Axial flux permanent magnet motor for ball screw cam elevator mechanism for reduced-head hard disk drive

1. An actuator elevator assembly for a reduced-head hard disk drive (HDD), the assembly comprising:

a ball screw cam assembly;

a head-stack assembly (HSA) translatably coupled with the cam assembly; and

an axial flux permanent magnet (AFPM) motor affixed to a screw of the cam assembly and configured to rotate about a fixed shaft around which the AFPM motor is positioned, to drive rotation of the screw to drive translation of the HSA along an axis of the screw.

2. The actuator elevator assembly of claim 1 , wherein the screw of the cam assembly comprises an upper flange to which an axial permanent magnet rotor of the AFPM motor is affixed.

3. The actuator elevator assembly of claim 2 , wherein the screw and the upper flange are composed of a ferritic stainless steel material.

4. The actuator elevator assembly of claim 2 , further comprising:

an integrated stator-top bracket assembly comprising:

a top actuator elevator assembly bracket comprising a plurality of AFPM motor stator core protrusions extending therefrom, and

a plurality of AFPM motor stator coils each wound around a corresponding stator core protrusion of the plurality of stator core protrusions.

5. The actuator elevator assembly of claim 4 , wherein the top actuator elevator assembly bracket is composed of a soft magnetic composite (SMC) material.

6. The actuator elevator assembly of claim 4 , wherein the top actuator elevator assembly bracket is composed of a ferritic stainless steel material.

7. A hard disk drive comprising the actuator elevator assembly of claim 4 .

8. The actuator elevator assembly of claim 1 , further comprising:

an integrated stator-top bracket assembly comprising:

a top actuator elevator assembly bracket comprising a plurality of AFPM motor stator core protrusions extending therefrom, and

a plurality of AFPM motor stator coils each wound around a corresponding stator core protrusion of the plurality of stator core protrusions.

9. The actuator elevator assembly of claim 8 , further comprising:

a lower inner bearing assembly;

an upper inner bearing assembly; and

a bearing housing coupled with and extending from the upper inner bearing assembly to the lower inner bearing assembly;

wherein an AFPM motor stator comprising a plurality of AFPM motor stator coils each wound around a corresponding stator core protrusion is mounted to an outer diameter of the bearing housing.

10. A hard disk drive comprising the actuator elevator assembly of claim 9 .

11. The actuator elevator assembly of claim 9 , wherein the screw of the cam assembly comprises an annular step structure extending radially inward from an inner diameter of the screw and to which an axial permanent magnet rotor of the AFPM motor is affixed.

12. The actuator elevator assembly of claim 11 , wherein the screw of the cam assembly is composed of a ferritic stainless steel material.

13. A hard disk drive comprising the actuator elevator assembly of claim 1 .

14. The actuator elevator assembly of claim 1 , wherein the ball screw cam assembly comprises:

a hollow screw comprising at least three starts,

a ball bearing assembly comprising a same number of balls as starts, wherein each ball rides in a corresponding start, thereby forming a plane on which the balls ride perpendicular to the axis of the screw.

15. The actuator elevator assembly of claim 1 , further comprising:

one or more proximity sensors coupled with the HSA; and

a magnetic encoder strip positioned in close proximity to the one or more proximity sensors, and configured to provide a magnetic field for sensing by the one or more proximity sensors.

16. A method for vertically translating a head-stack assembly (HSA) in a hard disk drive (HDD) to access multiple magnetic-recording disks, the method comprising:

driving an axial flux permanent magnet (AFPM) motor affixed to a screw of a ball screw cam assembly, thereby rotating the screw about a coaxial fixed shaft;

allowing a planar multi-ball bearing assembly that is coupled with the HSA to translate vertically in response to rotating the screw; and

while the bearing assembly is translating, sensing the vertical position of the HSA.

17. The method of claim 16 , wherein the AFPM motor is affixed to the screw by:

an upper flange, of the screw, to which an axial permanent magnet rotor of the AFPM motor is affixed; and

an integrated stator-top bracket assembly over the rotor and comprising:

a top actuator elevator assembly bracket comprising a plurality of AFPM motor stator core protrusions extending therefrom, and

a plurality of AFPM motor stator coils each wound around a corresponding stator core protrusion of the plurality of stator core protrusions.

18. The method of claim 16 , wherein the AFPM motor is affixed to the screw by:

an annular step structure, extending radially inward from an inner diameter of the screw, to which an axial permanent magnet rotor of the AFPM motor is affixed; and

a bearing housing coupled with and extending between a lower bearing assembly and an upper bearing assembly of the ball screw cam assembly, an outer diameter of the bearing housing to which an AFPM motor stator comprising a plurality of AFPM motor stator coils each wound around a corresponding stator core protrusion is mounted.

19. A reduced-head hard disk drive (HDD), comprising:

recording means for storing digital information;

reading/writing means for reading from and writing to the recording means;

means for moving the reading/writing means to access portions of the recording means;

axial flux permanent magnet (AFPM) motor rotating means for rotating cam means about a fixed shaft for translating the reading/writing means from one recording means to another recording means; and

means for sensing a vertical position of the reading/writing means.