a flow diagram according to an embodiment wherein defects detected during a defect scan are verified to determine whether the head is defective.

FIG. 3A shows an example drop-in defect on the disk according to an embodiment.

FIG. 3B shows an example drop-out defect on the disk according to an embodiment.

FIGS. 4A-4F show embodiments for detecting defects on the disk according to various embodiments.

FIG. 5A shows an embodiment wherein a drop-in defect detected during the defect scan is determined to be a false defect when verified after the defect scan.

FIG. 5B shows an embodiment wherein a drop-out defect detected during the defect scan is determined to be a false defect when verified after the defect scan.

FIG. 6 is a flow diagram according to an embodiment wherein if the number of drop-in defects detected during the defect scan exceeds a threshold, the head is assumed to be defective.

DETAILED DESCRIPTION

FIG. 2A shows a data storage device in the form of a disk drive comprising a head 16 actuated over a disk 18 comprising a plurality of tracks 20. The disk drive further comprises control circuitry 22 configured to execute the flow diagram of FIG. 2B wherein a defect scan is executed on at least one of the tracks and a log entry is generated when a defect is detected (block 24). After the defect scan, a verify operation is executed for at least two of the detected defects (block 26). When the verify operation detects a false defect (block 28), a counter is incremented (block 30), and whether the head is defective is determined based at least partly on the counter (block 32).

In the embodiment of FIG. 2A, servo tracks 20 are defined by servo sectors 34₀-34_N, where data tracks may be defined at the same or different radial density than the servo tracks 20. The control circuitry 22 processes a read signal 36 emanating from the head 16 to demodulate the servo sectors 34₀-34_N and generate a position error signal (PES) representing an error between the actual position of the head and a target position relative to a target track. A servo control system in the control circuitry 22 filters the PES using a suitable compensation filter to generate a control signal 38 applied to a voice coil motor (VCM) 40 which rotates an actuator arm 42 about a pivot in order to actuate the head 16 radially over the disk 18 in a direction that reduces the PES. The servo sectors 34₀-34_N may comprise any suitable head position information, such as a track address for coarse positioning and servo bursts for fine positioning. The servo bursts may comprise any suitable pattern, such as an amplitude based servo pattern or a phase based servo pattern (FIG. 1).

Any suitable defect scan operation may be executed to detect defects on the disk 18. In one embodiment, the defect scan comprises writing a periodic pattern (e.g., a 2T pattern) to the disk 18, and then reading the periodic pattern to evaluate the resulting sinusoidal read signal 36. The periodic pattern may be written to any suitable segment on the disk, such as a data sector of a data track, or a “wedge” comprising the segment of a track between consecutive servo sectors. In the absence of a defect, the sinusoidal read signal 36 will exhibit an expected amplitude and phase. When the head 16 passes over a defect, the defect will induce a disturbance in the sinusoidal read signal. FIG. 3A illustrates an example disturbance in the sinusoidal read signal due to a drop-in defect, and FIG. 3B illustrates a disturbance in the sinusoidal read signal due to a drop-out defect. In one embodiment, the drop-in defect and the drop-out defect may be detected by comparing the amplitude of the read signal 36 to corresponding thresholds as described in greater detail below.

FIGS. 4A-4F show various embodiments of control circuitry 22 for detecting a defect on the disk, including various defect thresholds which may be configured to any suitable value as well as increased or decreased in order to tune the defect detection accuracy. In one embodiment, the control circuitry 22 implements a single defect detector, and in an alternative embodiment, the control circuitry 22 implements multiple defect detectors that operate in parallel.

In the embodiment of FIG. 4A, the read signal 36 is sampled 46, and the read signal samples filtered by a defect filter 48 having an impulse response matched to a defect signature. When the output 50 of the defect filter 48 exceeds a defect threshold 52 at comparator 54, the defect 56 is detected. In the embodiment of FIG. 4B, the control circuitry 22 comprises an amplitude detector 58 which processes the read signal samples to detect deviations in the amplitude of the read signal. When the output 60 of the amplitude detector 58 falls below a drop-out defect threshold 62 at comparator 64, a drop-out defect 66 is detected. When the output 60 of the amplitude detector 58 rises above a drop-in defect threshold 68 at comparator 70, a drop-in defect 72 is detected. In the embodiment of FIG. 4C, the control circuitry 22 comprises a read channel 74 including a digital data detector for detecting an estimated data sequence from the read signal samples. A number of bit errors 76 is generated relative to the estimated data sequence and the correct data sequence (e.g., by comparing the estimated data sequence to a known data sequence, or by using an error correction code). When the number of bit errors 76 (or symbol errors) exceeds a defect threshold 78 at comparator 80, a defect 82 is detected. In the embodiment of FIG. 4D, the read channel 74 comprises suitable circuitry for generating a least mean square (LMS) error 84 between the read signal samples and expected signal samples. When the LMS error 84 exceeds a defect threshold 86 at comparator 88, a defect 90 is detected. Any suitable component in the read channel 74 may be employed to detect a defect. In the embodiment of FIG. 4E, a phase error 92 is generated by timing recovery circuitry which synchronizes to the read signal samples (e.g., using a phase-locked loop). When the phase error 92 exceeds a defect threshold 94 at comparator 96, a defect 98 is detected. In the embodiment of FIG. 4F, the control circuitry 22 comprises a read channel 100 including servo demodulation circuitry for demodulating the embedded servo sectors 34₀-34_N to generate a position error signal (PES) 102 representing a radial offset of the head 16 from a target track 20. When the PES 102 exceeds a defect threshold 104 at comparator 106, a defect 108 is detected in one or more of the servo sectors.

Regardless as to how a defect on the disk 18 is detected, in one embodiment when a defect is detected it may be due to a defect in the read element of the head 16 rather than to an actual defect on the disk. For example, in one embodiment the head 16 may comprise a magnetoresistive (MR) read element which exhibits a change in resistance in the presence of the magnetic field emanating from the disk, for example, when reading a periodic pattern from the disk during the defect scan. An MR read element may exhibit a defect referred to as baseline popping which is a form of instability (resistance change) due to structural damage, scratches on the active pole, pin layer damage, or improper application of the bias current or voltage. In one embodiment, the read element may exhibit a defective response (e.g., baseline popping) sporadically. Therefore if the control circuitry 22 executed a suitable manufacturing test of the read element to determine whether the head is defective, it may take an extensive amount of time to accurately make the determination. The read element may be stressed in order to expedite the manufacturing test, such as by increasing the bias applied to an MR read element, but stressing the read element may itself damage the read element rendering it defective.

Accordingly, in one embodiment the read element of the head 16 may be evaluated by evaluating the result of a defect scan of the disk. Since the defect scan is typically executed over substantially the entire disk surface, it increases the probability of detecting the sporadic occurrence of read element malfunctions by verifying the detected defects after the defect scan. That is, if a defect detected during the normal defect scan is not again detected during the verification scan, it may be assumed that the detected defect was due to a read element malfunction rather than due to a defect on the disk. This is illustrated in the example of FIG. 5A where during the initial defect scan, a drop-in defect may be detected when the amplitude 110A of the read signal 36 rises above a threshold Th1. During the verification scan, the same area of the disk is read again, and since the resulting amplitude of the read signal 110B does not rise above the threshold Th1, the initially detected defect is considered a false defect not caused by a drop-in defect on the disk but instead caused by a malfunctioning read element. In one embodiment, an initial defect may be scanned multiple times and/or the threshold Th1 adjusted during the verification scan to improve the accuracy in detecting false defects. FIG. 5B shows another example where a drop-out defect may be detected during the initial defect scan when the amplitude 112A of the read signal 36 falls below a threshold Th2. During the verification scan, the same area of the disk is read again, and since the resulting amplitude of the read signal 112B does not fall below the threshold Th2, the initially detected defect is considered a false defect not caused by a drop-out defect on the disk but instead caused by a malfunctioning read element. In one embodiment, when the number of false defects detected during the verification scan exceeds a threshold, the head is determined to be defective and either replaced or disabled (depopulated) in a multi-platter disk drive.

In one embodiment, during the defect scan the signature in the read signal corresponding to a malfunctioning read element may resemble a particular type of defect on the disk. For example, the signature caused by baseline popping of an MR read element may resemble the drop-in defect shown in FIG. 3A. Accordingly, in one embodiment only particular types of defects that are logged during the defect scan may be evaluated during the verification scan. An example of this embodiment is illustrated in the flow diagram of FIG. 6 wherein during a defect scan of multiple tracks on the disk (block 114), when a defect is detected (block 116) a drop-in counter is incremented (block 118) when a drop-in defect is detected (block 117), and a drop-out counter is incremented (block 122) when a drop-out defect is detected (block 120). Other types of defects may be detected with a corresponding counter incremented for each defect type. At block 124 the flow diagram is repeated from block 116 until several of the tracks (e.g., all of the tracks) have been scanned for defects.

If after the defect scan the drop-in counter exceeds a threshold (block 126), the head is determined to be defective (block 128) without performing the verification scan. That is, if there is an excessive number of drop-in defects detected during the defect scan, it is assumed that a significant number of the drop-in defects were caused by a malfunctioning read element and therefore the head is assumed to be defective without needing to perform the verification scan. If the number of drop-in defects is less than the threshold at block 126, then each drop-in defect in the defect log is processed during the verification scan (block 130). When a false drop-in defect is detected during the verification scan (block 132), a false defect counter is incremented (block 134). When all of the drop-in defects have been evaluated (block 136), the false defect counter is compared to a threshold (block 138). If the false defect counter exceeds the threshold, the head is determined to be defective (block 128); otherwise the head passes the verification scan (block 140). In one embodiment, the false defect counter may exceed the threshold during the verification scan and therefore the verification scan may terminate early since the head can be declared defective as soon as the false defect counter exceeds the threshold at block 136. Similarly, the initial defect scan may terminate early if the number of drop-in defects exceeds the threshold since the head may be declared defective as soon as the drop-in counter exceeds the threshold at block 126.

Any suitable control circuitry may be employed to implement the flow diagrams in the above embodiments, such as any suitable integrated circuit or circuits. For example, the control circuitry may be implemented within a read channel integrated circuit, or in a component separate from the read channel, such as a disk controller, or certain operations described above may be performed by a read channel and others by a disk controller. In one embodiment, the read channel and disk controller are implemented as separate integrated circuits, and in an alternative embodiment they are fabricated into a single integrated circuit or system on a chip (SOC). In addition, the control circuitry may include a suitable preamp circuit implemented as a separate integrated circuit, integrated into the read channel or disk controller circuit, or integrated into a SOC.

In one embodiment, the control circuitry comprises a microprocessor executing instructions, the instructions being operable to cause the microprocessor to perform the flow diagrams described herein. The instructions may be stored in any computer-readable medium. In one embodiment, they may be stored on a non-volatile semiconductor memory external to the microprocessor, or integrated with the microprocessor in a SOC. In another embodiment, the instructions are stored on the disk and read into a volatile semiconductor memory when the disk drive is powered on. In yet another embodiment, the control circuitry comprises suitable logic circuitry, such as state machine circuitry.

While the above examples concern a disk drive, the various embodiments are not limited to a disk drive and can be applied to other data storage devices and systems, such as magnetic tape drives, solid state drives, hybrid drives, etc. In addition, some embodiments may include electronic devices such as computing devices, data server devices, media content storage devices, etc. that comprise the storage media and/or control circuitry as described above.

The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure. In addition, certain method, event or process blocks may be omitted in some implementations. The methods and processes described herein are also not limited to any particular sequence, and the blocks or states relating thereto can be performed in other sequences that are appropriate. For example, described tasks or events may be performed in an order other than that specifically disclosed, or multiple may be combined in a single block or state. The example tasks or events may be performed in serial, in parallel, or in some other manner. Tasks or events may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently than described. For example, elements may be added to, removed from, or rearranged compared to the disclosed example embodiments.

While certain example embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the embodiments disclosed herein.