Data storage device calibrating fly height actuator based on laser power for heat assisted magnetic recording

Description

This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 14/253,491, filed on Apr. 15, 2014, entitled “DATA STORAGE DEVICE CALIBRATING FLY HEIGHT ACTUATOR BASED ON LASER POWER FOR HEAT ASSISTED MAGNETIC RECORDING” to Huanxiang Ruan et al., the disclosure of which is incorporated herein by reference.

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 embedded servo sectors. The embedded servo sectors comprise head positioning information (e.g., a track address) which is read by the head and processed by a servo controller to control the velocity of the actuator arm as it seeks from track to track.

Data is typically written to the disk by modulating a write current in an inductive coil to record magnetic transitions onto the disk surface in a process referred to as saturation recording. During readback, the magnetic transitions are sensed by a read element (e.g., a magnetoresistive element) and the resulting read signal demodulated by a suitable read channel. Heat assisted magnetic recording (HAMR) is a recent development that improves the quality of written data by heating the disk surface with a laser during write operations in order to decrease the coercivity of the magnetic medium, thereby enabling the magnetic field generated by the write coil to more readily magnetize the disk surface.

Since the quality of the write/read signal depends on the fly height of the head, conventional heads may comprise an actuator for controlling the fly height. Any suitable dynamic fly height (DFH) actuator may be employed, such as a heater which controls fly height through thermal expansion, or a piezoelectric (PZT) actuator. It is desirable to determine the appropriate DFH setting (e.g., appropriate current applied to a heater) that achieves the target fly height for the head.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B shows a data storage device in the form of a disk drive comprising a disk, a head comprising a laser configured to heat the disk while writing data to the disk, and a fly height actuator (FHA) configured to actuate the head vertically over the disk based on an FHA setting.

FIG. 1C is a flow diagram according to an embodiment wherein a FHA write setting is generated based on a calibrated write laser power and first and second fly height measurements.

FIG. 2 shows an embodiment for generating the FHA write setting based on the calibrated write laser power.

FIG. 3 shows an embodiment wherein a decrease in FHA touchdown settings relative to the write laser power are fitted to a curve (e.g., a line) that may be represented by a polynomial.

FIG. 4A shows an embodiment wherein a fly height is measured at two different laser power settings to generate a delta fly height.

FIG. 4B shows an embodiment for generating the FHA write setting based on the calibrated write laser power and the delta fly height.

FIG. 4C shows an embodiment where a number of curve fitted functions each corresponding to a particular delta fly height are stored in a table which is then indexed by the measured delta fly height for a particular disk drive.

FIG. 5 is a flow diagram wherein a first fly height measured at zero laser power and a second fly height is measured at a nominal laser power in order to generate the delta fly height.

FIG. 6 is a flow diagram according to an embodiment wherein the FHA write setting is adjusted to maintain a substantially constant fly height when calibrating the write laser power.

FIG. 7 is a flow diagram according to an embodiment wherein the data points shown in FIG. 3 may be generated by executing a touchdown procedure within a plurality of non-production disk drives in order to generate a plurality of functions each corresponding to a different delta fly height measurement.

FIG. 8 shows a number of curves representing a fly height relative to the laser power for a plurality of disk drives according to an embodiment.

FIG. 9 shows a number of curves representing a FHA delta touchdown setting relative to the laser power for a plurality of disk drives according to an embodiment.

FIG. 10 shows a nominal FHA delta touchdown setting relative to a delta in the fly height of the head due to a corresponding change in laser power applied to the laser according to an embodiment.

FIG. 11 shows curves for two different production disk drives representing a delta in the fly height of the head relative to the laser power.

DETAILED DESCRIPTION

FIG. 1A shows a data storage device in the form of a disk drive according to an embodiment comprising a disk 2, a head 4 (FIG. 2B) comprising a laser 6 configured to heat the disk 2 while writing data to the disk 2, and a fly height actuator (FHA) 8 configured to actuate the head 4 vertically over the disk 2 based on an FHA setting. The disk drive further comprises control circuitry 10 configured to execute the flow diagram of FIG. 1C, wherein a write laser power applied to the laser during a write operation is calibrated (block 12), a first fly height of the head is measured at a first laser power setting (block 14), and a second fly height of the head is measured at a second laser power setting different from the first laser power setting (block 16). A FHA write setting is generated based on the calibrated write laser power and the first and second fly height measurements (block 18), where the FHA write setting is applied to the FHA during the write operation.

In the embodiment of FIG. 1A, the disk 2 comprises a plurality of servo tracks 20 defined by servo sectors 22₀-22_N, wherein data tracks are defined relative to the servo tracks at the same or different radial density. The control circuitry 10 processes a read signal 24 emanating from the head 4 to demodulate the servo sectors 22₀-22_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. The control circuitry 10 filters the PES using a suitable compensation filter to generate a control signal 26 applied to a voice coil motor (VCM) 28 which rotates an actuator arm 30 about a pivot in order to actuate the head 4 radially over the disk 2 in a direction that reduces the PES. The servo sectors 22₀-22_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.

In the embodiment of FIG. 1B, the head 4 comprises a suitable write element 32, such as an inductive coil, and a suitable read element 34, such as a magnetoresistive element. The head 4 may comprise any suitable laser 6 for heating the disk 2, such as a laser diode, as well as any suitable optics for focusing the light emitted by the laser 6 onto the disk, such as a waveguide and a near field transducer (NFT). In addition, any suitable FHA 8 may be employed, such as a heater that actuates through thermal expansion, or a piezoelectric actuator that actuates through mechanical deflection.

In one embodiment, a laser power applied to the laser 6 during a write operation is calibrated to achieve optimal recording reliability. For example, if the laser power is too low it may result in under saturation of the magnetic media, and if the laser power is too high, it may cause erasure of data recorded in adjacent data tracks. In one embodiment, the calibration procedure involves writing a test pattern to the disk 2 and evaluating a suitable quality metric while reading the test pattern. This process is repeated at different laser powers until the quality metric exceeds a threshold.

Since the fly height of the head also affects the quality of the recorded data, and since the heating effect of the laser 6 on the head 4 decreases the fly height, in one embodiment an FHA write setting is generated based on the calibrated write laser power. FIG. 2 illustrates an embodiment for generating the FHA write setting based on the calibrated write laser power. In this embodiment, the laser power is set to zero (or near zero) so that the write components do not protrude toward the disk 2. The FHA setting is increased from an initial value until a touchdown of the head 4 onto the disk 2 is detected. In one embodiment, a fly height measurement is also generated at each incremental FHA setting in order to generate an FHA actuation curve as shown in FIG. 2. Once touchdown has been detected, the FHA setting is decreased by a backoff value that corresponds to a target fly height during read operations (FHA read setting). In one embodiment, the fly height measurement in the FHA actuation curve that corresponds to the FHA read setting as shown in FIG. 2 becomes a target fly height of a closed-loop feedback system that controls the fly height of the head during read operations.

FIG. 2 also illustrates how the entire actuation curve will decrease by an offset (from the dashed line to the solid line) during write operations due to the heating effect of the laser 6. In order to compensate for this heating effect, the FHA setting is decreased (from the FHA read setting) by a delta based on the calibrated write laser power (WLP) to generate a corresponding FHA write setting as shown in FIG. 2. In one embodiment, the fly height measurement in the FHA actuation curve that corresponds to the FHA write setting becomes a target fly height of a closed-loop feedback system that controls the fly height of the head during write operations. In the example shown in FIG. 2, the fly height target for write operations is higher than the fly height target for read operations due to the fly height offset between the write element 32 and the read element 34. That is, during write operations the write element 32 may fly lower than the read element 34 due to the heating effect of the laser 6 as shown in FIG. 4A. If the fly height of the head is measured relative to the read element 34 (e.g., by reading a periodic pattern from the disk), the higher write fly height target compensates for the fly height offset between the write element 32 and the read element 34. In another embodiment, the fly height of the head may be controlled by applying the FHA write setting shown in FIG. 2 to the FHA 8 using an open-loop control system during write operations.

The delta for decreasing the FHA setting as shown in FIG. 2 may be generated based on the calibrated write laser power in any suitable manner. In one embodiment illustrated in FIG. 3, the touchdown calibration procedure described above may be performed over a range of laser power settings (X1 to X2) and a corresponding decrement in the FHA touchdown setting (−Y1 to −Y2) determined. That is, for each incremental increase in laser power there will be a corresponding decrease in the FHA setting that causes a touchdown event. In one embodiment, the decrease in the FHA touchdown settings relative to the write laser power as shown in FIG. 3 are fitted to a curve (e.g., a line) that may be represented by a polynomial. The delta in the FHA touchdown setting may then be computed as a function of the write laser power, and in one embodiment the delta in the FHA touchdown setting may be used to generate the delta for the FHA write setting shown in FIG. 2. In one embodiment, the range evaluated from X1 to X2 for the WLP settings in FIG. 3 spans the calibrated values that may be employed in each production disk drive (e.g., WLP settings near zero may be ignored since they are not used in a production disk drive and may also exhibit a non-linear relationship with the delta in the FHA touchdown setting).

In one embodiment, applying power to the laser while executing a touchdown operation may damage one or more write components (e.g., the NFT) due to the thermal protrusion of the components toward the disk. Accordingly, in one embodiment the touchdown operation may be executed for a non-production disk drive in order to generate the data points and resulting curve fitted function shown in FIG. 3. The curve fitted function may then be loaded into each production disk drive so that the delta in the FHA write setting may be computed using the function without having to execute a touchdown operation. However, in one embodiment the curve fitted function shown in FIG. 3 may not be an accurate representation for all production disk drives due to manufacturing tolerances when fabricating the heads. For production disk drives where the curve fitted function of FIG. 3 is not an accurate representation, the error in the FHA write setting may degrade the performance of the write operations. Accordingly, in one embodiment a more accurate representation of the curve fitted function of FIG. 3 (or an equivalent thereof) is estimated for each production disk drive while still avoiding the need to execute the touchdown procedure that may damage the write components.

FIG. 4A illustrates an example of this embodiment wherein a delta fly height (ΔFH) measurement is generated based on two laser power settings in order to characterize how the laser power affects the fly height. This ΔFH will vary across disk drives depending on the variances in the fabrication of each head. In one embodiment, the data points shown in FIG. 3 are measured for a plurality of non-production disk drives having a range of different ΔFH measurements. In this manner a plurality of curve fitted functions may be generated each corresponding to a different ΔFH, wherein the curve fitted functions may be stored in a table as shown in FIG. 4C and loaded into each production disk drive. Each production disk drive may then measure the ΔFH for the particular installed head(s), and then generate the delta FHA write setting as shown in FIG. 4B based on the calibrate write laser power (WLP) as well as the function (e.g., in FIG. 4C) corresponding to the ΔFH measured for the production disk drive.

FIG. 5 is a flow diagram according to an embodiment wherein the write laser power for a production disk drive is calibrated (block 36), and an FHA read setting is calibrated by executing a touchdown operation (block 38). In one embodiment, the FHA read setting corresponds to a substantially zero laser power (and zero write current) and therefore there is essentially no damage to the write components due to thermal protrusion when executing the touchdown operation. While applying the FHA read setting to the FHA (block 40), a first fly height of the head is measured at zero laser power and zero write current (block 42), and then a second fly height of the head is measured at a nominal laser power and a nominal write current (block 44). In one embodiment, the nominal laser power and nominal write current are selected so as to ensure the write components of the head will not contact the disk. A delta fly height (ΔFH) measurement and corresponding function is generated (block 46) based on a difference between the first and second fly height measurements such as shown in FIG. 4A. An FHA write setting is then generated based on the calibrated write laser power (WLP) and the ΔFH (block 48) such as illustrated in FIG. 4B.

In one embodiment, the FHA write setting may be adjusted when calibrating the laser power. This embodiment is understood with reference to the flow diagram of FIG. 6 wherein after measuring the ΔFH for a production disk drive (block 50), the laser power is initialized, for example, to a low setting (block 52), and the FHA write setting is initialized based on the initial laser power (block 54). That is, the delta for the FHA write setting shown in FIG. 4B is generated based on the initial laser power and the measured ΔFH. Data is then written to the disk (block 56) and a quality metric of the write operation is generated (block 58) such as by measuring an off-track read capability. If the quality metric indicates a poor write quality (e.g., if the quality metric is less than a threshold at block 60), then the laser power is adjusted, for example, increased (block 62), and the FHA write setting is adjusted based on the adjusted laser power and the measured ΔFH (block 64). The flow diagram is then repeated from block 56 until the quality metric indicates a good write quality (e.g., until the quality metric is greater than the threshold at block 60). In this manner, the laser power is calibrated by evaluating the write quality at different laser power settings while maintaining a substantially constant fly height by making an appropriate adjustment to the FHA write setting as the laser power is adjusted.

As described above, the curve fitted functions shown in FIG. 4C corresponding to different ΔFH measurements may be generated by executing the touchdown operation for a plurality of non-production disk drives. This embodiment is understood with reference to the flow diagram of FIG. 7, wherein a first non-production disk drive is selected (block 66), the ΔFH measured for the disk drive (block 68) as described above, and the laser power initialized, for example, to a low setting (block 70). Data is then written to the disk (block 72) and the FHA setting is adjusted until a touchdown is detected (block 74). If more laser power settings are to be evaluated (block 78), the laser power is adjusted, for example, by increasing the laser power (block 74). Data is again written to the disk (block 72) and the FHA setting is adjusted until a touchdown is detected (block 74). When a sufficient number of data points shown in FIG. 3 have been measured for the current non-production disk drive, the flow diagram of FIG. 7 is repeated after selecting another non-production disk drive (block 82). After measuring the data points of FIG. 3 for a number of non-production disk drives (e.g., at least three), a plurality of functions (one for each ΔFH) for computing the delta FHA touchdown setting relative to the write laser power is generated (block 84). The functions are then loaded into each production disk drive (block 86) where it is used to calibrate the laser power and corresponding FHA write setting by executing the flow diagrams of FIG. 5.

The FHA actuation curve shown in FIGS. 2 and 4B may be generated by measuring the fly height of the head at different FHA settings using any suitable technique. For example, a known technique for measuring the fly height is a harmonic ratio technique (Wallace spacing equation) that measures an absolute head-media spacing (HMS) according to the ratio of the amplitude of the read signal at two different harmonics while reading a periodic pattern from the disk 2 (e.g., a test pattern or a pattern recorded in a servo sector). In one embodiment, this harmonic ratio can be generated by reading a periodic pattern at two different frequencies (e.g., a 2T and 6T pattern).

Although the embodiments are described above as generating a plurality of curve fitted functions (each corresponding to a particular ΔFH) that are loaded into the production disk drives, other techniques may be employed. For example, in one embodiment the array of data points shown in FIG. 3 generated for each ΔFH may instead be loaded into each production disk drive. Each production disk drive may then use the array of data points corresponding to the ΔFH measured for the production disk drive at block 46 of FIG. 5. For example, each production disk drive may generate a curve fitted function, or perform any other suitable operation, such as interpolating between data points or selecting the closest data point for the calibrated WLP. In yet another embodiment, a two-parameter function may be generated which outputs the delta for the FHA write setting based on the two inputs (the calibrated WLP and the measured ΔFH). This two-parameter function may then be loaded into each production disk drive for use in generating the FHA write setting for each production disk drive.

In an embodiment illustrated in FIG. 8, a number of curves representing a fly height of the head relative to the laser power are generated for a plurality of disk drives, such as a plurality of non-production disk drives. In addition to the curves shown in FIG. 8, a number of curves representing a FHA delta touchdown setting relative to the laser power are generated for the plurality of disk drives as shown in FIG. 9. The FHA delta touchdown setting represents a difference between a read touchdown FHA setting and a write touchdown FHA setting at different laser powers. In one embodiment, the curves shown in FIG. 9 are generated for a subset of non-production disk drives rather than in the production disk drives since the touchdown event may damage one or more components of the head. In one embodiment, the curves shown in FIGS. 8 and 9 are processed to generate a first function representing a nominal FHA delta setting between a read touchdown FHA setting and a write touchdown FHA setting relative to a delta in a fly height of the head due to a corresponding change in laser power applied to the laser. An example of this first function is illustrated in FIG. 10 wherein for a change in fly height corresponding to a change in the laser power there is a corresponding change in the FHA touchdown setting. In one embodiment, the first function comprises a second order polynomial such as shown in the example of FIG. 10, but the first function may comprise any suitable form, such as any suitable polynomial. In one embodiment, the nominal function such as shown in FIG. 10 may be generated by generating multiple ΔFHA/Δfly-height curves, each corresponding to one of the disk drives evaluated to generate the curves shown in FIGS. 8 and 9. The multiple ΔFHA/Δfly-height curves may then be averaged in one embodiment to generate the nominal ΔFHA/Δfly-height curve such as shown in FIG. 10.

In one embodiment, the first function representing the nominal curve such as shown in FIG. 10 is loaded into each production disk drive. The control circuitry within each production disk drive then makes at least two fly height measurements at different laser powers, wherein in one embodiment the FHA setting and laser powers are selected to ensure the head does not touchdown on the disk. From the at least two fly height measurements the control circuitry generates a second function representing the delta in fly height of the head relative to the laser power applied to the laser. An example of this second function for two different production disk drives is illustrated in FIG. 11. In this example, the second function comprises a linear function for each production disk drive; however, the second function may comprise any suitable function, such as a suitable polynomial generated by curve fitting the delta in fly height measurements relative to the laser power. In one embodiment, the control circuitry is configured to compute a calibrated delta in the fly height with the calibrated write laser power (at block 12 of FIG. 1C) as an input to the second function (such as shown in FIG. 11). The control circuitry then computes the FHA write setting with the calibrated delta in the fly height as an input to the first function (such as shown in FIG. 10). In the example of FIG. 11, for a particular laser power there may be a different delta in the fly height measurement for each head due to manufacturing tolerances when fabricating the heads. When the delta in the fly height measurement is input into the first function (such as shown in FIG. 10), the first function may generate a different FHA delta touchdown setting for each head. Accordingly, in one embodiment the FHA delta touchdown setting generated using the first function is used to generate the FHA write setting as the read touchdown backoff plus the FHA delta touchdown setting (see FIG. 4B).

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.

In various embodiments, a disk drive may include a magnetic disk drive, an optical disk drive, etc. In addition, 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.