Process controller, roll diagram generation system including same, and roll diagram generation method using same

Abstract

The embodiment of the invention provides a roll picture generation method. The method includes the steps of: collecting first data in a first storage area, the first data representing a first event of an electrode sheet performing a roll-to-roll process; and copying the first data to a second storage area.

Description

Technical Field

[0001] The present invention relates to a process controller, a roll map generation system including the process controller, and a roll map generation method using the process controller. This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0102917, filed on August 7, 2023, and the entire content of the Korean patent application is 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 an energy source for various types of wireless devices (such as mobile phones, laptop computers, and cordless vacuum cleaners). Recently, due to the significantly reduced manufacturing cost per unit capacity of secondary batteries due to improved energy density and economies of scale, and the increased driving range of battery electric vehicles (BEVs) to the same level as fuel vehicles, the main use of secondary batteries has evolved from mobile devices to mobility.

[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 production volume and performance of battery cells. The electrode process may include a coating process, a rolling process, and a slitting process. In the coating process, an active material and an insulating material can be applied to the surface of a current collector. In the rolling process, the electrode can be pressed by a pressing roller. In the rolling process, the density, performance, and surface quality of the electrode can be determined. In the slitting process, the electrode can be cut into multiple electrodes according to the design of the battery cell. Summary of the Invention

[0004] Technical Problem

[0005] The present invention relates to providing a process controller with improved reliability, a roll map generation system including the process controller, and a roll map generation method using the process controller.

[0006] Technical Solution

[0007] An exemplary embodiment of the present invention provides a roll map generation method. The roll map generation method includes: collecting first data in a first storage area, the first data representing a first event of an electrode sheet undergoing a roll-to-roll process; and copying the first data to a second storage area.

[0008] The first event may be the start of the roll-to-roll process.

[0009] The roll map generation method may further include: reading the first data from the second storage area and writing the first data to a server.

[0010] The first data may be collected based on a job command transmitted from the server to the controller.

[0011] The controller can be configured to control the roll-to-roll process based on the job command.

[0012] The roll map generation method may further include: collecting second data in a third storage area, the second data representing a second event of the roll-to-roll process; and copying the second data to a fourth storage area.

[0013] The second event may be the completion of the roll-to-roll process.

[0014] The second data may be collected based on the winding amount of the electrode sheet.

[0015] The roll map generation method may further include: reading the second data from the fourth storage area and writing the second data to a server.

[0016] The roll map generation method may further include: generating a roll map representing the roll-to-roll process based on the first data and the second data.

[0017] An exemplary embodiment provides a controller. The controller includes: a storage device including a first storage area and a second storage area; and a central processing unit (CPU) configured to access the first storage area and the second storage area, wherein the CPU is configured to collect start data representing the start of the roll-to-roll process of the electrode sheet in the first storage area and copy the start data from the first storage area to the second storage area. The storage device may further include a third storage area and a fourth storage area, and the CPU may be configured to collect completion data indicating the completion of the roll-to-roll process of the electrode sheet in the third storage area and copy the completion data from the third storage area to the fourth storage area.

[0018] An exemplary embodiment provides a roll map generation system. The roll map generation system includes: a controller configured to control the roll-to-roll process of an electrode sheet; and a server configured to access the controller, wherein the controller includes: a storage device including a first storage area and a second storage area; and a central processing unit (CPU) configured to access the first storage area and the second storage area. The CPU is configured to collect start data representing the start of the roll-to-roll process of the electrode sheet in the first storage area and copy the start data from the first storage area to the second storage area.

[0019] The memory device may further include a third storage area and a fourth storage area, and the CPU may be configured to collect completion data indicating the completion of the roll-to-roll process in the third storage area and copy the completion data from the third storage area to the fourth storage area.

[0020] The roll map generation system described above may further include: a server configured to generate a roll map representing the roll-to-roll process of the electrode sheet based on the first data and the second data.

[0021] The server may be configured to read the start data from the second storage area and read the completion data from the fourth storage area, and write the start data and the completion data to the server.

[0022] Advantageous Effects

[0023] According to an exemplary embodiment of the present invention, a process programmable logic controller (PLC) includes a storage area for long-term storage. Therefore, data crucial for generating a roll map (such as start data and completion data) can be prevented from being lost.

[0024] The effects that can be achieved according to the exemplary embodiments of the present invention are not limited to the above effects, and other effects not described herein will be clearly derived and understood by those of ordinary skill in the art to which the exemplary embodiments of the present invention pertain from the following description. That is, those of ordinary skill in the art can derive unanticipated effects achieved when implementing the exemplary embodiments of the present invention from the exemplary embodiments of the present invention. Brief Description of the Drawings

[0025] Figure 1 A roll map generation system according to an exemplary embodiment is shown.

[0026] Figure 2 is a block diagram of a controller.

[0027] Figure 3 is a flowchart of a roll map generation method according to an exemplary embodiment.

[0028] Figures 4 to 8 is a block diagram for describing a roll map generation method according to an exemplary embodiment.

[0029] Figure 9 is a block diagram of a controller according to another embodiment. Detailed Description of the Embodiments

[0030] 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, terms or expressions used in this specification and the claims should not be construed as being limited to those commonly understood or defined in a common dictionary, and should be understood based on the principle that the inventors of the present application can appropriately define terms or expressions to best explain the present invention according to the meanings and concepts corresponding to the present invention.

[0031] Therefore, the embodiments described herein and the configurations shown in the drawings are only examples of the present invention and do not reflect all the technical ideas of the present invention. Thus, it should be understood that there are various equivalent examples and variant examples of alternative configurations as of the filing date of the present application.

[0032] When it is determined that well-known configurations or functions related to the description of the present invention will obscure the subject matter of the present invention due to unnecessary details, such well-known configurations or functions will not be described in detail.

[0033] Since the embodiments of the present invention are provided to more comprehensively explain the present invention to those of ordinary skill in the art, for clarity, the shapes, sizes, etc. of the components shown in the drawings may be enlarged, omitted, or shown schematically. Therefore, it should not be understood that the dimensions or ratios of the components completely reflect their actual dimensions or ratios.

[0034] (First Embodiment and Second Embodiment)

[0035] Figure 1 A roll drawing generation system 100 according to an exemplary embodiment is shown.

[0036] Figure 2 is a block diagram of a controller 143.

[0037] Referring to Figure 1 and Figure 2 , the roll drawing generation system 100 may include an unwinder 111, a rewinder 113, a processing mechanism 115, a first rotary encoder 121, a second rotary encoder 123, a measuring device 131, an inspector 133, a controller 141, a controller 143, a server 145, and a server 150.

[0038] The unwinder 111 may be configured to unwind an electrode sheet ES from a first electrode roll ER1. The rewinder 113 may be configured to wind the electrode sheet ES into a second electrode roll ER2. Thus, the electrode sheet ES may move between the unwinder 111 and the rewinder 113.

[0039] A process of manufacturing a secondary battery (e.g., 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. Thus, this electrode process may be referred to as a roll-to-roll process.

[0040] Server 150 can be configured to generate a roll map. The roll map can represent events of a roll-to-roll process performed on the electrode sheet ES based on coordinates indicating positions on the electrode sheet ES. That is, the roll map can include event data of the process performed on the electrode sheet ES.

[0041] Generally, the event data is generated according to the process progress and is thus time-series data. Therefore, the data of the process events can include values indicating the events and time values matching them. The time-series data can be sorted by time. Sorting by time is a main feature of the time-series data and should be understood as organizing the events in the order in which they occur and arrive to be processed. That is, the time-series data can be stored based on the time points when the events occur (i.e., when inspections and measurements are performed or when process actions are taken), and the events can be matched with the time values.

[0042] The event data of the roll map can be related to coordinates. In the roll map, the time-series data constructed over time (i.e., according to the process progress) can be related to coordinate data CD based on the movement amount of the electrode sheet ES (i.e., the winding amount or the unwinding amount). Therefore, the roll map enables feedback, feedforward, and tracking of the secondary battery manufacturing process, as described below.

[0043] The manufacturing of a secondary battery 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 actual workpiece, intermediate product, and product, it is difficult to reflect the time-series data of the previous process in the subsequent process. Hereinafter, the operation of correcting the subsequent process based on the data generated according to the result of the previous process is referred to as feedforward.

[0044] Here, the workpiece is an article provided as a result of each process, for example, an electrode sheet on which a coating process, a rolling process, and a slitting process are performed. The intermediate product can include an electrode, a separator cut by a slitting process, or its components (i.e., an electrode assembly). The intermediate product can be one of an electrode, a separator cut by a slitting process, and its components. The intermediate product can be a structure including a case and an electrode assembly included in the case (in some cases, the structure further includes an electrolyte). The product is an article processed by an activation process to be operable as a secondary battery. The above definitions of the workpiece, intermediate product, and product are only definitions of one aspect of them and should not be understood as excluding their general definitions.

[0045] For feedforward, the time series data should be related to the positions on the actual workpieces, components, semi-finished products, and products. Here, the feedforward may include controlling the processing of the electrode sheet based on the coil diagrams generated in the previous process. The coil diagrams may allow the connection of the time series data with the coordinate data, which includes the coordinates of the positions on the actual workpieces, components, semi-finished products, and products. The coil diagrams may provide a match between the time series data and the actual workpieces, components, semi-finished products, and products based on the coordinate data. Thus, by generating the coil diagrams and the feedforward based on the coil diagrams, various aspects of the process that depend on the operator's judgment can be digitized and objectified to improve the productivity and quality of the secondary battery manufacturing process.

[0046] The coil diagrams of the previous batches can be used to improve the process of the subsequent batches, and this operation can be called process feedback. The process feedback using the coil diagrams may include identifying the process conditions and process parameters that cause problems and defects based on the data included in the coil diagrams.

[0047] In addition, as described below, the coil diagrams can be cumulatively generated for the workpieces, semi-finished products, and products of the unit process to track the process history of the products (such as battery cells, battery modules, or battery packs) on the market. For example, a battery cell may include a cell identifier (ID) on the electrode assembly or the casing. The cell ID may include the batch number and coordinate information of the electrodes and separators included in the battery cell. In other words, the cell ID may be related to the coil diagrams of the electrodes and separators included in the battery cell. Thus, when an event such as a quality problem occurs in the battery cells on the market, the historical data of the battery cell manufacturing can be retrieved based on the cell ID.

[0048] The electrode sheet ES can be processed by the processing mechanism 115. The processing mechanism 115 may include a die coater, a pressing roller, or a slitting knife. The die coater may be configured to perform a coating process on the electrode sheet ES. In the coating process, the electrode sheet can be coated with an electrode paste. The electrode paste may include an active material, a conductive agent, a binder, and a solvent. The electrode paste can be prepared by dissolving the active material, the conductive agent, the binder, etc. in the solvent. The pressing roller may be configured to perform a rolling process on the electrode sheet ES. In the rolling process, the electrode sheet coated with the electrode paste can pass between the pressing rollers. Through the rolling process, the surface of the electrode sheet can be flattened, and the bonding force between the active material and the current collector on the electrode sheet can be improved. The electrode sheet ES can be subjected to a slitting process by means of the slitting knife. The electrode sheet ES can be divided into multiple individual electrode sheets by means of the slitting process.

[0049] The roll images can be generated in batches. A batch is a production unit for the roll-to-roll process. After achieving the target winding length of the electrode sheet ES with the rewinder 113, the electrode sheet ES can be cut to separate the second electrode roll ER2. The completed second electrode roll ER2 is an example of a batch. The first electrode roll ER1 newly loaded on the unwinder 111 is also an example of a batch. The server 150 can generate and store roll images for each process (e.g., coating process, rolling process, or slitting process).

[0050] The first rotary encoder 121 can be configured to detect the amount of the electrode sheet ES unwound from the first electrode roll ER1 by the unwinder 111. Accordingly, the first rotary encoder 121 can be configured to generate an unwinding amount signal UWAS representing the unwinding amount of the electrode sheet ES. The first rotary encoder 121 can be configured to transmit the unwinding amount signal UWAS to the controller 141. The controller 141 can be configured to collect unwinding amount data based on the unwinding amount signal UWAS of the electrode sheet ES.

[0051] The second rotary encoder 123 can be configured to detect the amount of the electrode sheet ES wound into the second electrode roll ER2 by the rewinder 113. Accordingly, the second rotary encoder 123 can be configured to generate a winding amount signal WAS indicating the winding amount of the electrode sheet ES. The second rotary encoder 123 can be configured to transmit the winding amount signal WAS to the controller 141. The controller 141 can be configured to collect winding amount data based on the winding amount signal WAS of the electrode sheet ES.

[0052] In some cases, a part of the electrode sheet ES may be discarded, so the amount of the electrode sheet ES unwound by the unwinder 111 may be different from the amount of the electrode sheet ES wound by the rewinder 113. When the electrode sheet ES is stretched due to pressure during the rolling process, the amount of the electrode sheet ES unwound by the unwinder 111 can be different from the amount of the electrode sheet ES wound by the rewinder 113.

[0053] The controller 141 can be configured to collect coordinate data CD of the electrode sheet ES based on the input amount signal UWAS or the consumption amount signal WAS of the electrode sheet ES. For example, the controller 141 can determine the moving distance of the electrode sheet ES based on the consumption amount signal WAS of the electrode sheet ES. Accordingly, the controller 141 can be configured to determine the position on the electrode sheet ES of the portion of the electrode sheet ES wound by the rewinder 113 at each time point when an event occurs on the electrode sheet ES.

[0054] As another embodiment, the controller 141 may determine the moving distance of the electrode sheet ES based on the input amount signal UWAS of the electrode sheet ES or based on each of the consumption amount signal WAS and the input amount signal UWAS. Hereinafter, as a non-limiting embodiment, the technical concept of the present invention will be described with respect to an embodiment in which the controller 141 collects coordinate data CD based on the consumption amount signal WAS of the electrode sheet ES.

[0055] The coordinate data CD may include coordinates matching each part of the electrode sheet ES. That is, each arbitrary point on the electrode sheet ES may be matched with coordinates. The coordinates may be a one-dimensional (1D) quantity in the machine direction or the longitudinal direction of the electrode sheet ES, but are not limited thereto. The coordinates may be a two-dimensional (2D) quantity in the machine direction and the transverse direction (or width direction) of the electrode sheet ES.

[0056] The measuring device 131 may be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measuring device 131 may measure the electrode sheet ES by means of a scanning method. The measuring device 131 may move in the transverse direction. During one scan, the measuring device 131 may move from one end of the electrode sheet ES in the transverse direction to the other end of the electrode sheet ES in the transverse direction TD. When the measuring device 130 scans in the transverse direction, the electrode sheet ES may move in the machine direction by means of the unwinder 111 and the rewinder 113.

[0057] The measurement data may include inspection results represented by numerical values. For example, the measurement data may include dimensional data of the electrode sheet ES (e.g., thickness and width), data on the loading amount of the coating material on the electrode sheet ES, dimensional data such as the width of the insulating material on the coating material and the overlap width between the coating material and the insulating material, mismatch data between the coating tape on the upper surface of the electrode sheet ES and the coating tape on the lower surface of the electrode sheet E, etc. Here, the loading amount is the amount of the coating material loaded per unit area of the electrode sheet ES, and may be the surface density of the coating material. Whether the measured part of the electrode sheet ES is defective may be determined by processing the measurement data by a setting method.

[0058] When the amount of the coating material measured on the electrode sheet ES (e.g., the loading amount 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 part of the electrode sheet ES may be determined as a high-quality part. When the amount of the coating material measured on the electrode sheet ES (e.g., the loading amount 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 part of the electrode sheet ES may be determined as defective.

[0059] The measuring device 131 may include a sensing unit 131S and a processor 133P. The sensing unit 131S may be configured to detect a physical quantity of the electrode sheet ES to generate a measurement signal MS. For example, the sensing unit 131S may include a time delay integration (TDI) camera, a complementary metal oxide semiconductor (CMOS) image sensor, a time of flight (TOF) sensor, etc. The sensing unit 131S may include a transmitter and a receiver configured to perform measurements using non-destructive signals such as ultrasonic waves, microwaves, terahertz waves, or infrared rays. The sensing unit 131S 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 131 may include a pressure sensor, a temperature sensor, an ultrasonic sensor, a proximity sensor, a door status sensor, a motion tracking sensor, a humidity sensor, visible light and infrared sensors, a camera, etc.

[0060] The processor 133P may be configured to connect the coordinate data CD with the measurement data to generate coordinate-related measurement data CMD. Generally, the measurement data may be processed based on a trigger point. Embodiments of the measurement data processing may include storing the measurement data, manipulating the measurement data (e.g., generating coordinate-related measurement data CMD), and transmitting the measurement data. The processor 133P may be configured to transmit the coordinate-related measurement data CMD to the controller 141.

[0061] As a non-limiting example, the trigger point for processing the measurement data may be the completion of a scan. For example, the sensing unit 131S may scan the electrode sheet ES in the width direction of the electrode sheet ES, and whenever a scan is performed, the measurement data may be stored, processed, manipulated, and transmitted. As another example, the trigger point may be the completion of multiple scans or a partial completion of a scan.

[0062] According to an exemplary embodiment, the processor 131P may be configured to calibrate the coordinate data CD based on the position of the sensing unit 131S. More specifically, the processor 131P may be configured to calibrate the coordinate data CD based on the offset length of the sensing unit 131S such that the coordinates of the coordinate data CD may be connected to the measured values of the measurement data.

[0063] The measuring device 131 may collect measurement data of a portion corresponding (e.g., overlapping) to the sensing unit 131S, and the coordinate data CD is collected by a second encoder 125 spaced apart from the sensing unit 131S described above. Therefore, the portion of the electrode sheet ES corresponding to the coordinate data CD and the portion of the electrode sheet ES corresponding to the measurement data may be different from each other at the same time point.

[0064] The processor 131P can be configured to generate coordinate-related measurement data CMD based on coordinate data CD and measurement data. According to an exemplary embodiment, the coordinate-related measurement data CMD can be provided by calibrating the coordinate data CD collected at the same time point as the measurement data based on the offset length and connecting the calibrated coordinate data CD with the measurement data. The measured value (or representative value and judgment value of the measured value) of the coordinate-related measurement data CMD can match the calibrated coordinates. The measured value (or representative value and judgment value of the measured value) of the coordinate-related measurement data CMD can also match the time value.

[0065] Here, the representative value of the measured value can include an average value, a standard deviation, a median, a maximum value, or a minimum value, and the judgment value can be an evaluation of the process on the electrode sheet ES determined according to the representative value. As a non-limiting example, the coordinate-related measurement data CMD can include the representative value, the judgment value, and the start coordinate and end coordinate of the part of the electrode sheet ES from which the measurement data is collected.

[0066] A plurality of guide rollers can be interposed between the sensing unit 131S and the rewinder 113 to define the movement path of the electrode sheet ES. Accordingly, the offset length can be defined as the length of the electrode sheet ES between the sensing unit 131S and the rewinder 113. The offset length can be equal to or greater than the linear distance between the sensing unit 131S and the rewinder 113.

[0067] The inspector 133 can be configured to inspect the electrode sheet ES. The inspection data can include the judgment result of the quality of a part of the electrode sheet ES and process events. For example, the inspection data can include: data on the appearance of the electrode sheet ES collected by an image-based inspection device such as a vision machine; data on the disconnection and joints of the electrode sheet ES; data on the part of the electrode sheet ES that is sampled for inspection; data on the part of the electrode sheet ES to be discarded; data on the discarded part of the electrode sheet ES; data on whether there are defects in the coating material and insulating material on the electrode sheet ES; data on the reference points indicating the positions on the electrode sheet ES; and defect data such as pinhole defects, pit defects, line defects, crack defects, side loop defects, island defects, fold defects, wrinkle defects, scar defects, and scratch defects.

[0068] The inspector 133 can include a sensing unit 133S and a processor 133P. The sensing unit 133S can be configured to detect the electrode sheet ES to generate an inspection signal IS. For example, the sensing unit 133S can be an imaging device including a delay integration camera, a complementary metal oxide semiconductor (CMOS) image sensor, etc. The sensing unit 133S can include a barcode reader, an optical character reader (OCR), a color sensor, etc.

[0069] The processor 133P can be configured to collect inspection data by processing the inspection signal IS based on a set algorithm. The inspection data can include a judgment value for quality judgment and a time value matching the judgment value.

[0070] The processor 133P can be configured to connect the coordinate data CD with the inspection data to generate coordinate-related inspection data CID. According to an exemplary embodiment, the processor 133P can be configured to calibrate the coordinate data CD based on the position of the sensing unit 133S. More specifically, the processor 133P can be configured to calibrate the coordinate data CD based on the offset length of the sensing unit 133S such that the coordinates of the coordinate data CD can be connected to the judgment value of the inspection data. The offset length of the sensing unit 133S can be the length of the electrode sheet ES between the sensing unit 133S and the rewinder 113. The processor 133P can be configured to transmit the coordinate-related inspection data CID to the controller 141.

[0071] The controller 141 can be configured to transmit the coordinate-related measurement data CMD and the coordinate-related inspection data CID to the controller 143. The controller 143 can be, for example, a programmable logic controller (PLC). A PLC is a special type of microprocessor-based controller that uses programmable memory to store instructions and perform functions such as logic, sequencing, timing, counting, and arithmetic operations to control machines and processes. A PLC is easy to operate and program. The controller 141 can also be a PLC, but is not limited thereto.

[0072] The controller 143 can be configured to control the operations of the unwinder 111, the rewinder 113, and the processing mechanism 115. The controller 143 can be configured to receive a job command from the server 150. For process control, a communication line can be installed between the controller 143 and the server 150 to connect the controller 143 and the server 150 via the server 145. Therefore, compared with the cases where the first rotary encoder 121 and the second rotary encoder 125, the measuring device 131, and the inspector 133 communicate directly with the server 150 and the controller 141 communicates directly with the server 150, data transmission by means of the controller 143 can reduce the resources required for installing communication lines and can effectively process and manage data.

[0073] The server 145 can be a communication server. The server 145 can include a program for communication between the controller 143 of the manufacturing equipment and the server 150 as a superior server. The server 145 can be implemented by the hardware described below. The language and protocol of the server 150 can be different from those of the controller 143. For example, the language of the server 150 can be SQL, and the language of the controller 143 can be ladder diagram.

[0074] Server 145 can be configured to convert the job command WO transmitted from server 220 into the language of controller 143. Additionally, server 145 can be configured to convert the coordinate-related measurement data CMD, coordinate-related inspection data CID, and first data D1 and second data D2 (which will be described below) into the language of server 150, and write the converted coordinate-related measurement data CMD, coordinate-related inspection data CID, and first data D1 and second data D2 into the database of server 150.

[0075] The job command WO can include model information and recipes for processing the electrode sheet ES. The job command WO can include all matters related to the processing of the electrode sheet ES, such as the number of batches to be processed in the current process, the number of coating bands to be formed on the electrode sheet ES, process conditions such as temperature, humidity, and pressure, and process parameters such as the moving speed of the electrode sheet ES, the discharge rate of the coating die, and the pressure of the pressure roller.

[0076] Controller 143 can be configured to generate signals for operating or stopping the unwinder 111, rewinder 113, and processing mechanism 115 based on the job command WO. Controller 143 can be configured to collect the first data D1 based on the job command WO. The first data D1 can represent the first event of the roll-to-roll process of the electrode sheet ES. As a non-limiting example, the first event can be the start of the roll-to-roll process of the electrode sheet ES. Controller 143 can be configured to collect the second data D2 based on the winding amount signal WAS of the electrode sheet ES. The second data D2 can represent the second event of the roll-to-roll process of the electrode sheet ES. As a non-limiting example, the second event can be the completion of the roll-to-roll process of the electrode sheet ES.

[0077] Controller 143 can include a power supply 1431, a central processing unit (CPU) 1432, an input interface 1433, an output interface 1434, a communication interface 1435, and storage devices 1436 and 1437.

[0078] The power supply 1431 can be configured to supply operating power to the CPU 1432, input module 1433, output module 1414, communication interface 1435, and storage devices 1436 and 1437. In some cases, controller 143 can be powered from a separate power supply, and thus can be omitted in such cases. As a non-limiting example, the power supply 1431 can be configured to supply operating power based on a 220V AC voltage or a 24V DC voltage.

[0079] The storage device 1436 can be configured to store system programs. The storage device 1436 can be, for example, a read-only memory (ROM), and is configured to permanently store data for the operating system of controller 143.

[0080] The storage device 1437 can be configured to store user programs and data. The user program can be a program set by the user, enabling the CPU 1432 to perform specific functions. The data can include coordinate-related inspection data CID, coordinate-related measurement data CMD, and first data D1 and second data D2 described below. The storage device 1437 can also store the status information of input and output devices; the values of timers, counters, and other internal devices. The storage device 1437 can be, for example, a random access memory (RAM). Generally, user programs are frequently updated and can thus be stored in the storage device 1437. When the user program is completed, the user program can be stored in the storage device 1436. The user program can be written into the storage device 1436 by the device programmer DP. The device programmer DP can be a device separate from the controller 143 or can be included in the controller 143.

[0081] The CPU 1432 can be configured to implement the logical and control communication between modules that convert input signals into output operation signals. The CPU 1432 can operate based on the system program stored in the storage device 1436. The CPU 1432 can be configured to store the coordinate-related measurement data CMD, coordinate-related inspection data CID, first input data D1, and second input data D2 in the storage device 1437. The CPU can be configured to manipulate data based on the user program stored in the storage device 1437. The CPU 1432 can be configured to write the input data from the measurement device 131, checker 133, and user into the storage device 1437.

[0082] When the PLC operates, the CPU 1432 can scan the current input conditions and data and store them in the storage device 1437. Thereafter, the CPU 1432 can be configured to sequentially read and execute the user program and transfer the results to the output module 1434, communication module 1435, or storage device 1437.

[0083] Since the input module 1433 and output module 1434 perform isolation and signal conditioning, sensors and actuators can be directly connected to the input module 1433 and output module 1434 without additional circuitry. The input module 1433 and output module 1434 can be configured to transfer data between the CPU 1432 and external devices.

[0084] The conditions and data of industrial devices and production processes can be transmitted to the CPU 1432 via the input module 1433. The results of the processing performed by the CPU 1432 can be transmitted to the actuator via the output module 1434.

[0085] The input module 1433 may include, for example, mechanical switches, proximity switches, photoelectric switches, encoders, temperature and pressure switches, potentiometers, linear variable differential transformers, strain gauges, thermistors, thermal transistors, and digital and analog devices such as AC / DC thermocouple switches for position detection. The input module 1433 may provide an interface between the input devices and the CPU 1432 operating based on a low DC voltage. Some input devices may generate analog signals in a high voltage range. The input module 1433 may be configured to convert the signals generated by the input devices into voltages within a range acceptable to the CPU 1432.

[0086] The output module 1434 may be configured to generate signals for controlling the operation of the actuators. The output module 1434 may include relays, transistors, and triacs. The output module 1434 may include relays, contactors, solenoid valves, motors, etc.

[0087] The communication interface 1435 may be configured to transmit data to and receive data from the controller 141, or transmit data to and receive data from the server 150 via the server 145.

[0088] The server 150 may be configured to generate a roll chart based on the coordinate-related inspection data CID, the coordinate-related measurement data CMD, and the first data D1 and the second data D2. The roll chart may include data on the specifications of the lot. The specifications of the lot may include, for example, the lot number, the length of the wound electrode sheet ES, the width of the electrode sheet ES, and the materials and composition for processing the electrode sheet ES.

[0089] According to an exemplary embodiment, the server 150 may be a data processing system that supports managing all activities required for manufacturing secondary batteries, such as job scheduling management, job instructions, quality control, and job performance aggregation. The server 150 may be, for example, a manufacturing execution system (MES). The server 150 may be configured to perform input, processing, output, and communication of the data required for electrode manufacturing (including coating processes, rolling processes, and slitting processes).

[0090] 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 processed electrode sheets by continuously monitoring the processing of the electrode sheets based on the measurement 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 almost in real time to identify problematic situations in a timely manner and provide notifications to the operator before potential problems occur.

[0091] According to other exemplary embodiments, the server 150 can be, for example, a data warehouse and store the volume map for a long period of time according to, for example, the product quality assurance period.

[0092] According to other exemplary embodiments, the server 150 can perform all functions of MES, SPC, and the data warehouse, or be provided separately from MES, SPC, and the data warehouse to create the volume map.

[0093] The processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 can be implemented by hardware, firmware, software, or a combination thereof. For example, the processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 can include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 can include simple controllers, complex processors such as microprocessors, CPUs, or GPUs, and processors configured by software / specialized hardware and firmware. The processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 can be implemented, for example, by a general-purpose computer or specialized hardware such as a digital signal processor (DSP), a field-programmable gate array (FPGA), or an application-specific integrated circuit (ASIC).

[0094] The server 150 can include a physical server or a cloud server. The server 150 can provide data and analysis results to an operator through various frameworks. The frameworks can include protocols that support data transmission, such that a display device can visualize the data through a user interface and provide updated visualization when the server 150 calculates new data. The protocols that support data transmission can include HTML, JavaScript, and / or JSON.

[0095] The server 150 can include various application programming interfaces (APIs) and other data management tools for storing data in a database. The APIs can also be used to retrieve data from the databases of various data management systems. The data management systems can provide access to the database, extract or retrieve data from the database, and generate metrics. Here, a metric is a tool for visualizing data. The metrics can include measured values generated in a time series manner and can be used to monitor applications and generate status warnings.

[0096] The volume map generation system 100 can provide a plug-in architecture with APIs for obtaining data to provide a plug-and-play connection between sensors, measurement devices, and inspectors. Therefore, resources in a specific process step and a specific site can be easily transferred to different processes, and different sites or new resources can be easily introduced into each process step and each site.

[0097] In some embodiments, the roll map generation system 100 may further include a manual input system that allows an operator to input manufacturing data. The roll map generation system 100 may allow the operator to input data using input tools and computer-based input of manufacturing data such as Excel file scraping. The manual input system may be, for example, a human-machine interface (HMI) of a supervisory control and data acquisition (SCADA). Generally, SCADA may include a combination of software and hardware, such as a programmable logic controller (PLC) and a remote terminal unit (RTU). The HMI is a screen that supports communication between the operator and the SCADA system and is a key element of the SCADA system. For example, the manual input of the HMI may include selecting a defect type and reflecting the performance at completion.

[0098] According to some embodiments, the operations of the processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 may be implemented as instructions stored in a machine-readable medium that can be read and executed by one or more processors. Here, the 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). Examples of the machine-readable medium may include a read-only memory (ROM), a random access memory (RAM), a magnetic 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.

[0099] The processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 may include firmware, software, routines, and instructions for performing the above operations or the processes described below. For example, the processors 131P and 133P, the controllers 141 and 143, and the servers 145 and 150 may be instantiated in a memory.

[0100] (Third Embodiment)

[0101] Figure 3 is a flowchart of a roll map generation method according to an exemplary embodiment.

[0102] Figures 4 to 8 is a block diagram for describing a roll map generation method according to an exemplary embodiment.

[0103] Refer to Figures 1 to 4 , in P110, the first data D1 may be collected in the first storage area 1437R1 of the controller 143. The first data D1 may be written by the CPU 1432.

[0104] The storage device 1437 may include first to fourth storage areas 1437R1, 1437R2, 1437R3, and 1437R4 that operate independently. The CPU 1432 may be configured to access the first to fourth storage areas 1437R1, 1437R2, 1437R3, and 1437R4. The data type assigned to the first storage area 1437R1 (e.g., process start data) may be collected only in the first storage area 1437R1. The data in the first storage area 1437R1 may be copied to the second storage area 1437R2. The data type assigned to the third storage area 1437R3 (e.g., completion data) may be collected only in the third storage area 1437R3. The data in the third storage area 1437R3 may be copied to the fourth storage area 1437R4. As described above, the first to fourth storage areas 1437R1, 1437R2, 1437R3, and 1437R4 may be configured to perform different functions.

[0105] The data stored in each of the first to fourth storage areas 1437R1, 1437R2, 1437R3, and 1437R4 may be deleted at set time intervals. The time intervals for deleting data from the first to fourth storage areas 1437R1, 1437R2, 1437R3, and 1437R4 may be different from each other. The time interval for deleting data from the second storage area 1437R2 may be longer than the time interval for deleting data from the first storage area 1437R1. Thus, the data copied to the second storage area 1437R2 may be stored for a long time. The time interval for deleting data from the fourth storage area 1437R4 may be longer than the time interval for deleting data from the third storage area 1437R3. Thus, the data copied to the fourth storage area 1437R4 may be stored for a long time.

[0106] The first data D1 may be written by the CPU 1432 to the first storage area 1437R1. The first data D1 may be data that should be held by the storage device 1437 for a relatively long time. As described above, the first data D1 may be the start data of the roll-to-roll process of the electrode sheet ES, but is not limited thereto. The first data D1 may be one of the above-mentioned inspection data and measurement data.

[0107] Reference Figures 1 to 3 and Figure 5 , in P120, the first data D1 may be copied to the second storage area 1437R2 of the controller 143. The CPU 1432 may be configured to read the first data D1 from the first storage area 1437R1 and write the first data D1 to the second storage area 1437R2. After writing the first data D1 to the second storage area 1437R2, the first data D1 may be deleted from the first storage area 1437R1.

[0108] Reference Figures 1 to 3 andFigure 6 In P130, the second data D2 can be collected in the third storage area 1437R3 of the controller 143. The second data D2 can be written by the CPU 1432.

[0109] Reference Figures 1 to 3 and Figure 7 In P140, the second data D2 can be copied to the fourth storage area 1437R4 of the controller 143. The second data D2 can be data that should be held by the storage device 1437 for a relatively long time. The second data D2 can be, for example, the completion data of the roll-to-roll process of the electrode sheet ES, but is not limited thereto. The CPU 1432 can be configured to read the second data D2 from the third storage area 1437R3 and write the second data D2 to the fourth storage area 1437R4. After writing the second data D2 to the fourth storage area 1437R4, the first data D2 can be deleted from the third storage area 1437R3.

[0110] Reference Figures 1 to 3 and Figure 8 In P150, the first data D1 and the second data D2 can be written to the server 150. The server 145 can be configured to access the second storage area 1437R2 and the fourth storage area 1437R4 of the storage device 1437. The server 145 can be configured to read the first data D1 from the second storage area 1437R2, read the second data D2 from the fourth storage area 1437R4, and write the first data D1 and the second data D2 to the server 150. The server 145 can not access the collection areas (i.e., the first storage area 1437R2 and the third storage area 1437R4) of the storage device 1437.

[0111] Thereafter, the server can be configured to generate a roll map based on the coordinate-related inspection data CID, the coordinate-related measurement data CMD, and the first data D1 and the second data D2. The first data D1 and the second data D2 include information about the start and completion of the electrode sheet ES, and thus the data range of the roll map belonging to the corresponding batch can be determined based on the first data D1 and the second data D2 to generate a roll map.

[0112] (Fourth Embodiment)

[0113] Figure 9 is a block diagram of a controller 143' according to another embodiment.

[0114] Reference Figure 9 The controller 143' can include a power supply 1431, a CPU 1432, an input interface 1433, an output interface 1434, a communication interface 1435, and storage devices 1436, 1437, and 1438.

[0115] The power supply 1431, the CPU 1432, the input interface 1433, the output interface 1434, the communication interface 1435, and the storage devices 1436, 1437, and 1438 are the same as those described above. Figure 1 and Figure 2 Those described are basically the same, so their redundant descriptions are omitted here.

[0116] The storage device 1438 may be configured to store the first data D1 and the second data D2 copied thereto (see Figure 8 ). The storage device 1438 may be a memory chip separate from the storage device 1437, or may be a memory module. That is, the storage device 1438 may be a device different from the storage device 1437. According to an exemplary embodiment, the controller 143' may include the storage device 1438 to store data, such as first data D1 and second data D2 that should be stored for a relatively long time (see Figure 8 ).

[0117] Therefore, the storage device 1437 may include a first storage area 1437R1 and a third storage area 1437R3 for collecting data (see Figure 8 ), and the storage device 1438 may include a storage area for copying and storing data, similar to the second storage area 1437R2 and the fourth storage area 1437R4 (see Figure 8 ).

[0118] The storage device 1438 may be a different type of memory from the storage device 1437. For example, the storage device 1437 may be a static RAM (SRAM) or a dynamic RAM (DRAM), and the storage device 1438 may be a NAND flash memory, a ferroelectric RAM (FRAM), a magnetic RAM (MRAM), a phase change RAM (PRAM), or a resistive RAM (ReRAM).

[0119] The present invention has been described in more detail above with reference to the accompanying 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 that replace the configurations may have been made on the filing date of the present application.

Claims

1. A method for generating a roll graph, the method comprising: collecting first data in a first storage area, the first data representing a first event of an electrode sheet undergoing a roll-to-roll process; as well as The first data is copied to the second storage area.

2. The method for generating a roll map according to claim 1, wherein The first event is the start of the reel-to-reel process.

3. The method for generating a roll map according to claim 1, further comprising: The first data is read from the second storage area and written to a server.

4. The method for generating a roll map according to claim 3, wherein collecting the first data based on a job command transmitted from the server to the controller, and The controller is configured to control the roll-to-roll process based on the job commands.

5. The method for generating a roll graph according to claim 1, further comprising: collecting second data in a third storage area, the second data representing a second event of the reel-to-reel process; as well as The second data is copied to the fourth storage area.

6. The method for generating a roll map according to claim 5, wherein The second event is completion of the reel-to-reel process.

7. The method for generating a roll map according to claim 5, wherein The second data is collected based on a winding amount of the electrode sheet.

8. The method for generating a roll map according to claim 5, further comprising: The second data is read from the fourth storage area and written to a server.

9. The method for generating a roll map according to claim 7, further comprising: A roll map representing the roll-to-roll process is generated based on the first data and the second data.

10. A process controller, comprising: A storage device, the storage device comprising a first storage area and a second storage area; as well as a central processing unit CPU, the CPU being configured to access the first storage area and the second storage area, The CPU is configured to collect start data indicating the start of a roll-to-roll process of the electrode sheet in the first storage area, and copy the start data from the first storage area to the second storage area.

11. The process controller of claim 10, wherein The storage device further includes a third storage area and a fourth storage area, and The CPU is configured to collect completion data indicating completion of the roll-to-roll process of the electrode sheet in the third storage area, and copy the start data from the third storage area to the fourth storage area.

12. A volume graph generation system, the volume graph generation system comprising: a controller configured to control a roll-to-roll process of the electrode sheet; as well as a server configured to access the controller, Wherein, the controller comprises: A storage device, the storage device comprising a first storage area and a second storage area; and a central processing unit CPU, the CPU being configured to access the first storage area and the second storage area, The CPU is configured to collect start data indicating the start of the roll-to-roll process of the electrode sheet in the first storage area, and copy the start data from the first storage area to the second storage area.

13. The roll map generation system according to claim 12, wherein The storage device further includes a third storage area and a fourth storage area, and The CPU is configured to collect completion data indicating completion of the reel-to-reel process in the third storage area, and copy the completion data from the third storage area to the fourth storage area.

14. The scroll map generation system according to claim 13, further comprising: A server is configured to generate a roll map representing the roll-to-roll process of the electrode sheet based on the start data and the completion data.

15. The roll map generation system according to claim 14, wherein The server is configured to read the start data from the second storage area and the completion data from the fourth storage area, and write the start data and the completion data to the server.

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