System for manufacturing secondary battery and method for manufacturing secondary battery

Abstract

According to an exemplary embodiment, there is provided a system for manufacturing a secondary battery, the system including: a server configured to store a roll map including defect data indicating defects in an electrode roll and reference point data indicating reference points on the electrode roll; a controller configured to load the defect data and the reference point data from the server; and a reference point sensor configured to generate a reference point sensing signal by sensing the reference points on an electrode sheet unwound from the electrode roll, and the controller configured to generate reference point sensing data based on the reference point sensing signal and to compare the reference point data with the reference point sensing data.

Description

[Technical Field]

[0001] The present invention relates to a system for manufacturing a secondary battery and a method for manufacturing a secondary battery. This application claims the benefit of Korean Application No. 10-2023-0078372, filed on June 19, 2023, which is incorporated herein by reference in its entirety. [Background technology]

[0002] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. Secondary batteries are widely used as energy sources for a variety of wireless devices, such as handsets, laptops, and wireless vacuum cleaners. In recent years, improvements in energy density and economies of scale have dramatically reduced the manufacturing cost per unit capacity of secondary batteries. As the driving range of battery electric vehicles (BEVs) has increased to the same level as fuel-powered vehicles, the primary use of secondary batteries has shifted from mobile devices to mobility.

[0003] Secondary batteries are manufactured through an electrode process, an assembly process, and an activation process. Among these processes, the electrode process is the most crucial process for determining the yield and performance of the battery cell. The electrode process can include a coating process, a roll press process, and a slitting process. In the coating process, active materials and insulating materials can be applied to the surface of a current collector. In the roll press process, the electrode can be pressed by a pressure roll. The roll press process can determine the density, performance, and surface quality of the electrode. In the slitting process, the electrode can be cut into multiple electrodes according to the design of the battery cell. Summary of the Invention [Problem to be solved by the invention]

[0004] The problem to be solved by the technical idea of ​​the present invention is to provide a system for performing a secondary battery manufacturing process based on a roll map containing information on the quality and defects of the electrode manufacturing process, and a method for manufacturing a secondary battery using the same. [Means for solving the problem]

[0005] According to an exemplary embodiment of the present invention for solving the above-mentioned problems, there is provided a system for manufacturing a secondary battery, the system including: a server configured to store a roll map including defect data indicating defects in an electrode roll and reference point data indicating reference points on the electrode roll; a controller configured to load the defect data and the reference point data from the server; and a reference point sensor configured to generate a reference point sensing signal by sensing the reference points on an electrode sheet unwound from the electrode roll, and the controller is configured to generate reference point sensing data based on the reference point sensing signal and to compare the reference point data with the reference point sensing data.

[0006] The defect data includes a start coordinate value of the defect and an end coordinate value of the defect, the reference point data includes a stored coordinate value of the reference point, and the reference point sensing data includes a sensed coordinate value of the reference point.

[0007] The controller is configured to calibrate the fault data based on the reference point data and the reference point sensed data.

[0008] The controller is configured to calculate an offset between the stored coordinate value of the reference point and the sensed coordinate value of the reference point.

[0009] The controller is configured to calibrate the start coordinate value of the defect and the end coordinate value of the defect based on the offset.

[0010] The system further includes a roll map controller configured to receive the reference point sensed data and to transmit the reference point sensed data to the controller.

[0011] The fiducial sensor is configured to transmit the fiducial sensed data to the controller.

[0012] According to an exemplary embodiment, there is provided a method for manufacturing a secondary battery, the method including the steps of loading failure data indicating a failure of an electrode roll and reference point data indicating a reference point of the electrode roll, sensing the reference point of an electrode sheet unwound from the electrode roll to collect reference point sensing data, and calibrating the failure data based on the reference point data and the reference point sensing data to generate calibrated failure data.

[0013] The method further includes discarding portions of the electrode sheet based on the calibrated failure data.

[0014] The defect data includes coordinate values ​​of the defect, the reference point data includes stored coordinate values ​​of the reference point, and the reference point sensed data includes sensed coordinate values ​​of the reference point.

[0015] Calibrating the fault data includes calculating an offset between the stored coordinate value of the reference point and the sensed coordinate value of the reference point.

[0016] Calibrating the bad data includes calibrating start and end coordinates of the bad data based on the offset. [Effects of the Invention]

[0017] According to an exemplary embodiment of the present invention, a system configured to generate a roll map that enables feedback, feedforward, and tracking of an electrode process and perform a secondary battery manufacturing process based on the roll map, and a method for manufacturing a secondary battery using the same can be provided.

[0018] The effects that can be obtained from the exemplary embodiments of the present disclosure are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood from the following description by a person having ordinary skill in the art to which the exemplary embodiments of the present disclosure belong. In other words, unintended effects accompanying the implementation of the exemplary embodiments of the present disclosure can also be derived from the exemplary embodiments of the present disclosure by a person having ordinary skill in the art. [Brief explanation of the drawings]

[0019] [Figure 1] 1 illustrates a system for manufacturing a secondary battery according to an exemplary embodiment. [Figure 2] 1 is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment. [Figure 3] 1 illustrates a system for manufacturing a secondary battery according to an exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0020] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Before that, the terms and words used in the specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, but should be interpreted as meanings and concepts that are consistent with the technical idea of ​​the present invention, based on the principle that an inventor can appropriately define the concepts of terms to best describe his or her own invention.

[0021] Therefore, the embodiments described in this specification and the configurations shown in the drawings are merely the most preferred embodiments of the present invention and do not represent the entire technical idea of ​​the present invention, and there may be various equivalents and modifications that can replace them at the time of this application.

[0022] Furthermore, in the description of the present invention, if it is determined that a detailed description of related publicly known structures or functions may obscure the gist of the present invention, the detailed description will be omitted.

[0023] Since the embodiments of the present invention are provided to more completely explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or shown in a schematic manner for clearer explanation. Therefore, the sizes and proportions of each component do not completely reflect the actual sizes and proportions.

[0024] (First embodiment) FIG. 1 shows a system 100 for manufacturing a secondary battery according to an exemplary embodiment.

[0025] Referring to FIG. 1 , a system 100 for manufacturing a secondary battery may include an unwinder 111, a rewinder 113, a splicing table 115, a scrap port 117, a processing tool 119, a first rotary encoder 121, a second rotary encoder 125, an NG sensor 131, a reference point sensor 133, a roll map controller 141, a process controller 143, an EIF (Equipment Interface) 145, a server 150, and a display device 160.

[0026] The system 100 for manufacturing a secondary battery can be configured to generate a roll map including data related to the electrode sheet ES. The roll map can represent the electrode sheet ES based on coordinate values ​​indicating positions on the electrode sheet ES. As described below, processes for manufacturing a secondary battery can be performed on the electrode sheet ES. The roll map represents a history of processes performed on the electrode sheet ES and can include data related to the coordinates. This allows the roll map to enable feedback, feedforward, and tracking of the manufacturing process of the secondary battery, as described below.

[0027] The first electrode roll ER1, on which the previous process has been performed, can be loaded onto the unwinder 111. The unwinder 111 can unwind the electrode sheet ES from the first electrode roll ER1. The rewinder 113 can wind the electrode sheet ES to form the second electrode roll ER2. The electrode sheet ES is wound around the second electrode roll ER2, and can be cut and separated after reaching a predetermined winding length. Thus, the electrode sheet ES can move between the unwinder 111 and the rewinder 113 while the current process is being performed.

[0028] The roll map can be generated on a lot-by-lot basis. A lot is a production unit in a roll-to-roll process, and the second electrode roll ER2 separated for export after achieving the target unwinding amount is an example of a lot. Similarly, the first electrode roll ER1 newly loaded into the unwinder 111 is also an example of a lot. This allows the server 150 to 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 also generate and store a second roll map of the current process. The second roll map can correspond to the second electrode roll ER2.

[0029] A process for manufacturing a secondary 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 around the second electrode roll ER2, so the electrode process can also be called a roll-to-roll process.

[0030] The time series data generated in the roll map over time (i.e., as the process progresses) can be associated with coordinate data based on the amount of movement of the electrode sheet ES (i.e., either the amount consumed or the amount input).

[0031] For example, the first roll map may include defect data DD indicating a defect in the first electrode roll ER1 and reference point data DPD indicating a reference point. The defect data DD may include defect values ​​indicating the presence and type of defect in the first electrode roll ER1, and coordinate values ​​that match the defect values. Table 1 below shows an example of the defect data DD.

[0032] [Table 1]

[0033] The numbers in the third column (i.e., "154" and "171") are code numbers indicating the type of defect. The defect types may further include surface defects such as pinhole defects, line defects, crater defects, crack defects, side ring defects, Ireland defects, fold defects, wrinkle defects, poke defects, and dent defects. The defect types may further include defects determined based on measurement data such as mismatch, excessive loading, insufficient loading, excessive thickness, insufficient thickness, overlay of insulating coating and land lane, etc. The reference point data DPD may include an order value indicating the order of the reference points on the electrode sheet ES and coordinate values ​​matching the order value. Table 2 below shows an example of reference point data DPD.

[0034] [Table 2]

[0035] The reference points may be formed at equal intervals on the electrode sheet ES. In Table 2, the interval between the reference points is approximately 120 μm. However, this is for illustrative purposes only and does not limit the technical scope of the present invention in any way. The interval between the reference points may be determined according to the required accuracy of tracking process events on the electrode sheet ES. A subsequent reference point may be formed after a previous reference point. Because the subsequent reference point is wound on the outside of the first electrode roll ER1, it may have a relatively small coordinate value when the first electrode roll ER1 is unwound. The coordinate values ​​(i.e., start coordinate value and end coordinate value) of the reference point data DPD after the reference point data DPD is collected may be converted according to the winding and unwinding of the electrode sheet ES. The display format of the defect data DD and the reference point data DPD is not limited to the table described above. The defect data DD may have any format, including matching between the defect value (i.e., defect type) and coordinates. The reference point data DPD may have any format, including matching between the order of the reference points and coordinates.

[0036] The manufacturing of secondary batteries involves a series of different processes, and leading processes affect subsequent processes. However, if the time series data of a leading process cannot be directly matched with the real-world workpieces, intermediate products, and finished products, it is difficult to reflect the time series data of the leading process in the subsequent process. Hereinafter, the correction of the subsequent process based on the data generated according to the results of the leading process is called feedforward.

[0037] Here, the term "worked product" refers to an article provided as a result of each process, such as the electrode sheet ES, which has undergone the coating process, roll pressing process, and slitting process shown in FIG. 1. The semi-finished product may refer to one of a separator, an electrode, or an assembly thereof, which has been cut by the notching process. The semi-finished product may also be a structure including a housing and an electrode assembly housed in the housing (in some cases, the structure may further include an electrolyte). The product refers to an article that has been processed to be operable as a secondary battery by the activation process. The above definitions of the work product, semi-finished product, and product relate to one aspect of the same and do not exclude the usual definitions thereof.

[0038] The secondary battery electrode process involves a series of roll-to-roll processes. For feedforward, time-series data must be associated with the real-world locations of images of workpieces, parts, semi-finished products, and finished products. Here, feedforward can include controlling the process for the electrode sheet ES based on a roll map of the first electrode roll ER1 generated in a previous process. The roll map can associate the time-series data with coordinate data including coordinate values ​​indicating the real-world locations of images of workpieces, parts, semi-finished products, and finished products. The roll map can match the time-series data with the real-world locations of workpieces, parts, semi-finished products, and finished products based on the coordinate data. This allows roll map generation and roll-map-based feedforward to quantify and objectify aspects of the process that previously relied on operator discretion, thereby improving production efficiency and quality.

[0039] The roll map of a previous lot can also be used to improve the process for a subsequent lot, and such an operation can be called process feedback. Process feedback using a roll map can include identifying process conditions and process parameters that cause problems and defects based on the data contained in the roll map. For example, a second roll map can be generated for a second electrode roll ER2 that is wound with electrode sheets ES processed in a current process, and the processing of a subsequent lot can be controlled based on the second roll map.

[0040] Furthermore, as described below, roll maps are cumulatively generated for workpieces, parts, semi-finished products, and finished products of a unit process, thereby enabling tracking of the process history of shipped products (e.g., battery cells, battery modules, or battery packs). As an example, a battery cell may include a cell ID formed on an electrode assembly or a case. The cell ID may include lot number and coordinate information of the electrodes and separator included in the battery cell. In other words, the cell ID may be associated with a roll map of the electrodes and separator included in the battery cell. As a result, if an event such as a quality issue occurs in a battery cell that has already been shipped, historical data on the manufacture of the battery cell can be retrieved based on the cell ID.

[0041] The first rotary encoder 121 may be configured to sense the amount of electrode sheet ES unwound from the first electrode roll ER1 by the unwinder 111. Thus, the first rotary encoder 121 may be configured to generate a throw-in amount signal UWAS indicating the length of the electrode sheet ES unwound by the unwinder 111. The first rotary encoder 121 may be configured to transmit the throw-in amount signal UWAS to the roll map controller 141. The roll map controller 141 may be configured to collect throw-in amount data based on the throw-in amount signal UWAS of the electrode sheet ES.

[0042] The second rotary encoder 125 may be configured to sense the amount of electrode sheet ES wound onto the second electrode roll ER2 by the rewinder 113. Thus, the second rotary encoder 125 may be configured to generate an exhaustion amount signal WAS indicating the length of the electrode sheet ES wound by the rewinder 113. The second rotary encoder 125 may be configured to transmit the exhaustion amount signal WAS to the roll map controller 141. The roll map controller 141 may be configured to collect exhaustion amount data based on the exhaustion amount signal WAS of the electrode sheet ES.

[0043] The roll map controller 141 may be configured to collect coordinate data of the electrode sheet ES based on one of the input amount signal UWAS and the consumed amount signal WAS of the electrode sheet ES.

[0044] As an example, the roll map controller 141 can determine the distance traveled by the electrode sheet ES from the unwinder 111 based on the electrode sheet ES input amount signal UWAS. As a result, the roll map controller 141 can be configured to determine the coordinates within the electrode sheet ES of the portion of the electrode sheet ES that is unwound by the unwinder 111 at each time a process by the processing tool 119 is performed.

[0045] As another example, the roll map controller 141 can determine the distance the electrode sheet ES travels to the rewinder 113 based on the consumed amount signal WAS of the electrode sheet ES. This allows the roll map controller 141 to be configured to determine the coordinates within the electrode sheet ES of the portion of the electrode sheet ES that is wound by the rewinder 113 at each time a process by the processing tool 119 is performed.

[0046] Hereinafter, the technical concept of the present invention will be described focusing on an embodiment in which the roll map controller 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 electrode sheet ES being unwound can be sensed, making it possible to accurately determine losses of electrode sheet ES caused by factors such as a sample test of the first electrode roll ER1, movement of the first electrode roll ER1 from the previous process stage to the current process stage, loading of the first electrode roll ER1 onto the unwinder 111, connection between the electrode sheet ES on the loaded first electrode roll ER1 and the electrode sheet ES on the rewinder 113, and remaining amounts resulting from inability to unwind.

[0047] According to an exemplary embodiment, the roll map controller 141 may be further configured to collect additional coordinate data based on the consumed amount signal WAS. In this case, the coordinate data collected based on the input amount signal UWAS may be used to calibrate the defect data DD and reference 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 consumed amount signal WAS may be used to generate the roll map of the current process (i.e., the completed roll map of the second electrode roll ER2).

[0048] The coordinate data may include coordinate values ​​that are matched to each portion of the electrode sheet ES. That is, each arbitrary point on the electrode sheet ES can be matched with a coordinate. The coordinate values ​​may be one-dimensional quantities in the longitudinal direction of the electrode sheet ES, but are not limited thereto. The coordinate values ​​may also be two-dimensional quantities in the longitudinal direction and the width direction of the electrode sheet ES.

[0049] The NG sensor 131 may be configured to detect either an NG mark or an NG tag on the electrode sheet ES. The NG mark may be formed, for example, by an inkjet printer or the like, and may include information regarding the location and type of defect. The NG tag may be attached to the electrode sheet ES by an operator or an NG tag attacher, and may indicate the location of a defect on the electrode sheet ES. As a non-limiting example, the NG sensor 131 may include either a vision machine or a color sensor.

[0050] The NG sensor 131 may be configured to detect either an NG mark or an NG tag on the electrode sheet and transmit the NG detection signal NSS to the roll map controller 141.

[0051] The roll map controller 141 may be configured to collect NG sensing data NSD based on the NG sensing signal NSS and the coordinate data. The roll map controller 141 may be configured to collect NG sensing data NSD by associating the NG sensing signal NSS with the coordinate data. The NG sensing data NSD may include, for example, a defect value indicating the presence or absence of a defect and the type of the defect, and a coordinate value matched to the defect value.

[0052] To collect the NG sensing data NSD, the coordinate data can be calibrated based on the offset length OL1. Calibrating the coordinate data includes compensating for a difference between the portion of the electrode sheet ES sensed by the first rotary encoder 121, i.e., the portion of the electrode sheet ES unwound by the unwinder 111, and the portion of the electrode sheet ES sensed by the NG sensor 131.

[0053] According to an exemplary embodiment, the roll map controller 141 can calibrate the coordinate data collected at the same time as the NG sensing signal NSS based on the offset length OL1 to collect the NG sensing data NSD, and associate the calibrated coordinate data with the NG sensing signal NSS.

[0054] The offset length OL1 is the length of the electrode sheet ES between the NG sensor 131 and the unwinder 111 according to the movement path of the electrode sheet ES. The offset length OL1 may be the same as the linear distance between the NG sensor 131 and the unwinder 111, or may be longer than the linear distance between the NG sensor 131 and the unwinder 111.

[0055] The reference point sensor 133 may be configured to sense the reference points of the electrode sheet ES to collect reference point data of the electrode sheet ES. The reference point sensor 133 may include, for example, an OCR barcode reader. Each of the reference points on the electrode sheet ES may include any identification mark (e.g., a one-dimensional or two-dimensional barcode) containing information about the movement direction of the electrode sheet ES in the process of forming the reference points and the order in which they were formed. The reference point sensor 133 may be configured to sense the reference points on the electrode sheet ES to generate a reference point sense signal DSS. The reference point sensor 133 may be configured to transmit the reference point sense signal DSS to the roll map controller 141.

[0056] The roll map controller 141 may be configured to collect reference point sensing data DSD based on the coordinate data and the reference point sensing signal DSS. The roll map controller 141 may 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 may include, for example, the order of the reference points and coordinate values ​​matched to the reference points.

[0057] To collect the reference point sensing data DSD, the coordinate data can be calibrated based on the offset length OL2. Calibrating the coordinate data includes compensating for a difference between the portion of the electrode sheet ES sensed by the first rotary encoder 121, i.e., the portion of the electrode sheet ES unwound by the unwinder 111, and the portion of the electrode sheet ES sensed by the reference point sensor 133.

[0058] According to an exemplary embodiment, the roll map controller 141 can be configured to calibrate coordinate data collected at the same time as the reference point sensing signal DSS based on the offset length OL2 to collect the reference point sensing data DSD, and associate the calibrated coordinate data with the reference point sensing signal DSS.

[0059] The offset length OL2 is the length of the electrode sheet ES between the reference point sensor 133 and the unwinder 111 according to the movement path of the electrode sheet ES. The offset length OL2 is the same as the linear distance between the reference point sensor 133 and the unwinder 111, but may also be greater than the linear distance between the reference point sensor 133 and the unwinder 111.

[0060] The offset length OL2 may include a first portion OL2_1 and a second portion OL_2. The first portion OL2_1 may be a portion not processed by the processing tool 119, and the second portion OL_2 may be a portion processed by the processing tool 119. As a result, the length characteristics of the first portion OL2_1 may differ from the length characteristics of the second portion OL_2. For example, if the processing tool 119 includes a pressure roll for a roll press process, the first portion OL2_1 may not be stretched, and the second portion OL2_2 may be stretched. According to an exemplary embodiment, in calibrating the offset length OL2, the first portion OL2_1 may be calibrated to be different from the second portion OL2_2. For example, the second portion OL2_2 may be calibrated to compensate for changes in the length characteristics due to the processing tool 119, such as by back-calculating the elongation percentage.

[0061] According to an exemplary embodiment, the roll map controller 141 may be configured to transmit the NG sensing data NSD and the reference point sensing data DSD to the process controller 143. The process controller 143 may be configured to compare the reference point data DPD with the reference point sensing data DSD. The process controller 143 may be configured to calibrate the failure data DD based on the NG sensing data NSD. Calibrating the failure data DD based on the NG sensing data NSD may include calibrating coordinate values ​​of the failure data DD based on the coordinate values ​​of the NG sensing data NSD when the coordinate values ​​of the failure data DD and the coordinate values ​​of the NG sensing data NSD do not match.

[0062] Table 3 shows an example of the reference point sensing data DSD.

[0063] [Table 3]

[0064] The first and second columns of Table 3 may represent the reference point sensing data DSD. The display format of the reference point sensing data DSD is not limited to the table described above. The reference point sensing data DSD may have any format, including a matching between the order of the reference points and their coordinate values. The process controller 143 may be configured to calculate an offset, which is the difference between the stored coordinate values ​​of the reference point data DPD and the sensed coordinate values ​​of the reference point sensing data DSD. The third column of Table 3 shows the offset calculated by the process controller 143. The process controller 143 may be configured to calibrate the defect data DD based on the offset. Table 4 shows defect data calibrated by the process controller 143. Calibration of the defect data DD may be triggered by sensing a reference point. Although 15 reference points are displayed at once in Table 3, calibration of the defect data DD may be performed each time a reference point is sensed.

[0065] [Table 4]

[0066] More specifically, the process controller 143 may compare the sensed coordinate values ​​of the reference point with the stored coordinate values, and if the sensed coordinate values ​​differ from the stored coordinate values, perform a calculation to calculate an offset. For example, when the first-arriving reference point 15 is sensed, the sensed coordinate value 115m does not match the stored coordinate value 120m, so the process controller 143 may calculate an offset of 5m. The start coordinate value "130" of the defect "154" adjacent to the reference point 15 may be calibrated to "125" based on the offset value "5." The end coordinate value "150" of the defect "154" adjacent to the reference point 15 may be calibrated to "145" based on the offset value "5." The start coordinate value "750" and the end coordinate value "800" of the defect "171" adjacent to the reference point 10 may be calibrated to "735" and "785," respectively, based on the offset value "15." Unlike Table 4, different offsets may be applied to the start and end coordinates of the defect depending on the defect position of the electrode sheet ES. The coordinate values ​​of the defect data DD in the roll map of the first electrode roll ER1 may not match the coordinate values ​​of the defect in the actual electrode sheet ES unwound from the first electrode roll ER1. Such mismatches may be caused by losses due to sample testing of the first electrode roll ER1, losses occurring while moving the first electrode roll ER1, losses occurring while loading the first electrode roll ER1 onto the unwinder 111, connections between the electrode sheet ES of the loaded first electrode roll ER1 and the electrode sheet ES on the rewinder 113 side, etc.

[0067] According to an exemplary embodiment, by calibrating the defect data DD based on the reference point sensing data DSD and the reference point data DPD obtained by sensing the actual reference points of the electrode sheet ES, it is possible to prevent some of the defective portions DES of the electrode sheet ES from not being discarded or to prevent excessive discarding of normal portions of the electrode sheet ES. Furthermore, since the defect coordinate values ​​can be calibrated even for defects included in the defect data DD, even though no NG mark or NG tag is attached, it is possible to improve the productivity and yield of the electrode sheet ES.

[0068] The process controller 143 can be configured to control the operation of the unwinder 111, the rewinder 113, the scrap port 117, and the processing tools 119. The process controller 143 can be configured to generate signals for operating and interrupting the unwinder 111, the rewinder 113, the scrap port 117, and the processing tools 119. The signals for operating and interrupting the unwinder 111, the rewinder 113, the scrap port 117, and the processing tools 119 can be generated based on a body containing product ID and manufacturing recipe details.

[0069] The process controller 143 can receive the NG sensing data NSD from the roll map controller 141. The process controller 143 can be configured to generate signals for operation and interruption of the unwinder 111, the rewinder 113, the scrap port 117, and the processing tool 119 based on the NG sensing data NSD and the calibrated failure data. Here, the calibrated failure data can be generated by the process controller 143 based on the reference point data DPD, the reference point sensing data DSD, and the failure data DD, as described above.

[0070] When a defect on the electrode sheet ES identified by either the calibrated defect data or the NG sensing data NSD approaches the splicing table 115, the process controller 143 can slow down the movement speed of the electrode sheet ES or interrupt the winding and unwinding of the unwinder 111 and the rewinder 113.

[0071] After cutting the start position of the defect on the splicing table 115 (or a position adjacent to the start position of the defect taking into account a process margin), the scrap port 117 can be configured to wind up the defective portion DES of the electrode sheet ES, as represented by the thick dashed line. After the defective portion DES of the electrode sheet ES has been sufficiently wound up by the scrap port 117, the electrode sheet ES connected to the scrap port 117 and the electrode sheet ES connected to the unwinder 111 can be separated. Subsequently, 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 spliced ​​together, allowing the current process to continue. The portion of the electrode sheet ES connected to the unwinder 111 and the portion connected to the rewinder 113 can be spliced ​​together on the splicing table 115.

[0072] The processing tool 119 may be located downstream of the flow of the electrode sheets ES from the splicing table 115. That is, the processing tool 119 may be configured to process the electrode sheets ES from which defective portions DES have been discarded due to processing on the splicing table 115.

[0073] For example, the processing tool 119 may include a coater, and electrode slurry may be coated onto the electrode sheet ES. For another example, the processing tool 119 may include a pressure roll, and a roll pressing process may be performed on the electrode sheet ES coated with the electrode slurry. For another example, the processing tool may include a slitting knife, and the electrode sheet ES may be separated into a plurality of electrode sheets.

[0074] The system 100 for manufacturing a secondary battery may further include a measuring instrument and an inspection instrument. The measuring instrument may be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measuring instrument may measure the electrode sheet ES using a scanning method. The measurement data may include a plurality of measurement values ​​expressed as numerical values. For example, the measurement data may include dimensional data of the electrode sheet ES, such as thickness and width; data on the amount of coating material loaded on the electrode sheet ES; dimensional data, such as the width of the insulating material provided on the coating material and the overlap width between the coating material and the insulating material; and data on mismatch between the land lanes on the upper surface of the electrode sheet ES and the land lanes on the lower surface of the electrode sheet ES. Here, the loading amount represents the amount of coating material loaded per unit area of ​​the electrode sheet ES, and may be the areal density of the coating material.

[0075] The measurement data is processed in a set manner to determine whether the measured portion of the electrode sheet ES is good or bad. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is within a set range including an upper limit and a lower limit, the corresponding portion of the electrode sheet ES can be determined to be good. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is less than the lower limit or greater than the upper limit, the corresponding portion of the electrode sheet ES can be determined to be bad.

[0076] The instruments may include, for example, time delay and integration (TDI) cameras, complementary metal oxide semiconductor (CMOS) image sensors, and time of flight (TOF) sensors. The instruments may also include emitters and receivers configured to perform measurements using non-destructive signals such as ultrasound, microwaves, terahertz waves, and infrared. The instruments may also include analog and / or digital sensors such as biosensors, chemical sensors, composition sensors, current and / or power meters, air quality sensors, gas sensors, Hall effect sensors, brightness level sensors, and light sensors. The instruments may also include pressure sensors, temperature sensors, ultrasonic sensors, proximity sensors, door status sensors, motion tracking sensors, humidity sensors, visible light sensors, infrared sensors, and cameras.

[0077] The measuring instrument can be configured to generate coordinate-related measurement data by associating additional coordinate data based on the wasting amount signal WAS with the measurement data. To generate the coordinate-related measurement data, the additional coordinate data can be calibrated based on an offset length of the measuring instrument.

[0078] The measuring device can be configured to collect evaluation data based on the measurement data, and the evaluation data can be collected based on a comparison between measurement values ​​of multiple sections in the electrode sheet ES and a set range.

[0079] For example, a measurement (or an average of the measurement values) within a first range can be determined to be normal, a measurement (or an average of the measurement values) within a second range that is even larger than the first range can be determined to be excessive, a measurement (or an average of the measurement values) within a third range that is even larger than the second range can be determined to be very excessive, a measurement (or an average of the measurement values) within a fourth range that is even smaller than the first range can be determined to be insufficient, and a measurement (or an average of the measurement values) within a fifth range that is even smaller than the fourth range can be determined to be very insufficient.

[0080] Here, if the lower limit of the second range is equal to or greater than the upper limit of the first range, the second range is greater than the first range. Similarly, if the upper limit of the fourth range is equal to or less than the lower limit of the first range, the fourth range is smaller than the first range.

[0081] The evaluation values ​​of the evaluation data can be associated with coordinate values, for example, each of which can be matched with the start and end coordinate values ​​of the portion of the electrode sheet ES for which the evaluation value is calculated.

[0082] The inspector may be configured to inspect the electrode sheet ES to collect inspection data of the electrode sheet ES. The inspector may be configured to detect defects such as surface defects of the electrode sheet ES based on changes in color and reflectance on the surface of the electrode sheet ES. The inspector may be configured to collect inspection data of a portion corresponding to (e.g., overlapping with) the sensing unit.

[0083] The inspection data collected by the inspector may include judgments and process events related to the quality of portions of the electrode sheet ES. For example, the inspection data may include data on the appearance of the electrode sheet ES collected by an image-based inspection device such as a vision machine, data on breaks and seams on the electrode sheet ES, data on portions of the electrode sheet ES that have been sampled, data on portions of the electrode sheet ES scheduled for scrapping, data on scrapped portions of the electrode sheet ES, data on the quality of coating materials and insulating materials on the electrode sheet ES, data on reference points indicating the position of the electrode sheet ES, and defect data such as pinhole defects, crater defects, line defects, crack defects, side ring defects, Ireland defects, fold defects, wrinkle defects, poke defects, and dent defects. The reference points may be formed at predetermined intervals on the electrode sheet ES, and the positions of other elements on the electrode sheet ES may be known based on the reference points. The inspector may be any one of a color sensor, a seam sensor, a reference point sensor, and a vision machine.

[0084] The tester can be configured to generate coordinate-related test data by associating additional coordinate data based on the wasted amount signal WAS with the test data. To generate the coordinate-related test data, the additional coordinate data can be calibrated based on the offset length of the tester.

[0085] The measurement data and test data described above may be time-series data. The measurement data and test data may be temporally ordered. Temporal ordering is a key characteristic of time-series data, which is arranging events in the order in which they occur and arrive for processing. That is, the measurement data and test data may be sorted based on the time at which the measurements and tests were performed, and the measurement data and test data may be associated with time. This allows each measurement value of the measurement data to be matched to a time, and each test value of the test data to be matched to a time.

[0086] As an example, the measurement quantity (e.g., the amount of loading on the electrode sheet ES or the thickness of the electrode sheet ES) data may include a series of measurement quantity (e.g., the amount of loading on the electrode sheet ES or the thickness of the electrode sheet ES) values ​​and time values ​​associated with the series of measurement quantity values. The measurement quantity values ​​and the time values ​​may be matched one-to-one, but are not limited to this. As another example, the defect data may include a value indicating a defect and a time value associated with the value indicating a defect. Here, indicating a defect means including information regarding at least one of the presence or absence of a defect and the type of defect.

[0087] The roll map can include coordinate-related measurement data and coordinate-related inspection data generated by associating time-series measurement data and inspection data with coordinate data, thereby providing traceability to a previous process during a subsequent process or after a product has been shipped.

[0088] The roll map controller 141 may be in operative communication with the first rotary encoder 121, the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, the additional measuring instruments, and the additional inspection instruments via a wired or wireless data network. The data network may include unidirectional or bidirectional communication. The data network may be embodied by a public network and / or a dedicated network using a physical channel, Wi-Fi, Bluetooth, and / or other frequency bands. The first rotary encoder 121, the second rotary encoder 125, the NG sensor 131, the reference point sensor 133, the additional measuring instruments, and the additional inspection instruments may be configured to collect data or generate signals for collecting data from equipment, workpieces, semi-finished products, and finished products in the secondary battery manufacturing system 100.

[0089] The coordinate-related measurement data and coordinate-related inspection data transmitted from the roll map controller 141 to the process controller 143 may be transmitted to the server 150 via the process controller 143 and the EIF 145. The process controller 143 and the EIF 145 may relay data communication between the server 150 and the roll map controller 141. However, without being limited thereto, the roll map controller 141 may also transmit the coordinate data, coordinate-related measurement data, and coordinate-related inspection data directly to the server 150.

[0090] In order to control the process, a communication line connecting the process controller 143 and the server 150 via the EIF 145 can be installed between the process controller 143 and the server 150. As a result, data transmission via the process controller 143 can save resources required for installing a communication line and can make data processing and management more efficient, compared to when the first rotary encoder 121, the second rotary encoder 125, and the measuring instrument 135 communicate directly with the server 150 and when the roll map PLC 141 communicates directly with the server 150.

[0091] The EIF 145 may be a device for communication between the process controller 143 of the manufacturing facility and the server 150, which is a higher-level server.

[0092] The server 150 can be configured to generate and store a roll map. The roll map can be generated on a lot-by-lot basis. The roll map can include data related to lot specifications. The lot specifications can include, for example, the lot number, the length of the rolled electrode sheet ES, the width of the electrode sheet ES, and the materials and compositions used in processing the electrode sheet ES.

[0093] The server 150 can be configured to store a first roll map of the first electrode roll ER1, transmit the defect data DD and reference point data DPD of the first roll map to the process controller 143, and generate and store a second roll map of the second electrode roll ER2 based on the coordinate-related measurement data and the coordinate-related inspection data.

[0094] According to an exemplary embodiment, server 150 may be a data processing system that supports various activities required to manage the production of secondary batteries, such as work schedule management, work instructions, quality control, and work performance aggregation. Server 150 may be, for example, a manufacturing execution system (MES). Server 150 may be configured to perform input, processing, output, and communication of data required for electrode production, such as coating processes, pressing processes, and manufacturing processes.

[0095] According to another exemplary embodiment, server 150 may be configured to store and process raw measurement data. Server 150 may continuously monitor the processing of electrode sheets ES based on the measurement data, thereby managing the quality of the processing of electrode sheets ES. According to an exemplary embodiment, server 150 may be a statistical process controller (SPC). Server 150 may collect and analyze production data in substantially real time, thereby identifying problem conditions in a timely manner and providing an alarm to an operator before a potential problem occurs.

[0096] According to another exemplary embodiment, the server 150 may be, for example, a data warehouse, and may store NG sensing data NSD, coordinate data, coordinate-related measurement data, and coordinate-related inspection data for a long period of time based on, for example, a product's quality warranty period.

[0097] According to other exemplary embodiments, a server 150 may be provided separate from the MES, SPC, and data warehouse to create the role map.

[0098] The roll map controller 141, the process controller 143, the EIF 145, and the server 150 can be implemented using hardware, firmware, software, or a combination thereof. For example, the roll map controller 141, the process controller 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 controller 141, the process controller 143, the EIF 145, and the server 150 can also include any one of a simple controller, a complex processor such as a microprocessor, a CPU, or a GPU, a software-configured processor, or dedicated hardware and firmware. The roll map controller 141, the process controller 143, the EIF 145, and the server 150 can also be implemented using a general-purpose computer or application-specific hardware such as a digital signal processor (DSP), a field programmable gate array (FPGA), or an application-specific integrated circuit (ASIC).

[0099] The server 150 may include a physical server or a cloud server. The server 150 may provide data and analysis results to operators through various frameworks. The framework may include a protocol supporting data transmission so that the display device 160 can visualize the data through a user interface and provide updated visualizations when new data is calculated by the server 150. The protocol supporting data transmission may use HTML, JavaScript, and / or JSON. The server 150 may transmit a visualization command VC to the display device 160, and the display device 160 may visualize the role map and display the visualized role map.

[0100] The server 150 may include various APIs (Application Programming Interfaces) for storing data in databases and other data management tools. The APIs may also be used to retrieve data in the databases of the various data management systems. The data management systems may be configured to provide access to the databases, pull data from the databases, retrieve data, and generate metrics, where metrics are tools for visualizing data. Metrics include measurements generated over time and may be used to monitor applications and generate status alerts.

[0101] The system 100 for manufacturing secondary batteries may implement a plug-in architecture with an API for data acquisition to provide plug-and-play connection of the NG sensor 131, the reference point sensor 133, additional measuring instruments, and additional inspection instruments, thereby allowing resources at a specific process step and a specific site to be easily transferred to other processes and other sites, or new resources to be easily introduced to each process step and site.

[0102] The data network between elements of the system 100 for manufacturing secondary batteries can include various types of communication channels, including unidirectional, bidirectional wired, and wireless communication. As an example, the data network can be an industrial protocol network such as OPC, Modbus, or ProfiNet. The communication channel can be a dedicated conduit communication such as Universal Serial Bus (USB), IEEE 802 (Ethernet), IEEE 1394 (FireWire), or other high-speed data communication standard.

[0103] In some embodiments, the system 100 for manufacturing secondary batteries can further include a manual input system that allows an operator to input manufacturing data. The system 100 for manufacturing secondary batteries can allow operator data input using an input tool and computer-based input of manufacturing data, such as scraping an Excel file.

[0104] According to some embodiments, the operations of the roll map controller 141, the process controller 143, the EIF 145, and the server 150 may be embodied as instructions stored on a machine-readable medium that can be read and executed by one or more processors. Here, a machine-readable medium may include any mechanism for storing and / or transmitting information in a form readable by a machine (e.g., a computing device). For example, a machine-readable medium may include read-only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory, electrical, optical, acoustic, or other forms of radio signals (e.g., carrier waves, infrared signals, digital signals, etc.), and any other signals.

[0105] The roll map controller 141 may be embodied, for example, by software configured to collect coordinate data, NG sensing data NSD, and reference point sensing data DSD, and transmit the NG sensing data NSD and reference point sensing data DSD.

[0106] The process controller 143 may be embodied by software configured to receive the product ID, the product recipe, the defect data DD, the reference point data DPD, the NG sensing data NSD, and the reference point sensing data DSD, transmit the NG sensing data NSD and the reference point sensing data DSD, and generate control signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing tool 119 based on the product ID, the product recipe, the defect data DD, the reference point data DPD, the NG sensing data NSD, and the reference point sensing data DSD. More specifically, the process controller 143 may be embodied by software configured to calculate a reference point offset based on the reference point data DPD and the reference point sensing data DSD, calibrate the defect data DD based on the offset, and generate control signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing tool 119 based on the calibrated defect data.

[0107] By way of non-limiting example, the roll map controller 141 and the process controller 143 may be a PLC (Programmable Logic Controller). A PLC is a specialized form of microprocessor-based controller that uses programmable memory to store instructions and implements functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. PLCs are easy to operate and program.

[0108] The roll map controller 141 and the process controller 143 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 supply power to other elements of the roll map controller 141 and the process controller 143, such as the CPU, the input interface, the output interface, the communication interface, and the memory device. The memory device may include a read-only memory (ROM) configured to store system programs such as an operating system, and a random access memory (RAM) configured to store user programs and data such as status information of input / output devices, timers, counters, and other internal device values. The CPU may be configured to implement logic and control communication between modules that convert input signals into output operating signals. The CPU may operate based on system programs and user programs stored in the memory device. The CPU may be configured to write or read inspection data and measurement data to or from the data area of ​​the memory device based on the system programs and user programs. Conditions and data of industrial equipment and production processes may be transmitted to the CPU via the input module. The results processed by the CPU can be transmitted to the actuator via the output module. The communication interface can be configured to transmit and receive data between the roll map controller 141 and the process controller 143, or between the process controller 143 and the EIF 145.

[0109] The EIF 145 may be implemented by software for relaying the transmission of data and information between the process controller 143 and the server 150. More specifically, the EIF 145 may be implemented by software configured to perform flow control, error control, synchronization, sequence control, addressing, multiplexing, routing, format conversion, and the like of communications between the process controller 143 and the server 150.

[0110] The server 150 may be embodied, for example, by software configured to transmit the product ID, product recipe, defect data DD, and reference point data DPD to the process controller 143 and generate a roll map based on the coordinate-related measurement data and coordinate-related inspection data.

[0111] However, this is for convenience of explanation, and the roll map controller 141, process controller 143, EIF 145, and server 150 may also be driven by a computing device, a distributed computing device, a processor, firmware, software, routines, instructions, or other device that executes the instructions.

[0112] The architecture of the system 100 configured to generate a roll map can be realized by adding only the roll map controller 141 to the process controller 143, EIF 145, and server 150, which are essential elements of a modern process control system. The system according to the exemplary embodiment can utilize resources already installed at the manufacturing site, thereby saving additional capital expenditures. Furthermore, by applying the same architecture as existing manufacturing facilities to newly constructed manufacturing facilities, it is possible to improve the reliability of secondary battery manufacturing, identify / improve problematic processes, and introduce new processes more efficiently.

[0113] (Second embodiment) FIG. 2 is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment.

[0114] 1 and 2, in step P110, the defect data DD of the first electrode roll ER1 and the reference point data DPD of the first electrode roll ER1 can be loaded. The process controller 143 can receive the defect data DD of the first electrode roll ER1 and the reference point data DPD of the first electrode roll ER1 from the server 150.

[0115] Subsequently, at P120, the reference points of the electrode sheet ES can be sensed to collect reference point sensing data DSD, which can be collected by the reference point sensor 133 and the roll map controller 141 as described above.

[0116] Subsequently, in P130, the bad data DD can be calibrated based on the reference point sensing data DSD and the reference point data DPD. Calibration of the bad data DD can be triggered by sensing the reference point. Calibration of the bad data DD can include calculating an offset, which is the difference between the sensed coordinate values ​​of the reference point sensing data DSD and the coordinate values ​​of the reference point data DPD, and calibrating the coordinate values ​​(i.e., start coordinates and end coordinates) of the bad data DD based on the offset.

[0117] Subsequently, in P140, the defective portions DES of the electrode sheet ES can be discarded based on the calibrated defect data. To discard the defective portions DES of the electrode sheet ES, the process controller 143 can be configured to generate signals to control the operation of the unwinder 111, the rewinder 113, the scrap port 117, and the processing tool 119.

[0118] (Third embodiment) FIG. 3 shows a system 101 for manufacturing a secondary battery according to an exemplary embodiment.

[0119] Referring to FIG. 3 , a system 101 for manufacturing a secondary battery may include an unwinder 111, a rewinder 113, a splicing table 115, a scrap port 117, a processing tool 119, a first rotary encoder 121, a second rotary encoder 125, an NG sensor 131, a reference point sensor 133, an integrated controller 140, an EIF (Equipment Interface) 145, a server 150, and a display device 160.

[0120] The unwinder 111, rewinder 113, splicing table 115, scrap port 117, processing tool 119, first rotary encoder 121, second rotary encoder 125, NG sensor 131, reference point sensor 133, EIF (Equipment Interface) 145, server 150 and display device 160 are substantially the same as those described with reference to Figure 1, so duplicate descriptions of them will be omitted.

[0121] The integrated controller 140 may be configured to perform the functions of the roll map controller 141 and the process controller 143 of FIG. 1 . Thus, the integrated controller 140 may be configured to generate coordinate data based on one of the input amount signal UWAS and the consumed amount signal WAS, collect the NG sensing data NSD (see FIG. 1 ) and the reference point sensing data DSD (see FIG. 1 ), and receive the defect data DD and the reference point data DPD from the server 150 via the EIF 145. The integrated controller 140 may be configured to calibrate the defect data DD based on the reference point sensing data DSD and the reference point data DPD. The integrated controller 140 may be configured to generate signals for controlling the unwinder 111, the rewinder 113, the scrap port 117, and the processing tool 119 based on the calibrated defect data.

[0122] The present invention has been described in more detail above through the drawings and embodiments, etc. However, the configurations described in the drawings or embodiments in this specification are merely one embodiment of the present invention and do not represent all of the technical ideas of the present invention, and therefore, there may be various equivalents and modifications that can replace them at the time of filing this application. [Explanation of symbols]

[0123] 100 systems 111 Unwinder 113 Rewinder 115 Splicing Table 117 Scrapport 119 Processing equipment 121 1st rotary encoder 125 Second rotary encoder 131 NG sensor 133 Reference Point Sensor 135 Measuring Instruments 140 Controller 141 Role Map Controller 143 Process Controller 150 servers 160 Display device

Claims

1. a server configured to store a roll map including defect data indicating defects in the electrode roll and reference point data indicating reference points in the electrode roll; a controller configured to load the defect data and the reference point data from the server; and A system for manufacturing a secondary battery, comprising: a reference point sensor configured to generate a reference point sensing signal by sensing the reference point of an electrode sheet unwound from the electrode roll, The system for manufacturing a secondary battery, wherein the controller is configured to generate reference point sensing data based on the reference point sensing signal, and to compare the reference point data with the reference point sensing data.

2. the defect data includes a start coordinate value of the defect and an end coordinate value of the defect; the reference point data includes stored coordinate values ​​of the reference points; and The system for manufacturing a secondary battery according to claim 1 , wherein the reference point sensing data includes sensed coordinate values ​​of the reference points.

3. The system for manufacturing a secondary battery according to claim 2 , wherein the controller is configured to calibrate the failure data based on the reference point data and the reference point sensing data.

4. The system for manufacturing a secondary battery according to claim 2 , wherein the controller is configured to calculate an offset between the stored coordinate value of the reference point and the sensed coordinate value of the reference point.

5. The system for manufacturing a secondary battery according to claim 4 , wherein the controller is configured to calibrate the start coordinate value of the defect and the end coordinate value of the defect based on the offset.

6. The system for manufacturing a secondary battery according to claim 1 , further comprising a roll map controller configured to receive the reference point sensing data and transmit the reference point sensing data to the controller.

7. The system for manufacturing a secondary battery according to claim 1 , wherein the reference point sensor is configured to transmit the reference point sensing data to the controller.

8. loading defect data indicating a defect in the electrode roll and reference point data indicating a reference point of the electrode roll; sensing the reference point of the electrode sheet unwound from the electrode roll to collect reference point sensing data; and A method for manufacturing a secondary battery, comprising: calibrating the failure data based on the reference point data and the reference point sensed data to generate calibrated failure data.

9. The method for manufacturing a secondary battery according to claim 8 , further comprising the step of discarding a portion of the electrode sheet based on the calibrated defective data.

10. the defect data includes coordinate values ​​of the defect; the reference point data includes stored coordinate values ​​of the reference points; and The method of manufacturing a secondary battery according to claim 8 or 9, wherein the reference point sensing data includes sensed coordinate values ​​of the reference points.

11. The method of manufacturing a secondary battery according to claim 10 , wherein the calibration of the faulty data includes calculating an offset between the stored coordinate value of the reference point and the sensed coordinate value of the reference point.

12. The method of manufacturing a secondary battery according to claim 11 , wherein the calibration of the bad data comprises calibrating start and end coordinates of the bad data based on the offset.

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