Method for reporting work immediately at station in battery diaphragm production

Abstract

The invention discloses a method for reporting work immediately at a current station in battery diaphragm production. The battery diaphragm is suitable for being engraved by laser, and the label engraved on the diaphragm mother roll is not easy to damage and be interfered and read in the subsequent processing, so that the diaphragm mother roll in the manufacturing process is tracked in real time and the related manufacturing process is adjusted by laser code engraving and label reading in a plurality of process steps of the whole manufacturing process. On one hand, after a certain process step is finished, a label is engraved on a diaphragm mother roll in manufacturing through laser, and the label is used for marking a flow mark number of the diaphragm mother roll in manufacturing in the stage. On the other hand, before a certain process step is started, an existing label located on the diaphragm mother roll in manufacturing is read, and the label is used for mastering related information of the diaphragm mother roll in manufacturing to be processed this time. Certainly, the specific content indicated by each specific label can be stored in a computer or a mobile device and the like, so that the corresponding specific content is stored and the corresponding specific content is read when the laser engraving code and the specific label are read respectively.

Description

Technical Field

[0001] The present invention relates to using laser coding and reading labels during the production process of battery separators to store and read relevant information through the labels at the end and before the start of multiple process steps, so as to grasp the production line status in real time during multiple process steps of the battery separator production process for the full-cycle management of battery separators. Background Art

[0002] In recent years, in order to achieve quality traceability and improve production line efficiency, labels (such as two-dimensional code labels or other labels) are generally placed on the products during production to identify the products during production by reading the labels (such as scanning two-dimensional code labels or other labels) during the production process, and to obtain the content corresponding to the read label or even newly add the content corresponding to the read label through the control system. Compared with the traditional technology of manual inventory, recording and statistics, using label technologies such as RFID (Radio Frequency Identification), paper labels, printed ink codes, two-dimensional barcodes, etc., can not only reduce the large amount of manpower required for manually processing all relevant information in each process step of each batch of products and the problem of difficult to obtain the required content from a large amount of data, but also obtain the information related to the products during production and update the product-related information stored in the system by reading the labels at the start and after the end of any process step during the entire production process. Furthermore, the status of the products during production can be grasped immediately, and the production line can be adjusted immediately in case of abnormal conditions.

[0003] However, there are still some problems to be improved in the prior art. For example, the existing labels in some process steps may be damaged or covered by the ongoing process steps, such as being deformed due to high temperature, corroded by chemical agents, or covered by newly coated opaque materials, resulting in the problem of incorrect reading. For example, in some process steps, it may be necessary to integrate multiple small products into a large product or decompose a large product into multiple small products. At this time, the labels formed in the previous process steps may not only be covered or blocked, but also may not be enough to be allocated for use in subsequent process steps, resulting in the inability to normally obtain the stored information and / or update the stored information.

[0004] Based on this, continuous improvement is still needed to monitor each process step in the entire production process and save complete record data, so as to quickly identify changes affecting product quality and correspondingly adjust the production process, and then remove the formed defective products and prevent the formation of more defective products. Summary of the Invention

[0005] The present invention is directed to the production of battery separators. By using the separator master roll in production, it is suitable to use existing laser engraving technology to form labels on the separator master roll (such as using a laser to remove a part of the separator master roll to form a certain two-dimensional code pattern on the surface of the separator master roll). Also, during the production process of the separator master roll, there are basically no process steps such as high temperature, high pressure, use of highly reactive chemicals, or assembling the separator master roll with other hardware that are likely to damage the label or hinder the reading of the label. Thus, before and after the start and end of most process steps in the production process of the battery separator, the quality of the separator master roll in production and the status of each process step can be grasped in real time and efficiently by reading and updating the label.

[0006] The present invention provides a method for real-time reporting of work-in-process in the production of battery separators, which at least includes the following basic steps. First, a separator master roll is provided. Next, a first process step is performed on this separator master roll. Then, a first label is formed on the separator master roll that has completed this first process step using laser coding. Secondly, before performing a second process step on the separator master roll with this first label, this first label is read. Next, a second process step is performed on the separator master roll with this first label. Finally, a second label is formed on the separator master roll that has completed this second process step using laser coding. Here, when forming this first label, a first relevant message related to the separator master roll that has undergone this first process step is also stored in a control system. Here, when reading this first label, the first relevant message stored in this control system related to the separator master roll that has undergone this first process step is also read. Here, when forming this second label, a second relevant message related to the separator master roll that has undergone this second process step is also stored in this control system.

[0007] Optionally, before performing a third process step on the separator master roll with this first label and this second label, this second label is first read, then a third process step is performed on the separator master roll with this first label and this second label, and finally a third label is formed on the separator master roll that has completed this third process step using laser coding.

[0008] Optionally, either this first process step and this second process step are not carried out consecutively, or this second process step is carried out some time after the completion of this first process step.

[0009] Optionally, either this first label is formed on the edge of the separator master roll, or this second label is formed on the edge of the separator master roll, or this first label and this second label are separated from each other.

[0010] Optionally, when the diaphragm master roll is a single-layer film, both the first label and the second label are engraved on the same side of the diaphragm master roll, or when the diaphragm master roll is a double-layer film, the first label and the second label are engraved on two opposite sides of the diaphragm master roll.

[0011] Optionally, either the first label is a first serial number displayed in the form of a two-dimensional code, or the second label is a second serial number displayed in the form of a two-dimensional code.

[0012] Optionally, either the first relevant information includes the product quality inspection information and processing information of the first process step, or the second relevant information includes the product quality inspection information and processing information of the second process step.

[0013] Optionally, the possible changes in any process step further include: casting, blown film, annealing, lamination, stretching, aging, delamination, and cutting. For example: in the stretching process step, the thickness of the diaphragm master roll is adjusted by stretching the diaphragm master roll in the longitudinal and transverse directions. After the stretching process step is completed, a label is formed on the diaphragm master roll that has completed this stretching process step by laser engraving code. Before entering the next process step, such as the delamination process step, the product quality inspection information and processing information of the stretching process step stored in the control system can be obtained by reading this label. Specifically, as an example, the product quality inspection information corresponding to the stretching process step is the diaphragm master roll thickness data, and the processing information corresponds to the stretching ratios of the diaphragm in the transverse and longitudinal directions.

[0014] Optionally, when multiple diaphragm master rolls need to be laminated and processed into a multi-layer diaphragm master roll, before these diaphragm master rolls undergo the lamination process step, one or more labels previously formed by laser engraving code are sequentially read for each diaphragm master roll. After these diaphragm master rolls are processed through this lamination process step, a lamination label is formed on the formed multi-layer diaphragm master roll by using laser engraving code, and this lamination label is bound to the product quality inspection information and processing information of this lamination process step. Then, process step connections are established in this control system and a tree-shaped correspondence diagram of the structures of these diaphragm master rolls is formed.

[0015] Optionally, when it is necessary to separate a multi-layer diaphragm master roll into multiple single-layer diaphragm master rolls or multiple multi-layer diaphragm master rolls, before the separation process step of this multi-layer diaphragm master roll, first read one or more tags previously formed by laser engraving on this multi-layer diaphragm master roll, and after this multi-layer diaphragm master roll has undergone this separation process step, use laser engraving to form respective composite tags on each of the separated single-layer diaphragm master rolls and / or each multi-layer diaphragm master roll, and make the number of separated layers correspond to the number of layers to be separated. Then, establish the process step connection between the separated diaphragm master tags and the multi-layer diaphragm master tags to be separated in this control system and form a tree-like correspondence diagram of these diaphragm master rolls.

[0016] The present invention has at least the following beneficial effects. First, since laser engraving is already a commercial technology and using a scanner or a mobile device with an optical lens to read, such as two-dimensional barcodes, which are already commercial technologies, the method of using laser engraving to form tags on the battery diaphragm master roll and reading the tags located on the battery diaphragm master roll in the present invention can be achieved using commercial technologies without any difficulty. Second, since RFID and ink tags, etc. are already commercial technologies, that is, using the tags located on the product to display the serial number and obtaining or updating the corresponding product and / or production line information stored in the control system by reading and writing the tags is already a commercial technology. Therefore, in addition to using laser engraving to generate tags and using image recognition to read tags in the present invention, how to use the tags and how to read and write those data can be achieved using commercial technologies without any difficulty. In particular, although it is inevitable that there will be a need to combine multiple batch diaphragm master rolls into one or separate one into multiple ones, since the method of using laser engraving to form tags on the diaphragm master roll can easily form tags on the edge, end or even side of the diaphragm master roll, tags can be easily formed for the diaphragm master roll after combination and separation respectively to indicate which or that new diaphragm master roll is formed from which existing diaphragm master roll. Additionally, since the diaphragm master roll needs to be cut again after being manufactured to form various battery diaphragms with their respective contours and sizes, forming some tags on the edge or end of the diaphragm master roll to mark the two-dimensional codes (or serial numbers, etc.) of some process steps will not negatively affect the formed battery diaphragms. Description of the Drawings

[0017] Figure 1 is a flowchart of an embodiment of the present invention;

[0018] Figures 2A to 2D are some schematic diagrams of some embodiments of the present invention.

[0019] Component Label Description

[0020] 101, 102, 103, 104, 105, 106... Step blocks

[0021] 1001, 1002, 1003, 1004, 1005, 1006, 1007, 1008, 1009, 1010, 1011... Label codes Detailed implementation manners

[0022] The following provides a detailed description of the specific implementation manners of the present invention in conjunction with the accompanying drawings. It should be understood that the specific implementation manners described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0023] As Figure 1 shown, an embodiment of the present invention provides a method for real-time reporting of work-in-process in the production of battery diaphragms, including the following basic steps. First, as shown in step block 101, a mother roll of diaphragm is provided. Second, as shown in step block 102, a first process step is performed on this mother roll of diaphragm. Then, as shown in step block 103, a first label is formed on the mother roll of diaphragm that has completed this first process step by using laser coding. Here, when forming this first label, a first relevant message of the mother roll of diaphragm that has undergone this first process step is also stored in a control system. Then, as shown in step block 104, before performing a second process step on the mother roll of diaphragm with this first label, this first label is read. Here, when reading this first label, the first relevant message of the mother roll of diaphragm that has undergone this first process step stored in this control system is also read. Next, as shown in step block 105, a second process step is performed on the mother roll of diaphragm with this first label. Finally, as shown in step block 106, a second label is formed on the mother roll of diaphragm that has completed this second process step by using laser coding. Here, when forming this second label, a second relevant message of the mother roll of diaphragm that has undergone this second process step is also stored in this control system.

[0024] Generally speaking, since two-dimensional codes have been widely used in many occasions, there are many commercial solutions for the methods of encoding two-dimensional codes and the devices for reading two-dimensional codes. Therefore, this first label is a first serial number displayed in the form of a two-dimensional code, and this second label is a second serial number displayed in the form of a two-dimensional code. Of course, just in terms of the concept of using laser coding to form labels on the mother roll of diaphragm, these labels can also use other forms instead of two-dimensional codes, such as combinations directly composed of English letters and Arabic numerals.

[0025] Generally speaking, in order to simplify the label content, thereby reducing the workload of laser coding and the number of diaphragm master rolls to be used, the label content is simply a serial number. In contrast, the first relevant information includes the product quality inspection information and processing information of this first process step, and the second relevant information includes the product quality inspection information and processing information of this second process step. These relevant information are stored in the control system, such as a computer or a mobile device that can execute software programs, etc., and then when needed, the control system commands the laser engraving machine to perform laser coding on the diaphragm master roll, or the control system commands a scanner, etc. to read the label located on the diaphragm master roll. All message processing, as well as the analysis of the quality of the diaphragm master roll and various adjustments to the production line, are controlled by the control system.

[0026] Of course, although Figure 1 only the first process step, the first label, the second process step, and the second label are described, but this process of reading the existing label before a certain process step and creating a new label after the end of this process step can continue to extend from the third step, the third label, the fourth step, and the fourth label all the way to any number of process steps and the formation of any number of labels. Here, the various step blocks with substantially equal content will not be repeatedly described.

[0027] Of course, when proceeding to multiple process steps, when performing a certain specific process step, one can only read the label generated by the most recent previously performed process step, or read all the labels generated by all the previously performed process steps at once. Of course, one can also read some of the labels generated by the previously performed process steps that are relatively relevant to this specific process step as needed. These depend on the processing method to be performed on the diaphragm master roll for this specific process step.

[0028] Obviously, when the first process step and the second process step are two consecutive steps in a production line and the latter is to be carried out immediately after the former is completed, using labels to indicate which batch of products the diaphragm master roll in process is, the details of the process steps that have been carried out, or even its quality records, etc., are all good practices that can simplify the tracking of the manufacturing progress and details of the diaphragm products. In particular, when the first process step and the second process step are not carried out consecutively, or when the second process step is carried out some time after the first process step is completed, it is very helpful to confirm the status of the diaphragm master roll to be processed by reading the label before carrying out the second process step. After all, there are many changing factors in the production line, and being able to continuously and efficiently master the relevant information can minimize accidents and damages, etc. For example, after completing the previous process step, sometimes it is necessary to transfer the diaphragm master roll to another factory building or wait for the structure of the just-processed diaphragm master roll to be stable, etc., before the subsequent process step can be carried out. For example, sometimes due to a slight problem with the operation of the machinery used in a certain process step or the need to accumulate multiple diaphragm master rolls before processing them together, it is necessary to temporarily store some diaphragm master rolls in a centralized manner. In these situations, since the diaphragm master roll does not immediately carry out the second process step after just completing the first process step, in order to avoid any omission between the two process steps, it is very helpful to use a label formed directly on the diaphragm master roll through laser engraving to indicate the diaphragm master roll and link out relevant information. Because such a label is very difficult to separate from the diaphragm master roll and is also not easily damaged or interfered with.

[0029] Since some battery diaphragms are single-layer films and some are double-layer films, in some cases during the manufacturing process of the diaphragm master roll, it will be made into a single-layer film, but in some cases it will be made into a double-layer film. Therefore, when the diaphragm master roll is a single-layer film, both the first label and the second label are engraved on the same side of the diaphragm master roll. Therefore, when the diaphragm master roll is a double-layer film, both the first label and the second label are engraved on the opposite two sides of the diaphragm master roll. Because, no matter how the diaphragm master roll is placed and how it is processed in the subsequent process steps, it is possible to smoothly monitor the products and production line of the diaphragm master roll in process through laser engraving and reading the label.

[0030] Since the diaphragm master roll needs to be cut after production to form various battery diaphragms, any label can be formed on the edge or even the end of the diaphragm master roll. In this way, in the final cutting process, these labels can be simply separated from the formed battery diaphragms, and not too much of the diaphragm master roll will be consumed to place the labels. Generally speaking, different labels are not only separated from each other, but also concentrated in a certain part of the diaphragm master roll, so as to improve the efficiency of reading the label each time.

[0031] Figure 2ASchematic diagram of an embodiment of the present invention. Before the end of a certain process step, such as before the cutting and winding of the diaphragm master roll, a process step product QR code is engraved at a specific position at the end of the diaphragm master roll by using a laser engraving machine. Here, the situation where six diaphragm master rolls are respectively formed with codes 1001 - 1006 is shown. Although the relevant hardware details are not specifically illustrated, here the computer command mechanism movement device as the control system is used to drive the laser engraving machine to each specific position corresponding to each diaphragm master roll, so as to perform laser coding. At the computer end, each formed code is also bound to the respective corresponding product quality inspection information and processing information. After that, by subsequently reading the respective labels (codes 1001 - 1006) of these diaphragm master rolls, the product quality inspection information and processing information respectively corresponding to each diaphragm master roll can be read from the computer end.

[0032] Figure 2B Schematic diagram of another embodiment of the present invention. Before starting a certain specific multi - step process, first sequentially read the six labels (codes 1001 - 1006) engraved and formed on the six diaphragm master rolls to be processed in the previous process step, so as to complete the message collection before performing this specific process step. Generally speaking, to reduce the probability of confusion, the order of reading the labels is fixed and should not be changed midway. After this specific process step is completed, since the previous six diaphragm master rolls are stacked to form a six - layer diaphragm master roll, a new label with a code of 1007 is formed on this six - layer diaphragm master roll by using laser coding, and this new label is bound to the product quality inspection information related to this six - layer diaphragm master roll and the processing information related to this specific process step, and then the bound product quality inspection information and processing information are stored in the control system (such as the memory of a computer) so that the relevant information about this six - layer diaphragm master roll can be obtained by subsequently reading this new label. Here, it can be said that this new label and the previous six labels form a one - to - six tree - like structure, indicating that this six - layer diaphragm master roll is composed of the previous six diaphragm master rolls.

[0033] Figure 2CSchematic diagram of another embodiment of the present invention. Before starting a special process step that takes more than one minute, first sequentially read a label (code 1007) engraved on the six-layer diaphragm master roll to be processed during the previous process step, so as to complete the information collection before performing this special process step. After this special process step is completed, since the previous six-layer diaphragm master roll is decomposed into a two-layer diaphragm master roll and a four-layer diaphragm master roll, laser coding is used to form new labels with codes 1008 and 1009 on the two-layer diaphragm master roll and the four-layer diaphragm master roll respectively. Next, bind a new label (code 1008) with the two-layer diaphragm master roll newly formed with the product quality inspection information and processing information related to this special process step, and also bind another new label (code 1009) with the four-layer diaphragm master roll newly formed with the product quality inspection information and processing information related to this special process step. Finally, store the bound product quality inspection information and processing information in the control system (such as the memory of a computer) so that relevant information about this two-layer diaphragm master roll and this four-layer diaphragm master roll can be obtained by reading these two new labels in the future. Here, it can be said that a new label (code 1008) and the previous label (code 1007) form a one-to-two tree structure, and another new label (code 1009) and the previous label (code 1007) form a one-to-four tree structure, respectively showing how the previous six-layer diaphragm master roll is separated into this two-layer diaphragm master roll and this four-layer diaphragm master roll.

[0034] Figure 2DSchematic diagram of another embodiment of the present invention. Before performing a particular process step on a two-layer diaphragm master roll, such as before performing special treatments on both opposite sides of the two-layer diaphragm master roll, first read a label (code 1008) laser-engraved on the two-layer diaphragm master roll to be processed during a previous process step, so as to complete the information collection before performing this particular process step. After this particular process step is completed, respectively form labels (codes 1010-1011) corresponding to this particular process step on the processed diaphragm master roll through laser engraving, such as forming these two labels on both opposite sides of the two-layer diaphragm master roll respectively. Next, as described previously, bind these new labels (codes 1010-1011) with the product quality inspection information and processing information related to the newly processed diaphragm master roll for this particular process step, and then store the bound product quality inspection information and processing information in a control system (such as the memory of a computer), so that relevant information about this newly processed diaphragm master roll can be obtained by reading these new labels (codes 1010-1011) later. Obviously, if tracing back from each label on this batch of diaphragm master rolls, such as from code 1010 to code 1008, then to code 1007, and then to code 1001, it is possible to accurately know each previous process step and the product batch of each process step, thereby realizing the full production line traceability of the manufacturing process of the diaphragm master roll, saving both the labor hours and resource occupancy consumed during the tracing process, and also being able to efficiently and low-costly realize it by taking advantage of the low manufacturing cost of laser engraving, the labels not being easily damaged, and the labels being easy to read.

[0035] It should be noted that, in order to simplify the description of the present application disclosure and thus help the understanding of one or more embodiments of the invention, in the previous description of the embodiments of the present application, sometimes multiple features are merged into one embodiment, drawing, or description thereof. However, this disclosure method does not mean that the features required by the subject matter of the present application are more than those mentioned in the claims.

[0036] In some embodiments, numbers are used to describe components and attribute quantities. It should be understood that such numbers used in the description of the embodiments, in some examples, are modified by the modifiers "about", "approximately", or "substantially". Unless otherwise stated, "about", "approximately", or "substantially" indicate that the said numbers allow for variations in quantity. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, and these approximate values can change according to the characteristics required by individual embodiments.

[0037] The above are only some specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. within the spirit and principle of the present invention shall be included within the protection scope of the present invention. The technical scope of this invention is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A method for real-time reporting of work-in-progress in the production of battery separators, including: providing a separator master roll; performing a first process step on this separator master roll; using laser coding to form a first label on the separator master roll that has completed this first process step; before performing a second process step on the separator master roll with this first label, reading this first label; performing a second process step on the separator master roll with this first label; and using laser coding to form a second label on the separator master roll that has completed this second process step; here, when forming this first label, a first relevant message of the separator master roll that has undergone this first process step is also stored in a control system; here, when reading this first label, the first relevant message of the separator master roll that has undergone this first process step and is stored in this control system is also read; here, when forming this second label, a second relevant message of the separator master roll that has undergone this second process step is also stored in a control system.

2. The separator production method according to claim 1, characterized in that it further includes: before performing a third process step on the separator master roll with this first label and this second label, reading this second label; performing a third process step on the separator master roll with this first label and this second label; and using laser coding to form a third label on the separator master roll that has completed this third process step.

3. The separator production method according to claim 1, characterized in that it further includes: this first process step and this second process step are not carried out consecutively; and this second process step is carried out some time after this first process step is completed.

4. The separator production method according to claim 1, characterized in that it further includes: this first label is formed on the edge of this separator master roll; this second label is formed on the edge of this separator master roll; and this first label and this second label are separated from each other.

5. The separator production method according to claim 1, characterized in that it further includes: when this separator master roll is a single-layer film, both this first label and this second label are engraved on the same side of this separator master roll; and when this separator master roll is a double-layer film, both this first label and this second label are engraved on the opposite two sides of this separator master roll.

6. The separator production method according to claim 1, characterized in that it further includes: this first label is a first serial number displayed in the form of a two-dimensional code; and this second label is a second serial number displayed in the form of a two-dimensional code.

7. The separator production method according to claim 1, characterized in that it further includes: this first relevant message includes product quality inspection information and processing information of this first process step; and this second relevant message includes product quality inspection information and processing information of this second process step.

8. The separator production method according to claim 1, characterized in that possible variations of any process step further include: casting, blown film, annealing, lamination, stretching, aging, delamination, and cutting.

9. The separator production method according to claim 1, characterized in that When multiple diaphragm master rolls need to be compounded and processed into a multi-layer diaphragm master roll, before the compounding process steps of these diaphragm master rolls, one or more labels previously formed by laser coding are sequentially read for each diaphragm master roll. After these diaphragm master rolls are processed through this compounding process step, a compound label is formed on this multi-layer diaphragm master roll formed by this compounding process step using laser coding, and this compound label is bound to the product quality inspection information and processing information of this compounding process step. Then, the process step connection is established in this control system and a tree-like correspondence diagram of the structures of these diaphragm master rolls is formed.

10. The diaphragm production method according to claim 1, characterized in that when a multi-layer diaphragm master roll needs to be separated and processed into multiple single-layer diaphragm master rolls or multiple multi-layer diaphragm master rolls, before the separation process step of this multi-layer diaphragm master roll, one or more labels previously formed by laser coding are read on this multi-layer diaphragm master roll. After this multi-layer diaphragm master roll is processed through this separation process step, respective compound labels are formed on each of the separated single-layer diaphragm master rolls and / or each of the multi-layer diaphragm master rolls using laser coding, and the number of separated layers corresponds to the number of layers to be separated. Then, the process step connection between the separated diaphragm master labels and the multi-layer diaphragm master labels to be separated is established in this control system and a tree-like correspondence diagram of these diaphragm master rolls is formed.

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