HCL Infosystems Ltd.

Material Handling and ESD

An Introduction to Disk Drives

A disk drive contains a disk that stores information, a motor that rotates the disk, a
magnet, and an actuator with read/ write heads, which magnetically and electronically
read and write information on the disk surface attached to delicate suspension arms.

It works in a similar way to a record player but without a groove in the disk for the read/
write heads to follow.

Instead, the motor is powered up, the disk rotates, and this, in turn, causes the read/
write heads to fly above the disk surface on a cushion of air.

When the drive is non- operational, the heads are situated in the landing zone (like a
car- park for the heads), a non- data area. If there is sudden impact, the heads can
break free from the landing zone, causing damage to both heads and disks.

Many disk drives now use load/ unload technology which enables the head to "park" on
a ramp thus keeping the head out of contact with the disk when the drive is non-
operational. This significantly reduces the likelihood of some types of damage upon
impact. Usually, there is one head for each disk surface on which data is stored. These
heads fly at a height of two or three microns above the disk surface (one micron = one
thousandth of a millimeter). Depending on the type of drive, these disks can rotate up to
10,000 RPM, which means the heads fly at speeds approaching 100 MPH.

Basic Components
Disk: Thin film (usually an aluminum or glass disk, coated with a thin film of magnetic
material) which magnetically records information.

Motor: Resides in the hub (center of the disk); rotates the disk up to 10,000 RPM or
higher.

Actuator (or arm): Moves the heads across the disk surface.

Heads: Dual element - Thin film write and magneto- resistive read heads fabricated on a
"slider" that flies over the disk. No head- to- disk contact during normal operation.

Electronics: Control the operation and interface to the computer.

Causes of Damage
While hard disk drives may be impaired by other factors, they are specifically vulnerable
to damage by shock, vibration, or electrostatic discharge (ESD).

Impact to Disk drive - dropped, shaken, jarred, or bumped.

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Effects of Poor Handling

• Mechanical damage from a 1” drop on hard surface

• Casting " Can affect the air seal, cause contamination, distort casting

• Motor Damage " Causes flat spots on the bearings which can cause vibration,
noise, the inability to stay on- track and possible data errors.

• Head Slap " Causes indents and high spots on the disk surface " Particles can
detach from the head assembly and embed in the disk" Offsets the heads, or
causes data loss

• Actuator Damage " Damages the pivot bearings " Head position changes and
unable to follow track

• Disk Shift " Causes the heads to be off- track " Results in imbalance and inability
to stay on- track

How to Prevent Handling Damage

• Only carry one disk drive in each hand.

• Remove disk drives individually and PLACE them separately onto a cushioned,
grounded surface.

• Always pick up or remove disk drives carefully.

• NEVER stack disk drives.

• Don’t knock or bang benches or trolleys on which disk drives are stored.

• Clearly identify and separate all suspect damaged or faulty disk drives.

• Keep parts in their original packaging until you are ready to use them.

• Take care when removing cables from the disk drives, remove squarely.

Disk Drive Handling Do’s

• Wear ESD protection at all times

• Handle drives One at a Time

• Handle drives by Sides Only

• Pad All drive Work Areas (1" foam w/1/ 4" antistatic pad)

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• Pad All drive Transport Areas (1" foam w/1/ 4" anti- static pad)

• Pad All drive Holding Areas (1" foam w/ 1/ 4" antistatic pad)

• Keep work area clear of anything not needed for the job

• Remove/ Install each drive separately

• Treat drives as you would “Egg” or “Glass Stemware”

• Report any drive that may have been dropped

Disk Drive Handling Don’ts

• Don't Drop Drives (> 1" drop can cause defects)

• Don't Handle drives by the Circuit Board Side

• Don't Contact the drive to hard surfaces

• Don't Stack drives (Even in ESD Bags!)

• Don't Contact drive/ PCB with tooling (drivers, etc.)

• Don't Rush installation - May lead to drive contact

• Don't "SLAM" drive into carrier

• Don't "SEAT" drive with tooling, screw drivers, etc.

• Don't Stand drive on side or end (Tip Hazard)

• Don't Allow drives to contact each other

Precautions
• Regular training of new personnel is paramount

• Take note of how the drives are received - any shipping damage?

• All suspect drives should be clearly marked, (they can be screened and returned
to work- in- progress if no damage is detected)

• Any failed drives need to be treated as if they were new. Failed drives returned to
IBM with handling damage could result in loss of warranty

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• All personnel should be made aware of disk drive handling procedures

• All processes from the RECEIVING DOCK onward should incorporate handling
procedures

• All end- user customers should be made aware of disk drive sensitivity

• If you see potential problem areas, where handling damage is likely to occur,
report it

Electro Static Discharge (ESD)

• Static electricity is an electrical charge at rest on the surface of an object or a
person.

• A static charge stays in place until it has a chance to move.

• ESD is the movement of a static charge from one object to another.

• STATIC ELECTRICITY is a natural phenomenon which occurs in everyday life.

We are all familiar with the effects of static, the shock we get from metal door
handles, clothes which cling together, clicks on records and hair standing on end
after combing.

• Everyone, in our day- to- day lives, at home and at work, creates static.
Whenever there is a movement, an electrostatic charge is created. People are
good conductors of electricity.

• All electronic parts, components, boards and subassemblies can be damaged at

every stage of their life. We rarely see or feel an event which may cause damage
because we only sense the effects of ESD at over 3000V, while devices can be
damaged by as little as 20V.

• Because we can't anticipate the event which will cause damage, we must treat
ALL components as sensitive to ESD at ALL TIMES.

• Only a few components will suffer catastrophic damage where they fail
immediately. For every one of these, it is estimated that 10 will suffer damage but
not be recognized. These are 'latent' failures and are subject to premature failure
in the field.

• ESD is a quality problem and must be regarded as a major factor in the quality
and reliability of products.

• The great problem with ESD is that it is unpredictable, there is no way of knowing
the rate at which the discharge will occur nor what, if any, the resulting damage
will be.

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How and When ESD occurs

Three ways ESD occurs

1. Two conductors with different potentials come in contact

2. Induction from a negatively charged object
3. Induction from a field of high voltage power source

When damage happens and types of damage

1. IMMEDIATE (CATASTROPHIC FAILURE)

Failure occurs at the time of ESD
Causes permanent damage to component

2. LATENT (UPSET FAILURE)

Failure may happen at some future point several days, weeks, months or even
years later
Causes malfunctions but not permanent damage

3. CUMULATIVE (UPSET FAILURE)

Failure is the result of several ESD's over a period of time
Causes malfunctions and can lead to permanent damage

How to Prevent ESD Damage

• Always wear an ESD wrist strap or heel strap, correctly grounded and checked
daily, when handling disk drives

• Avoid touching the connector pins on the drives

• Bench tops — covered with soft foam and anti- static mats connected to ground

• Disk drives should only be transported in closed and labeled ESD containers or
bags

• The ESD protected areas should be free of all items which are not necessary to
the job and free from items made from nonconductive (insulating) material

• Avoid wearing nylon based clothing

• ESD Jackets or smocks recommended

• Only essential staff should be allowed in areas where ESD precautions are
required

• Local ionizers can help limit static voltage build up

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• Induction from a negatively charged object

• Induction from a field of high voltage power source (e. g. a television or CRT.)

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