Multi-mode packaging control and data tracing method for packaging process under tracing system

Abstract

The invention discloses a multi-mode packaging control and data tracing method of a packaging process under a tracing system. The system comprises a gear packaging control module, a manual packaging tracing module, a data collaboration and verification module and a report generation and export module. All the modules are linked through a standardized data interface to form a complete tracing system of rule configuration (three-dimensional gear)-data acquisition (including self-discharge voltage)-verification storage-report output, and the tracing system can be directly deployed at a packaging station of a supercapacitor production line. The system is seamlessly connected with an upstream core manufacturing system (including electrolyte, pole piece data and key raw material data) and a downstream delivery system (including application end self-discharge requirements). According to the method, the tracing requirements of the industries such as downstream medical treatment and new energy on the long-term reliability (capacity, ESR and self-discharge performance) of products are met, and an efficient and reliable packaging and tracing solution is provided for the supercapacitor manufacturing industry.

Description

Multi-mode packaging control and data traceability methods for packaging processes under a traceability system Technical Field

[0001] This invention relates to the field of electronic component manufacturing and product traceability technology, and more specifically, to a multi-mode packaging control and data traceability method for packaging processes under a traceability system. Background Technology

[0002] In the manufacturing of electronic components such as supercapacitors, the packaging process not only provides physical protection against moisture and damage, but also needs to achieve precise traceability across the entire supply chain, encompassing "core characteristics - packaging parameters - downstream applications," focusing on three core dimensions: capacity (e.g., 1F / 5F / 10F), ESR (e.g., ≤30mΩ / ≤50mΩ), and self-discharge voltage (e.g., ≤0.2V / ≤0.3V). As a high-power energy storage component, the capacity of a supercapacitor determines its energy storage limit, ESR affects power output stability, and self-discharge voltage directly relates to the product's storage life and long-term reliability. These three factors together determine its suitability for scenarios such as start-stop systems for new energy vehicles (requiring low self-discharge to ensure backup power), industrial backup power supplies (requiring long storage life), and medical equipment (requiring stable capacity + low ESR + ultra-low self-discharge). The packaging process must simultaneously link capacity deviation detection reports, high-frequency ESR test data, and long-term self-discharge voltage test data to ensure the traceability of the three-dimensional performance parameters of each batch of products.

[0003] Current mainstream traceability systems have significant deficiencies in their packaging functionality: Insufficient dimensional coverage: They only support single-dimensional (e.g., capacity only) or two-dimensional (capacity + ESR) tier rules, ignoring the self-discharge voltage dimension. This leads to situations where "high-capacity, low-ESR supercapacitors with excessive self-discharge voltage are mistakenly introduced into equipment," causing insufficient equipment lifespan or storage failure risks, failing to meet the performance traceability standards of downstream high-requirement applications; Traceability gaps in special scenarios: They lack manual packaging solutions that include self-discharge voltage. When dealing with small-batch customized low-self-discharge supercapacitors or emergency scenarios involving automated packaging equipment failures, they either cannot quickly configure "capacity - ESR - self-discharge voltage" settings. The three-dimensional gearing rules cause production to stagnate, either because key self-discharge voltage data cannot be collected after manual packaging, creating a traceability blind spot; and because cross-stage data collaboration is weak: it is impossible to automatically link key data affecting self-discharge voltage in upstream core manufacturing (such as electrolyte composition and sealing process parameters), and there is no three-dimensional repeated verification mechanism of "capacity-ESR-self-discharge voltage". Manual data processing is prone to errors, forming "core-packaging" data silos, making it difficult to locate the root cause of performance problems later (such as whether the excessive self-discharge voltage is due to core electrolyte defects or electrode defects). Summary of the Invention

[0004] The technical problem to be solved by this invention is that the existing technology has problems such as poor adaptability of the three-dimensional range of "capacity-ESR-self-discharge voltage" of supercapacitors, traceability gaps in special scenarios, and weak cross-link data collaboration. The invention provides a multi-mode packaging control and data traceability method for packaging processes under a traceability system.

[0005] This invention discloses a multi-mode packaging control and data traceability method for packaging processes under a traceability system, implemented through the following technical solution: a graded packaging control module, a manual packaging traceability module, a data collaboration and verification module, and a report generation and export module. These modules are linked through a standardized data interface. The graded packaging control module is the core automated execution unit, including three-dimensional graded rule configuration, automatic three-dimensional graded identification and compliance verification, and automatic cross-process three-dimensional data association. The three-dimensional graded rule configuration is designed for the "capacity-ESR-self-discharge voltage" three-dimensional grades of supercapacitors: three-dimensional grades are set according to "capacity range + self-discharge voltage threshold," and each grade is bound to a unique traceability rule, including: data collection items, traceability code generation logic, and compliance verification standards. The data collection items include: capacity deviation detection values, ESR high-frequency test data, self-discharge voltage test data, raw material batches, packaging box numbers, and assembly batches. The traceability code generation logic uses "graded identifier + capacity-ESR-self-discharge voltage code + SN". The compliance verification standard is as follows: if the packaging ESR exceeds the threshold, the capacity deviation exceeds the threshold, or the self-discharge voltage exceeds the threshold, it is judged as a defective product; the automatic three-dimensional level identification and compliance verification is achieved through "dual-source data comparison": the first source is to scan the QR code / barcode pre-printed on the core, read the basic data of capacity, ESR, and self-discharge voltage stored in the core manufacturing process, and automatically determine the level of each capacitor according to the "capacity-ESR-self-discharge voltage" system preset level standard; the second source is to retrieve the "capacity-ESR-self-discharge voltage" level automatically generated by the upstream process and compare it with the level determined by the packaging process; when the two data are consistent, the preset three-dimensional level is automatically matched; if the data exceeds the standard, an audible and visual alarm is immediately triggered, and a signal is output to divert the defective product to the rework area, and the reason for the defect is recorded simultaneously; the automatic association of cross-process three-dimensional data is as follows: after the verification is qualified, the module uses API The interface retrieves relevant data from the upstream core management system and integrates it with the parameters of the current packaging stage to generate a structured traceability file containing "core characteristics - packaging parameters - capacity - ESR - self-discharge voltage". This file is then bound to the traceability code for that level, achieving "one item, one code, one complete 3D file". The manual packaging traceability module consists of scenario-based task configuration and 3D level adaptation, multi-mode 3D data acquisition and real-time verification, and offline operation and 3D data synchronization. When a manual packaging task is initiated via the terminal, the scenario-based task configuration and 3D level adaptation can select the corresponding type from a preset scenario list. These types include: small-batch customization, equipment failure emergency, and defective product rework. The system automatically loads the scenario-specific "capacity - ESR - self-discharge voltage" 3D level template. The multi-mode 3D data acquisition and real-time verification includes a self-discharge voltage data import function: barcode scanning, manual entry, and file import.The offline operation and 3D data synchronization: supports local data storage in offline environments, automatically synchronizing locally stored manual packaging 3D data to the device's core database and completing the "core-packaging-shipment" full-link traceability chain; the data collaboration and verification module: includes full-link 3D data association and integration, 3D uniqueness and consistency verification, 3D data secure storage and log management; the full-link 3D data association and integration associates the packaging 3D data collected by the grade packaging control module and the manual packaging traceability module with core production parameters and shipment data, forming a complete 3D traceability data chain for supercapacitors from "core manufacturing → packaging → distribution"; the 3D uniqueness and consistency verification includes uniqueness verification: establishing a unique index of "capacity-ESR-self-discharge voltage-traceability code", and consistency verification: periodically comparing "core 3D basic data" and "packaging measured 3D data" in the traceability file; the 3D data secure storage and log management uses the AES-256 encryption algorithm to store core performance data such as capacity, ESR, and self-discharge voltage, accessible only to authorized personnel via account password + USB. The system features dual-key authentication for viewing; it also automatically generates tamper-proof operation logs; the report generation and export module includes automatic generation of structured 3D traceability reports and multi-format export with system integration; the automatic generation of structured 3D traceability reports generates multiple report types based on "3D level dimension," "time dimension," and "batch dimension," all including self-discharge voltage analysis; the multi-format export and system integration support exporting reports to Excel and PDF formats; it also reserves API interfaces for integration with industry regulatory platforms and customer traceability systems, pushing "capacity-ESR-self-discharge voltage" 3D traceability data as needed.

[0006] The "scanning and input" method involves scanning the product's core code, and the system automatically fills the traceability form with basic data such as capacity, ESR, and self-discharge voltage. The "manual input" method is for products without pre-generated codes, where users manually input the capacity, ESR, and self-discharge voltage values. The "file import" method supports batch importing capacity, ESR, and self-discharge voltage data via Excel templates for customized products of less than 50 units, and the system automatically generates temporary traceability codes.

[0007] The structured 3D traceability report is automatically generated, including 3D grade dimension report and batch dimension report.

[0008] Compared with existing technologies, the beneficial effects of this invention are: 1. Precise three-dimensional grading to adapt to high-requirement scenarios: Through the three-dimensional grading design of "capacity-ESR-self-discharge voltage", it solves the problem that existing two-dimensional grading cannot cover the core downstream needs (such as the need for low ESR and low self-discharge in backup power supplies for new energy vehicles, and the need for precise three-dimensional parameter matching in medical equipment), and meets the requirements for self-discharge voltage traceability in the latest revision of AEC-Q200 (capacitors); 2. No traceability blind spots in all scenarios: The manual packaging module supports offline input and synchronization of three-dimensional data, avoiding the loss of self-discharge voltage data in automated equipment failures and small-batch customization scenarios, and eliminating traceability gaps; 3. Three-dimensional data full-link closed loop: It integrates core electrolyte (affecting self-discharge), packaging sealing process (affecting self-discharge), and downstream application requirements (self-discharge threshold) across links, realizing "core-packaging-distribution". 3D traceability closed loop improves the efficiency of quality problem location by 40% (e.g., exceeding self-discharge limits can quickly pinpoint electrolyte batches or other key raw material information); 4. High compliance and practicality: encrypted storage of core 3D data, operation logs record self-discharge voltage modification traces to meet compliance requirements; structured reports support cross-analysis of self-discharge voltage and other parameters, helping enterprises optimize production processes (e.g., the report reveals that "electrolyte batch E202508 has a higher self-discharge pass rate"). Attached Figure Description

[0009] Figure 1 is a data flow layout diagram according to the present invention; Figure 2 is a flowchart according to the present invention. Detailed Implementation

[0010] To better understand the above-mentioned objects, features, and advantages of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. The described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terminology used herein is for the purpose of describing specific embodiments only and is not intended to limit the present invention.

[0011] As shown in Figures 1 and 2, this invention includes a graded packaging control module, a manual packaging traceability module, a data collaboration and verification module, and a report generation and export module. Each module is linked through a standardized data interface. (I) Graded Packaging Control Module This module is the core execution unit for automation of the device. It is specifically designed for the three-dimensional graded design of supercapacitors, which includes "capacity-ESR-self-discharge voltage". Its specific functions are as follows: 1. Three-dimensional graded rule configuration allows administrators to set the three-dimensional graded design through a visual interactive interface according to "capacity range (e.g., 1F / 5F / 10F) + ESR threshold (e.g., ≤30mΩ / ≤50mΩ) + self-discharge voltage threshold (e.g., ≤0.2V / ≤0.3V)" (for example, "1F capacity + ≤30mΩ ESR + ≤0.2V self-discharge voltage" is defined as graded A1, "5F capacity + ≤50mΩ ESR + ≤0.3V self-discharge voltage" is defined as graded A1). Defined as gear B1); and each gear is bound to a unique traceability rule, including: data collection items: capacity deviation detection value, ESR high-frequency test data, self-discharge voltage test data (including initial and final test voltages), raw material batch (including electrolyte batch), packaging box number, assembly batch, etc.; traceability code generation logic: adopts the format of "gear identifier + capacity-ESR-self-discharge voltage code + SN code" (such as "A1-1F30M02S-123456789", where "A1" is the gear A1 identifier, "1F30M" represents 1F capacity, ≤30mΩ ESR, and "02S" represents ≤0.2V self-discharge voltage); compliance verification standard: if the packaging ESR exceeds the gear threshold, the capacity deviation exceeds the threshold, or the self-discharge voltage exceeds the threshold, it is judged as a defective product.

[0012] 2. Automatic 3D Grade Recognition and Compliance Verification: When supercapacitors enter the packaging line, the module achieves grade recognition through "dual-source data comparison": First source: Scans the QR code / barcode pre-printed on the core, reads the basic data of capacity, ESR, and self-discharge voltage stored in the core manufacturing process, and automatically determines the grade of each capacitor according to the system's preset grade standard of "capacity-ESR-self-discharge voltage"; Second source: The system retrieves the "capacity-ESR-self-discharge voltage" grade automatically generated by the upstream process and compares it with the grade determined by the packaging process; When the two data are consistent, the preset 3D grade is automatically matched; If the data exceeds the standard (e.g., the self-discharge voltage generated by grade A1 product is 0.5V, and the self-discharge grade is determined to be unqualified), an audible and visual alarm is immediately triggered (buzzer frequency 2kHz, warning light is constantly red), and a signal is output to divert defective products to the rework area, and the reason for the defect is recorded simultaneously ("self-discharge voltage exceeds the standard, voltage 0.5V").

[0013] 3. After the cross-stage 3D data is automatically correlated and verified, the module retrieves the associated data (including key parameters affecting 3D performance such as core electrode coating thickness, electrode batch number, and electrolyte batch) from the upstream core management system via the API interface. This data is then integrated with the parameters of the current packaging stage (model, packaging time, operator) to generate a structured traceability file containing "core characteristics (electrolyte / sealing process) - packaging parameters - capacity - ESR - self-discharge voltage". This file is then bound to the traceability code for that stage, achieving "one item, one code, one complete 3D file".

[0014] (II) Manual Packaging Traceability Module This module serves as a supplementary unit to automated packaging, adapting to special scenarios such as "small-batch customization of supercapacitors (e.g., low self-discharge products for medical equipment), automated equipment failure, and rework of defective products." Its specific functions are as follows: 1. Scenario-based task configuration and 3D gear adaptation When operators initiate manual packaging tasks through the terminal, they can select the corresponding type from the preset scenario list ("small-batch customization," "emergency equipment failure," and "rework of defective products"). The system automatically loads the scenario-specific "capacity-ESR-self-discharge voltage" 3D gear template: Small-batch customization scenario: Loads the "customized 3D gear template," supporting the input of special capacities (e.g., 3.5F), ESR thresholds (e.g., ≤25mΩ), and self-discharge voltage thresholds (e.g., ≤0.5V), without the need to repeatedly configure basic rules; Defective product rework scenario: Scans the original traceability code of defective products, automatically retrieves historical capacity, ESR, self-discharge voltage data, and reasons for defects (e.g., "abnormal self-discharge voltage test during initial packaging"), and assists in supplementing rework parameters (e.g., retested self-discharge voltage value after rework, and optimized sealing process parameters).

[0015] 2. 3D Data Multi-Mode Acquisition and Real-Time Verification: Supports three data acquisition methods to meet the needs of different scenarios, all of which include self-discharge voltage data import functionality: Scan Entry: For products with scanned core codes, the system automatically fills the traceability form with basic data on capacity, ESR, and self-discharge voltage; Manual Entry: For products without pre-generated codes, manually enter the capacity, ESR, and self-discharge voltage values. The system verifies the "rationality of the 3D combination" in real time (e.g., rejecting "5F capacity + ≤20mΩ ESR + ≤0.2V self-discharge voltage"—high-capacity, low-ESR products typically require even lower self-discharge voltages, and this combination does not conform to industry norms); File Import: For small-batch customized products (e.g., less than 50 pieces), support batch import of capacity, ESR, and self-discharge voltage data via Excel templates (the template includes a mandatory "self-discharge voltage test condition" field). The system automatically generates temporary traceability codes (formatted the same as the automated 3D grade traceability code). During all entry processes, the module provides pop-up prompts for missing data (e.g., missing self-discharge voltage test temperature) to ensure complete traceability information.

[0016] 3. Offline operation and 3D data synchronization support local data storage in offline environments (based on SQLite local database). Operators can complete the offline entry of capacity, ESR, and self-discharge voltage data. When the device is restored to the network, the module automatically synchronizes the locally stored manual packaging 3D data to the device's core database and completes the "core-packaging-shipment" full-link traceability chain, avoiding traceability gaps caused by missing self-discharge data.

[0017] (III) Data Collaboration and Verification Module This module is the data hub of the device, responsible for the integration, accuracy verification and secure storage of three-dimensional data. Its specific functions are as follows: 1. Integration and connection of three-dimensional data across the entire chain. It connects with the upstream core manufacturing system (including electrolyte batch and sealing process parameters) and the downstream shipping system (including customer requirements for self-discharge voltage, such as ≤0.2V for medical equipment). It links the three-dimensional packaging data collected by the grade packaging control module and the manual packaging traceability module with the core production parameters (electrode material batch and formation process) and shipping data (logistics tracking number and customer self-discharge requirements) to form a complete three-dimensional traceability data chain for supercapacitors from "core manufacturing → packaging → distribution". It supports one-click query of the entire process three-dimensional information through the traceability code (such as "core electrolyte batch E202508 → packaging self-discharge voltage 0.45V → customer requirement ≤0.5V").

[0018] 2. Three-dimensional uniqueness and consistency verification: Uniqueness verification: Establish a unique index of "Capacity - ESR - Self-discharge voltage - Traceability code". If the core code of a packaged product is scanned, the system will immediately prompt "This product has completed the A1 packaging (1F+30mΩ+0.5V), and repeated operation is prohibited"; Consistency verification: Regularly compare the "core three-dimensional basic data" and "package measured three-dimensional data" in the traceability file. If the deviation exceeds the threshold (e.g., core self-discharge voltage ≤0.5V, package measured ≤0.6V), an abnormal report will be automatically generated to locate the difference ("core electrolyte batch E202508 defect" or "capacity exceeds the threshold").

[0019] 3. Secure storage and log management of 3D data employs AES-256 encryption algorithm to store core performance data such as storage capacity, ESR, and self-discharge voltage. Only authorized personnel (through dual authentication of account password + USB key) can view this data. Simultaneously, an immutable operation log is automatically generated, recording the entry and modification of 3D data during each packaging operation (automated / manual) (e.g., "2025-08-29 10:30, OP001 modified the measured self-discharge voltage from 0.55V to 0.45V, reason: retesting after test equipment calibration"), meeting industry compliance audit requirements.

[0020] (IV) Report Generation and Export Module This module is designed for the supercapacitor industry's need for statistical analysis of three-dimensional data on "capacity-ESR-self-discharge voltage". Specific functions are as follows: 1. Automatic generation of structured three-dimensional traceability reports. Supports the generation of multiple report types based on "three-dimensional level dimension", "time dimension", and "batch dimension", all including self-discharge voltage analysis: Three-dimensional level dimension report: Includes packaging quantity, pass / fail rate (classified by ESR exceedance, capacity deviation, and self-discharge voltage exceedance) for each three-dimensional level (e.g., level A1 / A2, B1 / B2), and associated core electrolyte batch distribution (e.g., 80% of the electrolyte used in level A1 is batch E202508); Batch dimension report: For a single batch of products, presents the percentage of automated / manual packaging, the average capacity / ESR / self-discharge voltage of the entire batch, and the correlation analysis between self-discharge voltage and electrolyte batch (e.g., "When electrolyte batch E202508 is used, the self-discharge voltage failure rate decreases by 15%"); The report automatically marks key indicators (e.g., "Level A1..."). The self-discharge voltage defect rate is 0.3%, which is lower than the industry average of 0.7%, directly reflecting the production and traceability situation.

[0021] 2. Multi-format export and system integration support: Reports can be exported to Excel (for cross-analysis of self-discharge voltage and capacity / ESR) and PDF (for archiving). API interfaces are also reserved for integration with industry regulatory platforms (such as electronic component quality traceability platforms) and customer traceability systems. Three-dimensional traceability data of "capacity-ESR-self-discharge voltage" can be pushed as needed to meet downstream customers' traceability requirements for product storage life and long-term reliability (e.g., medical device manufacturers need to verify whether the self-discharge voltage meets usage cycle requirements).

[0022] III. Workflow of the device The workflow of this device is divided into "automated three-dimensional grade packaging process" and "manual packaging process", covering the entire process of supercapacitor packaging, and both include the self-discharge voltage control link: (1) Automated three-dimensional grade packaging process 1. Rule initialization: The administrator configures the three-dimensional grades of "capacity-ESR-self-discharge voltage" and corresponding rules (including self-discharge voltage test standards) in the grade packaging control module; 2. Product identification and three-dimensional verification: When the supercapacitor enters the packaging line, the module scans the code to read the core three-dimensional data + retrieves the capacity / ESR / self-discharge voltage through special equipment, matches the three-dimensional grade and generates the grade; 3. Three-dimensional data association and file generation: After the verification is qualified, the core electrolyte / sealing process data and packaging parameters are associated to generate a traceability file and traceability code containing three-dimensional performance; 4. Data synchronization and report collection: The packaging three-dimensional data is synchronized to the data collaboration module, and the report module automatically collects data according to the three-dimensional grade, which supports subsequent export.

[0023] (2) Manual Packaging Process 1. Task Initiation: The operator selects the scenario (e.g., "small batch customization"), loads the corresponding "capacity-ESR-self-discharge voltage" three-dimensional level template (e.g., 0.4V self-discharge voltage for medical equipment), and submits the manual task; 2. Three-dimensional Data Acquisition and Verification: By scanning / importing / manually entering capacity, ESR, and self-discharge voltage data, the system verifies the rationality of the three-dimensional combination in real time and generates a temporary traceability code; 3. Offline / Online Storage: When the network is disconnected, the three-dimensional data is stored locally and synchronized to the core database after the network is connected; 4. Data Integration: The three-dimensional data of manual packaging and the automated data are collected in a unified manner and participate in the report generation.

[0024] This embodiment demonstrates the application of the device in three-dimensional tracking of "capacity-ESR-self-discharge voltage" of supercapacitors, emergency packaging in special scenarios, and cross-link data collaboration through specific operation procedures, solving the problems of confusion of levels, traceability gaps, and data silos in the existing system.

[0025] 1. Device Initialization and Hardware Interconnection 1.1 Hardware Connection Configuration The core module of the device is connected to the existing equipment on the supercapacitor packaging line. New hardware related to self-discharge testing is added: Gradient Packaging Control Module: Connects to the core scanning device and robotic arm diversion device via RS485 interface (response ≤0.5s); Manual Packaging Traceability Module: Connects to the operating terminal (10.1-inch touchscreen), portable barcode scanner (wireless ≤50m), and portable self-discharge tester (suitable for small-batch on-site testing) via USB interface; Data Collaboration and Verification Module: Connects to the upstream core manufacturing system (MES system, storing electrolyte batches and sealing process parameters) and the downstream shipping system (WMS system, storing customer self-discharge requirements) via Ethernet, using a MySQL database (supporting 1000 data entries / second write, including self-discharge fields).

[0026] 1.2 System Parameter Initialization: Basic parameter settings are completed through the visual management interface. New self-discharge related configurations are added: Traceability Code Rules: The format is set to "3D Gear Identifier + Capacity - ESR - Self-Discharge Voltage Code + 8-bit Random Sequence", such as "A1-1F30M05D-12345678" ("A1" is the gear identifier, "1F30M" is 1F capacity + 30mΩ ESR, and "05D" is 0.5V self-discharge voltage); Data Storage Parameters: ≥15GB of space is reserved in the local offline database (SQLite) to store 3D data, and the network synchronization frequency is set to once every 5 minutes; Access Control: Administrators can configure capacity, ESR, and self-discharge voltage thresholds; operators can only import capacity, ESR, and self-discharge data; auditors can view relevant logs, as shown in Table 1.

[0027] Table 1: Basic Information Table

[0028] 2. Three-Dimensional Grading Rules Preset and Automated Packaging Process: Taking "1F / 5F / 10F Supercapacitor Packaging (Adapted for New Energy Vehicle Backup Power)" as an example, the automated operation is described as follows: 2.1 Three-Dimensional Grading Rule Configuration: The administrator login interface creates 3 sets of three-dimensional grading: Grading A1: Capacity 1F±5%+ESR≤30mΩ+ Self-discharge voltage≤0.5V, bound to data collection items (including electrolyte batch, electrode coating thickness, and key raw material batch); Grading B1: Capacity 5F±5%+ESR≤50mΩ+ Self-discharge voltage≤0.1V, bound to data collection items (including electrolyte batch, electrode coating thickness, and key raw material batch); Grading C1: Capacity 10F±5%+ESR≤80mΩ+ Self-discharge voltage≤0.3V, bound to data collection items (including electrolyte batch, electrode coating thickness, and key raw material batch); Compliance Standard: If any parameter exceeds the standard (such as self-discharge voltage 0.6V), it is judged as a defective product, triggering an audible and visual alarm.

[0029] 2.2 Product loading and 3D information reading: When the supercapacitor enters the packaging station, the barcode scanning device reads the core data (such as "capacity 1F, ESR 28mΩ, self-discharge voltage 0.45V, electrolyte batch E202508, electrode coating thickness 8μm") and uploads it to the module database.

[0030] 2.3 Real-time 3D Detection and Gear Matching Module Interfacing with Dedicated Equipment for Actual Measurement: A certain 1F product has a capacity of 0.98F, ESR of 29mΩ, and self-discharge voltage of 0.48V (electrolyte batch E202508, electrode coating thickness 8μm). According to the system's preset gear standard, it is determined to be "gear A1". The module compares the gear generated upstream of the core with the gear determined in the packaging process, automatically matches "gear A1", and loads the packaging parameters (electrolyte batch E202508, electrode coating thickness 8μm).

[0031] 2.4 Compliance Verification and Defective Product Diversion: A certain 5F product has a self-discharge voltage of 0.72V. The module determines it to be a defective product, controls the robotic arm to divert it to the rework area, records the reason ("self-discharge voltage exceeds the standard, 0.72V"), ​​and generates a rework order.

[0032] Table 2: Statistics of Defective Products (related to Table 2)

[0033] 2.5 After the 3D data association and file generation verification is qualified, the module retrieves the batch information of core and electrolyte E202508, integrates the packaging parameters (time 2025-08-29 10:30, operator OP001), generates a traceability file, and binds the traceability code "A1-1F30M05D-8A7B9C0D".

[0034] Table 3: Packaging Data Sheet for Different Price Ranges (Core of Automated Packaging)

[0035] 2.6 Data Synchronization and Report Collection After packaging is completed, the 3D data is synchronized to the core database, and the report module is statistically analyzed according to grade A1 (current batch of 2000 packages, self-discharge voltage qualification rate 100%).

[0036] 3. Manual Packaging Traceability Process (Small Batch Customization Scenario) Taking "Customizing 50 3.5F, ESR≤25mΩ, self-discharge voltage≤0.4V supercapacitors for a certain device" as an example, the operation is described as follows: 3.1 Manual Task Initiation and Scenario Selection The operator logs into the terminal, selects the "Small Batch Customization" scenario, and submits the task (number MD20250829001, quantity 50 pieces, three-dimensional parameters 3.5F+25mΩ+0.4V).

[0037] 3.2 The three-dimensional gear template loading and parameter supplementation system loads customized templates, and operators supplement special parameters (injection volume) without having to repeatedly configure capacity, ESR, and self-discharge voltage test standards.

[0038] 3.3 3D Data Acquisition and Real-time Verification: The operator imports data for 50 products in batches using an Excel template (e.g., “3.5F / 24mΩ / 0.38V”, “3.48F / 23mΩ / 0.39V”). During system verification, one erroneous data entry (“3.5F / 24mΩ / 0.5V”) is intercepted, and a pop-up window displays the message: “Self-discharge voltage exceeds the customized threshold of 0.4V. Please re-enter the data.”

[0039] 3.4 Offline Operation and Data Storage If the packaging line experiences a sudden network outage, the module switches to offline mode. The operator continues to enter data, which is temporarily stored in the local path "D:\ManualData\MD20250829001" (including self-discharge voltage test records).

[0040] 3.5 Network Data Synchronization and Traceability Completion After network outage recovery (August 29, 2025, 15:00), the module automatically synchronizes the 3D data of 50 products to the core database and generates a manual packaging report (completion rate 100%, data accuracy 100%).

[0041] Table 4: Manual Packaging Record Sheet (Special Scenarios)

[0042] 4. Data Collaboration and Report Generation Process: Taking 3D data integration as an example, the operation is described as follows: 4.1 Multi-stage 3D Data Association: The data collaboration module connects to the systems of three factories, integrating: Factory 1: Grade A1 packaging 2000 pieces (self-discharge voltage qualification rate 99.5%, electrolyte batch E202508); Factory 2: Grade B1 packaging 3000 pieces (self-discharge voltage qualification rate 99.8%); Factory 3: Manual packaging 500 pieces (3.5F+25mΩ+0.4V, qualification rate 100%); Linking core electrolyte data and downstream customer self-discharge requirements (e.g., customer requires ≤0.4V), a full-chain 3D traceability chain is formed.

[0043] 4.2 Three-dimensional data uniqueness and consistency verification Uniqueness verification: Scan the traceability code "A1-1F30M05D-8A7B9C0D" of the packaged product. The system prompts "Packaging of grade A1 has been completed. Repeated operation is prohibited". Consistency verification: It was found that the core self-discharge voltage of a certain batch of products in Factory 1 was ≤0.5V, while the actual measured voltage after packaging was ≤0.6V (exceeding the threshold of 0.1V). The problem link was located as "poor self-discharge", and an abnormal report was generated.

[0044] Table 5: Data Collaboration Verification Table (Cross-stage Integration)

[0045] 4.3 Structured 3D Report Generation and Export Module: Tier Dimension Report: Tier A1 monthly packaging of 5000 pieces, self-discharge voltage defect rate of 0.3%, electrolyte batch E202508 accounting for 80%; Time Dimension Report: August 2025, group-wide packaging of 10000 pieces, automation rate of 95%, average self-discharge voltage of 0.42V; Exported to Excel format for process optimization (analyzing the correlation between electrolyte batch and self-discharge voltage), and simultaneously pushed to the industry regulatory platform.

[0046] Table 6: Report Summary Table (Automatically Calculated)

[0047] 5. Summary of Implementation Results Through the application of this embodiment, the following technical effects were achieved: Automated packaging efficiency increased by 50%: single-shift packaging volume increased from 2000 pieces to 3000 pieces, and the accuracy rate of 3D parameter defective product triage reached 100%; Manual packaging time was reduced by 70%: data entry time for small-batch customization of 50 pieces was reduced from 3 hours to 1 hour, and the accuracy rate of 3D data reached 100%; Efficiency in locating self-discharge-related issues increased by 40%: the time for locating quality issues within the group was reduced from 3 days to 1.8 days, and the self-discharge exceedance rate decreased from 2% to 0.5%; Traceability file completeness reached 98%: covering the three-dimensional link of "core-packaging-distribution," meeting the traceability needs of downstream industries such as medical and new energy for long-term product reliability.

[0048] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A multi-mode packaging control and data traceability method for packaging processes under a traceability system, characterized in that, The system includes a graded packaging control module, a manual packaging traceability module, a data collaboration and verification module, and a report generation and export module. These modules are interconnected through standardized data interfaces. The graded packaging control module is the core automated execution unit, comprising three-dimensional grade setting rule configuration, automatic three-dimensional grade identification and compliance verification, and automatic cross-stage three-dimensional data association. The three-dimensional grade setting rule configuration is designed for the "capacity-ESR-self-discharge voltage" three-dimensional grade design of supercapacitors: three-dimensional grades are set according to "capacity range + self-discharge voltage threshold," and each grade is bound to a unique traceability rule, including: data collection items, traceability code generation logic, and compliance verification standards. The data collection items include: capacity deviation detection values, ESR high-frequency test data, self-discharge voltage test data, raw material batch, packaging box number, and assembly batch. The traceability code generation logic uses the format "grade identifier + capacity-ESR-self-discharge voltage code + SN code." The compliance verification standard: if the packaging ESR exceeds the grade threshold, the capacity deviation exceeds the threshold, or the self-discharge voltage exceeds the threshold, it is judged as a defective product. The automatic three-dimensional grade identification and compliance verification is achieved through "dual-source data comparison." Capacitor level identification is achieved through two main methods: First, scanning the pre-printed QR code / barcode on the capacitor core, reading the basic data of capacity, ESR, and self-discharge voltage stored during the core manufacturing process, and automatically determining the level of each capacitor based on the preset level standard of "capacity-ESR-self-discharge voltage"; Second, the system retrieves the "capacity-ESR-self-discharge voltage" level automatically generated by the upstream process and compares it with the level determined by the packaging process; If the two data match, the preset three-dimensional level is automatically matched; If the data exceeds the standard, an audible and visual alarm is immediately triggered, and a signal is output to divert defective products to the rework area, simultaneously recording the cause of the defect; The automatic association of cross-process three-dimensional data: After verification, the module automatically associates the data via API. The interface retrieves relevant data from the upstream core management system, integrates it with the parameters of the current packaging stage, and generates a structured traceability file containing "core characteristics - packaging parameters - capacity - ESR - self-discharge voltage". This file is then bound to a traceability code for that level, achieving "one item, one code, one complete 3D file". The manual packaging traceability module consists of scenario-based task configuration and 3D level adaptation, multi-mode 3D data acquisition and real-time verification, and offline operation and 3D data synchronization. When a manual packaging task is initiated via the terminal, the scenario-based task configuration and 3D level adaptation allows selection of a corresponding type from a preset scenario list. These types include: small-batch customization, equipment failure emergency, and defective product rework. The system automatically loads the scenario-specific "capacity - ESR - self-discharge voltage" 3D level template. The multi-mode 3D data acquisition and real-time verification includes a self-discharge voltage data import function: barcode scanning, manual entry, and file import. The offline operation and 3D data synchronization supports local data storage in offline environments, automatically synchronizing locally stored manual packaging 3D data to the device's core database and completing the "core-packaging-shipment" full-link traceability chain.The data collaboration and verification module includes end-to-end 3D data association and integration, 3D uniqueness and consistency verification, and 3D data secure storage and log management. The end-to-end 3D data association and integration links the 3D packaging data collected by the grade packaging control module and the manual packaging traceability module with core production parameters and shipping data, forming a complete 3D traceability data chain for supercapacitors from "core manufacturing → packaging → distribution." The 3D uniqueness and consistency verification includes uniqueness verification by establishing a unique index of "capacity - ESR - self-discharge voltage - traceability code," and consistency verification by periodically comparing the "core 3D basic data" and "packaging measured 3D data" in the traceability archive. The 3D data secure storage and log management uses the AES-256 encryption algorithm to store core performance data such as capacity, ESR, and self-discharge voltage, accessible only to authorized personnel through dual authentication of account password + USB key; it also automatically generates tamper-proof operation logs. The report generation and export module includes automatic generation of structured 3D traceability reports and multi-format export with system integration. The automatic generation of structured 3D traceability reports is categorized by "3D grade dimension," "time dimension," and "batch dimension." The system generates multiple report types, all including self-discharge voltage analysis; the multi-format export and system integration support exporting reports to Excel and PDF formats; it also reserves API interfaces for integration with industry regulatory platforms and customer traceability systems, pushing "capacity-ESR-self-discharge voltage" three-dimensional traceability data as needed.

2. The multi-mode packaging control and data traceability method for packaging processes under a traceability system according to claim 1, characterized in that, The "scanning and input" method involves scanning the product's core code, and the system automatically fills the traceability form with basic data such as capacity, ESR, and self-discharge voltage. The "manual input" method is for products without pre-generated codes, where users manually input the capacity, ESR, and self-discharge voltage values. The "file import" method supports batch importing capacity, ESR, and self-discharge voltage data via Excel templates for customized products of less than 50 units, and the system automatically generates temporary traceability codes.

3. The multi-mode packaging control and data traceability method for packaging processes under the traceability system according to claim 1, characterized in that, The structured 3D traceability report is automatically generated, including 3D grade dimension report and batch dimension report.

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