Secondary battery manufacturing system and secondary battery manufacturing method

Abstract

According to an exemplary embodiment, a secondary battery manufacturing system is provided. The system includes: a server configured to store a roll map including defect data indicating a defect of an electrode roll and reference point data indicating a reference point of the electrode roll; a controller configured to load the defect data and the reference point data from the server; and a reference point sensor configured to generate a reference point sensing signal by sensing a reference point on an electrode sheet unwound from the electrode roll, in which the controller is configured to generate reference point sensing data based on the reference point sensing signal and compare the reference point data with the reference point sensing data.

Description

Technical Field

[0001] The present invention relates to a secondary battery manufacturing system and a secondary battery manufacturing method. This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0078372 filed on Jun. 19, 2023, the entire contents of which are incorporated herein by reference. Background Art

[0002] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. Secondary batteries have been widely used as energy sources for various types of wireless devices (such as handheld devices, laptops, and cordless vacuum cleaners). Recently, the main use of secondary batteries has developed from mobile devices to the mobile field, because the unit capacity manufacturing cost of secondary batteries has been significantly reduced due to improved energy density and economies of scale, and the cruising range of battery electric vehicles (BEVs) has increased to the same level as fuel vehicles.

[0003] Secondary batteries are manufactured through electrode processes, assembly processes, and activation processes. Among these processes, the electrode process is a key process that determines the yield and performance of the battery cell. The electrode process may include a coating process, a rolling process, and a slitting process. In the coating process, active materials and insulating materials may be applied to the surface of the current collector. In the rolling process, the electrode may be pressed by a pressing roller. In the rolling process, the density, performance, and surface quality of the electrode may be determined. In the slitting process, the electrode may be cut into multiple electrodes according to the design of the battery cell. Summary of the invention

[0004] Technical issues

[0005] The present invention is directed to providing a system for performing a manufacturing process of a secondary battery based on a roll map including information on quality and defects in an electrode manufacturing process, and a secondary battery manufacturing method using the system.

[0006] Technical Solution

[0007] An embodiment of the present invention provides a secondary battery manufacturing system. The secondary battery manufacturing system includes: a server configured to store a roll map, the roll map including defect data indicating defects of an electrode roll and reference point data indicating reference points on the electrode roll; a controller configured to load the defect data and the reference point data from the server; and a reference point sensor configured to generate a reference point sensing signal by sensing a reference point on an electrode sheet unwound from the electrode roll, wherein the controller is configured to generate reference point sensing data based on the reference point sensing signal and compare the reference point data with the reference point sensing data.

[0008] The defect data may include a start coordinate of the defect and an end coordinate of the defect, the reference point data may include a stored coordinate of the reference point, and the reference point sensing data may include a sensed coordinate of the reference point.

[0009] The controller may be configured to calibrate the defect data based on the reference point data and the reference point sensing data.

[0010] The controller may be configured to calculate an offset between the stored coordinates of the reference point and the sensed coordinates of the reference point.

[0011] The controller may be configured to calibrate the start coordinate of the defect and the end coordinate of the defect based on the offset.

[0012] The secondary battery manufacturing system may further include a reel controller configured to receive the reference point sensing data and transmit the reference point sensing data to the controller.

[0013] The reference point sensor may be configured to transmit the reference point sensing data to the controller.

[0014] According to an exemplary embodiment, a secondary battery manufacturing method is provided. The secondary battery manufacturing method includes: loading defect data indicating a defect of an electrode roll and reference point data indicating a reference point on the electrode roll; sensing the reference point on an electrode sheet unwound from the electrode roll to collect reference point sensing data; and calibrating the defect data based on the reference point data and the reference point sensing data to generate calibrated defect data.

[0015] The secondary battery manufacturing method may further include discarding a portion of the electrode sheet based on the calibrated defect data.

[0016] The defect data may include coordinates of the defect, the reference point data may include stored coordinates of the reference point, and the reference point sensing data may include sensed coordinates of the reference point.

[0017] The calibration of the defect data may include calculating an offset between the stored coordinates of the reference point and the sensed coordinates of the reference point.

[0018] The calibrating of the defect data may include calibrating start coordinates and end coordinates of the defect data based on the offset.

[0019] Beneficial Effects

[0020] Exemplary embodiments of the present invention provide a system configured to generate a reel map that implements feedback, feedforward, and tracking of an electrode process and perform a secondary battery manufacturing process based on the reel map, and a secondary battery manufacturing method using the same.

[0021] The effects that can be achieved according to the exemplary embodiments of the present invention are not limited to the above-mentioned effects, and other effects not described herein will be clearly derived and understood from the following description by those of ordinary skill in the art to which the exemplary embodiments of the present invention belong. That is, those of ordinary skill in the art can derive from the exemplary embodiments of the present invention the unexpected effects achieved when implementing the exemplary embodiments of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A secondary battery manufacturing system according to an exemplary embodiment is shown.

[0023] Figure 2 is a flowchart of a secondary battery manufacturing method according to an exemplary embodiment.

[0024] Figure 3 A secondary battery manufacturing system according to an exemplary embodiment is shown. DETAILED DESCRIPTION

[0025] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Before describing the embodiments of the present invention, the terms or expressions used in this specification and claims should not be interpreted as limited to those commonly understood or defined in commonly used dictionaries, and should be understood based on the meaning and concept corresponding to the present invention based on the inventor of the present application who can appropriately define the terms or expressions to best explain the principles of the present invention.

[0026] Therefore, the embodiments described herein and the configurations shown in the accompanying drawings are merely embodiments of the present invention and do not reflect all technical ideas of the present invention. Therefore, it should be understood that various equivalent examples and modifications of alternative configurations already exist on the filing date of this application.

[0027] When it is determined that well-known configurations or functions related to describing the present invention will obscure the subject matter of the present invention due to unnecessary detail, such well-known configurations or functions are not described in detail.

[0028] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes, sizes, etc. of the components shown in the drawings may be exaggerated, omitted, or schematically illustrated for clarity. Therefore, it should not be understood that the sizes or ratios of the components fully reflect their actual sizes or ratios.

[0029] (First Embodiment)

[0030] Figure 1 A secondary battery manufacturing system 100 according to an exemplary embodiment is shown.

[0031] refer to Figure 1 The secondary battery manufacturing system 100 may include an unwinder 111, a rewinder 113, a splicing station 115, a waste port 117, a processing device 119, a first rotary encoder 121, a second rotary encoder 125, an NG sensor 131, a reference point sensor 133, a roll map controller 141, a process controller 143, an equipment interface (EIF) 145, a server 150 and a display device 160.

[0032] The secondary battery manufacturing system 100 can be configured to generate a roll map including data about the electrode sheet ES. The roll map can represent the electrode sheet ES based on coordinates indicating positions on the electrode sheet ES. As described below, a secondary battery manufacturing process can be performed on the electrode sheet ES. The roll map may include data representing the history of the process performed on the electrode sheet ES and related to the coordinates. Therefore, the roll map enables feedback, feedforward, and tracking of the secondary battery manufacturing process as described below.

[0033] The first electrode roll ER1 on which the previous process is performed may be loaded into the unwinder 111. The unwinder 111 may unwind the electrode sheet ES from the first electrode roll ER1. The rewinder 113 may wind the electrode sheet ES to form a second electrode roll ER2. The electrode sheet ES may be wound into the second electrode roll ER2, and may be cut and separated after reaching a certain winding length. Therefore, while the current process is being performed, the electrode sheet ES may be moved between the unwinder 111 and the rewinder 113.

[0034] The roll diagram can be generated in batches. A batch is a production unit of a roll-to-roll process, and the second electrode roll ER2 separated for output after reaching the target winding amount is an embodiment of a batch. The first electrode roll ER1 newly loaded on the unwinder 111 is also an embodiment of a batch. Therefore, the server 150 can store the first roll diagram of the previous process. The first roll diagram can correspond to the first electrode roll ER1. In addition, the server 150 can generate and store the second roll diagram of the current process. The second roll diagram can correspond to the second electrode roll ER2.

[0035] A process of manufacturing a secondary battery (eg, an electrode process) may be performed on the electrode sheet ES. The electrode process is performed on the electrode sheet ES unwound from the first electrode roll ER1 and wound into the second electrode roll ER2, and thus may be referred to as a roll-to-roll process.

[0036] In the volume graph, time series data constructed over time (ie, according to process progress) may be correlated with coordinate data based on the movement amount (ie, consumption amount or input amount) of the electrode sheet ES.

[0037] For example, the first roll map may include: defect data DD indicating a defect of the first electrode roll ER1; and reference point data DPD indicating a reference point. The defect data DD may include a defect value indicating whether there is a defect in the first electrode roll ER1 and a defect type and coordinates matched to the defect value. Table 1 below shows an embodiment of the defect data DD.

[0038] [Table 1]

[0039] Starting coordinate m End coordinate m Defect Type 130 150 154 750 800 171

[0040] The numerical values ​​in the third column (i.e., "154" and "171") are code numbers indicating the defect types. The defect types may further include surface defects such as pinhole defects, line defects, pit defects, crack defects, side ring defects, island defects, folding defects, wrinkle defects, dent defects, and scratch defects. The defect types may further include defects determined based on the measurement data, such as mismatch, excessive loading, insufficient loading, excessive thickness, insufficient thickness, insulating coating, and coating overlap. The reference point data DPD may include: a sequence value indicating a sequence of reference points on the electrode sheet ES; and coordinates matching the sequence values. Table 2 below shows an embodiment of the reference point data DPD.

[0041] [Table 2]

[0042] sequence Stored coordinates m 15 120 14 240 13 360 12 480 11 600 10 720 9 840 8 960 7 1080 6 1200 5 1320 4 1440 3 1560 2 1680 1 1800

[0043] The reference points can be formed at equal intervals on the electrode sheet ES. In Table 2, the interval between the reference points is about 120m, but it is provided as an example, and the technical concept of the present invention should not be understood as being limited to this in any sense. The interval between the reference points can be determined according to the requirements for the accuracy of tracking process events on the electrode sheet ES. The rear reference point can be formed after the front reference point. The rear reference point is wound to the outside of the first electrode roll ER1, so it will be assigned relatively small coordinates when the first electrode roll ER1 is unwound. After collecting the reference point data DPD, the coordinates of the reference point data DPD (ie, the starting coordinates and the ending coordinates) can be converted when the electrode sheet ES is wound or unwound. The format for displaying the defect data DD and the reference point data DPD is not limited to the above table. The defect data DD can be in a format that includes a match between a defect value (ie, a defect type) and a coordinate. The reference point data DPD can be in a format that includes a match between a sequence of reference points and coordinates.

[0044] The manufacture of secondary batteries involves a series of different processes, and the previous process affects the subsequent process. In this case, when the time series data of the previous process does not directly match the workpieces, intermediate products and products of the real world, it is difficult to reflect the time series data of the previous process in the subsequent process. Hereinafter, correcting the subsequent process based on the data generated according to the results of the previous process will be referred to as feedforward.

[0045] Here, the workpiece is a product provided as a result of each process, for example, a coating process, a rolling process, and a slitting process. Figure 1 The intermediate product may be one of the diaphragms cut by the slotting process, an electrode and / or its components. The intermediate product may be a structure including a housing and an electrode assembly included in the housing (in some cases, the structure also includes an electrolyte). The product is a product that is processed by an activation process to be used as a secondary battery. The above definitions of workpieces, intermediate products and products are only definitions thereof in one aspect and should not be understood as excluding their general definitions.

[0046] The electrode process of the secondary battery includes a series of roll-to-roll processes. For feedforward, the time series data should be related to the positions on the real-world workpieces, components, intermediate products, and products. Here, the feedforward can include controlling the processing of the electrode sheet based on the roll map of the first electrode roll ER1 generated in the previous process. The roll map can allow the time series data to be related to coordinate data, which includes the coordinates of the positions on the real-world workpieces, components, intermediate products, and products. The roll map can provide a match between the time series data and the real-world workpieces, components, intermediate products, and products based on the coordinate data. Therefore, the feedforward and roll map based on the generation of the roll map can improve production efficiency and quality by digitizing and concretizing various aspects of the process that depend on the operator's judgment.

[0047] The reel map of a previous batch can be used to improve the process of a subsequent batch, and this operation can be called process feedback. Process feedback using the reel map can include identifying process conditions and process parameters that cause problems and defects based on data included in the reel map. For example, a second reel map of a second electrode reel ER2 can be generated by winding an electrode sheet ES processed in the current process, and the processing of subsequent batches can be controlled based on the second reel map.

[0048] In addition, as described below, roll graphs can be cumulatively generated for workpieces of unit processes, intermediate products, and products to track the process history of products on the market (e.g., battery cells, battery modules, or battery packs). For example, a battery cell may include a cell identifier (ID) on an electrode assembly or a housing. The cell ID may include batch numbers and coordinate information of electrodes and diaphragms included in the battery cell. In other words, the cell ID may be associated with a roll graph of electrodes and diaphragms included in the battery cell. Therefore, when an event (e.g., a quality issue) occurs in a battery cell on the market, historical data on the manufacture of the battery cell may be retrieved based on the cell ID.

[0049] The first rotary encoder 121 may be configured to sense the amount of the electrode sheet ES unwound from the first electrode roll ER1 by the unwinder 111. Therefore, the first rotary encoder 121 may be configured to generate an input amount signal UWAS indicating the length of the electrode sheet ES unwound by the unwinder 111. The first rotary encoder 121 may be configured to transmit the input amount signal UWAS to the roll graph controller 141. The roll graph controller 141 may be configured to collect input amount data based on the input amount signal UWAS of the electrode sheet ES.

[0050] The second rotary encoder 125 may be configured to sense the amount of the electrode sheet ES wound into the second electrode roll ER2 by the rewinder 113. Therefore, the second rotary encoder 125 may be configured to generate a consumption signal WAS indicating the length of the electrode sheet ES wound by the rewinder 113. The second rotary encoder 125 may be configured to transmit the consumption signal WAS to the roll graph controller 141. The roll graph controller 141 may be configured to collect consumption data based on the consumption signal WAS of the electrode sheet ES.

[0051] The roll map controller 141 may be configured to collect coordinate data of the electrode sheet ES based on one of the input amount signal UWAS and the consumption amount signal WAS of the electrode sheet ES.

[0052] For example, the winding graph controller 141 can determine the moving distance of the electrode sheet ES from the unwinder 111 based on the input amount signal UWAS of the electrode sheet ES. Therefore, the winding graph controller 141 can be configured to determine the coordinates of the portion of the electrode sheet ES to be unwound by the unwinder 111 on the electrode sheet ES at each time point when the processing device 119 is processed.

[0053] As another embodiment, the winding controller 141 may determine the moving distance of the electrode sheet ES to the rewinder 113 based on the consumption signal WAS of the electrode sheet ES. Therefore, the winding controller 141 may be configured to determine the coordinates of the portion of the electrode sheet ES to be wound by the rewinder 113 on the electrode sheet ES at each time point when the processing device 119 performs processing.

[0054] Hereinafter, the technical idea of ​​the present invention will be described with respect to an embodiment in which the winding controller 141 collects coordinate data based on the input quantity signal UWAS of the electrode sheet ES. When the coordinate data is collected based on the input quantity signal UWAS, the amount of the electrode sheet ES to be unwound can be sensed, and the loss of the electrode sheet ES due to some factors can be accurately determined, such as sampling test of the first electrode roll ER1, movement of the first electrode roll ER1 from the previous process stage to the current process stage, loading of the first electrode roll ER1 on the unwinder 111, connection of part of the electrode sheet ES of the loaded first electrode roll ER1 with part of the electrode sheet ES on the rewinder 113, or the remaining amount due to the inability to unwind the electrode sheet ES.

[0055] According to an exemplary embodiment, the roll image controller 141 may be configured to further collect additional coordinate data based on the consumption signal WAS. In this case, the coordinate data collected based on the input signal UWAS may be used to calibrate the defect data DD and the reference point data DPD transmitted from the roll image of the previous process (i.e., the first roll image of the first electrode roll ER1), and the additional coordinate data collected based on the consumption signal WAS may be used to generate the roll image of the current process (i.e., the completed roll image of the second electrode roll ER2).

[0056] The coordinate data may include coordinates that match each part of the electrode sheet ES. That is, any point on the electrode sheet ES may match the coordinates. The coordinates may be one-dimensional (1D) quantities in the longitudinal direction of the electrode sheet ES, but are not limited thereto. The coordinates may be two-dimensional (2D) quantities in the length direction of the electrode sheet ES and the width direction of the electrode sheet ES.

[0057] The NG sensor 131 may be configured to sense one of an NG mark and an NG label on the electrode sheet ES. The NG mark may be formed by, for example, an inkjet printer, etc., and include information about the location and type of the defect. The NG label may be attached to the electrode sheet ES by an operator or an NG label attachment, and indicates the location of the defect of the electrode sheet ES. As a non-limiting example, the NG sensor 131 may include a vision machine or a color sensor.

[0058] The NG sensor 131 may be configured to generate an NG sensing signal NSS to sense one of an NG mark and an NG label on the electrode sheet. The NG sensor 131 may be configured to transmit the NG sensing signal NSS to the reel controller 141 .

[0059] The reel controller 141 may be configured to collect NG sensing data NSD based on the NG sensing signal NSS and the coordinate data. The reel controller 141 may be configured to collect NG sensing data NSD by associating the NG sensing signal NSS with the coordinate data. The NG sensing data NSD may include, for example: a defect value indicating whether there is a defect and an aspect of the defect; and coordinates matching the defect value.

[0060] In order to collect NG sensing data NSD, the coordinate data may be calibrated based on the offset length OL1. The calibration of the coordinate data includes compensating for the difference between the portion of the electrode sheet ES sensed by the first rotary encoder 121 (i.e., the portion of the electrode sheet ES wound by the unwinder 111) and the portion of the electrode sheet ES sensed by the NG sensor 131.

[0061] According to an exemplary embodiment, the reel controller 141 may calibrate coordinate data collected simultaneously with the NG sensing signal NSS based on the offset length OL1 and associate the calibrated coordinate data with the NG sensing signal NSS to collect NG sensing data NSD.

[0062] The offset length OL1 is the length of the electrode sheet ES between the NG sensor 131 and the unwinder 111 according to the moving path of the electrode sheet ES. The offset length OL1 may be equal to or greater than a straight distance between the NG sensor 131 and the unwinder 111.

[0063] The reference point sensor 133 can be configured to sense the reference points on the electrode sheet ES to collect the reference point data of the electrode sheet ES. The reference point sensor 133 can include, for example, an OCR barcode reader. Each reference point on the electrode sheet ES can include any identification mark (for example, a 1D or 2D barcode), which includes information about the moving direction of the electrode sheet ES and the reference point sequence formed in the process of forming the reference point. The reference point sensor 133 can be configured to sense the reference points on the electrode sheet ES to generate a reference point sensing signal DSS. The reference point sensor 133 can be configured to transmit the reference point sensing signal DSS to the roll controller 141.

[0064] The scroll controller 141 may be configured to collect reference point sensing data DSD based on the coordinate data and the reference point sensing signal DSS. The scroll controller 141 may be configured to collect the reference point sensing data DSD by associating the reference point sensing signal DSS with the coordinate data. The reference point sensing data DSD may include, for example, a sequence of reference points and coordinates matching the reference points.

[0065] In order to collect the reference point sensing data DSD, the coordinate data can be calibrated based on the offset length OL2. The calibration of the coordinate data includes compensating for the difference between the portion of the electrode sheet ES sensed by the first rotary encoder 121 (i.e., the portion of the electrode sheet ES unwound by the unwinder 111) and the portion of the electrode sheet ES sensed by the reference point sensor 133.

[0066] According to an exemplary embodiment, the reel controller 141 may be configured to calibrate coordinate data collected simultaneously with the reference point sensing signal DSS based on the offset length OL2 and associate the calibrated coordinate data with the reference point sensing signal DSS to collect the reference point sensing data DSD.

[0067] The offset length OL2 is the length of the electrode sheet ES between the reference point sensor 133 and the unwinder 111 according to the moving path of the electrode sheet ES. The offset length OL2 may be equal to or greater than the straight-line distance between the NG sensor 131 and the unwinder 111.

[0068] The offset length OL2 may include a first portion OL2_1 and a second portion OL_2. The first portion OL2_1 may be a portion that has not been processed by the processing device 119, and the second portion OL_2 may be a portion that has been processed by the processing device 119. Therefore, the length characteristics of the first portion OL2_1 may be different from the length characteristics of the second portion OL_2. For example, when the processing device 119 includes a pressing roller for a rolling process, the first portion OL2_1 may not be elongated, and the second portion OL2_2 may be elongated. According to an exemplary embodiment, in the calibration of the offset length OL2, the first portion OL2_1 may be calibrated differently from the second portion OL2_2. For example, the second portion OL2_2 may be calibrated by reverse calculation of elongation, etc. to compensate for the change in length characteristics by the processing device 119.

[0069] According to an exemplary embodiment, the reel controller 141 may be configured to transmit the NG sensing data NSD and the reference point sensing data DSD to the process controller 143. The process controller 143 may be configured to compare the reference point data DPD with the reference point sensing data DSD. The process controller 143 may be configured to calibrate the defect data DD based on the NG sensing data NSD. Calibrating the defect data DD based on the NG sensing data NSD may include calibrating the coordinates of the defect data DD based on the coordinates of the NG sensing data NSD when the coordinates of the defect data DD do not match the NG sensing data NSD.

[0070] Table 3 shows an example of reference point sensing data DSD.

[0071] [Table 3]

[0072] sequence Sensed coordinates m Offset 15 115 5 14 235 5 13 350 10 12 470 10 11 590 10 10 705 15 9 825 15 8 945 15 7 1065 15 6 1180 20 5 1300 20 4 1420 20 3 1540 20 2 1660 20 1 1780 20

[0073] In Table 3, the first column and the second column may represent reference point sensing data DSD. The display format of the reference point sensing data DSD is not limited to the above table. The reference point sensing data DSD may be in a format including a match between a reference point sequence and coordinates. The process controller 143 may be configured to calculate an offset, which is the difference between the storage coordinates of the reference point data DPD and the sensed coordinates of the reference point sensing data DSD. In Table 3, the third column represents the offset calculated by the process controller 143. The process controller 143 may be configured to calibrate the defect data DD based on the offset. Table 4 shows defect data calibrated by the process controller 143. Calibration of the defect data DD may be triggered by sensing the reference point. Although Table 3 shows fifteen reference points at the same time, the defect data DD may be calibrated whenever a reference point is sensed.

[0074] [Table 4]

[0075] Calibrated starting coordinates m Calibrated end coordinate m Defect Type 125 145 154 735 785 171

[0076] More specifically, when the comparison between the sensed coordinates and the stored coordinates of the reference point shows that these coordinates are different from each other, the process controller 143 can perform an operation for calculating an offset. For example, when the first fifteenth reference point is sensed, the sensed 115m does not match the stored 120m, so the process controller 143 can calculate 5m as an offset. Next, the starting coordinate "130" of the defect "154" adjacent to the fifteenth reference point can be calibrated to "125" based on the offset value "5". Next, the ending coordinate "150" of the defect "154" adjacent to the fifteenth reference point can be calibrated to "145" based on the offset value "5". In addition, the starting coordinate "750" and the ending coordinate "800" of the defect "171" adjacent to the tenth reference point can be calibrated to "735" and "785" respectively based on the offset value "15". Unlike Table 4, different offsets can be applied to the starting coordinates and the ending coordinates of the defect according to the position of the defect on the electrode sheet ES. The coordinates of the defect data DD of the roll image of the first electrode roll ER1 and the coordinates of the defect of the actual electrode sheet ES unwound from the first electrode roll ER1 may not match. This mismatch may be caused by the loss caused by the sampling test of the first electrode roll ER1, the loss during the movement of the first electrode roll ER1, the loss during the loading of the first electrode roll ER1 onto the unwinder 111, the connection of the electrode sheet ES of the loaded first electrode roll ER1 and the electrode sheet ES on the rewinder 113, etc.

[0077] According to the exemplary embodiment, by calibrating the defect data DD based on the reference point sensing data DSD and the reference point data DPD obtained by sensing the actual reference point on the electrode sheet ES, it is possible to prevent the defective portion DES of the electrode sheet ES from being partially discarded or the normal portion of the electrode sheet ES from being excessively discarded. In addition, for the defects included in the defect data DD, their coordinates can be calibrated without an NG mark or NG label to improve the productivity and yield of the electrode sheet ES.

[0078] The process controller 143 may be configured to control the operation of the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119. The process controller 143 may be configured to generate signals for operating or stopping the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119. The signals for operating or stopping the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119 may be generated based on a body including details of a product ID and a manufacturing recipe.

[0079] The process controller 143 may receive the NG sensing data NSD from the reel controller 141. The process controller 143 may be configured to generate a signal for operating or stopping the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119 based on the NG sensing data NSD and the calibrated defect data. Here, the calibrated defect data may be generated by the process controller 143 based on the reference point data DPD, the reference point sensing data DSD, and the defect data DD as described above.

[0080] When a defect on the electrode sheet ES identified by the calibrated defect data or the NG sensing data NSD approaches the splicing station 115 , the process controller 143 may reduce the moving speed of the electrode sheet ES or stop winding and unwinding by the unwinder 111 and the rewinder 113 .

[0081] After cutting the starting point of the defect on the splicing station 115 (or cutting a point adjacent to the starting point of the defect in consideration of the process margin), the waste port 117 can be configured to wind the defective portion DES of the electrode sheet ES, as shown by the thick dotted line. After the defective portion DES of the electrode sheet ES is fully wound by the waste port 117, the portion of the electrode sheet ES connected to the waste port 117 and the portion of the electrode sheet ES connected to the unwinder 111 can be separated from each other. Next, the current process can be continued by connecting the portion of the electrode sheet ES connected to the unwinder 111 and the portion of the electrode sheet ES connected to the rewinder 113. The portion of the electrode sheet ES connected to the unwinder 111 and the portion of the electrode sheet ES connected to the rewinder 113 can be connected on the splicing station 115.

[0082] The processing device 119 may be located downstream of the flow of the electrode sheet ES compared to the splicing station 115. That is, the processing device 119 may be configured to process the electrode sheet ES whose defective portion DES is processed at the splicing station 115 to be discarded.

[0083] For example, the processing device 119 may include a coater, and the electrode sheet ES may be coated with the electrode slurry. As another embodiment, the processing device 119 may include a pressing roller, and a rolling process may be performed on the electrode sheet ES coated with the electrode slurry. As another embodiment, the processing device 119 may include a slitting knife, and the electrode sheet ES may be divided into a plurality of electrode sheets.

[0084] The secondary battery manufacturing system 100 may further include a measuring device and an inspector. The measuring device may be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measuring device may measure the electrode sheet ES by a scanning method. The measurement data may include multiple measurement values ​​represented by numbers. For example, the measurement data may include dimensional data (e.g., thickness and width) of the electrode sheet ES, data on the loading amount of the coating material on the electrode sheet ES, dimensional data (e.g., the width of the insulating material on the coating material and the overlap width between the coating material and the insulating material), the coating tape on the upper surface of the electrode sheet ES and the coating tape on the lower surface of the electrode sheet ES. Mismatch data, etc. Here, the loading amount is the amount of coating material loaded per unit area of ​​the electrode sheet ES, and may be the surface density of the coating material.

[0085] Whether the measured portion of the electrode sheet ES is defective can be determined by processing the measurement data using a set method. When the amount of coating material measured on the electrode sheet ES (e.g., the amount of loading on the electrode sheet ES or the thickness of the electrode sheet ES) is within a set range including an upper limit and a lower limit, the corresponding portion of the electrode sheet ES can be determined as a high-quality portion. When the amount of coating material measured on the electrode sheet ES (e.g., the amount of loading on the electrode sheet ES or the thickness of the electrode sheet ES) is less than the lower limit or greater than the upper limit, the corresponding portion of the electrode sheet ES can be determined to be defective.

[0086] The measuring device may include, for example, a time delay and integration (TDI) camera, a complementary metal oxide semiconductor (CMOS) image sensor, and a time of flight (TOF) sensor. The measuring device may include a transmitter and a receiver configured to use non-destructive signals such as ultrasound, microwaves, terahertz waves, or infrared to perform measurements. The measuring device may include analog and / or digital sensors, such as biosensors, chemical sensors, component sensors, current and / or power meters, air quality sensors, gas sensors, Hall effect sensors, brightness level sensors, and optical sensors. The measuring device may include pressure sensors, temperature sensors, ultrasonic sensors, proximity sensors, door status sensors, motion tracking sensors, humidity sensors, visible light and infrared sensors, cameras, etc.

[0087] The measuring device may be configured to generate coordinate-dependent measurement data by associating additional coordinate data based on the consumption signal WAS with the measurement data. To generate the coordinate-dependent measurement data, the additional coordinate data may be calibrated based on an offset length of the measurement data.

[0088] The measuring device may be configured to collect evaluation data based on the measurement data.The evaluation data may be collected based on a comparison between the measured values ​​of a plurality of sections in the electrode sheet ES and a set range.

[0089] For example, a measurement value (or an average value of the measurement values) within a first range may be determined as normal, a measurement value (or an average value of the measurement values) within a second range greater than the first range may be determined as excessive, a measurement value (or an average value of the measurement values) within a third range greater than the second range may be determined as very excessive, a measurement value (or an average value of the measurement values) within a fourth range less than the first range may be determined as insufficient, and a measurement value (or an average value of the measurement values) within a fifth range less than the fourth range may be determined as very insufficient.

[0090] Here, when the lower limit of the second range is greater than or equal to the upper limit of the first range, the second range is greater than the first range. Similarly, when the upper limit of the fourth range is less than or equal to the lower limit of the first range, the fourth range is less than the first range.

[0091] The evaluation values ​​of the evaluation data may be associated with coordinates. For example, each evaluation value may be matched with the start coordinates and the end coordinates of the portion of the electrode sheet ES for which the evaluation value is calculated.

[0092] The inspector may inspect the electrode sheet ES to collect inspection data of the electrode sheet ES. The inspector may be configured to sense defects such as surface defects of the electrode sheet ES based on a change in color of the surface of the electrode sheet ES, a change in reflectivity, etc. The inspector may be configured to collect inspection data of a portion (e.g., an overlapping portion) of the first electrode sheet ES1 corresponding to the sensing portion.

[0093] The inspection data collected by the inspector may include the results and process events of judging the quality of the portion of the electrode sheet ES. For example, the inspection data may include data on the appearance of the electrode sheet ES, data on disconnections and seams on the electrode sheet ES, data on the portion of the electrode sheet ES that is sampled for inspection, data on the portion of the electrode sheet ES to be discarded, data on the discarded portion of the electrode sheet ES, data on whether the coating material and the insulating material on the electrode sheet ES are defective, data on the reference point indicating the position of the electrode sheet ES, and defect data such as pinhole defects, pit defects, line defects, crack defects, side ring defects, island defects, folding defects, wrinkle defects, pit defects, and scratch defects. The reference points may be formed on the electrode sheet ES at certain intervals, and other elements on the electrode sheet ES may be positioned based on the reference points. The inspector may be a color sensor, a seam sensor, a reference point sensor, or a visual machine.

[0094] The inspector may be configured to generate coordinate-dependent inspection data by associating additional coordinate data based on the consumption signal WAS with the inspection data. To generate the coordinate-dependent inspection data, the additional coordinate data may be calibrated based on an offset length of the inspector.

[0095] The above-mentioned measurement data and inspection data may be time series data. The measurement data and inspection data may be ordered in time. Time ordering is the main feature of time series data. Time ordering is to organize events in the order in which they occur and arrive to be processed. That is, the measurement data and inspection data may be stored based on the time point at which the measurement and inspection are performed, and may be related to time. Therefore, each measurement value of the measurement data may be matched with time, and each inspection value of the inspection data may be matched with time.

[0096] For example, the data of a measurement quantity (e.g., the amount of load on the electrode sheet ES or the thickness of the electrode sheet ES) may include a series of measurements (e.g., the amount of load on the electrode sheet ES or the thickness of the electrode sheet ES) and time values ​​associated with the series of measurements. The measured quantities and time values ​​may be matched in a one-to-one manner, but are not limited thereto. As another embodiment, the defect data may include a value indicating a defect and a time value associated with the value indicating the defect. Here, a value indicating a defect should be understood to mean that the value includes information about at least one of the presence of a defect and the type of defect.

[0097] The roll map may include coordinate-related measurement data and coordinate-related inspection data generated by associating measurement data and inspection data as time series data with coordinate data. Therefore, the roll map may provide traceability for all processes during subsequent processes or after the product is shipped.

[0098] The roll controller 141 can be operably communicated with the first rotary encoder 121 and the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, and the additional measuring device and the inspector by means of a wired or wireless data network. The data network can be a one-way or two-way communication. The data network can be implemented by a physical channel, WiFi, a public network, and / or a dedicated network using Bluetooth or other frequency bands. The first rotary encoder 121 and the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, and the additional measuring device and the inspector can be configured to collect data from the equipment, workpieces, intermediate products, and products in the secondary battery manufacturing system 100, or generate a signal for collecting data therefrom.

[0099] The coordinate-related measurement data and the coordinate-related inspection data transmitted from the reel controller 141 to the process controller 143 may be transmitted to the server 150 via the process controller 143 and the EIF 145. The process controller 143 and the EIF 145 may relay data communication between the server 150 and the reel controller 141. However, the present invention is not limited thereto, and the reel controller 141 may transmit the coordinate data, the coordinate-related measurement data, and the coordinate-related inspection data directly to the server 150.

[0100] In order to control the process, a communication line for connecting the process controller 143 and the server 150 via the EIF 145 may be installed between the process controller 143 and the server 150. Therefore, compared with the case where the first rotary encoder 121 and the second rotary encoder 125 and the measuring device directly communicate with the server 150 and the case where the roll chart PLC 141 directly communicates with the server 150, data transmission via the process controller 143 can reduce resources required for installing the communication line, and can efficiently process and manage data.

[0101] The EIF 145 may be a device for communication between the process controller 143 of the manufacturing equipment and the server 150 as an upper server.

[0102] The server 150 may be configured to generate and store a roll map. The roll map may be generated in batches. The roll map may include data about the specifications of the batch. The specifications of the batch may include, for example, a batch number, a length of the wound electrode sheet ES, a width of the electrode sheet ES, and materials and ingredients used to process the electrode sheet ES.

[0103] The server 150 may be configured to store a first roll image of the first electrode roll ER1 , transmit defect data DD and reference point data of the first roll image to the process controller 143 , and generate and store a second roll image of the second electrode roll ER2 based on the coordinate-related measurement data and the coordinate-related inspection data.

[0104] According to an exemplary embodiment, the server 150 may be a data processing system that supports all activities required for managing the manufacture of secondary batteries, such as work scheduling management, work instructions, quality control, and work performance aggregation. The server 150 may be, for example, a manufacturing execution system (MES). The server 150 may be configured to input, process, output, and communicate data required for electrode manufacturing (including coating processes, pressing processes, and slitting processes).

[0105] According to other exemplary embodiments, the server 150 may be configured to store and process raw measurement data. The server 150 may manage the quality of the electrode sheet ES by continuously monitoring the processing of the electrode sheet ES based on the inspection data. According to an exemplary embodiment, the server 150 may be a static process controller (SPC). The server 150 may collect and analyze manufacturing data in almost real time, thereby identifying problematic conditions in a timely manner and providing notifications to operators before potential problems occur.

[0106] According to other exemplary embodiments, the server 150 may be, for example, a data warehouse, and stores NG sensing data NSD, coordinate data, coordinate-related measurement data, and coordinate-related inspection data for a long period of time based on a quality assurance period of a product.

[0107] According to other exemplary embodiments, in order to create a volume map, the server 150 may be provided separately from the MES, SPC, and data warehouse.

[0108] The reel controller 141, process controller 143, EIF 145, and server 150 may be implemented by hardware, firmware, software, or a combination thereof. For example, the reel controller 141, process controller 143, EIF 145, and server 150 may include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The reel controller 141, process controller 143, EIF 145, and server 150 may include simple controllers, complex processors such as microprocessors, CPUs or GPUs, processors configured by software, dedicated hardware, or firmware. The reel controller 141, process controller 143, EIF 145, and server 150 may be implemented, for example, by a general-purpose computer or dedicated hardware such as a digital signal processor (DSP), a field programmable gate array (FPGA), or an application-specific integrated circuit (ASIC).

[0109] The server 150 may include a physical server or a cloud server. The server 150 may provide data and analysis results to the operator through various frameworks. The framework may include a protocol that supports data transmission so that the display device 160 can visualize the data with the help of a user interface and provide updated visualization when the server 150 calculates new data. The protocol that supports data transmission may use HTML, JavaScript and / or JSON. The server 150 may transmit a visualization command VC to the display device 160, and the display device 160 may visualize the volume map and display the visualized volume map.

[0110] Server 150 may include various types of application programming interfaces (APIs) and other data management tools for storing data in a database. The API may also be used to retrieve data from databases of various data management systems. The data management system may be configured to provide access to the database, pull or retrieve data from the database, and generate metrics. Here, metrics are tools for visualizing data. Metrics include measurements generated in a time series manner and may be used to monitor applications and generate status alerts.

[0111] The secondary battery manufacturing system 100 can implement a plug-in architecture together with an API for obtaining data to provide plug-and-play connections for the NG sensor 131, the reference point sensor 133, and additional measuring devices and inspectors. Therefore, resources in a certain process step and a specific site can be easily transferred to a different process and a different site, or new resources can be easily introduced into each process step and each site.

[0112] The data network between the components of the secondary battery manufacturing system 100 may include various types of communication channels, including unidirectional and bidirectional wired and wireless communications. For example, the data network may include an industrial protocol network such as OPC, Modbus, or ProfiNet. The communication channel may be a channel for dedicated pipe communication, such as a universal serial bus (USB), IEEE 802 (Ethernet), IEEE 1394 (Firewire), or other high-speed data communication standards.

[0113] In some embodiments, the secondary battery manufacturing system 100 may further include a manual input system that allows an operator to input manufacturing data. The secondary battery manufacturing system 100 may allow for input of data by an operator using an input tool and computer-based input of manufacturing data such as captured from an Excel file.

[0114] According to some embodiments, the operations of the reel controller 141, the process controller 143, the EIF 145, and the server 150 may be implemented as instructions stored on a machine-readable medium that can be read and executed by one or more processors. Here, a machine-readable medium may include any mechanism for storing and / or transmitting information in a form readable by a machine (e.g., a computing device). For example, a machine-readable medium may include a read-only memory (ROM), a random access memory (RAM), a disk storage medium, an optical storage medium, a flash memory, an electrical, optical, acoustic, or other type of radio signal (e.g., a carrier wave, an infrared signal, a digital signal, etc.), and other signals.

[0115] The reel controller 141 may be implemented by, for example, software configured to collect coordinate data, NG sensing data NSD, and reference point sensing data DSD and transmit the NG sensing data NSD and the reference point sensing data DSD.

[0116] The process controller 143 may be implemented by software configured to receive a product ID, a product recipe, defect data DD, reference point data DPD, NG sensing data NSD, and reference point sensing data DSD, transmit the NG sensing data NSD and the reference point sensing data DSD, and generate control signals for controlling the unwinder 111, the rewinder 113, the waste port 117, and the processing equipment 119 based on the product ID, the product recipe, the defect data DD, the reference point data DPD, the NG sensing data NSD, and the reference point sensing data DSD. More specifically, the process controller 143 may be implemented by software configured to calculate an offset between reference points based on the reference point data DPD and the reference point sensing data DSD, calibrate the defect data DD based on the offset, and generate control signals for controlling the unwinder 111, the rewinder 113, the waste port 117, and the processing equipment 119 based on the calibrated defect data.

[0117] As a non-limiting example, the reel controller 141 and the process controller 143 may be a programmable logic controller (PLC). A PLC is a special type of microprocessor-based controller that uses programmable memory to store instructions and implement functions such as logic, sequencing, timing, counting, and arithmetic operations to control machines and processes. PLCs are easy to operate and program.

[0118] The reel controller 141 and the process controller 143 may include a power supply, a CPU, an input interface, an output interface, a communication interface, and a storage device. The power supply may be configured to supply power to other components of the reel controller 141 and the process controller 143 (such as the CPU, input interface, output interface, communication interface, and storage device for the reel controller 141 and the process controller 143). The storage device may include a read-only memory (ROM) configured to store a system program (such as an operating system) and a random access memory (RAM) configured to store data (such as user programs, state information of input and output devices, and values ​​of timers, counters, and other internal devices). The CPU may be configured to control the communication between modules that implement the logic and convert input signals into output operation signals. The CPU may operate based on the system program and the user program stored in the storage device. The CPU may be configured to write inspection data and measurement data to the data area of ​​the storage device or read inspection data and measurement data from the data area of ​​the memory device based on the system program and the user program. The conditions or data of the industrial device and the production process may be transmitted to the CPU via the input module. The result of the processing performed by the CPU may be transmitted to the actuator via the output module. The communication interface may be configured to transmit and receive data between the reel controller 141 and the process controller 143 or between the process controller 143 and the EIF 145 .

[0119] The EIF 145 may be implemented by software for relaying the transmission of data and information between the process controller 143 and the server 150. More specifically, the EIF 145 may be implemented by software configured to control the communication flow between the process controller 143 and the server 150 and perform error control, synchronization, sequence control, addressing, multiplexing, routing, format conversion, etc.

[0120] The server 150 may be implemented by, for example, software configured to transmit the product ID, product recipe, defect data DD, and reference point data DPD to the process controller 143 and generate a roll map based on the coordinate-related measurement data and the coordinate-related inspection data.

[0121] However, the above description is provided only for ease of description, and the reel controller 141, process controller 143, EIF 145 and server 150 may also be generated by computing devices, distributed computing devices, processors, firmware, software, routines and other devices that execute routines and instructions.

[0122] The architecture of the secondary battery manufacturing system 100 configured to generate a roll map can be implemented by adding only the roll map controller 141 to the process controller 143, the EIF 145, and the server 150, which are basic elements in modern process management systems. In the system according to the exemplary embodiment, the resources of the already installed manufacturing site can be used, and additional capital expenditures can be reduced. In addition, applying the same architecture as the existing manufacturing equipment to the newly constructed manufacturing equipment can improve the manufacturing reliability of the secondary battery, detect / improve the process with problems, and effectively introduce new processes.

[0123] (Second Embodiment)

[0124] Figure 2 is a flowchart of a secondary battery manufacturing method according to an exemplary embodiment.

[0125] refer to Figure 1 and Figure 2 In P110 , the defect data DD and the reference point data DPD of the first electrode roll ER1 may be loaded. The process controller 143 may receive the defect data DD and the reference point data DPD of the first electrode roll ER1 from the server 150 .

[0126] Next, in P120 , reference points on the electrode sheet ES may be sensed to collect reference point sensing data DSD. As described above, the reference point sensing data DSD may be collected by the reference point sensor 133 and the reel controller 141 .

[0127] Next, in P130, the defect data DD may be calibrated based on the reference point sensing data DSD and the reference point data DPD. The calibration of the defect data DD may be performed by triggering the sensing of the reference point. The calibration of the defect data DD may include calculating an offset that is a difference between the sensed coordinates of the reference point sensing data DSD and the coordinates of the reference point data DPD, and calibrating the coordinates of the defect data DD (i.e., the start coordinates and the end coordinates) based on the offset.

[0128] Thereafter, in P140, the defective portion DES of the electrode sheet ES may be discarded based on the calibrated defect data. To discard the defective portion DES of the electrode sheet ES, the process controller 143 may be configured to generate signals for controlling the operation of the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119.

[0129] (Third Embodiment)

[0130] Figure 3 A secondary battery manufacturing system 101 according to an exemplary embodiment is shown.

[0131] refer to Figure 3 The secondary battery manufacturing system 101 may include an unwinder 111, a rewinder 113, a splicing station 115, a waste port 117, a processing device 119, a first rotary encoder 121, a second rotary encoder 125, an NG sensor 131, a reference point sensor 133, an integrated controller 140, an equipment interface (EIF) 145, a server 150 and a display device 160.

[0132] The unwinder 111, the rewinder 113, the splicing station 115, the waste port 117, the processing device 119, the first rotary encoder 121, the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, the EIF 145, the server 150 and the display device 160 are the same as those described above. Figure 1 Those described are basically the same, so redundant descriptions thereof are omitted here.

[0133] The integrated controller 140 may be configured to perform Figure 1 The integrated controller 140 can be configured to generate coordinate data based on the input quantity signal UWAS or the consumption quantity signal WAS, collect NG sensing data NSD (see Figure 1 ) and reference point sensing data DSD (see Figure 1 ), and receives the defect data DD and the reference point data DPD from the server 150 via the EIF 145. The integrated controller 140 may be configured to calibrate the defect data DD based on the reference point sensing data DSD and the reference point data DPD, and the integrated controller 140 may be configured to generate a signal for controlling the unwinder 111, the rewinder 113, the waste port 117, and the processing device 119 based on the calibrated defect data.

[0134] The present invention has been described in more detail above with reference to the drawings, embodiments, etc. However, the configurations shown in the drawings or the embodiments described in this specification are merely embodiments of the present invention and do not reflect all the technical ideas of the present invention, and therefore it should be understood that various equivalent examples and modifications of alternative configurations will be made on the filing date of this application.

Claims

1. A secondary battery manufacturing system, comprising: a server configured to store a roll map, the roll map including defect data indicating defects of the electrode roll and reference point data indicating reference points on the electrode roll; a controller configured to load the defect data and the reference point data from the server; as well as a reference point sensor configured to generate a reference point sensing signal by sensing a reference point on an electrode sheet unwound from the electrode roll, The controller is configured to generate reference point sensing data based on the reference point sensing signal and compare the reference point data with the reference point sensing data.

2. The secondary battery manufacturing system according to claim 1, wherein: The defect data includes the starting coordinates of the defect and the ending coordinates of the defect, The reference point data includes stored coordinates of the reference point, and The reference point sensing data includes sensing coordinates of the reference point.

3. The secondary battery manufacturing system according to claim 2, wherein: The controller is configured to calibrate the defect data based on the reference point data and the reference point sensing data.

4. The secondary battery manufacturing system according to claim 2, wherein: The controller is configured to calculate an offset between the stored coordinates of the reference point and the sensed coordinates of the reference point.

5. The secondary battery manufacturing system according to claim 4, wherein: The controller is configured to calibrate a start coordinate of the defect and an end coordinate of the defect based on the offset. 6 . The secondary battery manufacturing system according to claim 1 , further comprising a reel controller configured to receive the reference point sensing data and transmit the reference point sensing data to the controller.

7. The secondary battery manufacturing system according to claim 1, wherein: The reference point sensor is configured to transmit the reference point sensing data to the controller.

8. A method for manufacturing a secondary battery, the method comprising: loading defect data indicating a defect of the electrode roll and reference point data indicating a reference point on the electrode roll; sensing the reference point on the electrode sheet unwound from the electrode roll to collect reference point sensing data; as well as The defect data is calibrated based on the reference point data and the reference point sensing data to generate calibrated defect data. 9 . The secondary battery manufacturing method according to claim 8 , further comprising discarding a portion of the electrode sheet based on the calibrated defect data.

10. The secondary battery manufacturing method according to claim 8, wherein: The defect data includes coordinates of the defect, The reference point data includes stored coordinates of the reference point, and The reference point sensing data includes sensing coordinates of the reference point.

11. The method for manufacturing a secondary battery according to claim 10, wherein: The calibration of the defect data includes calculating an offset between the stored coordinates of the reference point and the sensed coordinates of the reference point.

12. The secondary battery manufacturing method according to claim 11, wherein: The calibration of the defect data includes calibrating a start coordinate and an end coordinate of the defect data based on the offset.

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