Abstract:
A media processing system for processing media having differing properties, the media processing system having a base. The base has a base radial alignment portion, a base vertical alignment portion, and a base retention portion. A set of removable media clamps is included, where each of the set of removable media clamps is adapted for the differing properties of the media, each removable media clamp has a removable media clamp radial alignment portion for engaging the base radial alignment portion and radially aligning the removable media clamp with the base, a removable media clamp vertical alignment portion for engaging the base vertical alignment portion and vertically aligning the removable media clamp with the base, and a media engagement portion for engaging the media. The retention portion is controllable by the media processing system to selectively retain and release a mounted one of the removable media clamps without manual intervention.

Description:
This application claims all rights and priority to U.S. provisional patent application Ser. No. 61/059,879 filed 2008 Jun. 9. This invention relates to the field of data storage media, such as disk media. More particularly, this invention relates to a system for the automated handling of different sizes of media. 
    
    
     FIELD 
     Background 
     Media for the storage of digital data, such as computer data, is in high demand in the current market. As the term is used herein, media includes disk media such as magnetic disks for hard drives, magnetic disks for floppy drives, and optical disks such as CD and DVD disks. While demand for such media is very high, the demand is only high for media that is relatively reliable and can be provided at a relatively low price. Careful inspection and handling of the media through the fabrication process tends to make the media more reliable. The automation of the handling of the media through such processing tends to make the media less expensive. Thus, robotic handlers have become commonplace in media processing facilities, especially in applications such as testing and inspection. 
     Such media comes in a number of different sizes. These various sizes of media require different sizes of tooling, where the size of the tooling is adapted to the size of the media. For example, a separate and properly sized tool (generally called an end effector herein) is provided to hold each of the different sizes of media to be processed. Therefore, each time a different size of media is processed, a different size of end effector must be swapped out and mounted, which is a time-consuming—and thereby costly—process. 
     Current disk media inspection systems can only accommodate two different sizes of media without requiring human intervention to swap out the end effectors. They do this by having duplicate end effectors of different sizes within each system. Of course, scaling this to additional media sizes means having more and more duplicated end effectors, which runs into a tremendous capital cost. Thus, to handle more than two sizes of media with these systems requires the manual removal of one end effector and the subsequent installation of a different sized end effector. 
     This is accomplished by halting the system, unscrewing or unbolting the end effector, replacing the end effector with a different end effector, and screwing or bolting the new end effector in place. Typically, some type of realignment process must also be completed, due to the nature of the swap-out procedure. Not only is this time consuming and expensive, but improper installation or removal of the end effectors may permanently damage either the end effectors themselves or other parts of the system. The more that the system is subjected to such a manual process, the greater the risk that such damage will occur. 
     What is needed, therefore, is a system that overcomes problems such as those described above, at least in part. 
     SUMMARY 
     The above and other needs are met by a media processing system for processing media having differing properties, the media processing system having a base. The base has a base radial alignment portion, a base vertical alignment portion, and a base retention portion. A set of removable media clamps is included, where each of the set of removable media clamps is adapted for the differing properties of the media, each removable media clamp has removable media clamp radial alignment portion for engaging the base radial alignment portion and radially aligning the removable media clamp with the base, a removable media clamp vertical alignment portion for engaging the base vertical alignment portion and vertically aligning the removable media clamp with the base, and a media engagement portion for engaging the media. The retention portion is controllable by the media processing system to selectively retain and release a mounted one of the removable media clamps without manual intervention. 
     In this manner, the embodiments of the present invention enable quick exchange of removable media clamps having different properties, such as configurations for different sizes of media, with a relatively high degree of precision and repeatability, as generally compared to the manual procedure described above. The embodiments according to the present invention allow the system so equipped to quickly and easily load and unload more than two different sizes of media, and some of the embodiments enable this without the operator having to stop and manually reconfigure the system. 
     In various embodiments according to this aspect of the invention, a robotic arm engages and moves the media within the system. In some embodiments a robotic arm removes a current removable media clamp that is mounted on the base, moves the current removable media clamp to a store of the removable media clamps, selects a new removable media clamp, moves the new removable media clamp to the base, and mounts the new removable media clamp on the base. In some embodiments the same robotic arm performs all these function. In some embodiments the media is disk-based digital data storage media. In some embodiments the differing properties of the media include the size of the media. The media processing system in some embodiments is at least one of an optical measurement system, an electrical measurement system, an optical inspection system, and an electrical inspection system. 
     In some embodiments the base radial alignment portion is a central bore having a chamfered edge and the removable media clamp radial alignment portion is a stub depending from a bottom of the removable media clamp, where the stub is sized to engage within the bore, and the stub has a rounded edge for forming a single line of contact with an inner circumferential surface of the central bore. In some embodiments the base vertical alignment portion is a lip and the removable media clamp vertical alignment portion is a rim, where the lip and the rim engage one another with a sufficient precision so as to form a substantially air tight seal. 
     In some embodiments the retention portion includes ports formed in the base for drawing a vacuum between the base and the removable media clamp, thereby releasably retaining the removable media clamp against the base. In some embodiments the media processing system selectively retains and releases a desired one of the removable media clamps by selectively applying a vacuum between the base and the removable media clamp via the retention portion. In some embodiments the set of removable media clamps includes one removable media clamp sized for each size of media to be processed on the processing system. 
     According to another aspect of the invention there is described a method for mounting a removable media clamp, by providing a base having a central bore and a rim, and a removable media clamp having a stub with a rounded edge and a lip. The removable media clamp is mounted by inserting the stub of the removable media clamp into the central bore of the base such that the rounded edge forms a single line contact between the stub and a circumferential surface of the central bore. The stub and the central bore thereby provide radial alignment between the base and the removable media clamp. The lip of the removable media clamp is rested against the rim of the base, thereby providing vertical alignment between the base and the removable media clamp. A vacuum is selectively provided between the base and the removable media clamp, where the removable media clamp is retained to base when the vacuum is enabled, and the removable media clamp is removable from the base when the vacuum is not enabled. 
     In various embodiments according to this aspect of the invention the step of mounting the removable media clamp is performed by a robotic arm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further advantages of the invention are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein: 
         FIG. 1  is a perspective view a system according to an embodiment of the present invention. 
         FIG. 2  is a perspective cutaway view a system according to an embodiment of the present invention, showing media and a robotic arm. 
         FIG. 3  is a cross-sectional view of a removable media clamp and a base according to an embodiment of the present invention. 
         FIG. 4  is perspective view of a base according to an embodiment of the present invention. 
         FIG. 5  is perspective view of a set or store of removable media clamps for different sizes of media, according to an embodiment of the present invention. 
         FIG. 6  is perspective view of a claw according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments of the present invention generally provide a universal base piece that is manually attached to the system, which base piece engages a variety of different sizes or types of removable media clamps in simplified manner, which in some embodiments requires no operator intervention. Changing a removable media clamp to one that can handle a given size or configuration of media then becomes an operation that can be automatically controlled via the system controller, without the need for any operator intervention. 
     With reference now to  FIG. 1 , there is depicted a media processing system  100 . The system  100  in various embodiments can perform one or more of a number of different operations on the media. For example, the system  100  in various embodiments is a measurement system, an optical inspection system, an electrical inspection system, an etcher, a coater, an exposure system, and so forth. With reference now to  FIG. 2 , there is depicted a robotic handler  102  disposed within the system  100 . The handler  102  has a robotic arm  106  that grasps the media  104  in some manner, and moves it from one place to another within the system  100 . For example the handler  102  can remove the media  104  from a cassette  108  and place the media  104  into a processing portion of the system  100 . When processing is completed, the handler  102  then moves the media  104  back into the cassette  108 . Media  104   a  and  104   b  are different sizes, in that at least a central aperture in the media  104   a  and  104   b  are different diameters. In other embodiments, the outside diameter of the media  104   a  and  104   b  can be of different diameters, for example. 
     With reference now to  FIG. 3 , there is depicted a cross section view of a removable media clamp  10 , which accepts the media  104  from the handler  102 , and holds the media  104  during processing in the system  100 , such as during an inspection or measurement process. The removable media clamp  10  is configured for a certain configuration of media  104 , such as a certain size of media  104  or a certain type of media  104 . For example, the diameter of different removable media clamps  10  can be different sizes, so as to accommodate different sizes of media  104 . In some embodiments, the specific nature of the clamping or grasping mechanism  14  that retains the media  104  to the removable media clamp  10  is different from one removable media clamp  10  to the next, so as to accommodate different sizes or configurations of media  104 . Thus, according to some embodiments of the present invention, the removable media clamp  10  comes in a variety of different configurations, and can be easily swapped out to accommodate different sizes and configurations of media  104 , in some embodiments without any direct intervention by the operator of the system  100 . 
     This simplified or automated swapping process is enabled by the base  12 , to which the removable media clamp  10  mounts. The base  12  is mounted such as by being screwed or clipped or bolted in some manner to the system  100 . The mounting system used for attaching the base  12  to the system  100  is secure enough that it does not require inspection and adjustment with any kind of frequency or regularity. A recess  28  in the base  12  is provided in some embodiments, for engaging the mounting portion of the system  100  to which the base  12  is mounted, and assisting in the proper concentric and vertical alignment of the base  12  to the system  100 . 
     The base  12  is designed to be a mount that releasably engages a variety of different removable media clamps  10 . Thus, with the base  12  affixed to the system  100 , the base  12  can then releasably engage a number of different removable media clamps  10 , a store of which could be provided in a location within the system  100 . 
     The base  12  includes several features that enable the functions and benefits described herein. A central bore  26  is provided in the base  12 , which central bore  26  engages a locating stub  20 , which is disposed on an underside of the removable media clamp  10 . the bore  26  and the stub  20  operate in combination to centrally locate the removable media clamp  10  on the base  12 . The stub  20  has a rounded edge  22 , so that a sharp corner doesn&#39;t bind on the edge of the bore  26  as the stub  20  moves into the bore  26 . Similarly, the bore  26  has a chamfered upper rim, so that the stub  20  slides easily into the bore  26 . Both of these features, the chamfered upper rim and the rounded edge  22 , enable the removable media clamp  10  and the base  12  to engage as desired, even when the alignment between the two during the engagement process is not exact. 
     The rounded edge  22  on the stub  20  also serves another function, in that in some embodiments it provides a single line of contact around the inner circumferential surface of the bore  26 . By having only a single line of contact between the stub  20  and the bore  26 , stiction between the stub  20  and the bore  26  is generally reduced, thereby aiding in the smooth engagement and disengagement of the removable media clamp  10  to and from the base  12 . 
     While the stub  20  and bore  26  are used to align the removable media clamp  10  and the base  12  to one another radially, a lip  16  on the removable media clamp  10  and a rim  24  on the base  12  are used to align the removable media clamp  10  to the base  12  vertically. These two surfaces  16  and  24  in some embodiments are machined with a high degree of precision to engage one another to a very close tolerance. In some embodiments this takes the form of both of the surfaces  16  and  24  being extremely flat. However, in other embodiments the surfaces  16  and  24  are undulating or saw-toothed, but nonetheless engage one another with a very minimal gap between the two. 
     One reason for the high degree of precision between the two surfaces  16  and  24  is so that the exact position of the removable media clamp  10  is known by the system  100 , which information can be programmed into the system  100 . In this manner, the handler  102  doesn&#39;t unintentionally ram the media  104  through the removable media clamp  10 , for example. Another reason for the high degree of precision between the two surfaces  16  and  24  is that it enables a convenient method for retaining the removable media clamp  10  with the base  12 , which method is to draw a vacuum between the removable media clamp  10  and the base  12 , such as through vacuum ports  30 . The vacuum draws the surface  18  of the removable media clamp  10  toward the base  12 , such that the removable media clamp  10  is retained by the base  12 . Further, because of the radial alignment between the removable media clamp  10  and the base  12  as provided by the stub  20  and the bore  26 , and the vertical alignment between the removable media clamp  10  and the base  12  as provided by the lip  16  and the rim  24 , the position of the removable media clamp  10  and the grasping mechanism  14  are known by the system  100 . 
       FIG. 4  is perspective view of the base  12 , providing more detail in regard to the central bore  26 , the vacuum ports  30 , and the rim  24 . Also depicted are threaded holes  32 , such as could be used for bolting the base  12  to the system  100 .  FIG. 5  is a perspective view of a set or store of the removable media clamps  10   a  and  10   b , for different sizes of media  104 , providing additional detail in regard to the stub  20 , the rounded edge  22 , the surface  18 , and the lip  16 . 
     One embodiment of the use of the handler as describe above is now provided. The system  100  is loaded with a cassette  108  of media  104  of a given size, and the operator starts a processing program for the media  104  on the system  100 , such as by selecting the program from a keyboard or touch screen. The system  100  identifies the media  104  by the program that has been selected. The system  100  then determines whether it has the proper removable media clamp  10  loaded in the system  100  for the identified media. If the proper removable media clamp  10  is indeed loaded in the system  100 , then the system  100  processes the media  104  according to the selected program, by removing the media  104  from the cassette  108  with the robotic arm  106 , moving it to proper removable media clamp  10  within the system  100 , performing one or more operations on the media  104 , and returning the media  104  to the cassette  108 . 
     However, if the system  10  determines that the proper removable media clamp  10  for the selected media  104  is not currently installed in the system  100 , then the system  100  can perform an action depending upon whether a manual or an automatic swap of the removable media clamps  10  is to be performed. 
     If the system  100  is only configured for a manual swap of the removable media clamps  10 , then the system  100  signals the operator that a different removable media clamp  10  is required, and stops further processing. In some embodiments the system  100  also configures the elements of the system  100  so that the removable media clamp  10  to be swapped out is disposed in a convenient location for the operator to access. The vacuum that retains the current removable media clamp  10  to the base  12  is cut, so that the operator can easily remove the removable media clamp  10  from the base  12 . The operator then places the desired removable media clamp  10 , which in some embodiments is indicated on a display by the system  100 , and signals to the system  100 , such as through pressing a key, that the desired removable media clamp  10  is in place. The system  100  then restores the vacuum to the base  12 , securing the removable media clamp  10  to the base  12 , moves the base  12  and removable media clamp  10  into the proper position as needed, and continues with the normal processing of the media  104 . 
     In this manner, the removable media clamp  10  is easily and quickly swapped out, without the operator having to unbolt the removable media clamp  10 , bolt a new removable media clamp  10  in place, and perform a calibration of some sort to ensure that the new removable media clamp  10  is properly aligned. The vacuum retention of the removable media clamp  10  against the base  12  removes the need for any bolting and unbolting, and the radial alignment provided by the central bore  26  and the stub  20  and the vertical alignment provided by the lip  16  and the rim  28  remove the need for any calibration and alignment. Thus, the process for swapping the removable media clamp  10  is greatly simplified. 
     In some embodiments the replacement of the removable media clamp  10  is automated. In these embodiments, the system  100  directs the robotic arm  106  to engage a claw  200  that is adapted to grasp, hold, and move various sizes of removable media clamps  10 , using an adjustable jaw  202 . The vacuum to the base  12  is cut, so that the current removable media clamp  10  is not retained to the base  12 . The robotic arm  106  uses the claw  200  to grasp the current removable media clamp  10  and remove it from the base  12 . The robotic arm  106  then moves the removable media clamp  10  to where a store of removable media clamps  10  is disposed. In some embodiments this store is disposed within the system  100 . In other embodiments the store is disposed outside of the system  100 , but within reach of the robotic arm  106 . 
     The robotic arm  106  moves the current removable media clamp  10  into a position within the store where the current removable media clamp  10  can be released from the claw  200  and reside until it is needed again. Once the current removable media clamp  10  has been placed within its position in the store, the robotic arm  106  moves to and grasps the desired removable media clamp  10  in the store, and moves it to the base  12 . The robotic arm  106  moves the desired removable media clamp  10  toward the base  12  in such a manner that the stub  20  of the removable media clamp  10  begins to engage the central bore  26  of the base  12 . The rounded edge  22  of the stub  20  and the chambered edge of the bore  26  enable the removable media clamp  10  and the base  12  to align properly one with another in a radial fashion, without binding, and with allowance for some slight degree of misalignment as the robotic arm  106  moves the removable media clamp  10  onto the base  12 . The robotic arm  106  continues to move the removable media clamp  10  onto the base  12  until the rim  24  engages the lip  16 . 
     Once the rim  24  and the lip  16  are engaged, the system  100  initiates the vacuum through the ports  30 , drawing the removable media clamp  10  onto the base  12  and retaining the removable media clamp  10  in place. Once the desired removable media clamp  10  is attached in this manner to the system  100 , the claw  200  is disengaged from the robotic arm  106 , and the robotic arm  106  is moved to engage the media  104  as desired, and remove it from the cassette  108  for further processing, as described above. In some embodiments separate robotic arms are used for handling the media  104  and for using the claw  200 . 
     In this manner, the interchange of removable media clamps  10  can be automated in the system  100  through software commands, bypassing the need for bring the system  100  down and manual intervention. This makes the interchange of removable media clamps  10  much faster than the manual interchange methods and thereby enables increased yield on the system  100 . Further, the present embodiments provide for more precise handling of the removable media clamps  10 , thereby protecting them from the damage that can otherwise occur through manual handling. 
     The foregoing description of preferred embodiments for this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.