Secondary battery manufacturing system and method for manufacturing a secondary battery

Abstract

A method for manufacturing a secondary battery is provided. The method includes: the steps of collecting supply history data and manufacturing history data; and the steps of analyzing the supply history data and manufacturing history data, wherein the manufacturing history data represents the state of a main equipment configured to perform a manufacturing process, and the supply history data represents the state of a supply unit configured to supply electrode rolls to the main equipment.

Description

Technical Field

[0001] This disclosure relates to a secondary battery manufacturing system and a method for manufacturing secondary batteries.

[0002] This application claims the benefit of Korean Patent Application No. 10-2024-0134135, filed on October 2, 2024, the disclosure of which is incorporated herein by reference. Background Technology

[0003] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. They are widely used as a power source for various wireless devices such as mobile phones, laptops, and cordless vacuum cleaners. Recently, due to increased energy density and economies of scale, the manufacturing cost per unit capacity of secondary batteries has decreased significantly, and the driving range of BEVs (battery electric vehicles) has increased to a level comparable to that of gasoline vehicles, thus shifting the primary use of secondary batteries from mobility devices to transportation.

[0004] Secondary batteries are manufactured through electrode processes, assembly processes, and activation processes. Among these, the electrode process is the most critical process for determining the yield and performance of the battery cell. The electrode process may include coating, rolling, and slitting processes. In the coating process, active and insulating materials are applied to the surface of the current collector. In the rolling process, the electrodes are pressed using pressing rollers. The rolling process determines the electrode density, performance, and surface quality. In the slitting process, the electrodes are cut into multiple electrodes according to the battery cell design. Summary of the Invention

[0005] Technical issues

[0006] The technical idea of ​​this disclosure is to provide a secondary battery manufacturing system with improved ability to identify factors that cause equipment operational losses.

[0007] Technical solution

[0008] According to an exemplary embodiment of this disclosure that addresses the aforementioned problems, a method for manufacturing a secondary battery is provided. The method includes the steps of: collecting supply history data and manufacturing history data; and analyzing the supply history data and the manufacturing history data, wherein the manufacturing history data represents the state of a main equipment configured to perform a manufacturing process, and the supply history data represents the state of a supply unit configured to supply electrode rolls to the main equipment.

[0009] The steps of analyzing the supply history data and the manufacturing history data include: determining the portion of the idle time in the supply history data that matches the idle time in the manufacturing history data in terms of time.

[0010] The steps of analyzing the supply history data and the manufacturing history data include: determining the occupancy rate of the loss codes of the manufacturing history data that time-matches the idle time of the manufacturing history data.

[0011] The occupancy rate is calculated as a percentage of the total idle time in the manufacturing history data.

[0012] According to an exemplary embodiment, a secondary battery manufacturing system is provided. The system includes: a secondary battery manufacturing apparatus; an automated logistics system configured to deliver electrode rolls to the secondary battery manufacturing apparatus; and a server, wherein the secondary battery manufacturing apparatus includes: a main apparatus configured to process the electrode rolls; and a supply unit configured to supply the electrode rolls delivered by the automated logistics system, wherein the main apparatus includes a process controller configured to collect manufacturing history data representing the state of the main apparatus and transmit the manufacturing history data to the server, and wherein the supply unit includes a supply controller configured to collect supply history data representing the state of the main apparatus and transmit the supply history data to the server.

[0013] The supply unit includes: a first shuttle, the first shuttle including a first unwinding machine; a second shuttle, the second shuttle including a second unwinding machine; and a lift, the lift being configured to lift the electrode roll from the automated logistics system and load the electrode roll onto one of the first unwinding machine and the second unwinding machine.

[0014] The supply controller is configured to control the first shuttle, the second shuttle, and the elevator.

[0015] The server is an MES (Manufacturing Execution System).

[0016] The server is configured to store the supply history data and the manufacturing history data.

[0017] The server is configured to analyze the supply history data and the manufacturing history data.

[0018] Analyzing the supply history data and the manufacturing history data includes: determining the portion of the idle time in the supply history data that matches the idle time in the manufacturing history data in terms of time.

[0019] Analyzing the supply history data and the manufacturing history data includes: determining the occupancy rate of the loss codes in the manufacturing history data that match the idle time of the manufacturing history data in time.

[0020] The occupancy rate is calculated as a percentage of the total idle time in the manufacturing history data.

[0021] Beneficial effects

[0022] According to exemplary embodiments of this disclosure, when equipment downtime occurs in a secondary battery manufacturing system, it is possible to identify which component among the main processing equipment, the automatic electrode supply unit, and the automated logistics system is causing the downtime. Therefore, by quickly addressing the factors leading to downtime loss, the reliability and yield of secondary battery manufacturing can be improved.

[0023] The effects that can be obtained from the exemplary embodiments of this disclosure are not limited to those mentioned above, and other effects not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of this disclosure pertain. That is, those skilled in the art can also derive unforeseen effects from practicing the exemplary embodiments of this disclosure. Attached Figure Description

[0024] Figure 1 The illustration shows a secondary battery manufacturing system according to an exemplary embodiment.

[0025] Figure 2 The illustration shows a secondary battery manufacturing system according to an exemplary embodiment.

[0026] Figure 3 The illustration includes an exemplary logistics event scenario in which logistics events are time-aligned when the master device is in standby mode.

[0027] Figure 4 The diagram illustrates the idle portions of the manufacturing history data, which are matched and aligned temporally with the supply history data.

[0028] Figure 5 This is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment. Detailed Implementation

[0029] The preferred embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be noted that the terms and words used in this specification and claims should not be interpreted in their conventional or dictionary sense, but rather based on the principle that the inventors can define the concepts of the terms in a manner they deem appropriate in order to best interpret the disclosure, and should be interpreted in a meaning and concept consistent with the technical idea of ​​this disclosure.

[0030] Therefore, it should be understood that the embodiments described herein and the configurations shown in the accompanying drawings are merely the most preferred embodiments of this disclosure and do not represent all the technical ideas of this disclosure. Various equivalents and modifications that can replace them may exist at the time of filing this application.

[0031] Furthermore, in describing this disclosure, specific descriptions of relevant disclosed configurations or features are omitted when such detailed descriptions are considered to obscure the key points of this disclosure.

[0032] Because the embodiments of this disclosure are provided to more fully illustrate the disclosure to those skilled in the art, the shapes and dimensions of the components in the drawings may be exaggerated, omitted, or shown schematically for clarity. Therefore, the dimensions or proportions of each component do not necessarily represent their actual dimensions or proportions.

[0033] (First Implementation)

[0034] Figure 1 The illustration shows a secondary battery manufacturing system 10 according to an exemplary embodiment.

[0035] Figure 2 The illustration shows a secondary battery manufacturing system 10 according to an exemplary embodiment.

[0036] Reference Figure 1 and Figure 2 The secondary battery manufacturing system 10 may include secondary battery manufacturing equipment 100, automated logistics systems 210 and 220, and servers 310 and 320.

[0037] According to an exemplary embodiment, the secondary battery manufacturing apparatus 100 can be configured to perform a secondary battery manufacturing process. Hereinafter, the technical ideas of this disclosure will be described focusing on an example of the secondary battery manufacturing apparatus 100 performing a grooving process, according to an exemplary embodiment. Those skilled in the art will be able to readily implement embodiments in which the secondary battery manufacturing apparatus performs any of the coating, rolling, and slitting processes based on the description herein.

[0038] The secondary battery manufacturing equipment 100 can be configured to perform a roll-to-roll process. The automated logistics system 210 can be configured to supply the secondary battery manufacturing equipment 100 with electrode rolls ER1 that have been completed in a previous process.

[0039] The secondary battery manufacturing equipment 100 may include a main unit 110, a supply unit 120, and a discharge unit 130. The main unit 110 may include a controller 111. The supply unit 120 may include a controller 121, a lift 122, a first shuttle 123, and a second shuttle 124. The discharge unit 130 may include a controller 131, a lift 132, a first shuttle 133, and a second shuttle 134.

[0040] Electrode roll ER1 is loaded onto first shuttle 123 and second shuttle 124. Elevator 122 can be configured to lift electrode roll ER1 conveyed by automated logistics system 210 and load electrode roll ER1 onto one of first unwinding machine 123UW of first shuttle 123 and second unwinding machine 124UW of second shuttle 124.

[0041] The electrode sheet ES can be unwound from the electrode roll ER1 loaded onto the first unwinding machine 123UW of the first shuttle 123. The electrode sheet ES can be unwound by the first unwinding machine 123UW. When the electrode roll ER1 is loaded onto the second unwinding machine 124UW of the second shuttle 124, the electrode roll ER1 is processed in a similar manner to when the electrode roll ER1 is loaded onto the first unwinding machine 123UW of the first shuttle 123.

[0042] The electrode sheet ES can be processed by the main equipment 110. The main equipment 110 can be configured to perform, for example, a grooving process. In the grooving process, multiple master tabs can be formed on the electrode sheet ES. The main equipment 110 can be configured to perform, for example, a laser grooving process.

[0043] The electrode sheet ES processed by the main device 110 can be wound by a first rewinder 133UW of the first shuttle 133. The electrode sheet ES processed by the main device 110 can also be wound by a second rewinder 134UW of the second shuttle 134. When processing by the main device 110 is completed, the second electrode roll ER2 can be separated from the electrode sheet ES. Completion of the second electrode roll ER2 may include, for example, achieving a target winding amount.

[0044] The completed second electrode roll ER2 can be unloaded from the first rewinder 133UW of the first shuttle 133 via elevator 132 and transferred to the automated logistics system 220. The automated logistics system 220 can then transfer the second electrode roll ER2 to subsequent processing equipment or a buffer.

[0045] Controller 111 can be configured to control the operation of various components of master equipment 110. Controller 111 can also be referred to as a process controller. Controller 111 can be configured to collect manufacturing history data (MHD) representing control signals generated by controller 111 and process events occurring from master equipment 110.

[0046] Manufacturing history data (MHD) can represent the status of master equipment 110. The MHD can include the status value of master equipment 110 and the time that matches that status value. The status value of master equipment 110 can indicate that master equipment 110 is in operation, or it can include a loss code. The loss code can represent factors that cause a loss in uptime.

[0047] Controller 121 can be configured to control the elevator 122, the first shuttle 123, and the second shuttle 124 of the supply unit 120. Controller 121 can also be referred to as a supply controller. Controller 121 can be configured to collect supply history data (SHD) representing control signals generated by controller 121 and logistics events occurring from elevator 122, the first shuttle 123, and the second shuttle 124.

[0048] The Supply History Data (SHD) can represent the status of the elevator 122, the first shuttle 123, and the second shuttle 124. The SHD can include the status value of the loading unit 120 (i.e., the corresponding status values ​​of the elevator 122, the first shuttle 123, and the second shuttle 124) and the time that matches that status value. The status value of the loading unit 120 can indicate that the loading unit 120 is in operation, or it can include a loss code. The loss code can represent factors that cause a loss in operating rate.

[0049] The controller 131 can be configured to control the elevator 132, the first shuttle 133 and the second shuttle 134 of the discharge section 130.

[0050] Each of controllers 111, 121, and 131 can be a PLC (Programmable Logic Controller). A PLC is a microprocessor-based controller that uses programmable memory to store instructions and implement functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. PLCs are easy to operate and program.

[0051] Each of controllers 111, 121, and 131 may include a power supply, a CPU, an input interface, an output interface, a communication interface, and a memory device. The power supply may be configured to power other components of each of controllers 111, 121, and 131, such as the CPU, input interface, output interface, communication interface, and memory device, for operation of each of controllers 111, 121, and 131. The memory device may include ROM (Read Only Memory) configured to store system programs such as an operating system, and RAM (Random Access Memory) configured to store data such as user programs and status information of input and output devices, timers, counters, and values ​​of other internal devices. The CPU may be configured to implement logic and control communication between modules that convert input signals into output operation signals. The CPU may operate based on system programs and user programs stored in the memory device. The CPU may be configured to write check data and measurement data to or read check data and measurement data from the data area of ​​the memory device based on the system program and user program. The status or data of industrial equipment and production processes may be transmitted to the CPU via input modules. The results processed by the CPU can be transmitted to the actuator via the output module. The communication interface can be configured to send and receive data from controllers 111, 121, and 131.

[0052] However, this disclosure is not limited thereto, and each of controllers 111, 121, and 131 may include any of the following: a simple controller, a complex processor such as a microprocessor, CPU, GPU, etc., a software-configurable processor, proprietary hardware, and firmware. Each of controllers 111, 121, and 131 may be implemented by, for example, a general-purpose computer or by special-purpose hardware such as a DSP (Digital Signal Processor), FPGA (Field Programmable Gate Array), and ASIC (Application Specific Integrated Circuit).

[0053] Controller 121 can be configured to send Manufacturing History Data (MHD) to server 310. Controller 121 can be configured to send Supply History Data (SHD) to server 310. Controller 121 can be configured to send Volume Request Signal (RRS) to server 310.

[0054] Server 310 can be configured to send Volume Request Signal (RRS), Supply History Data (SHD), and Manufacturing History Data (MHD) to server 320. Server 310 can be a communication server. Figure 1 and Figure 2 The difference shown can be that server 310 can be omitted, and controllers 111 and 121 can be configured to communicate directly with server 320.

[0055] According to an exemplary embodiment, server 320 may be a data processing system that supports various activities required for managing the manufacture of secondary batteries, such as work schedule management, work instructions, quality control, and work performance summarization. According to an exemplary embodiment, server 320 may be a Manufacturing Execution System (MES). Server 320 may be configured to perform input, processing, output, and communication of data required for manufacturing secondary batteries.

[0056] According to other exemplary embodiments, server 320 can be configured to store and process raw measurement data. Server 320 can manage the processing quality of the electrode sheet ES by continuously monitoring the processing of the electrode sheet ES based on the measurement data. According to an exemplary embodiment, server 320 can be an SPC (Statistical Process Controller). Server 320 can collect and analyze manufacturing data in near real-time to identify problem conditions in a timely manner and can provide alerts to operators before potential problems occur.

[0057] Server 320 can be configured to send a roll transfer command RTC to automated logistics system 210 in response to a roll request signal RRS. Automated logistics system 210 can be configured to operate in response to the roll transfer command RTC to transfer the first electrode roll ER1 to supply unit 120.

[0058] Server 320 can be configured to store supply history data (SHD) and manufacturing history data (MHD). Server 320 can be configured to process supply history data (SHD) and manufacturing history data (MHD). Server 320 can be configured to identify the causes of operational rate losses occurring in master equipment 110 based on supply history data (SHD) and manufacturing history data (MHD).

[0059] Figure 3 The illustration includes an exemplary logistics event scenario in which logistics events are time-aligned when the master device 110 is in standby mode.

[0060] Reference Figures 1 to 3During the period from the first time point T1 to the seventh time point T7, the master device 110 can be in standby mode. That is to say, the supply history data SHD when the master device 110 is in standby mode can be aligned in time.

[0061] At the first time point T1, the controller 121 can send a roll request signal RRS to the server 320. The server 320 can send a roll transfer command RTC to the automated logistics system, and in response, the automated logistics system 210 can transfer the first electrode roll ER1 with batch number B to the supply department 120.

[0062] The first electrode roll ER1 with batch number B can arrive at the supply unit 120 at a second time point T2 after the first time point T1. The preparation of the first electrode roll ER1 with batch number B can begin from a third time point T3 after the second time point T2. The preparation of the first electrode roll ER1 with batch number B may include loading the first electrode roll ER1 with batch number B onto one of the first shuttle member 123 and the second shuttle member 124.

[0063] For example, when the first electrode roll ER1 with batch number A is loaded onto the first shuttle 123 and processed by the main device 110, the first electrode roll ER1 with batch number B can be loaded onto the second shuttle 124. Conversely, when the first electrode roll ER1 with batch number A is loaded onto the second shuttle 124 and processed by the main device 110, the first electrode roll ER1 with batch number B can be loaded onto the first shuttle 123. The case where the first electrode roll ER1 with batch number B is loaded onto the second shuttle 124 will be described below.

[0064] A failure may occur in supply unit 120 at a fourth time point T4, following the third time point T3. When a failure occurs in supply unit 120, controller 121 can be configured to generate a signal for generating an alarm. An operator can respond to the alarm by arriving at the scene at a fifth time point T5, following the fourth time point T4, resetting the alarm and initiating action. At the fifth time point T5, supply unit 120 can be stopped by operator intervention.

[0065] At the sixth time point T6, following the fifth time point T5, the action to resolve the malfunction of the supply unit 120 can be completed, and from the sixth time point T6 onwards, the supply unit 120 can be in operation. At the seventh time point T7, following the sixth time point T6, the first electrode roll ER1 with batch number B can be prepared, and from the seventh time point T7 onwards, the main equipment 110 can be in operation.

[0066] Figure 4The diagram illustrates the idle portion of the manufacturing history data MHD and the supply history data SHD, which are time-matched and time-aligned.

[0067] The device status of the supply historical data SHD is categorized by loss code. The device status stored in server 320 can be... Figure 4 The loss code, but not limited to this.

[0068] Reference Figures 1 to 4 Standby and operator-stopped states can be categorized in the loss codes as Idle, BM (Breakdown Maintenance), and PD (Process Down). Loss codes can be determined by the operator or by an algorithm or model configured to select loss codes.

[0069] Here, BM refers to the work of repairing machines or equipment when they break down. In BM, repair and maintenance are performed only after a machine or system has failed, without any preventative measures. PD refers to a production process interruption. PD is a term used primarily to describe a process stoppage caused by machine failure, material shortages, manpower issues, or electrical and environmental factors.

[0070] The standby from the first time point T1 to the third time point T3 was not caused by a fault in the supply unit 120, therefore the loss code used for the standby from the first time point T1 to the third time point T3 can be idle. The loss code of the master device 110 from the first time point T1 to the seventh time point T7 can also be idle.

[0071] The loss code for the earlier part of the fault between the fourth time point T4 and the fifth time point T5 can be BM, and the loss code for the later part of the fault between the fourth time point T4 and the fifth time point T5 can be PD.

[0072] The loss code for the earlier portion of the operator stoppage between time point T5 and time point T6 can be PD, and the loss code for the later portion of the operator stoppage between time point T5 and time point T6 can be BM.

[0073] According to an exemplary embodiment, supply history data (SHD) and manufacturing history data (MHD) are collected by server 320, and server 320 can distinguish between the operating rate loss of main equipment 110 and the operating rate loss caused by external factors of main equipment 110 (i.e., supply unit 120) by aligning supply history data (SHD) and manufacturing history data (MHD) in time.

[0074] Furthermore, since the cause of the loss in operating rate due to the standby of the main equipment 110 from the first time point T1 to the seventh time point T7 can be identified, the factors contributing to the loss in operating rate can be identified and resolved.

[0075] Server 320 can be configured to determine the occupancy rate of loss codes for the supply history data SHD that matches the idle time of master device 110. The occupancy rate of loss codes can be calculated as a ratio to the total idle time of the supply history data MHD.

[0076] For example, if the standby time from the first time point T1 to the seventh time point T7 accounts for 7% of the total standby time of the main device 110, and 20% of the time between the first time point T1 and the seventh time point T7 is classified as idle loss code, 20% as BM loss code, 30% as PD loss code, and 30% as in operation, then it is determined that approximately 2% of the standby time of the main device 110 is attributable to the idle time of the supply unit 120, approximately 2% of the standby time of the main device 110 is attributable to the BM time of the supply unit 120, and approximately 3% of the standby time of the main device 110 can be attributed to the PD time of the supply unit 120.

[0077] (Second Implementation)

[0078] Figure 5 This is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment.

[0079] Reference Figures 1 to 5 In P110, supply history data (SHD) and manufacturing history data (MHD) can be collected. Supply history data (SHD) can be collected by controller 121 and sent to server 320. Manufacturing history data (MHD) can be collected by controller 111 and sent to server 320.

[0080] Subsequently, on P120, the supply history data (SHD) and manufacturing history data (MHD) can be analyzed. The analysis of the supply history data (SHD) and manufacturing history data (MHD) can be performed by server 320. The analysis of the supply history data (SHD) and manufacturing history data (MHD) may include determining the portion of the supply history data (SHD) whose idle time matches that of the manufacturing history data (MHD) in time, and aligning the portion of the supply history data (SHD) whose idle time matches that of the manufacturing history data (MHD) in time. The analysis of the supply history data (SHD) and manufacturing history data (MHD) may also include determining the loss codes and loss code occupancy rates of the supply history data (SHD) whose idle time matches that of the manufacturing history data (MHD).

[0081] According to the exemplary embodiment, in addition to identifying the operating rate loss caused by the supply unit 120 (which is an external factor of the main equipment 110), it is also possible to provide insights into the detailed factors and occurrence patterns of the operating rate loss caused by the supply unit 120. These insights enable preventive maintenance or predictive maintenance, thereby improving the yield, reliability, and throughput of secondary battery manufacturing.

[0082] The present disclosure has been described in more detail above with reference to the accompanying drawings and embodiments. However, it should be understood that the configurations shown in the drawings or the embodiments described herein are merely one embodiment of the present disclosure and do not represent all the technical ideas of the present disclosure. Various equivalents and modifications may exist to replace them at the time of filing this application.

Claims

1. A method for manufacturing a secondary battery, comprising: Steps for collecting historical supply data and historical manufacturing data; as well as The steps of analyzing the supply history data and the manufacturing history data, wherein, The manufacturing history data represents the status of the master equipment configured to execute the manufacturing process, and The supply history data indicates the status of the supply unit configured to supply electrode rolls to the main device.

2. The method for manufacturing a secondary battery according to claim 1, wherein, The steps of analyzing the supply history data and the manufacturing history data include: determining the portion of the idle time in the supply history data that matches the idle time in the manufacturing history data in terms of time.

3. The method for manufacturing a secondary battery according to claim 1, wherein, The steps of analyzing the supply history data and the manufacturing history data include: determining the occupancy rate of the loss codes of the manufacturing history data that time-matches the idle time of the manufacturing history data.

4. The method for manufacturing a secondary battery according to claim 3, wherein, The occupancy rate is calculated as a percentage of the total idle time in the manufacturing history data.

5. A secondary battery manufacturing system, comprising: Secondary battery manufacturing equipment; An automated logistics system configured to convey electrode rolls to the secondary battery manufacturing equipment; as well as Servers, among which The secondary battery manufacturing equipment includes: a main unit configured to process the electrode rolls; and a supply unit configured to supply the electrode rolls conveyed by the automated logistics system, wherein... The main equipment includes a process controller configured to collect manufacturing history data representing the status of the main equipment and transmit the manufacturing history data to the server. The supply unit includes a supply controller configured to collect supply history data representing the status of the master device and transmit the supply history data to the server.

6. The secondary battery manufacturing system according to claim 5, wherein, The supply unit includes: a first shuttle, the first shuttle including a first unwinding machine; a second shuttle, the second shuttle including a second unwinding machine; and a lift, the lift being configured to lift the electrode roll from the automated logistics system and load the electrode roll onto one of the first unwinding machine and the second unwinding machine.

7. The secondary battery manufacturing system according to claim 6, wherein, The supply controller is configured to control the first shuttle, the second shuttle, and the elevator.

8. The secondary battery manufacturing system according to claim 5, wherein, The server is an MES (Manufacturing Execution System).

9. The secondary battery manufacturing system according to claim 5, wherein, The server is configured to store the supply history data and the manufacturing history data.

10. The secondary battery manufacturing system according to claim 5, wherein, The server is configured to analyze the supply history data and the manufacturing history data.

11. The secondary battery manufacturing system according to claim 10, wherein, Analyzing the supply history data and the manufacturing history data includes: determining the portion of the idle time in the supply history data that matches the idle time in the manufacturing history data in terms of time.

12. The secondary battery manufacturing system according to claim 10, wherein, Analyzing the supply history data and the manufacturing history data includes: determining the occupancy rate of the loss codes in the manufacturing history data that match the idle time of the manufacturing history data in time.

13. The secondary battery manufacturing system according to claim 12, wherein, The occupancy rate is calculated as a percentage of the total idle time in the manufacturing history data.

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