Method, system, and computer readable medium for septum production

Abstract

A method, system and computer readable medium for producing a diaphragm. In one aspect, data of various process parameters of the diaphragm during production is recorded, and in another aspect, some diaphragm samples are tested after a diaphragm master roll is produced. Since the movement of the continuously produced diaphragm master roll from casting to winding is controllable, the production time of each diaphragm sample and the corresponding process parameter data can be inferred from the position of each diaphragm sample in the diaphragm master roll. Thus, the variation of the diaphragm master roll production process can be evaluated from the sequentially sampled diaphragm samples, and the process parameter data can be adjusted in real time when the process parameter data situation is abnormal, thereby improving the quality of the produced diaphragm.

Description

Technical Field

[0001] This invention relates to diaphragm production, and more specifically to a method, system, and computer-readable medium that integrates a process parameter database and a quality parameter database to adjust the process parameters used in diaphragm production in real time based on changes in process parameter data during production. Background Technology

[0002] Currently, the production processes of many products involve subsystems that collect process parameter data and subsystems that record product quality parameter data. However, these two subsystems operate independently with little correlation. Often, only after a batch of products has been produced are the product quality data and process parameter data compared to determine product quality issues and how the production process should be adjusted. This approach inevitably leads to problems such as low efficiency, high cost, inability to fully grasp changes in product quality, and inability to effectively adjust the production process. Furthermore, it consistently fails to address real-time changes in the production process during production. This is especially true for products requiring multiple process steps or using various process parameters, where the entire production process becomes a black box, making it impossible to analyze the impact of changes in individual process steps or parameter values ​​on the final product quality.

[0003] For example, the separator is a crucial component of a battery, used to isolate the positive and negative electrodes internally, allowing only electrolyte ions to freely pass between them. A typical separator manufacturing process involves multiple steps. After the material is melted, it undergoes sequential processes such as casting, longitudinal stretching, transverse stretching, extraction, shaping, and winding to finally form the required separator master roll. For later application, the separator is cut from the master roll according to the required dimensions. Each process step affects the quality of the resulting separator master roll. However, current technology can only address the combined impact of all process steps on the quality of all resulting separator master rolls after the entire process is completed, and cannot address the real-time impact of each process step on different parts of the separator master roll during manufacturing.

[0004] Therefore, continuous improvements are needed to more efficiently combine quality parameter data with process parameter data, thereby improving the yield rate of products such as diaphragms. Summary of the Invention

[0005] This invention provides a method, system, and computer-readable medium for diaphragm production. Based on the controllable movement of the diaphragm master roll in existing diaphragm production processes, the invention records relevant process parameters during the production process and samples the generated diaphragm master roll to obtain quality parameter data for each sample. Thus, the corresponding process parameters for each sample can be calculated from the position of the diaphragm master roll during production. Furthermore, by analyzing the relationship between the quality parameter data of each sample and the corresponding process parameter data, it is possible to determine how changes in various process parameters during the entire diaphragm master roll production process lead to diaphragm quality degradation, and to analyze the impact of changes in a particular process parameter on diaphragm quality.

[0006] The diaphragm production method provided by this invention includes at least the following basic steps. First, when the production process of the diaphragm master roll begins, data on at least one process parameter of the diaphragm master roll during the production process are acquired. Here, this production process of the diaphragm master roll includes at least the following sequentially performed stages: casting stage, longitudinal stretching stage, transverse stretching stage, extraction stage, shaping stage, and winding stage. Next, when data on at least one quality parameter of the diaphragm master roll during production is required, a diaphragm sample is obtained from a sampling position of the diaphragm master roll during production, and the diaphragm sample is analyzed to obtain data on at least one quality parameter of the diaphragm master roll during production corresponding to the sampling position. Then, based on the movement mode of the diaphragm master roll during production, data on at least one process parameter corresponding to the production time corresponding to the sampling position of the diaphragm master roll during production is calculated. Finally, the at least one process parameter data and the at least one quality parameter data are compared to establish a correspondence.

[0007] Optionally, at least two diaphragm samples can be obtained and analyzed from at least two sampling positions on the diaphragm master roll to obtain data on at least two sets of at least one quality parameter corresponding to the at least two sampling positions on the diaphragm master roll. Then, based on the movement mode of the diaphragm master roll, data on at least two sets of at least one process parameter corresponding to the at least two production times at the at least two sampling positions on the diaphragm master roll are calculated. Finally, a correspondence model is established by comparing the at least two sets of at least one process parameter data with the at least two sets of at least one quality parameter data.

[0008] Alternatively, by analyzing this correspondence model, the quality of the diaphragm master roll can be correlated with the diaphragm master roll production process. By analyzing the impact of at least one process parameter on at least one quality parameter, the causes affecting the quality of the diaphragm master roll can be identified.

[0009] Alternatively, based on the correspondence model, when the data of at least one process parameter in a certain set of process parameters becomes abnormal, the data of at least one process parameter in the production process of this diaphragm master roll can be modified in real time. In other words, the condition of the production line can be corrected and adjusted in real time when a problem occurs on the production line.

[0010] Optionally, when the start time of this diaphragm master roll is To and the distance from a quality inspection position to the start position of this diaphragm master roll is x, when the distance from a process parameter acquisition position to the end of the winding stage of this diaphragm master roll and the average speed are La and Vo respectively, and when the distance from the process parameter acquisition position to the end of the longitudinal stretching stage of this diaphragm master roll is Lm, the time tp when the quality inspection position passes through the data acquisition point is... Where x1 represents the production line distance from the quality inspection point to the data acquisition point when the starting position of this diaphragm master roll is at this data acquisition point during the production process, v1 represents the average speed of this diaphragm on the production line in segment x1, and when this data acquisition point is before the diaphragm begins longitudinal tensile deformation, x1 = x / α, and when this data acquisition point is after the diaphragm begins longitudinal tensile deformation, x1 <= L m When x1 = x, and when x1 > L m When x1 = L m +(xL m ) / α, where α represents the stretching ratio of the longitudinal stretching process section.

[0011] Alternatively, in a typical production line, the commonly used value for α is 4.

[0012] Alternatively, multiple diaphragm samples with different contours and sizes can be obtained from the produced diaphragm master roll, according to the different requirements for diaphragm samples when testing different quality parameter data.

[0013] Alternatively, when acquiring data for at least one quality parameter of the diaphragm master roll each time, the number of diaphragm samples obtained is greater than or equal to the number of devices used to measure the quality parameter data.

[0014] Alternatively, the possible types of process parameters may include, but are not limited to, temperature, humidity, pressure, speed, flow rate, and torque.

[0015] Alternatively, the possible types of quality parameters may include, but are not limited to, porosity, air permeability, puncture strength, tensile strength, thermal shrinkage, and electrochemical properties.

[0016] The diaphragm production system proposed in this invention includes at least a process parameter data measurement assembly, a quality parameter data measurement assembly, and a processor. The process parameter data measurement assembly is used to measure data of at least one process parameter at at least one stage of the diaphragm master roll production process. The quality parameter data measurement assembly is used to obtain data of at least one quality parameter from at least one sampling position of the diaphragm master roll during the diaphragm master roll production process. The processor is used to receive the at least one process parameter data and the at least one quality parameter data, and execute computer program code to process the at least one process parameter data and the at least one quality parameter data, thereby implementing the basic steps and various optional variations of the diaphragm production method proposed in this invention.

[0017] The present invention provides a computer-readable medium for diaphragm production, which stores computer program code so that when the computer program code is executed by a processor, the basic steps and various optional variations of the diaphragm production method proposed in the present invention are implemented.

[0018] This invention offers at least the following advantages. First, by utilizing the controllable movement of the diaphragm master roll in existing diaphragm manufacturing processes, process parameter databases and quality data databases can be integrated in real time without the need for additional devices. Since the movement speed and distance of the diaphragm master roll are known from the start of its movement, the production time of each sample within the entire diaphragm master roll process can be estimated from its different positions within the roll. Therefore, the process parameter data corresponding to each sample during its production process can be obtained, and thus correlated with the quality parameter data of each sample. Furthermore, by processing several samples, a correspondence model between multiple sets of process parameter data and multiple sets of quality parameter data can be established, allowing for the analysis of the impact of changes in the manufacturing process on the produced diaphragm master roll. Therefore, if problems occur during production, they can be detected early by intermittently taking samples during production, rather than waiting until the entire diaphragm master roll is manufactured before inspection. Furthermore, through the established correlation model, it is possible to determine in real time which process parameters are causing the problem and immediately determine how to adjust these parameters. Additionally, since the diaphragm master roll needs to be cut to form various diaphragms with their own contours and sizes after manufacturing, intermittently taking portions from the diaphragm master roll as diaphragm samples will not negatively affect the formed diaphragms. Attached Figure Description

[0019] Figures 1A to 1C This is a flowchart illustrating some embodiments of the diaphragm production method proposed in this invention;

[0020] Figures 2A to 2B For illustrative purposes only, some details of the invention are presented.

[0021] Figure 3 The diagram illustrates an embodiment of the diaphragm production system proposed in this invention.

[0022] Component labeling explanation

[0023] Steps 101, 102, 103, 104, 105, 106…

[0024] 30…Diaphragm Production System

[0025] 301…Process Parameter Data Measurement Assembly

[0026] 302… Quality Parameter Data Measurement Assembly

[0027] 303… processor Detailed Implementation

[0028] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0029] like Figure 1A As shown, one embodiment of the present invention provides a diaphragm manufacturing method, comprising the following basic steps. First, as shown in step block 101, when the production process of the diaphragm master roll begins, data of at least one process parameter of the diaphragm master roll at at least one stage of the production process is acquired. Next, as shown in step block 102, when data of at least one quality parameter of the diaphragm master roll is required, a diaphragm sample is obtained from a sampling position of the diaphragm master roll, and the diaphragm sample is analyzed to obtain data of at least one quality parameter of the diaphragm master roll corresponding to this sampling position. Then, as shown in step block 103, based on the movement mode of the diaphragm master roll during the production process, data of at least one process parameter corresponding to a certain production time at this sampling position of the diaphragm master roll is calculated. And, as shown in step block 104, the at least one process parameter data and the at least one quality parameter data are compared to establish a correspondence.

[0030] In other similar embodiments, the above-described embodiment, which establishes a correspondence from a single diaphragm sample, can be extended to establish a correspondence model starting from multiple diaphragm samples located at different positions on the diaphragm master roll. For example, at least two diaphragm samples can be obtained from at least two sampling positions on the diaphragm master roll, and these at least two diaphragm samples can be analyzed to obtain data on at least one quality parameter from at least two sets corresponding to the diaphragm master roll at these at least two sampling positions. Next, based on the movement of the diaphragm master roll during the production process, data on at least one process parameter from at least two sets corresponding to at least two production times at these at least two sampling positions on the diaphragm master roll can be calculated. Finally, a correspondence model is established by comparing the at least one process parameter data from these at least two sets with one quality parameter data from these at least two sets. That is, steps 102 to 104 can be repeated to extend the correspondence into a correspondence model.

[0031] Therefore, as Figure 1B and Figure 1C As shown, the diaphragm production method provided in other embodiments of the present invention further includes other basic steps. For example, after step 104, step 105 can be performed to analyze the correspondence model and correlate the quality of the diaphragm master roll with the production process of the diaphragm master roll, thereby finding the cause affecting the quality of the diaphragm master roll by analyzing the influence of at least one process parameter data on at least one quality parameter data. Or, after step 104, step 106 can be performed, which further includes, based on the correspondence model, modifying the data of at least one process parameter in the production process of the diaphragm master roll in real time according to the changes in the data of at least one process parameter during the production process of the diaphragm master roll.

[0032] It is particularly important to emphasize that since the various process parameters of the diaphragm master roll are recorded based on the production time of the diaphragm master roll, and the various quality parameters of the diaphragm master roll are recorded based on the position of the sampled diaphragm sample on the diaphragm master roll, the movement of the diaphragm master roll is controllable. For example, its movement speed can be continuously monitored. By observing how the moving distance of the sampled portion of the diaphragm master roll before sampling accumulates over time, the quality parameters of the sampled sample can be correlated with the corresponding process parameters. For example, if the distance from a diaphragm sample sampling position to the starting position of the diaphragm master roll is x, the starting time of the diaphragm master roll is To, the distance and average speed from the previous data acquisition position to the end of the winding stage in the production process are La and Vo, respectively, and the distance from the current data acquisition position to the end of the longitudinal stretching stage is Lm, then the time tp when this quality detection position passes the data acquisition position is... Here, La and Vo can be calculated from data acquired by the data acquisition platform. Here, x1 represents the production line distance from the quality inspection point to the data acquisition point when the diaphragm roll starts at this data acquisition point during production; v1 represents the average speed of the diaphragm on the production line in segment x1. Furthermore, when the data acquisition point is before the diaphragm begins longitudinal tensile deformation, x1 = x / α; and when the data acquisition point is after the diaphragm begins longitudinal tensile deformation, x1 <= L. m When x1 = x, and when x1 > L m When x1 = L m +(xL m ) / α, where α represents the stretching ratio of the longitudinal stretching process, which is usually related to the diaphragm stretching degree. In a typical production line, the commonly used value for α is 4. Of course, the correspondence between process parameter data and quality parameter data at other data collection points can also be calculated in the same way. Here, Figure 2A Here is an example where several data collection points for process parameters are located in the casting stage, the longitudinal stretching stage, and the extraction stage, and the distance from each collection point to the end of the winding stage is indicated by different combinations of codes.

[0033] For example, if the winding stage of a diaphragm master roll begins at 08:00:00, and the distance from a data acquisition point P on the production line to the end of the production line is 600m, and the distance to the longitudinal stretching stage is 100m, then a diaphragm sample quality inspection position P can be selected 200m away from the starting position of the diaphragm master roll. Based on the above calculation, the average speed from point P to the end of the production line is 55m / min. When the diaphragm master roll starts at point P, the average speed from the quality inspection point to point P is 30m / min. Therefore, the time it takes for the starting position of the diaphragm master roll to pass through point P is 08:10:54. Since 600 / 55 equals 10.9, approximately 10 minutes and 54 seconds, the distance from the quality inspection point to point P is 125m (because 100 + (200-100) / 4 equals 125). Similarly, based on the above content, we can calculate that the time when the quality inspection point passes through the collection point P is 08:15:04, because 08:15:04 equals 08:10:54 + 125 / 30.

[0034] Generally, commercial data acquisition platforms such as Apache Flume, Fluentd, Logstash, Chukwa, Scribe, and SplunkForwarder can be used to receive process and quality parameter data for these diaphragm master rolls. The production process of the diaphragm master roll includes at least the following sequential stages: casting, longitudinal stretching, transverse stretching, extraction, setting, and winding. The collected process parameters can include temperature, humidity, pressure, speed, flow rate, and torque during the production process, as well as other unlisted process parameters. This invention does not limit these variations. Furthermore, the type of sensor used to collect the process parameter data—whether it is continuous measurement or measurement at fixed time intervals—is also not limited.

[0035] When it is necessary to obtain quality parameter data of the diaphragm master roll, a unit inspection method is often used, which involves cutting a diaphragm sample at a known distance from the starting position of the diaphragm master roll during the winding stage, or multiple diaphragm samples at different known distances, and then transferring them to the corresponding quality inspection unit for inspection using a robotic arm. For example, Figure 2B As shown, depending on the equipment used to measure the quality parameters of the diaphragm samples, different diaphragm samples often have their own profiles and dimensions. Generally, the number of diaphragm samples selected must exceed the number of testing devices, because the same diaphragm sample often needs to be repeatedly tested for different quality parameters. For example, the quality parameters to be measured can be, but are not limited to, porosity, permeability, puncture strength, tensile strength, thermal shrinkage, and electrochemical properties. This invention does not need to limit these details, nor does it need to limit other details, such as the communication protocol used by the devices for measuring these process parameters and the devices for measuring the diaphragm sample quality parameters to transmit the measurement results to the data acquisition platform via the Internet of Things.

[0036] Another embodiment of the present invention provides a diaphragm production system. For example... Figure 3As shown, the diaphragm production system 30 includes at least a process parameter data measurement assembly 301, a quality parameter data measurement assembly 302, and a processor 303. The process parameter data measurement assembly 301 can measure data of at least one process parameter at at least one stage of the diaphragm master roll 300 production process. Clearly, the process parameter data measurement assembly 301 includes at least one or more measuring devices for measuring one or more process parameter data, and a communication device for transmitting the measured process parameter data. The quality parameter data measurement assembly 302 can obtain data of at least one quality parameter from at least one sampling position of the diaphragm master roll during the diaphragm master roll production process. Clearly, the quality parameter data measurement assembly 302 includes at least one or more measuring devices for measuring one or more quality parameter data, and a communication device for transmitting the measured quality parameter data. Here, the various measuring devices used in the process parameter data measurement assembly 301 and the quality parameter data measurement assembly 302 depend on the specific process and quality parameters to be measured. For example, a thermometer and hygrometer might be used to measure temperature and humidity, while a puncture strength meter and a tensile strength meter might be used to measure puncture strength and tensile strength. The various communication devices used in the process parameter data measurement assembly 301 and the quality parameter data measurement assembly 302 could be IoT devices, Bluetooth devices, Ethernet cables, or even electrical cables. The processor 303 can receive at least one process parameter data and at least one quality parameter data measured by the process parameter data measurement assembly 301 and the quality parameter data measurement assembly 302, respectively, and further execute computer program code to process them, thereby implementing the basic steps and various variations of the above method embodiments. This includes calculating a correspondence or correspondence model, further identifying the influence of at least one process parameter data on at least one quality parameter to find the cause affecting the quality of the diaphragm master roll, or modifying the data of at least one process parameter in the diaphragm master roll production process in real time when an anomaly occurs in the data of at least one set of quality parameters. The processor 303 can be one or more application-specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DAPDs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, or combinations thereof. The operation of the processor 303 can also be combined with a hard disk or memory to store the measured process parameter data and quality parameter data. This part can be implemented using any existing technology and does not need to be detailed or limited.

[0037] Another embodiment of the present invention provides a computer-readable medium for diaphragm production. It stores computer program code that, when executed by a processor, can implement the basic steps and various variations of the method embodiments described above. The computer-readable medium may contain a propagated data signal containing computer program encoding, for example, on baseband or as part of a carrier wave. This propagated signal may have various forms, including electromagnetic, optical, and so on, or suitable combinations thereof. The computer-readable medium can be any computer-readable medium other than a computer-readable storage medium, which can be connected to an instruction execution system, apparatus, or device to enable communication, propagation, or transmission of a program for use. The program encoding located on the computer-readable medium can be propagated through any suitable medium, including radio, cable, fiber optic cable, radio frequency signals, or similar media, or any combination of the above media.

[0038] It should be noted that, in order to simplify the description of the present application and thus aid in the understanding of one or more embodiments of the invention, the foregoing description of the embodiments of the present application may sometimes combine multiple features into a single embodiment, drawing, or description thereof. However, this disclosure method does not imply that the features required by the subject matter of the application are more numerous than those mentioned in the claims.

[0039] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are sometimes modified by the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are permissible in terms of quantity. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the desired characteristics of individual embodiments.

[0040] The above content involving common knowledge will not be described in detail, as those skilled in the art will understand.

[0041] The above descriptions are merely some specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for producing a diaphragm, comprising: When a production process of a diaphragm master roll is started, data of at least one process parameter of the diaphragm master roll in at least one stage of the production process is obtained, wherein the production process includes at least the casting stage, longitudinal stretching stage, transverse stretching stage, extraction stage, shaping stage and winding stage performed in sequence. When it is necessary to obtain data on at least one quality parameter of this diaphragm mother roll, a diaphragm sample is obtained from the sampling position of this diaphragm mother roll, and the diaphragm sample is analyzed to obtain data on at least one quality parameter of the diaphragm mother roll corresponding to this sampling position. Based on the movement pattern of this diaphragm roll during the production process, calculate the data of at least one process parameter corresponding to a production time at this sampling location of the diaphragm roll; and Compare the data of at least one process parameter with the data of at least one quality parameter to establish a correspondence; When the start time of this diaphragm master roll is To and the distance from the sampling position to the start position of this diaphragm master roll is X, when the distance from the process parameter acquisition position to the end of the winding stage of this diaphragm master roll and the average speed are La and Vo respectively, and when the distance from the process parameter acquisition position to the end of the longitudinal stretching stage of this diaphragm master roll is Lm, then the time tp when the sampling position passes the process parameter acquisition position is... ,in, This represents the production line distance from the sampling point to the process parameter acquisition point when the starting position of this diaphragm master roll is at this process parameter acquisition point during the production process. This indicates that the diaphragm is on the production line. The average speed of the segment, and when this process parameter is collected before the diaphragm begins longitudinal tensile deformation. Furthermore, when this process parameter is collected at the location after the diaphragm begins to undergo longitudinal tensile deformation, then... <= hour = And when > hour ,in This indicates the stretching ratio of the longitudinal stretching process section.

2. The diaphragm production method according to claim 1, characterized in that, Including: At least two diaphragm samples are obtained from at least two sampling locations of the diaphragm mother roll, and the at least two diaphragm samples are analyzed to obtain data on at least one quality parameter of at least two sets corresponding to the at least two sampling locations of the diaphragm mother roll. Based on the movement of this diaphragm roll in this production process, the data of at least one process parameter corresponding to at least two sets of at least two production times corresponding to at least two sampling positions of this diaphragm roll are calculated. and Compare at least one process parameter data from at least two sets with one quality parameter data from at least two sets to establish a correspondence model.

3. The diaphragm production method according to claim 2, characterized in that, It also includes analyzing this correspondence model to correlate the quality of the diaphragm master roll with the production process of the diaphragm master roll, so as to find the reasons affecting the quality of the diaphragm master roll by analyzing the impact of at least one process parameter data on at least one quality parameter data.

4. The diaphragm production method according to claim 2, characterized in that, Furthermore, based on this correspondence model, during the production of the diaphragm master roll, the data of at least one process parameter in the production process of the diaphragm master roll is modified in real time according to the changes in the data of at least one process parameter.

5. The diaphragm production method according to claim 1, characterized in that, The value is 4.

6. The diaphragm production method according to claim 1, characterized in that, Includes at least one of the following: On the produced diaphragm master roll, multiple diaphragm samples with different contours and sizes are obtained according to the different requirements for diaphragm samples when testing different quality parameters; and Each time data for at least one quality parameter of this diaphragm master roll is acquired, the number of diaphragm samples obtained shall not be less than the number of devices used to measure the quality parameter data.

7. The diaphragm production method according to claim 1, characterized in that, Includes one of the following: This process parameter includes at least temperature, humidity, pressure, speed, flow rate, and torque; and This quality parameter includes at least porosity, air permeability, puncture strength, tensile strength, thermal shrinkage, and electrochemical properties.

8. A diaphragm production system, comprising: A process parameter data measurement assembly for measuring data of at least one process parameter at at least one stage of a diaphragm master roll production process; A quality parameter data measurement assembly is used to measure data from a diaphragm master roll during the production process. At least one sampling location of the diaphragm mother roll is used to obtain data for at least one quality parameter; and A processor for executing computer program code to process the received at least one process parameter data and at least one quality parameter data to implement the method as claimed in any one of claims 1-7.

9. A computer-readable medium for diaphragm production, storing computer program code that, when executed by a processor, can implement the method as described in any one of claims 1-7.

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