Battery manufacturing system and battery manufacturing method

Abstract

A battery manufacturing system is provided according to an example embodiment. The battery manufacturing system is configured to unwind an electrode sheet from a first electrode roll and wind an electric electrode into a second electrode roll, and includes: a server configured to store coordinate data of the first electrode roll and reference point data indicating a reference point on the first electrode roll; a programmable logic controller (PLC) configured to load coordinate data and reference point data of the first electrode roll from a server; and a reference point sensor configured to sense a reference point on the electrode sheet unwound from the first electrode roll and generate a reference point sensing signal. The PLC may be configured to obtain coordinate data of the second electrode roll by calibrating an inverted coordinate value of a stored coordinate value included in coordinate data of the first electrode roll based on an inverted coordinate value of a stored reference point coordinate value included in the reference point data and a coordinate value of a sensing reference point.

Description

TECHNICAL FIELD

[0001] The present application relates to a battery manufacturing system and a battery manufacturing method.

[0002] This application claims the priority benefit of Korean Patent Application No. 10-2023-0117944, filed on September 5, 2023, and the entire contents of which are incorporated herein by reference. BACKGROUND

[0003] Unlike primary batteries, a battery (secondary battery) can be charged and discharged multiple times. 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, the main use of batteries has developed from mobile devices to mobile travel as the manufacturing cost per unit capacity of the battery has sharply decreased due to improved energy density and economies of scale, and the range of battery electric vehicles (BEVs) has increased to the same level as fuel vehicles.

[0004] A battery is manufactured through an electrode process, an assembly process, and an activation process. Among these processes, the electrode process is a key process that determines the yield and performance of a battery cell. The electrode process can include a coating process, a roll-pressing 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 roll-pressing process, an electrode can be pressed by a press roll. In the roll-pressing process, the density, performance, and surface quality of the electrode can be determined. In the slitting process, the electrode can be cut into a plurality of electrodes according to the design of the battery cell. SUMMARY

[0005] TECHNICAL PROBLEM

[0006] The present application aims to provide a battery manufacturing system having improved reliability and traceability and a battery manufacturing method.

[0007] TECHNICAL SOLUTION

[0008] An example embodiment of the present invention provides a battery manufacturing system. The battery manufacturing system configured to unroll an electrode sheet from a first electrode roll and wind the electrode sheet into a second electrode roll, the battery manufacturing system comprising: a server configured to store coordinate data of the first electrode roll and reference point data indicating a reference point on the first electrode roll; a programmable logic controller (PLC) configured to load the coordinate data of the first electrode roll and the reference point data from the server; and a reference point sensor configured to sense a reference point on the electrode sheet unrolled from the first electrode roll and generate a reference point sensing signal, wherein the PLC is configured to obtain coordinate data of the second electrode roll by calibrating inverse coordinates of stored coordinates included in the coordinate data of the first electrode roll based on inverse coordinates of stored reference point coordinates included in the reference point data and coordinates of the sensed reference point.

[0009] By inverting the stored coordinates, a start coordinate of the coordinate data of the first electrode roll can be calibrated to an end coordinate of the coordinate data of the second electrode roll, and an end coordinate of the coordinate data of the first electrode roll can be calibrated to a start coordinate of the coordinate data of the second electrode roll.

[0010] The inversion of the stored reference point coordinates and the inversion of the stored coordinates included in the coordinate data can be performed by the server or the PLC.

[0011] The PLC can calculate an offset between the inverse coordinates of the stored reference point coordinates and the coordinates of the sensed reference point, and calibrate the inverse coordinates of the stored coordinates of the first electrode roll based on the offset.

[0012] The reference point sensor can calibrate the coordinates of the sensed reference point based on an offset length, the offset length being a length of the electrode sheet between a rewinding machine configured to wind the second electrode roll and a portion of the electrode sheet at a point in time at which the reference point is sensed.

[0013] The server can store a first roll map including the coordinate data of the first electrode roll and the reference point data.

[0014] The server can generate a second roll map of the second electrode roll or calibrate coordinate data of the generated second roll map based on the reference point sensing data and the obtained coordinate data of the second electrode roll.

[0015] An exemplary embodiment provides a battery manufacturing method in which an electrode sheet is unwound from a first electrode roll and wound into a second electrode roll. The battery manufacturing method includes loading coordinate data including storage coordinates of the first electrode roll and storage reference point data of the first electrode roll, collecting reference point sensing data by sensing a reference point on the electrode sheet unwound from the first electrode roll, the reference point sensing data including coordinates of a sensed reference point, and obtaining coordinate data of the second electrode roll by calibrating inverse coordinates of the storage coordinates of the first electrode roll based on inverse coordinates of the storage reference point coordinates and the coordinates of the sensed reference point.

[0016] The battery manufacturing method can further include discarding a defective portion of the electrode sheet unwound from the first electrode roll based on the calibrated coordinates.

[0017] By inverting the storage coordinates, a start coordinate of coordinate data of the first electrode roll can be calibrated to an end coordinate of coordinate data of the second electrode roll, and an end coordinate of coordinate data of the first electrode roll can be calibrated to a start coordinate of coordinate data of the second electrode roll.

[0018] In the battery manufacturing method, an offset between inverse coordinates of the storage reference point coordinates and the coordinates of the sensed reference point can be calculated, and the inverse coordinates of the storage coordinates of the first electrode roll can be calibrated based on the offset.

[0019] The step of calibrating the sensed reference point can be calibrated based on an offset length, which is a length of the electrode sheet between an unwinder configured to unwind the first electrode roll and a portion of the electrode sheet at a point in time at which the reference point is sensed.

[0020] The coordinate data and the reference point data of the first electrode roll can be loaded based on a first roll map of the first electrode roll including the coordinate data and the reference point data.

[0021] A second roll map of the second electrode roll can be generated based on the reference point sensing data and the obtained coordinate data of the second electrode roll, or coordinate data of the generated second roll map can be calibrated.

[0022] An embodiment of the present invention provides a second electrode roll wound by an electrode sheet unwound from a first electrode roll formed of the electrode sheet and including a plurality of first reference points in a longitudinal direction.

[0023] The electrode sheet wound into the second electrode roll includes a plurality of second reference points corresponding to the plurality of first reference points, and each of the plurality of second reference points is located at one of inverted positions of the plurality of first reference points on the electrode sheet in the longitudinal direction or one of offset positions of the inverted positions of the plurality of first reference points on the electrode sheet in the longitudinal direction.

[0024] Advantageous Effects

[0025] Example embodiments of the present application provide a system configured to generate a roll map supporting feedback, feedforward, and tracking of an electrode process and perform a battery manufacturing process based on the roll map, and a battery manufacturing method using the same.

[0026] Effects achievable by example embodiments of the present application are not limited to the above-mentioned effects, and other effects not described herein will be clearly derived and understood by those of ordinary skill in the art to which the example embodiments of the present application belong from the following description. That is, those of ordinary skill in the art can derive unintended effects achieved when implementing the example embodiments of the present application from the example embodiments of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 A battery manufacturing system according to an example embodiment is illustrated.

[0028] Figure 2 is a flowchart of a battery manufacturing method according to an example embodiment.

[0029] Figure 3 A battery manufacturing system according to an example embodiment is illustrated. DETAILED DESCRIPTION

[0030] Hereinafter, embodiments of the present application will be described in detail with reference to the accompanying drawings. Prior to describing the embodiments of the present application, the terms or expressions used in the specification and claims should not be interpreted as being limited to the commonly- understood or generally-used meanings defined in dictionaries, and should be interpreted based on the meanings and concepts of the inventor of the present application that can be properly defined to best explain the principles of the present application according to the corresponding meanings and concepts of the present application.

[0031] Therefore, the embodiments set forth herein and the configurations shown in the drawings are merely examples of the present application, and do not reflect all technical ideas of the present application, and thus it should be understood that various equivalents and modifications of alternative configurations can have been made at the filing date of the present application.

[0032] Well-known configurations or functions related to the present application are not described in detail when it is determined that they make the subject matter of the present application obscure due to unnecessary details.

[0033] Because the embodiments of the present application are provided to more fully explain the present application to those having ordinary skill in the art, the shapes, sizes, etc. of the components shown in the drawings can be exaggerated, omitted, or schematically shown for the sake of clarity. Therefore, the sizes or ratios of the components should not be understood to fully reflect the actual sizes or ratios thereof.

[0034] (First Embodiment)

[0035] Figure 1 A battery manufacturing system 100 according to an example embodiment is shown.

[0036] Referring to Figure 1 The battery manufacturing system 100 can include an unwinder 111, a rewinder 113, a splicing table 115, a scrap port 117, a processing device 119, a first rotary encoder 121, a second rotary encoder 125, an NG sensor 131, a reference point sensor 133, a roll map programmable logic controller (PLC) 141, a process PLC 143, an equipment interface (EIF) 145, a server 150, and a display device 160.

[0037] The battery manufacturing system 100 can be configured to generate a roll map including data about the electrode sheet ES. The roll map can represent the electrode sheet ES based on coordinates indicating positions on the electrode sheet ES. As described below, a battery manufacturing process can be performed on the electrode sheet ES. The roll map can include data representing a history of the process performed on the electrode sheet ES and related to the coordinates. Accordingly, the roll map enables feedback, feedforward, and tracking of the battery manufacturing process, which will be described below.

[0038] A first electrode roll ER1 on which a previous process (a first process) is performed can be loaded on the unwinder 111. The unwinder 111 can unroll the electrode sheet ES from the first electrode roll ER1. The rewinder 113 can rewind the electrode sheet ES to form a second electrode roll ER2. The electrode sheet ES can be rewound into the second electrode roll ER2 and cut and separated after reaching a certain rewinding length. Accordingly, the electrode sheet ES can move between the unwinder 111 and the rewinder 113 when a current process (a second process) is performed.

[0039] The roll map can be generated in units of a lot. A lot is a production unit of a roll-to-roll process, and the second electrode roll ER2 separated after reaching a target rewinding amount is an example of a lot. The first electrode roll ER1 newly loaded on the unwinder 111 is also an example of a lot. Accordingly, the server 150 can store a first roll map of the previous process. The first roll map can correspond to the first electrode roll ER1. The server 150 can generate and store a second roll map of the current process. The second roll map can correspond to the second electrode roll ER2.

[0040] A process of manufacturing a battery (e.g., an electrode process) can be performed on the electrode sheet ES. The electrode process is performed on the electrode sheet ES that is unwound from the first electrode roll ER1 and wound into the second electrode roll ER2, and thus can be referred to as a roll-to-roll process.

[0041] In the roll graph, time series data constructed over time (i.e., according to progress of the process) can be related to coordinate data based on an amount of movement (i.e., an amount of winding or an amount of input) of the electrode sheet ES.

[0042] For example, the first roll graph can include coordinate data CD1 of the first electrode roll ER1 and reference point data DPD indicating a reference point (a first reference point). The coordinate data CD1 can include coordinates indicating a position of the first electrode sheet ES1.

[0043] As a non-limiting example, the second roll graph can be generated by updating the first roll graph. Alternatively, the second roll graph can be generated based on data obtained in a current process.

[0044] The outer winding of the first electrode roll ER1 is the inner winding of the second electrode roll ER2, and the inner winding of the first electrode roll ER1 is the outer winding of the second electrode roll ER2. Accordingly, the end coordinate (the maximum coordinate in the first process) of the coordinate data of the first electrode roll ER1, i.e., the coordinate of the beginning portion of the electrode sheet ES wound from the first electrode roll ER1 is the start coordinate (the minimum coordinate in the second process) of the coordinate data of the second electrode roll ER2, i.e., the coordinate of the innermost portion of the second electrode roll ER2. Conversely, the start coordinate (the minimum coordinate in the first process) of the coordinate data of the first electrode roll ER1, i.e., the coordinate of the end portion of the electrode sheet ES wound from the first electrode roll ER1 is the end coordinate (the maximum coordinate in the second process) of the coordinate data of the second electrode roll ER2, i.e., the coordinate of the outermost portion of the second electrode roll ER2.

[0045] Accordingly, this inversion of the coordinates should be considered during generation of the second roll graph. When the second roll graph is independently generated by obtaining data in a current process, the coordinate data of the second roll graph needs to be calibrated as described below so that the state of the same real electrode can be compared with the state in a previous process.

[0046] Accordingly, the generation of the second roll graph of the second electrode roll ER2 can include inverting the coordinate data of the first roll graph of the first electrode roll ER1. By inverting the coordinate data, the start coordinate of the first roll graph can be calibrated to the end coordinate of the second roll graph, and the end coordinate of the first roll graph can be calibrated to the start coordinate of the second roll graph.

[0047] For example, when the start coordinate of the first roll map of the first electrode roll ER1 is S1 and the end coordinate thereof is E1, any coordinate X on the first roll map of the first electrode roll ER1 can be calibrated to a coordinate X' on the second roll map of the second electrode roll ER2 according to Equation 1 below.

[0048] [Equation 1]

[0049] X' = E1 - (X - S1)

[0050] For example, when the start coordinate of the first roll map is 0 and the end coordinate thereof is 1600, the coordinate "100" can be calibrated to 1600 - (100 - 0) = 1500. Here, the coordinates are expressed in arbitrary units.

[0051] The coordinate data of the second roll map of the second electrode roll ER2 is calibrated according to Equation 1 above, but the relationship between the coordinate data and other data (e.g., measurement data and inspection data) of the first roll map is unchanged. That is, the value of data related to the coordinate X on the first roll map of the first electrode roll ER1 can be matched to the coordinate X' on the second roll map of the second electrode roll ER2.

[0052] For example, the first roll map can include coordinate data CD1 of the first electrode roll ER1 and datum point data DPD indicating a datum point.

[0053] The coordinate data CD1 can include stored coordinates indicating positions of portions of the electrode sheet ES unwound from the first electrode roll ER1. Table 1 below shows an example of coordinate data CD1 of a plurality of positions on the first electrode roll ER1 formed by winding an electrode sheet ES of 2000 m in length.

[0054] [Table 1]

[0055] Stored coordinates (m) Reversed coordinates (m) 1880 120 1870 130 1290 710 1270 730

[0056] The values in the first column of Table 1 are stored coordinates of a plurality of positions on the electrode sheet ES when the first electrode roll ER1 is wound in the first process. Positions with larger coordinates correspond to the outside of the first electrode roll ER1, and positions with smaller coordinates correspond to the inside of the first electrode roll ER1. The plurality of positions can be positions of defect points or intervals detected when the first process is performed.

[0057] The values of the second column of Table 1 are inverted coordinates of positions corresponding to the plurality of positions on the first electrode roll ER1 when the electrode sheet ES is wound into the second electrode roll ER2 in the second process. Positions with larger inverted coordinates correspond to the inside of the first electrode roll ER1, and positions with smaller inverted coordinates correspond to the outside of the first electrode roll ER1.

[0058] The inverted coordinates can be calculated by Equation 1 above.

[0059] The reference point data DPD can include a sequence value indicating a sequence of reference points on the electrode sheet ES and coordinates matching the sequence value. Table 2 below shows an example of the reference point data DPD and the inverted coordinates of the reference point data DPD obtained in the first process when the length of the electrode sheet wound into the first electrode roll ER1 is 2000 m.

[0060] [Table 2]

[0061]

[0062]

[0063] The reference points (first reference points) can be formed at equal intervals on the electrode sheet ES. In Table 1, the interval between the reference points is 100 m, but this is merely an example, and the technical idea of the present application should not be construed as being limited to this in any sense. The interval between the reference points can be determined according to the requirement for the accuracy of tracking the process events on the electrode sheet ES.

[0064] In the first process, the reference points with lower priority can be formed after the reference points with higher priority. The reference points with lower priority can have relatively large coordinates because the amount of input is large compared to the amount of input electrode sheet when the electrode sheet ES is wound into the first electrode roll ER1 in the first process. On the other hand, the reference points with higher priority can have relatively small coordinates because the amount of input is small compared to the amount of input electrode sheet. The reference points with lower priority are wound on the outside of the first electrode roll ER1, and thus can be inverted when the first electrode roll ER1 is unwound in the second process and have relatively small coordinates compared to the amount of input electrode sheet.

[0065] The stored reference point coordinates and the stored coordinates included in the above-mentioned coordinate data can be inverted by the server or the PLC.

[0066] The manufacturing of a battery involves a series of different processes, and the main process affects the following processes. In this case, when the timing data of the previous process does not directly match the real workpiece, intermediate product, and product, it is difficult to reflect the timing data of the previous process in the subsequent process. Hereinafter, the correction of the succeeding process based on the data generated according to the result of the previous process will be referred to as feedforward.

[0067] Here, the workpiece is an artifact provided as a result of each process, for example, an electrode sheet ES on which a coating process, a rolling process, and a slitting process are performed. The intermediate product can be one of a separator cut by a slitting process, an electrode, and an assembly thereof. 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 artifact processed by an activation process that is usable as a battery. The above definitions of the workpiece, the intermediate product, and the product are only in one aspect of its definition, and thus should not be understood as excluding its general definition.

[0068] The electrode process includes a series of roll-to-roll processes. For feedforward, the time series data should be related to a position on a real workpiece, component, intermediate product, and product. Here, the feedforward can include controlling a process of an electrode sheet ES based on a roll map of a first electrode roll ER1 generated in a previous process. The roll map can allow the time series data to be related to coordinate data including coordinates of a position on a real workpiece, component, intermediate product, and product. The roll map can provide a match between the time series data and the real workpiece, component, intermediate product, and product based on the coordinate data. Accordingly, the feedforward based on the roll map generation and the roll map can improve the productivity and quality of the process by digitizing and objectifying process aspects that depend on operator judgment.

[0069] The roll map of a previous batch can be used to improve a process of a subsequent batch, and this behavior can be referred to as process feedback. The process feedback using the roll map can include identifying process conditions and process parameters that have caused problems and defects based on data included in the roll map. For example, a second roll map of a second electrode roll ER2 can be generated by winding an electrode sheet ES processed in a current process, and processing of a subsequent batch can be controlled based on the second roll map.

[0070] In addition, as described below, the roll map can be cumulatively generated for a workpiece, an intermediate product, and a unit product of a cell process to track a process history of a product (for example, a battery cell, a battery module, or a battery pack) on the market. For example, the battery cell can include an electrode assembly or a cell identifier (ID) on a case. The cell ID can include batch numbers and coordinate information of electrodes and separators included in the battery cell. In other words, the cell ID can be related to the roll map of the electrodes and the separators included in the battery cell. Accordingly, when an event (for example, a quality problem) occurs in the battery cell on the market, historical data of the manufacturing of the battery cell can be retrieved based on the cell ID.

[0071] The first rotary encoder 121 can be configured to sense an 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 input amount signal UwAs indicative of a length of the electrode sheet ES unwound by the unwinder 111. The first rotary encoder 121 can be configured to transmit the input amount signal UwAs to the roll map PLC 141. The roll map PLC 141 can be configured to collect input amount data based on the input amount signal UwAs of the electrode sheet ES.

[0072] The second rotary encoder 125 can be configured to sense an amount of the electrode sheet ES wound into the second electrode roll ER2 by the rewinder 113. Accordingly, the second rotary encoder 125 can be configured to generate a winding amount signal WAS indicative of a length of the electrode sheet ES wound by the rewinder 113. The second rotary encoder 125 can be configured to transmit the winding amount signal WAS1 to the roll map PLC 141. The roll map PLC 141 can be configured to collect winding amount data based on the winding amount signal WAS of the electrode sheet ES.

[0073] The roll map PLC 141 can be configured to collect coordinate data of the electrode sheet ES based on one of the input amount signal UwAs and the winding amount signal WAS of the electrode sheet ES.

[0074] For example, the roll map PLC 141 can determine a moving distance of the electrode sheet ES from the unwinder 111 based on the input amount signal UwAs of the electrode sheet ES. Accordingly, the roll map PLC 141 can be configured to determine a coordinate of a portion of the electrode sheet ES to be unwound by the unwinder 111 on the electrode sheet ES at each point of time when the processing is performed by the processing device 119.

[0075] As another example, the roll map PLC 141 can determine a moving distance of the electrode sheet ES to the rewinder 113 based on the winding amount signal WAS of the electrode sheet ES. Accordingly, the roll map PLC 141 can be configured to determine a coordinate of a portion of the electrode sheet ES to be wound by the rewinder 113 on the electrode sheet ES at each point of time when the processing is performed by the processing device 119.

[0076] Hereinafter, the technical idea of the present application will be described with reference to an embodiment in which the roll map PLC 141 collects coordinate data based on the input amount signal UwAS of the electrode sheet ES. When the coordinate data is collected based on the input amount signal UwAS, the amount of the electrode sheet ES to be unwound can be sensed, and thus, the loss of the electrode sheet ES due to factors such as a sample test of the first electrode roll ER1, movement of the first electrode roll ER1 from a previous process stage to a current process stage, loading of the first electrode roll ER1 on the unwinder 111, connection of a portion of the electrode sheet ES of the loaded first electrode roll ER1 with a portion of the electrode sheet ES on the rewinder 113, or a remaining amount due to failure to unwind the electrode sheet ES, etc., can be accurately determined.

[0077] According to an example embodiment, the roll map PLC 141 can be configured to further collect additional coordinate data based on the roll-up amount signal WAS. In this case, the coordinate data collected based on the input amount signal UwAS can be used to calibrate the coordinate data CD and the datum point data DPD transmitted from the roll map of the previous process (i.e., the first roll map of the first electrode roll ER1), and the additional coordinate data collected based on the roll-up amount signal WAS can be used to generate the roll map of the current process (i.e., the second roll map of the completed second electrode roll ER2).

[0078] The coordinate data can include coordinates matched with each portion of the electrode sheet ES. That is, each of the arbitrary points on the electrode sheet ES can be matched with a coordinate. The coordinate can be a one-dimensional (1D) quantity along the longitudinal direction of the electrode sheet ES, but is not limited thereto. The coordinate can be a two-dimensional (2D) quantity along the longitudinal direction of the electrode sheet ES and the width direction of the electrode sheet ES.

[0079] The NG sensor 131 can be configured to sense one of the NG mark and the NG tag on the electrode sheet ES. The NG mark can be formed by, for example, an inkjet printer, etc., and include information about the location and type of a defect. The NG tag can be attached to the electrode sheet ES by an operator or an NG tag attacher, and indicate the location of a defect of the electrode sheet ES. As a non-limiting example, the NG sensor 131 can include a vision machine or a color sensor.

[0080] The NG sensor 131 can be configured to generate an NG sensing signal NSS to sense one of the NG mark and the NG tag on the electrode sheet. The NG sensor 131 can be configured to transmit the NG sensing signal NSS to the roll map PLC 141.

[0081] The map PLC 141 can be configured to collect NG sensing data NSD based on the NG sensing signal NSS and the coordinate data. The map PLC 141 can be configured to collect the NG sensing data NSD by associating the NG sensing signal NSS with the coordinate data. The NG sensing data NSD can include, for example, a defect value indicating presence of a defect and aspects of the defect, and coordinates matching the defect value.

[0082] To collect the NG sensing data NSD, the coordinate data can be calibrated based on the offset length OLI. The calibration of the coordinate data includes compensating for a difference between a portion of the electrode sheet ES sensed by the first rotary encoder 121 (i.e., a portion of the electrode sheet ES unwound by the decoiler 111) and a portion of the electrode sheet ES sensed by the NG sensor 131.

[0083] According to an example embodiment, the map PLC 141 can calibrate the coordinate data collected simultaneously with the NG sensing signal NSS based on the offset length OLI, and associate the calibrated coordinate data with the NG sensing signal NSS to collect the NG sensing data NSD.

[0084] The offset length OLI is a length of the electrode sheet ES between the NG sensor 131 and the decoiler 111 according to a movement path of the electrode sheet ES. The offset length OLI can be equal to or greater than a straight-line distance between the NG sensor 131 and the decoiler 111.

[0085] The reference point sensor 133 can be configured to sense a reference point on the electrode sheet ES to collect reference point data of the electrode sheet ES. The reference point sensor 133 can include, for example, an OCR barcode reader. Each reference point on the electrode sheet ES can include a unique identification mark (e.g., a 1D or 2D barcode) including information about a moving direction of the electrode sheet ES and a formation sequence of the reference point in a process of forming the reference point. The reference point sensor 133 can be configured to sense the reference point on the electrode sheet ES to generate a reference point sensing signal DSS. The reference point sensor 133 can be configured to transmit the reference point sensing signal DSS to the map PLC 141.

[0086] The map PLC 141 can be configured to collect reference point sensing data DSD based on the coordinate data and the reference point sensing signal DSS. The map PLC 141 can be configured to collect the reference point sensing data DSD by associating the reference point sensing signal DSS with the coordinate data. The reference point sensing data DSD can include, for example, a sequence of the reference points and coordinates matching the reference points.

[0087] To collect the reference point sensing data DSD, the coordinate data can be calibrated based on the offset length OL2. The calibration of the coordinate data includes compensating for a difference between a portion of the electrode sheet ES sensed by the first rotary encoder 121 (i.e., a portion of the electrode sheet ES wound by the unwinder 111) and a portion of the electrode sheet ES sensed by the reference point sensor 133.

[0088] According to an example embodiment, the winding chart PLC 141 can be configured to calibrate the coordinate data collected simultaneously with the reference point sensing signal DSS based on the offset length OL2, and to associate the calibrated coordinate data with the reference point sensing signal DSS to collect the reference point sensing data DSD.

[0089] The offset length OL2 is a length of the electrode sheet ES between the reference point sensor 133 and the unwinder 111 according to a movement path of the electrode sheet ES. The offset length OL2 can be equal to or greater than a straight-line distance between the reference point sensor 133 and the unwinder 111.

[0090] The offset length OL2 can include a first portion OL2_1 and a second portion OL2_2. The first portion OL2_1 can be a portion that has not been processed by the processing device 119, and the second portion OL2_2 can be a portion that has been processed by the processing device 119. Accordingly, a length characteristic of the first portion OL2_1 can be different from a length characteristic of the second portion OL2_2. For example, when the processing device 119 includes a press roller for a press process, the first portion OL2_1 can not be elongated, and the second portion OL2_2 can be elongated. According to an example embodiment, in the calibration of the offset length OL2, the first portion OL2_1 can be calibrated differently from the second portion OL2_2. For example, the second portion OL2_2 can be calibrated by compensating for a change in the length characteristic by inversely calculating an elongation rate or the like by the processing device 119.

[0091] According to an example embodiment, the winding chart PLC 141 can be configured to transmit the NG sensing data NSD and the reference point sensing data DSD to the process PLC 143. Alternatively, the reference point data DPD can be transmitted from the process PLC 143.

[0092] The roll map PLC 141 and / or the process PLC 143 can be configured to compare the datum point data DPD (e.g., first datum point data) with the datum point sensing data DSD (e.g., second datum point data). In this case, the coordinates of the stored datum point data DPD can be inverted by the server 150, and the datum point data DPD with respect to the inverted coordinates can be transmitted from the server 150 to the roll map PLC 141 or the process PLC 143. Alternatively, the roll map PLC 141 or the process PLC 143 can receive the datum point data DPD that is not inverted from the server 150, and invert the stored datum point coordinates of the datum point data DPD.

[0093] In all cases, the roll map PLC 141 and / or the process PLC 143 can be configured to compare the datum point sensing data DSD with inverted coordinates of the stored datum point coordinates included in the datum point data DPD.

[0094] The roll map PLC 141 and / or the process PLC 143 can be configured to calibrate the coordinate data of the defective portion based on the NG sensing data NSD. Calibrating the coordinate data of the defective portion based on the NG sensing data NSD can include calibrating the coordinates of the coordinate data of the defective portion based on the coordinates of the NG sensing data NSD when the coordinates of the coordinate data of the defective portion do not match the coordinates of the NG sensing data NSD.

[0095] Table 3 shows an example of the datum point sensing data DSD.

[0096] [Table 3]

[0097]

[0098] The second column of Table 3 indicates (first) datum point data DPD obtained in a previous process (first process) of the first electrode roll ER1. The third column of Table 3 indicates data obtained by inverting the datum point data DPD. The values in the second and third columns are the same as the data shown in Table 2.

[0099] The fourth column of Table 3 indicates datum point sensing data DSD (second datum point data) in a current process (second process). The format in which the datum point sensing data DSD is displayed is not limited to the above table. The datum point sensing data DSD can be in a format including matching between a datum point sequence and coordinates.

[0100] The roll map PLC 141 and / or the process PLC 143 can be configured to calculate an offset, which is a difference between a coordinate obtained by reversing the reference point coordinates of the stored reference point data DPD and a sensed reference point coordinate of the reference point sensing data DSD. The fifth table of Table 2 represents the offset calculated by the roll map PLC 141 and / or the process PLC 143. The roll map PLC 141 and / or the process PLC 143 can be configured to calibrate the reversed coordinates of the stored coordinates included in the coordinate data CD1 of the first electrode roll ER1 based on the offset.

[0101] Table 4 shows the coordinate data calibrated by the roll map PLC 141 and / or the process PLC 143. The calibration of the coordinate data CD1 can be triggered by the sensing of the reference points. Although Table 4 shows nineteen reference points at the same time, the coordinate data CD1 can be calibrated whenever a reference point is sensed.

[0102] [Table 4]

[0103] Stored coordinates (m) Reversed coordinates (m) Calibrated coordinates (m) 1880 120 115 1870 130 125 1290 710 695 1270 730 715

[0104] More specifically, when a comparison between the sensed reference point coordinates and the reversed coordinates of the stored reference point coordinates shows that the sensed reference point coordinates and the stored reference point coordinates are not identical to each other, the roll map PLC 141 or the process PLC 143 can perform an operation for calculating an offset. For example, when the nineteenth reference point that comes first is sensed, the sensed 95m does not match the reversed reference point coordinate of 100m, and thus an offset of 5m can be calculated by the roll map PLC 141 or the process PLC 143. Next, the coordinate "120" adjacent to the nineteenth reference point can be calibrated to "115" based on the offset "5". Next, the coordinate "130" adjacent to the nineteenth reference point can be calibrated to "125" based on the offset "5". The coordinates "710" and "730" adjacent to the thirteenth reference point can be calibrated to "695" and "715", respectively, based on the offset "15". Unlike Table 4, different offset amounts can be applied according to the coordinate positions on the electrode sheet ES.

[0105] The calibrated coordinates can be obtained as the coordinate data CD2 of the second electrode roll ER2 (or a second roll map of the second electrode roll ER2).

[0106] The stored coordinates of the coordinate data CD of the first roll figure of the first electrode roll ER1 can not match the coordinates on the real electrode sheet ES unwound from the first electrode roll ER1. Such a mismatch can be caused by a loss of a sample test of the first electrode roll ER1, a loss that occurs during movement of the first electrode roll ER1, a loss that occurs during loading of the first electrode roll ER1 onto the uncoiler 111, connection of a portion of the electrode sheet ES of the loaded first electrode roll ER1 to a portion of the electrode sheet ES on the rewinder 113, or the like.

[0107] According to an example embodiment, the coordinate data can be calibrated based on the reference point sensing data DSD and the reference point data DPD obtained by sensing the real reference point on the real electrode sheet ES in the second process. Based on the calibrated accurate coordinate data, for example, a defective portion of the electrode sheet ES or the like can be removed. Thus, when the defective portion is scrapped in the second process or a subsequent process, it can be prevented that a portion of the defective portion is scrapped or a normal portion of the electrode sheet ES is excessively scrapped. Accordingly, the productivity and yield of the electrode sheet ES can be increased.

[0108] The process PLC 143 can be configured to control the operation of the uncoiler 111, the rewinder 113, the scrap port 117, and the processing device 119. The process PLC 143 can be configured to generate a signal for operating or stopping the uncoiler 111, the rewinder 113, the scrap port 117, and the processing device 119. The signal for operating or stopping the uncoiler 111, the rewinder 113, the scrap port 117, and the processing device 119 can be generated based on a subject including a product ID and details of a manufacturing recipe.

[0109] The process PLC 143 can receive the NG sensing data NSD from the roll figure PLC 141. The process PLC 143 can be configured to generate a signal for operating or stopping the uncoiler 111, the rewinder 113, the scrap port 117, and the processing device 119 based on the NG sensing data NSD and the coordinate data of the defective portion based on the calibrated coordinates. Here, as described above, the coordinate data of the defective portion can be generated by the roll figure PLC 141 or the process PLC 143 based on the reference point data DPD, the reference point sensing data DSD, and the inverted coordinate data.

[0110] When the coordinate data of the defective portion obtained based on the calibrated coordinate data or the NG sensing data NSD identified on the electrode sheet ES approaches the splicing table 115, the process PLC 143 can reduce the movement speed of the electrode sheet ES or stop the winding and unwinding performed by the uncoiler 111 and the rewinder 113.

[0111] After cutting out the start point of the defect (or a point adjacent to the start point of the defect in consideration of a process allowance) on the splicing table 115, the scrap port 117 can be configured to wind the defective portion DES of the electrode sheet ES, as indicated by the thick dashed line. After the defective portion DES of the electrode sheet ES is sufficiently wound by the scrap port 117, the portion of the electrode sheet ES connected to the scrap port 117 and the portion of the electrode sheet ES connected to the unwinder 111 can be separated from each other. Next, the current process can be continued by connecting the portion of the electrode sheet ES connected to the unwinder 111 and the portion of the electrode sheet ES connected to the rewinder 113. The portion of the electrode sheet ES connected to the unwinder 111 and the portion of the electrode sheet ES connected to the rewinder 113 can be connected on the splicing table 115.

[0112] The processing device 119 can be located downstream of the electrode sheet ES flow compared to the splicing table 115. That is, the processing device 119 can be configured to process the electrode sheet ES, the defective portion DES of which is scrapped by being processed on the splicing table 115.

[0113] For example, the processing device 119 can include an applicator, and the electrode sheet ES can be coated with an electrode paste. As another example, the processing device 119 can include a press roll, and a roll-pressing process can be performed on the electrode sheet ES coated with the electrode paste. As another example, the processing device 119 can include a slitting knife, and the electrode sheet ES can be divided into a plurality of electrode sheets.

[0114] The battery manufacturing system 100 can further include a measuring device and an inspector. The measuring device can be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measuring device can measure the electrode sheet ES by a scanning method. The measurement data can include a plurality of measurement values expressed in numbers. For example, the measurement data can include size data of the electrode sheet ES (e.g., thickness and width), loading amount data of a coating material on the electrode sheet ES, width of an insulating material on the coating material, and overlap width between the coating material and the insulating material, etc., mismatch data between a coating band on an upper surface of the electrode sheet ES and a coating band on a lower surface of the electrode sheet E, etc. Here, the loading amount of the coating material is an amount of the coating material loaded per unit area of the electrode sheet ES, and can be an areal density of the coating material.

[0115] Whether the measurement portion of the electrode sheet ES is defective can be determined by processing the measurement data by a setting method. When the amount of the measurement coating material on the electrode sheet ES (e.g., the loading amount of the coating material on the electrode sheet ES or the thickness of the electrode sheet ES) is within a set range including an upper limit and a lower limit, the corresponding portion of the electrode sheet ES can be determined as a portion of good quality. When the amount of the measurement coating material on the electrode sheet ES (e.g., the loading amount of the coating material on the electrode sheet ES or the thickness of the electrode sheet ES) is less than the lower limit or greater than the upper limit, the corresponding portion of the electrode sheet ES can be determined as defective.

[0116] The measurement device can include, for example, a time delay and integration (TDI) camera, a complementary metal-oxide semiconductor (CMOS) image sensor, and a time-of-flight (TOF) sensor. The measurement device can 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 measurement device can include analog and / or digital sensors such as biological sensors, chemical sensors, composition sensors, current and / or power meters, air quality sensors, gas sensors, Hall effect sensors, brightness level sensors, and optical sensors. The measurement device can include pressure sensors, temperature sensors, ultrasonic sensors, proximity sensors, door status sensors, motion tracking sensors, humidity sensors, visible light and infrared sensors, cameras, and the like.

[0117] The measurement device can be configured to generate coordinate-related measurement data by associating additional coordinate data with the measurement data based on the winding amount signal WAS. To generate the coordinate-related measurement data, the additional coordinate data can be calibrated based on the offset length of the measurement data.

[0118] The measurement device can be configured to collect evaluation data based on the measurement data. The evaluation data can be collected based on a comparison between the measurement values of the plurality of sections of the electrode sheet ES and the set range.

[0119] For example, a measurement value (or an average of measurement values) within a first range can be determined as normal, a measurement value (or an average of measurement values) within a second range greater than the first range can be determined as excessive, a measurement value (or an average of measurement values) within a third range greater than the second range can be determined as very excessive, a measurement value (or an average of measurement values) within a fourth range less than the first range can be determined as insufficient, and a measurement value (or an average of measurement values) within a fifth range less than the fourth range can be determined as very insufficient.

[0120] Here, when the lower limit of the second range is greater than or equal to the upper limit of the first range, the second range is greater than the first range. Similarly, when the upper limit of the fourth range is less than or equal to the lower limit of the first range, the fourth range is less than the first range.

[0121] The evaluation values of the evaluation data can be associated with the coordinates. For example, each evaluation value can match the start coordinate and the end coordinate of one of the portions in which the evaluation values of the electrode sheet ES are calculated.

[0122] The inspector can be configured to inspect the electrode sheet ES to collect inspection data of the electrode sheet ES. The inspector can be configured to detect defects such as surface defects of the electrode sheet ES based on a color change, a reflectance change, etc. of the surface of the electrode sheet ES. The inspector can be configured to collect inspection data of a portion of the electrode sheet ES corresponding to (e.g., overlapping) the sensing portion.

[0123] The inspection data collected by the inspector can include determining the quality of a portion of the electrode sheet ES and the result of a process event. For example, the inspection data can include data on the appearance of the electrode sheet ES, data on breaks and seams on the electrode sheet ES, data on a portion of the electrode sheet ES on which a sampling inspection is performed, data on a portion of the electrode sheet ES to be scrapped, data on a scrapped portion of the electrode sheet ES, data on whether a coating material and an insulating material on the electrode sheet ES are defective, data on a reference point indicating the position of the electrode sheet ES, and defect data such as pinhole defects, crater defects, line defects, crack defects, side ring defects, island defects, folding defects, wrinkle defects, dent defects, and scratch defects, collected by an image-based inspection device such as a vision machine. The reference points can be formed at intervals on the electrode sheet ES, and other elements on the electrode sheet ES can be positioned based on the reference points. The inspector can be a color sensor, a joint sensor, a reference point sensor, or a vision machine.

[0124] The inspector can be configured to generate coordinate-related inspection data by associating additional coordinate data based on the winding amount signal WAS with the inspection data. To generate the coordinate-related inspection data, the additional coordinate data can be calibrated based on the offset length of the inspector.

[0125] The above-described measurement data and inspection data can be time-series data. The measurement data and the inspection data can be chronologically ordered. Chronological ordering is a main feature of time-series data, and should be understood as organizing events in the order in which they occur and arrive to be processed. That is, the measurement data and the inspection data can be stored based on the time point at which the measurement and the inspection are performed, and can be related to time. Accordingly, each of the measurement values of the measurement data can match the time, and each of the inspection values of the inspection data can match the time.

[0126] For example, the data of the measurement amount (e.g., the load amount on the electrode sheet ES or the thickness of the electrode sheet ES) can include a series of measurement amounts (e.g., the load amount on the electrode sheet ES or the thickness of the electrode sheet ES) and time values related to the series of measurement amounts. The measurement amounts and the time values can be matched in a one-to-one manner, but are not limited thereto. As another example, the defect data can include a value indicating a defect and a time value related to the value indicating a defect. Here, the value indicating a defect should be understood to mean that the value contains information on at least one of the presence of a defect or a defect type.

[0127] The roll map can include coordinate-related measurement data and coordinate-related inspection data generated by associating measurement data and inspection data, which are time series data, with coordinate data. Accordingly, the roll map can provide traceability for all processes during execution of subsequent processes or after product shipment.

[0128] The roll map PLC 141 can be in operative communication with the first rotary encoder 121 and the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, and additional measurement devices and inspectors through a wired or wireless data network. The data network can be one-way or two-way communication. The data network can be implemented through a physical channel, WiFi, a public network, and / or a dedicated network using Bluetooth or other frequency bands. The first rotary encoder 121 and the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, and additional measurement devices and inspectors can be configured to collect data from equipment, workpieces, intermediate products, and products in the battery manufacturing system 100 or generate signals for collecting data therefrom.

[0129] The coordinate-related measurement data and the coordinate-related inspection data transmitted from the roll map PLC 141 to the process PLC 143 can be transmitted to the server 150 through the process PLC 143 and the EIF 145. The process PLC 143 and the EIF 145 can relay data communication between the server 150 and the roll map PLC 141. However, the present application is not limited thereto, and the roll map PLC 141 can directly transmit the coordinate data, the coordinate-related measurement data, and the coordinate-related inspection data to the server 150.

[0130] In order to control the process, a communication line for connecting the process PLC 143 and the server 150 via the EIF 145 can be installed between the process PLC 143 and the server 150. Accordingly, compared to the case where the first rotary encoder 121 and the second rotary encoder 125 and the measurement devices directly communicate with the server 150 and the case where the roll map PLC 141 directly communicates with the server 150, data transmission through the process PLC 143 can reduce resources required to install the communication line and enable efficient processing and management of data.

[0131] The EIF 145 can be a device for communication between the process PLC 143 for the manufacturing equipment and the server 150 as an upper layer server.

[0132] The server 150 can be configured to generate and store a roll map. The roll map can be generated in units of a batch. The roll map can include data on specifications of the batch. The specifications of the batch can include, for example, a batch number, a length of the wound electrode sheet ES, a width of the electrode sheet ES, and a material and composition used for processing the electrode sheet ES.

[0133] The server 150 can be configured to store a first roll map of the first electrode roll ER1, transmit coordinate data CD1 and datum point data DPD of the first roll map to the process PLC 143, and generate and store a second roll map of a second electrode roll ER2 based on coordinate-related measurement data and coordinate-related inspection data. Further, coordinate data CD2 of the second roll map can be calibrated based on an offset that is a difference between datum point sensing data DSD transmitted from the roll map PLC 141 or the process PLC 143 and inverted coordinates of the datum point data DPD. Alternatively, the second roll map of the second electrode roll ER2 can be generated based on the datum point sensing data DSD and the obtained coordinate data CD2 of the second electrode roll, or the coordinate data CD2 of the second roll map can be calibrated.

[0134] According to an example embodiment, the server 150 can be a data processing system that supports management of all activities required for manufacturing of a battery, such as work schedule management, work instructions, quality control, and work performance counting. The server 150 can be, for example, a manufacturing execution system (MES). The server 150 can be configured to perform input, processing, output, and communication of data required for electrode manufacturing, including a coating process, a pressing process, and a slitting process.

[0135] According to other example embodiments, the server 150 can be configured to store and process raw measurement data. The server 150 can manage a processing quality of the electrode sheet ES by continuously monitoring the processing of the electrode sheet ES based on the inspection data. According to an example embodiment, the server 150 can be a static process controller (SPC). The server 150 can collect and analyze manufacturing data in almost real time in order to timely identify problematic conditions and provide a notification to an operator before a potential problem occurs.

[0136] According to other example embodiments, the server 150 can be, for example, a data warehouse, and store NG sensing data NSD, coordinate data, coordinate-related measurement data, and coordinate-related inspection data for a long time based on a product quality assurance period.

[0137] According to other example implementations, to create the roll map, the server 150 can be provided separately from the MES, SPC, and data warehouse.

[0138] The roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can be implemented by hardware, firmware, software, or a combination thereof. For example, the roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can include simple controllers, complex processors such as microprocessors, CPUs, or GPUs, processors configured by software, special-purpose hardware, or firmware. The roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can be implemented, for example, by a general-purpose computer or special-purpose hardware such as a digital signal processor (DSP), a field-programmable gate array (FPGA), or an application-specific integrated circuit (ASIC).

[0139] The server 150 can include a physical server or a cloud server. The server 150 can provide data and analysis results to the operator through various frameworks. The frameworks can include protocols that support data transmission so that the display device 160 can visualize the data through a user interface and provide updated visualizations as the server 150 computes new data. The protocols that support data transmission can include HTML, JavaScript, and / or JSON. The server 150 can send a visualization command VC to the display device 160, and the display device 160 can visualize the roll map and display the visualized roll map.

[0140] The server 150 can include various types of application programming interfaces (APIs) for storing data in databases and other data management tools. The APIs can also be used to retrieve data from databases of various data management systems. The data management systems can be configured to provide access to databases, pull or retrieve data from the databases, and generate metrics. Here, a metric is a tool for visualizing data. The metrics can include measurement values generated in a time series manner and used to monitor the application and generate status warnings.

[0141] The battery manufacturing system 100 can implement a plug-and-play architecture with APIs for obtaining data to provide plug-and-play connectivity of the NG sensors 131, the fiducial point sensors 133, and additional measurement devices and inspectors. Thus, it is possible to easily transfer resources in a certain process step and a specific station to a different process, and to easily introduce different stations or new resources into each process step and each station.

[0142] The data network between components of the battery manufacturing system 100 can include various types of communication channels, including one-way and two-way wired and wireless communications. For example, the data network can include an industrial protocol network, such as OPC, Modbus, or ProfiNet. The communication channels can be channels of dedicated pipe communication, such as Universal Serial Bus (USB), IEEE 802 (Ethernet), IEEE 1394 (Firewire), or other high-speed data communication standards.

[0143] In some embodiments, the battery manufacturing system 100 can also include a manual input system that allows an operator to input manufacturing data. The battery manufacturing system 100 can allow an operator to input data with an input tool and allow computer-based input of manufacturing data, such as Excel file grabbing.

[0144] According to some embodiments, the operations of the roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can be implemented as instructions stored on a machine-readable medium, which are readable and executable by one or more processors. Here, a machine-readable medium can include any mechanism for storing and / or transmitting information in a form readable by a machine (e.g., a computing device). Examples of a machine-readable medium can include read-only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory, electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.), and others.

[0145] The roll map PLC 141 can be implemented by, for example, software configured to collect coordinate data CD1, NG sensing data NSD, and datum point sensing data DSD, and transmit the NG sensing data NSD and the datum point sensing data DSD.

[0146] The process PLC 143 can be implemented by software configured to receive the product ID, the product recipe, the defect data DD, the datum point data DPD, the NG sensing data NSD, and the datum point sensing data DSD, transmit the NG sensing data NSD and the datum point sensing data DSD, and generate control signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing device 119 based on the product ID, the product recipe, the defect data DD, the datum point data DPD, the NG sensing data NSD, and the datum point sensing data DSD. More specifically, the process PLC 143 can be implemented by software configured to calculate an offset between datum points based on the datum point data DPD and the datum point sensing data DSD, calibrate the coordinate data CD1 based on the offset, and generate control signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing device 119 based on the calibrated coordinate data.

[0147] The EIF 145 can be implemented by software for relaying transmission of data and information between the process PLC 143 and the server 150. More specifically, the EIF 145 can be implemented by software configured to control communication flow between the process PLC 143 and the server 150 and perform error control, synchronization, sequence control, addressing, multiplexing, routing, format conversion, etc.

[0148] The server 150 can be implemented by, for example, software configured to transmit the product ID, the product recipe, the coordinate data CD1, and the datum point data DPD to the process PLC 143 and generate a roll map based on the coordinate-related measurement data and the coordinate-related inspection data.

[0149] However, the above description is provided only for the convenience of description, and the operations of the roll map PLC 141, the process PLC 143, the EIF 145, and the server 150 can also be produced by a computing device, a distributed computing device, a processor, firmware, software, routines, and other devices that execute routines and instructions.

[0150] The architecture of the battery manufacturing system 100 configured to generate a roll map can be implemented by adding only the roll map PLC 141 to the process PLC 143, the EIF 145, and the server 150, which are essential elements in a modern process management system. In the system according to the example embodiment, resources of a manufacturing site that have already been installed can be used, and additional capital expenditure can be reduced. In addition, applying the same architecture as the existing manufacturing equipment to newly constructed manufacturing equipment can lead to an improvement in reliability of battery manufacturing, sensing / improvement of problematic processes, and effective introduction of new processes.

[0151] Embodiments of the present invention

[0152] (Second Embodiment)

[0153] Figure 2 is a flowchart of a battery manufacturing method according to an example embodiment.

[0154] Referring to Figure 1 and Figure 2 In P110, the coordinate data CD1 of the first electrode roll ER1 and the datum point data DPD of the first electrode roll ER1 can be loaded. The process PLC 143 or the roll map PLC 131 can receive the coordinate data CD1 of the first electrode roll ER1 and the datum point data DPD of the first electrode roll ER1 from the server 150.

[0155] Next, in P120, the datum points on the electrode sheet ES can be sensed to collect datum point sensing data DSD. The datum point sensing data DSD can be collected by the datum point sensor 133 and the roll map PLC 141, as described above.

[0156] Next, in P130, the coordinate data CD1 can be calibrated based on the reference point sensing data DSD and the reference point data DPD. The calibration of the coordinate data CD1 can be triggered by the sensing of the reference point. The calibration of the coordinate data CD1 can include calculating an offset as a difference between the sensed reference point coordinates of the reference point sensing data DSD and the inverted reference point coordinates of the reference point data DPD and inverting the stored coordinates of the coordinate data CD1 based on the offset.

[0157] Thereafter, in P140, the defective portion DES of the electrode sheet ES can be scrapped based on the calibrated coordinate data. To scrap the defective portion DES of the electrode sheet ES, the process PLC 143 can be configured to generate signals for controlling the operations of the unwinder 111, the rewinder 113, the scrap port 117, and the handling device 119.

[0158] (Third Embodiment)

[0159] Figure 3 A battery manufacturing system 101 according to an example embodiment is shown.

[0160] Reference Figure 3 The battery manufacturing system 101 can include the unwinder 111, the rewinder 113, the splicing table 115, the scrap port 117, the handling device 119, the first rotary encoder 121, the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, the integrated PLC 140, the EIF 145, the server 150, and the display device 160.

[0161] The unwinder 111, the rewinder 113, the splicing table 115, the scrap port 117, the handling device 119, the first rotary encoder 121, the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, the EIF 145, the server 150, and the display device 160 are substantially the same as described above with reference to Figure 1 , and thus redundant descriptions thereof are omitted here.

[0162] The integrated PLC 140 can be configured to perform the functions of the winding map PLC 141 and the process PLC 143 of Figure 1 . Thus, the integrated PLC 140 can be configured to generate coordinate data based on the input amount signal UWAS or the winding amount signal WAS, collect the NG sensing data NSD (see Figure 1 ) and the reference point sensing data DSD (see Figure 1), and receives coordinate data CD1 and datum point data DPD from the server 150 through the EIF 145. The integrated PLC 140 can be configured to calibrate inverted coordinates of the coordinate data CD1 based on inverted data of the datum point sensing data DSD and the datum point data DPD. The integrated PLC 140 can be configured to generate signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing device 119 based on the calibrated coordinate data.

[0163] The present application is described in more detail above with reference to the drawings, embodiments, etc. However, the configurations shown in the drawings or embodiments described in the present specification are merely embodiments of the present application, and do not reflect all technical ideas of the present application, and thus various equivalents and modifications of alternative configurations will be understood to be made as of the filing date of the present application.

[0164] (Reference Signs)

[0165] 100: battery manufacturing system

[0166] 111: unwinder, 113: rewinder, 115: splicing table

[0167] 117: scrap port, 119: processing device

[0168] 121, 125: rotary encoder

[0169] 131: NG sensor, 133: datum point sensor

[0170] 140, 141, 143: PLC (programmable logic controller)

[0171] 145: EIF (equipment interface)

[0172] 150: server

[0173] 160: display device

Claims

1. A battery manufacturing system in which an electrode sheet is unwound from a first electrode roll and wound into a second electrode roll, the battery manufacturing system comprising: a server configured to store coordinate data of the first electrode roll and reference point data indicating a reference point on the first electrode roll; a programmable logic controller (PLC) configured to load the coordinate data and the reference point data of the first electrode roll from the server; and a reference point sensor configured to sense a reference point on the electrode sheet unwound from the first electrode roll and generate a reference point sensing signal, wherein the PLC is configured to obtain coordinate data of the second electrode roll by calibrating inverse coordinates of stored coordinates included in the coordinate data of the first electrode roll based on inverse coordinates of stored reference point coordinates included in the reference point data and coordinates of a sensed reference point. The start coordinate of the coordinate data of the first electrode roll is calibrated to the end coordinate of the coordinate data of the second electrode roll and the end coordinate of the coordinate data of the first electrode roll is calibrated to the start coordinate of the coordinate data of the second electrode roll by inverting the stored coordinates.

2. The battery manufacturing system of claim 1, wherein, The inversion of the stored reference point coordinates and the inversion of the stored coordinates included in the coordinate data are performed by the server or the PLC.

3. The battery manufacturing system of claim 1, wherein, The PLC calculates an offset between the inverse coordinates of the stored reference point coordinates and the coordinates of the sensed reference point and calibrates the inverse coordinates of the stored coordinates of the first electrode roll based on the offset.

4. The battery manufacturing system of claim 1, wherein, The reference point sensor calibrates the coordinates of the sensed reference point based on an offset length, which is a length of the electrode sheet between a rewinder configured to wind the second electrode roll and a portion of the electrode sheet at a point in time at which the reference point is sensed.

5. The battery manufacturing system of claim 1, wherein, The server stores a first roll map including the coordinate data of the first electrode roll and the reference point data.

6. The battery manufacturing system of claim 1, wherein, The server generates a second roll map of the second electrode roll or calibrates coordinate data of the generated second roll map based on the reference point sensing data and the obtained coordinate data of the second electrode roll.

7. The battery manufacturing system of claim 1, wherein, 8.A battery manufacturing method in which an electrode sheet is unwound from a first electrode roll and wound into a second electrode roll, the battery manufacturing method comprising the steps of: loading coordinate data including stored coordinates of the first electrode roll and stored reference point data of the first electrode roll; collecting reference point sensing data by sensing a reference point on the electrode sheet unwound from the first electrode roll, the reference point sensing data including coordinates of a sensed reference point; and obtaining coordinate data of the second electrode roll by calibrating inverse coordinates of the stored coordinates of the first electrode roll based on inverse coordinates of stored reference point coordinates and the coordinates of the sensed reference point. 9.The battery manufacturing method of claim 8, further comprising discarding a defective portion of the electrode sheet unwound from the first electrode roll based on the calibrated coordinates. ​ ​ 10. The battery manufacturing method according to claim 8, wherein, by inverting the stored coordinates, aligning a start coordinate of coordinate data of the first electrode roll to an end coordinate of coordinate data of the second electrode roll, and by aligning an end coordinate of coordinate data of the first electrode roll to a start coordinate of coordinate data of the second electrode roll. 11.The battery manufacturing method of claim 10, further comprising calculating an offset between an inverted coordinate of the stored reference point coordinate and a coordinate of the sensed reference point, wherein, aligning an inverted coordinate of the stored coordinates of the first electrode roll based on the offset.

12. The battery manufacturing method according to claim 8, wherein, The step of aligning the sensed reference point is based on an offset length, which is a length of the electrode sheet between an uncoiler configured to unroll the first electrode roll and a portion of the electrode sheet at a point in time when the reference point is sensed.

13. The battery manufacturing method according to claim 8, wherein, loading the coordinate data and the reference point data of the first electrode roll based on a first roll map of the first electrode roll including the coordinate data and the reference point data. 14.The battery manufacturing method of claim 13, further comprising generating a second roll map of the second electrode roll or aligning coordinate data of the generated second roll map based on the reference point sensing data and the obtained coordinate data of the second electrode roll. 15.A second electrode roll formed by winding an electrode sheet around a first electrode roll formed of the electrode sheet unrolled by the first electrode roll and including a plurality of first reference points in a longitudinal direction, wherein, the electrode sheet wound into the second electrode roll includes a plurality of second reference points corresponding to the plurality of first reference points, and each of the plurality of second reference points is located at one of inverted positions of the plurality of first reference points on the electrode sheet in the longitudinal direction or at one of offset positions of the inverted positions of the plurality of first reference points on the electrode sheet in the longitudinal direction.

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