High-reliability automation for hard disk media scrubber
Project snapshot
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Challenge
Increase reliability and throughput while minimizing system impact
A major HDD manufacturer needed to improve the reliability and cleanliness of their media scrubber modules without replacing the entire cleanline. Existing automation dropped disks frequently, had low MTBF due to corrosion and seal failures, and limited throughput. The solution needed to integrate seamlessly with upstream and downstream process stations while maximizing the value of existing equipment and factory layout.
Innovation
Custom media and brush drive system for ultra-reliable cleaning
We developed a high-performance automation solution focused on reliability, cleanliness, and throughput:
- Designed a robust media handoff between cassette and brush, reducing dropped disk rates from 1:1,000 to 1:1,000,000.
- Engineered an innovative brush drive system to improve scrubbing performance and reduce wear.
- Integrated the scrubber module into the existing cleanline without requiring major layout changes.
- Optimized motion sequencing and automation to increase throughput by 20%.
- Delivered full design, build, and system integration in under 20 weeks.
Result
Faster, cleaner, and more reliable HDD media processing
The automated scrubber dramatically improved reliability, cleanliness, and throughput. The fast implementation and robust design allowed the manufacturer to achieve a rapid payback on investment while maintaining compatibility with existing process stations.
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