Process controller, roll map generation system including the same, and method for generating a roll map using the same

Abstract

According to an exemplary embodiment of the present invention, there is provided a method for generating a roll map, the method comprising the steps of collecting first data in a first memory area, the first data representing a first event of an electroded sheet undergoing a roll-to-roll process, and copying the first data to a second memory area.

Description

[Technical Field]

[0001] The present invention relates to a process controller, a roll map generation system including the same, and a method for generating a roll map using the same. This application claims the benefit of Korean Application No. 10-2023-0102917, filed on August 7, 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 cordless devices, such as handsets, laptops, and cordless 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 process controller with improved reliability, a roll map generation system including the same, and a method for generating a roll map using the same. [Means for solving the problem]

[0005] According to an exemplary embodiment of the present invention, there is provided a method for generating a roll map, the method including the steps of collecting first data representing a first event of an electroded sheet undergoing a roll-to-roll process in a first memory area, and copying the first data to a second memory area.

[0006] The first event is the start of the roll-to-roll process.

[0007] The method further includes the steps of reading the first data from the second memory area and writing the first data to a server.

[0008] The first data is collected based on a work order transmitted from the server to the controller.

[0009] The controller is configured to control the roll-to-roll process based on the work order.

[0010] The method further includes collecting second data representative of a second event of the roll-to-roll process in a third memory area, and copying the second data to a fourth memory area.

[0011] The second event is the completion of the roll-to-roll process.

[0012] The second data is collected based on the winding amount of the electrode sheet.

[0013] The method further includes reading the second data from the fourth memory area and recording the second data in a server.

[0014] The method further includes generating a roll map representing the roll-to-roll process based on the first data and the second data.

[0015] According to an exemplary embodiment, a controller is provided, the controller including: a memory device including a first memory area and a second memory area; and a central processing unit (CPU) configured to access the first memory area and the second memory area, the CPU configured to collect start data indicating a start of a roll-to-roll process of an electrode sheet in the first memory area and copy the start data from the first memory area to the second memory area.

[0016] The memory device further includes a third memory area and a fourth memory area, and the CPU is configured to collect completion data indicating completion of the roll-to-roll process of the electrode sheet in the third memory area and copy the completion data in the third memory area to the fourth memory area.

[0017] According to an exemplary embodiment, there is provided a roll map generation system including: a controller configured to control a roll-to-roll process of an electrode sheet; and a server configured to access the controller, the controller including a memory device including a first memory area and a second memory area; and a central processing unit (CPU) configured to access the first memory area and the second memory area, the CPU configured to collect start data indicating a start of the roll-to-roll process of the electrode sheet in the first memory area and copy the start data from the first memory area to the second memory area.

[0018] The memory device further includes a third memory area and a fourth memory area, and the CPU is configured to collect completion data indicating completion of the roll-to-roll process in the third memory area and copy the completion data in the third memory area to the fourth memory area.

[0019] The system further includes a server configured to generate a roll map representing the roll-to-roll process of the electroded sheet based on the first data and the second data.

[0020] The server is configured to read the start data in the second memory area and the completion data in the fourth memory area, and the server is configured to record the start data and the completion data. [Effects of the Invention]

[0021] According to an exemplary embodiment of the present invention, the process PLC includes a memory area for long-term storage, which can prevent the loss of data critical to the generation of the role map, such as start and completion data.

[0022] 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]

[0023] [Figure 1] 1 illustrates a role map generation system according to an exemplary embodiment. [Figure 2] FIG. 2 is a block diagram showing a controller. [Figure 3]1 is a flowchart illustrating a method for generating a role map according to an exemplary embodiment. [Figure 4] FIG. 1 is a block diagram illustrating a method for generating a role map according to an exemplary embodiment. [Figure 5] FIG. 1 is a block diagram illustrating a method for generating a role map according to an exemplary embodiment. [Figure 6] FIG. 1 is a block diagram illustrating a method for generating a role map according to an exemplary embodiment. [Figure 7] FIG. 1 is a block diagram illustrating a method for generating a role map according to an exemplary embodiment. [Figure 8] FIG. 1 is a block diagram illustrating a method for generating a role map according to an exemplary embodiment. [Figure 9] FIG. 10 is a block diagram illustrating another exemplary controller. DETAILED DESCRIPTION OF THE INVENTION

[0024] 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 own invention.

[0025] 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.

[0026] 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.

[0027] 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 schematically for clearer explanation. Therefore, the sizes and proportions of each component do not completely reflect the actual sizes and proportions.

[0028] (First and second embodiments) FIG. 1 illustrates a role map generation system 100 according to an example embodiment.

[0029] FIG. 2 is a block diagram illustrating the controller 143.

[0030] Referring to Figures 1 and 2, the roll map generation system 100 may include an unwinder 111, a rewinder 113, a processing instrument 115, a first rotary encoder 121, a second rotary encoder 125, a measuring instrument 131, an inspector 133, a controller 141, a controller 143, a server 145, and a server 150.

[0031] The unwinder 111 can be configured to unwind the electrode sheet ES from the first electrode roll ER1. The rewinder 113 can be configured to wind the electrode sheet ES onto the second electrode roll ER2. This allows the electrode sheet ES to move between the unwinder 111 and the rewinder 113.

[0032] A process for manufacturing a secondary battery (e.g., an electrode process) can be performed on the electrode sheet ES. Because 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, the electrode sheet ES process can also be called a roll-to-roll process.

[0033] Server 150 can be configured to generate a roll map. The roll map can represent roll-to-roll process events performed on electrode sheet ES based on coordinates indicating positions on electrode sheet ES. That is, the roll map can include process event data performed on electrode sheet ES.

[0034] Event data is generally time-series data because it occurs as the process progresses. Therefore, process event data can include a value representing the event and a time value that matches it. Time-series data can be ordered temporally. Temporal ordering is a key characteristic of time-series data, which is organizing events in the order in which they occur and arrive for processing. That is, time-series data can be sorted based on the time at which an event occurred (i.e., when an inspection or measurement was performed or a process action was taken), and events can be matched with time values.

[0035] Event data in the roll map can be associated with coordinates. Time series data configured according to the flow of time in the roll map (i.e., according to the progress of the process) can be associated with coordinate data CD based on the movement amount of the electrode sheet ES (i.e., either the winding amount or the unwinding amount). This allows the roll map to enable feedback, feedforwarding, and tracking of the secondary battery manufacturing process, as described below.

[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 "work product" refers to an article provided as a result of each process, such as an electrode sheet, after the coating process, roll pressing process, and slitting process. The term "intermediate product" refers to one of a separator, an electrode, and an assembly thereof (i.e., an electrode assembly) cut by the notching process. The intermediate product may 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 term "product" refers to an article that has been processed to be operable as a secondary battery through an activation process. The above definitions of work product, intermediate product, and product relate to one aspect of the same and do not exclude the usual definitions thereof.

[0038] For feedforward, time-series data must be associated with the positions of images of workpieces, parts, semi-finished products, and finished products in the real world. Here, feedforward can include controlling processing of the electrode sheet based on a roll map generated in a previous process. The roll map can associate the time-series data with coordinate data including coordinates indicating the positions of images of workpieces, parts, semi-finished products, and finished products in the real world. The roll map can provide matching between the time-series data and the workpieces, parts, semi-finished products, and finished products in the real world based on the coordinate data. Thus, generation of the roll map and feedforward based on the roll map can improve the productivity and quality of the secondary battery manufacturing process by quantifying and objectifying aspects of the process that were previously dependent on the discretion of the worker.

[0039] The roll map of a previous lot can also be used to improve the process for subsequent lots, and such an action can be called process feedback. Process feedback using a roll map can include identifying process conditions and process parameters that lead to problems and defects based on the data contained in the 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 problem 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 electrode sheet ES may be processed by the processing tool 115. The processing tool 115 may include any one of a die coater, a pressure roll, and a slitting knife. The die coater may be configured to perform a coating process on the electrode sheet ES. In the coating process, an electrode slurry may be coated on the electrode sheet. The electrode slurry may include an active material, a conductive material, a binder, and a solvent. The electrode slurry may be prepared by dissolving the active material, the conductive material, and the binder in a solvent. The pressure roll may be configured to perform a roll pressing process on the electrode sheet ES. In the roll pressing process, the electrode sheet coated with the electrode slurry may pass between the pressure rolls. The roll pressing process may flatten the surface of the electrode sheet and improve the bonding strength between the active material of the electrode sheet ES and the current collector. The slitting knife may perform a slitting process on the electrode sheet ES. In the slitting process, the electrode sheet ES may be cut into a plurality of individual electrode sheets.

[0042] The roll map can be generated on a lot-by-lot basis. A lot is a production unit in a roll-to-roll process. After the target winding length of the electrode sheet ES by the rewinder 113 is achieved, the electrode sheet ES can be cut to separate the second electrode roll ER2. The completed second electrode roll ER2 is an example of a lot. The first electrode roll ER1 newly loaded on the unwinder 111 is also an example of a lot. The server 150 can generate and store a roll map for each process (e.g., coating process, roll pressing process, or slitting process).

[0043] 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 unwinding amount signal UWAS indicating the unwound amount of electrode sheet ES. The first rotary encoder 121 may be configured to transmit the unwinding amount signal UWAS to the controller 141. The controller 141 may be configured to collect unwinding amount data based on the unwinding amount signal UWAS of the electrode sheet ES.

[0044] 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 a winding amount signal WAS indicating the wound amount of the electrode sheet ES. The second rotary encoder 125 may be configured to transmit the winding amount signal WAS to the controller 141. The controller 141 may be configured to collect winding amount data based on the winding amount signal WAS of the electrode sheet ES.

[0045] Portions of the electrode sheet ES may be scrapped in some cases, which may cause the amount of electrode sheet ES taken up by the unwinder 111 to differ from the amount of electrode sheet ES taken up by the rewinder 113. Furthermore, when the electrode sheet ES is stretched by pressure in the roll pressing process, the amount of electrode sheet ES taken up by the unwinder 111 may differ from the amount of electrode sheet ES taken up by the rewinder 113.

[0046] The controller 141 may be configured to collect coordinate data CD of the electrode sheet ES based on the consumed amount signal WAS and / or the input amount signal UWAS of the electrode sheet ES. As an example, the controller 141 may determine the movement distance of the electrode sheet ES based on the consumed amount signal WAS of the electrode sheet ES. This allows the controller 141 to determine the position within the electrode sheet ES of the portion of the electrode sheet ES that is being wound by the rewinder 113 at each time an event occurs on the electrode sheet ES.

[0047] As another example, the controller 141 may determine the movement distance of the electrode sheet ES based on the input amount signal UWAS of the electrode sheet ES, or may determine the movement distance of the electrode sheet ES based on both the consumed amount signal WAS and the input amount signal UWAS. Hereinafter, the technical idea of ​​the present invention will be described with reference to an embodiment in which the controller 141 collects coordinate data CD based on the consumed amount signal WAS of the electrode sheet ES, as a non-limiting example.

[0048] The coordinate data CD may include coordinates 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 coordinates may be one-dimensional quantities in the machine direction (or longitudinal direction) of the electrode sheet ES, but are not limited thereto. The coordinates may also be two-dimensional quantities in the machine direction and the transverse direction (or width direction) of the electrode sheet ES.

[0049] The measuring device 131 can be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measuring device 131 can measure the electrode sheet ES by a scanning method. The measuring device 131 can move along the lateral direction. During one scanning, the measuring device 131 can move from one lateral end of the electrode sheet ES to the other lateral end of the electrode sheet ES. While the measuring device 131 performs the lateral scanning, the electrode sheet ES can be moved in the forward direction by the unwinder 111 and the rewinder 113.

[0050] The measurement data may include inspection results 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 mismatch data between the coating lane on the upper surface of the electrode sheet ES and the coating lane 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. The measurement data may be processed according to a set method to determine whether the measured portion of the electrode sheet ES is good or bad.

[0051] 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 a good product. 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 a defective product.

[0052] The measuring instrument 131 may include a sensing unit 131S and a processing unit 133P. The sensing unit 131S may be configured to sense a physical quantity of the electrode sheet ES to generate a measurement signal MS. For example, the sensing unit 131S may include a time delay and integration (TDI) camera, a complementary metal oxide semiconductor (CMOS) image sensor, a time of flight (TOF) sensor, etc. The sensing unit 131S may also include an emitter and a receiver configured to perform measurements using non-destructive signals such as ultrasound, microwaves, terahertz waves, and infrared rays. The sensing unit 131S 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 measuring instrument 131 may also include pressure sensors, temperature sensors, ultrasonic sensors, proximity sensors, door status sensors, motion tracking sensors, humidity sensors, visible light sensors, infrared sensors, cameras, etc.

[0053] The processing unit 133P can be configured to associate the measurement data with the coordinate data CD to generate coordinate-related measurement data CMD. Generally, the measurement data can be processed based on the trigger point. Examples of processing the measurement data can include storing the measurement data, manipulating the measurement data (e.g., generating the coordinate-related measurement data CMD), and transmitting the measurement data. The processing unit 133P can be configured to transmit the coordinate-related measurement data CMD to the controller 141.

[0054] As a non-limiting example, the trigger point for processing the measurement data may be the completion of a scan. For example, the sensing unit 131S may scan the electrode sheet ES in the width direction of the electrode sheet ES, and the measurement data may be stored, processed, modulated, and transmitted for each scan. In other examples, the trigger point may be the completion of multiple scans or the completion of a portion of a scan.

[0055] According to an exemplary embodiment, the processing unit 131P may be configured to calibrate the coordinate data CD based on the position of the sensing unit 131S. More specifically, the processing unit 131P may be configured to associate coordinates of the coordinate data CD with measurement values ​​of the measurement data by calibrating the coordinate data CD based on the offset length of the sensing unit 131S.

[0056] The measuring instrument 131 can collect measurement data of the portion corresponding to (e.g., overlapping with) the sensing portion 131S, and the coordinate data CD is collected by the second encoder 125 spaced apart from the sensing portion 131S as described above, so that at the same point in time, the portion of the electrode sheet ES corresponding to the coordinate data CD and the portion of the electrode sheet ES corresponding to the measurement data may be different.

[0057] The processing unit 131P can be configured to generate coordinate-related measurement data CMD based on the coordinate data CD and the measurement data. According to an exemplary embodiment, the coordinate-related measurement data CMD can be provided by calibrating the coordinate data CD collected at the same time as the measurement data based on the offset length and associating the calibrated coordinate data CD with the measurement data. The measurement values ​​(or representative and determined values ​​of the measurement values) of the coordinate-related measurement data CMD can be matched with the calibrated coordinates. Each of the measurement values ​​(or representative and determined values ​​of the measurement values) of the coordinate-related measurement data CMD can be further matched with a time value.

[0058] Here, the representative value of the measurement values ​​may include any one of the mean, standard deviation, median, maximum value, and minimum value, and the judgment value may be an evaluation of the process on the electrode sheet ES determined from the representative value. The coordinate-related measurement data CMD may include, as a non-limiting example, the representative value, the judgment value, and the start coordinate and end coordinate of the portion of the electrode sheet ES from which the measurement data was collected.

[0059] A plurality of guide rolls for defining a moving path of the electrode sheet ES may be interposed between the sensing unit 131S and the rewinder 113. Thus, the offset length may be defined as the length of the electrode sheet ES between the sensing unit 131S and the rewinder 113. The offset length may be the same as the linear distance between the sensing unit 131S and the rewinder 113, or may be longer than the linear distance between the sensing unit 131S and the rewinder 113.

[0060] The inspector 133 can be configured to inspect the electrode sheet ES. The inspection data can include judgments and process events related to the quality of portions of the electrode sheet ES. For example, the inspection data can include data on the appearance of the electrode sheet ES collected by an image-based inspection device such as a vision machine, data on breaks and seams in the electrode sheet ES, data on portions of the electrode sheet ES that have been sampled, data on portions of the electrode sheet ES that are scheduled for scrapping, data on the 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 that indicate the position of the electrode sheet ES, and defect data such as pinhole defects, crater defects, line defects, crack defects, side ring defects, island defects, fold defects, wrinkle defects, poke defects, and dent defects.

[0061] The inspector 133 may include a sensing unit 133S and a processing unit 133P. The sensing unit 133S may be configured to sense the electrode sheet ES to generate an inspection signal IS. The sensing unit 133S may be an imaging device including a delay and integration (DUI) camera, a complementary metal oxide semiconductor (CMOS) image sensor, etc. The sensing unit 133S may include a barcode reader, an optical character reader (OCR), a color sensor, etc.

[0062] The processing unit 133P may be configured to collect test data by processing the test signal IS based on a preset algorithm. The test data may include a quality judgment value and a time value matching the judgment value.

[0063] The processing unit 133P may be configured to associate the inspection data with the coordinate data CD to generate coordinate-related inspection data CID. According to an exemplary embodiment, the processing unit 133P may be configured to calibrate the coordinate data CD based on the position of the sensing unit 133S. More specifically, the processing unit 133P may be configured to associate the coordinates of the coordinate data CD with the judgment value of the inspection data by calibrating the coordinate data CD based on an offset length of the sensing unit 133S. The offset length of the sensing unit 133S may be the length of the electrode sheet ES between the sensing unit 133S and the rewinder 113. The processing unit 133P may be configured to transmit the coordinate-related inspection data CID to the controller 141.

[0064] The controller 141 may be configured to transmit the coordinate-related measurement data CMD and the coordinate-related inspection data CID to the controller 143. The controller 143 may be, for example, a programmable logic controller (PLC). A PLC is a special type of microprocessor-based controller that uses programmable memory to store instructions and implements functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. PLCs are easy to operate and program. The controller 141 may also be, but is not limited to, a PLC.

[0065] The controller 143 may be configured to control the operation of the unwinder 111, the rewinder 113, and the processing tool 115. The controller 143 may be configured to receive work orders from the server 150. To control the process, a communication line may be installed between the controller 143 and the server 150 via the server 145, connecting the controller 143 and the server 150. As a result, data transmission via the controller 143 can save resources required for installing communication lines and improve the efficiency of data processing and management, compared to when the first rotary encoder 121, the second rotary encoder 125, the measuring instrument 131, and the inspection instrument 133 communicate directly with the server 150 and when the controller 141 communicates directly with the server 150.

[0066] The server 145 may be a communication server. The server 145 may include a program for communication between the controller 143 of the manufacturing facility and the server 150, which is an upper server. The server 145 may also be implemented as hardware, as described below. The language and protocol of the server 150 may be different from the language and protocol of the controller 143. For example, the language of the server 150 may be SQL, and the language of the controller 143 may be ladder diagram.

[0067] The server 145 may be configured to convert the work order WO transmitted from the server 150 into a language of the controller 143. The server 145 may also be configured to convert the coordinate-related measurement data CMD, the coordinate-related inspection data CID, and first data D1 and second data D2 (described later) into a language of the server 150, and record the converted coordinate-related measurement data CMD, the coordinate-related inspection data CID, and first data D1 and second data D2 (described later) in a database of the server 150.

[0068] The work order WO can include model information and a recipe related to the processing of the electrode sheet ES. The work order WO can include various items related to the processing of the electrode sheet ES, such as the number of lots to be processed in the current process, the number of coating lines to be formed on the electrode sheet ES, process conditions including temperature, humidity, and pressure, and process parameters including the moving speed of the electrode sheet ES, the discharge amount of the coating die, and the pressure of the pressure roll.

[0069] The controller 143 may be configured to generate signals for operating and interrupting the unwinder 111, the rewinder 113, and the processing tools 115 based on the work order WO. The controller 143 may be configured to collect first data D1 based on the work order WO. The first data D1 may represent a first event in the roll-to-roll process of the electrode sheet ES. As a non-limiting example, the first event may be the start of the roll-to-roll process of the electrode sheet ES. The controller 143 may be configured to collect second data D2 based on the winding amount signal WAS of the electrode sheet ES. The second data D2 may represent a second event in the roll-to-roll process of the electrode sheet ES. As a non-limiting example, the second event may be the completion of the roll-to-roll process of the electrode sheet ES.

[0070] The controller 143 may include a power supply 1431 , a CPU (Central Processing Unit) 1432 , an input interface 1433 , an output interface 1434 , a communication interface 1435 , and memory devices 1436 , 1437 .

[0071] The power supply 1431 may be configured to supply operating power to the CPU 1432, the input module 1433, the output module 1414, the communication interface 1435, and the memory devices 1436 and 1437. In some cases, the controller 143 may be powered by a separate power supply, in which case the power supply 1431 may be omitted. As a non-limiting example, the power supply 1431 may be configured to supply operating power based on an AC voltage of 220 V or a DC voltage of 24 V.

[0072] The memory device 1436 can be configured to store system programs. The memory device 1436 can be, for example, a read-only memory (ROM) and can be configured to permanently store data for the operating system of the controller 143.

[0073] The memory device 1437 may be configured to store user programs and data. A user program may be a program set by a user to cause the CPU 1432 to perform a specific function. The data may include coordinate-related inspection data CID, coordinate-related measurement data CMD, and first data D1 and second data D2 (described below). The memory device 1437 may also store status information of input and output devices, timers, counters, and other internal device values. The memory device 1437 may be, for example, a random access memory (RAM). Generally, user programs are frequently updated and therefore may be stored in the memory device 1437. When a user program is completed, it may also be stored in the memory device 1436. The user program may be recorded in the memory device 1436 by a device programmer DP. The device programmer DP may be a device separate from the controller 143 or may be included in the controller 143.

[0074] The CPU 1432 may be configured to embody logic and control communication between modules that convert input signals into output operating signals. The CPU 1432 may operate based on a system program stored in the memory device 1436. The CPU 1432 may be configured to store the coordinate-related measurement data CMD, the coordinate-related inspection data CID, the first input data D1, and the second input data D2 in the memory device 1437. The CPU 1432 may be configured to manipulate data based on a user program in the memory device 1437. The CPU 1432 may be configured to record input data from the measuring instrument 131, the inspection instrument 133, and the user in the memory device 1437.

[0075] When the PLC operates, the CPU 1432 can scan the current input conditions and data and store them in the memory device 1437. The CPU 1432 can then be configured to read and execute the user program step by step and transmit the results to any one of the output module 1434, the communication module 1435, and the memory device 1437.

[0076] The input module 1433 and the output module 1434 provide isolation and signal conditioning so that sensors and actuators can be directly coupled to the input module 1433 and the output module 1434 without other circuitry. The input module 1433 and the output module 1434 can be configured to communicate data between the CPU 1432 and external devices.

[0077] Conditions and data of industrial equipment and production processes can be transmitted to the CPU 1432 via the input module 1433. Results processed by the CPU 1432 can be transmitted to actuators via the output module 1434.

[0078] The input module 1433 can include, for example, mechanical switches for position sensing, proximity switches, photoelectric switches, encoders, temperature and pressure switches, digital and analog devices such as potentiometers, linear variable differential transformers, strain gauges, thermistors, thermal transistors, and AC or DC thermocouples. The input module 1433 can provide an interface between the input devices and the CPU 1432, which operates based on a low DC voltage. Some input devices can generate analog signals with a high voltage range. The input module 1433 can be configured to convert signals generated by the input devices to a voltage range acceptable to the CPU 1432.

[0079] The output module 1434 can be configured to generate a signal to control the operation of an actuator. The output module 1434 can include a relay, a transistor, a triac, a relay, a contactor, a solenoid valve, a motor, etc.

[0080] The communication interface 1435 may be configured to send and receive data to and from the controller 141 or to send and receive data to and from the server 150 via the server 145 .

[0081] The server 150 can be configured to generate a roll map based on the coordinate-related inspection data CID, the coordinate-related measurement data CMD, the first data D1, and the second data D2. 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.

[0082] 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.

[0083] According to another exemplary embodiment, server 150 may be configured to store and process raw measurement data. Server 150 may continuously monitor the electrode sheet processing based on the measurement data, thereby managing the quality of the electrode sheet processing. According to an exemplary embodiment, server 150 may be a statistical process controller (SPC). Server 150 may collect and analyze manufacturing data in near real time, thereby identifying problem conditions in a timely manner and providing an alarm to an operator before a potential problem occurs.

[0084] According to other example embodiments, server 150 may be, for example, a data warehouse, and may store role maps for long periods of time, such as based on product warranty periods.

[0085] According to other exemplary embodiments, server 150 may perform all of the functions of the MES, SPC, and data warehouse, or may be provided separately from the MES, SPC, and data warehouse to create the role map.

[0086] The processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may be implemented using hardware, firmware, software, or a combination thereof. For example, the processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may also include any one of a simple controller, a complex processor such as a microprocessor, a CPU, or a GPU, a software-configured processor, dedicated hardware, and firmware. The processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may be implemented using, for example, 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).

[0087] 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 that supports data transmission so that a display device can visualize data through a user interface and provide updated visualizations when new data is calculated by the server 150. The protocol that supports the data transmission may use HTML, JavaScript, and / or JSON.

[0088] The server 150 can include various APIs (Application Programming Interfaces) for storing data in databases and other data management tools. The APIs can also be used to retrieve data in the databases of various data management systems. The data management systems can 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 can be used to monitor applications and generate status alerts.

[0089] The role map generation system 100 can provide a plug-in architecture along with an API for data acquisition to provide plug-and-play connectivity of sensors, measuring instruments, and inspection equipment, so that resources at a particular process step and site can be easily transferred to other processes and sites, or new resources can be easily introduced to each process step and site.

[0090] In some embodiments, the roll map generation system 100 may further include a manual input system that allows an operator to input manufacturing data. The roll map generation system 100 may allow operator data entry using an input tool or computer-based input of manufacturing data, such as scraping an Excel file. The manual input system may be, for example, a Supervisory Control and Data Acquisition (SCADA) HMI (Human-Machine Interface). SCADA typically includes a combination of software and hardware, such as PLCs and Remote Terminal Units (RTUs). The HMI is a screen that assists communication between an operator and the SCADA system and is a key element of the SCADA system. For example, manual input via the HMI may include selecting a defect type and reflecting performance upon completion.

[0091] According to some embodiments, the operations of processing units 131P, 133P, controllers 141, 143, server 145, and 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.

[0092] The processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may be configured with firmware, software, routines, and instructions to perform the operations described above or any of the steps described below. For example, the processing units 131P, 133P, the controllers 141, 143, the server 145, and the server 150 may be instantiated in memory.

[0093] (Third embodiment) FIG. 3 is a flowchart illustrating a method for generating a role map according to an exemplary embodiment.

[0094] 4 to 8 are block diagrams illustrating a method for generating a role map according to an exemplary embodiment.

[0095] 1-4, at P110, first data D1 may be collected in a first memory area 1437R1 of the controller 143. The first data D1 may be recorded by the CPU 1432.

[0096] The memory device 1437 may include first to fourth memory areas 1437R1, 1437R2, 1437R3, and 1437R4 that operate separately. The CPU 1432 may be configured to access the first to fourth memory areas 1437R1, 1437R2, 1437R3, and 1437R4. Data of a type (e.g., start data) assigned to the first memory area 1437R1 may be collected only in the first memory area 1437R1. Data in the first memory area 1437R1 may be copied to the second memory area 1437R2. Data of a type (e.g., completion data) assigned to the third memory area 1437R3 may be collected only in the third memory area 1437R3. Data in the third memory area 1437R3 may be copied to the fourth memory area 1437R4. As described above, the first to fourth memory areas 1437R1, 1437R2, 1437R3, and 1437R4 can be configured to perform different functions from each other.

[0097] The first to fourth memory areas 1437R1, 1437R2, 1437R3, and 1437R4 can each delete stored data at a set interval. The deletion intervals of the first to fourth memory areas 1437R1, 1437R2, 1437R3, and 1437R4 can be different from each other. The deletion interval of the second memory area 1437R2 can be longer than the deletion interval of the first memory area 1437R1. This allows data copied to the second memory area 1437R2 to be stored for a long period of time. The deletion interval of the fourth memory area 1437R4 can be longer than the deletion interval of the third memory area 1437R3. This allows data copied to the fourth memory area 1437R4 to be stored for a long period of time.

[0098] The first data D1 may be recorded in the first memory area 1437R1 by the CPU 1432. The first data D1 may be data to be retained by the memory device 1437 for a relatively long time. The first data D1 may be, but is not limited to, start data for the roll-to-roll process of the electrode sheet ES as described above. The first data D1 may be any one of the inspection data and measurement data described above.

[0099] 1-3 and 5, at P120, the first data D1 may be copied to the second memory area 1437R2 of the controller 143. The CPU 1432 may be configured to read the first data D1 from the first memory area 1437R1 and record the first data D1 in the second memory area 1437R2. After the first data D1 is recorded in the second memory area 1437R2, the first data D1 in the first memory area 1437R1 may be deleted.

[0100] 1-3 and 6, at P130, the second data D2 may be collected in the third memory area 1437R3 of the controller 143. The second data D2 may be recorded by the CPU 1432.

[0101] 1 to 3 and 7, in P140, the second data D2 may be copied to the fourth memory area 1437R4 of the controller 143. The second data D2 may be data to be maintained by the memory device 1437 for a relatively long period of time. The second data D2 may be, for example, but is not limited to, completion data of a roll-to-roll process of the electrode sheet ES. The CPU 1432 may be configured to read the second data D2 from the third memory area 1437R3 and record the second data D2 in the fourth memory area 1437R4. After the second data D2 is recorded in the fourth memory area 1437R4, the first data D2 in the third memory area 1437R3 may be deleted.

[0102] 1 to 3 and 8, at P150, the first data D1 and the second data D2 can be recorded in the server 150. The server 145 can be configured to access the second memory area 1437R2 and the fourth memory area 1437R4 of the memory device 1437. The server 145 can be configured to read the first data D1 from the second memory area 1437R2 and read the second data D2 from the second memory area 1437R4, and record the first data and the second data in the server 150. The server 145 does not need to access the collection areas of the memory device 1437 (i.e., the first memory area 1437R2 and the third memory area 1437R4).

[0103] The server can then be configured to generate a roll map based on the coordinate-related inspection data CID, the coordinate-related measurement data CMD, the first data D1, and the second data D2. Because the first data D1 and the second data D2 include information regarding the start and completion of the electrode sheet ES, the range of data belonging to the roll map for the lot can be determined based on the first data D1 and the second data D2, thereby generating the roll map.

[0104] (Fourth embodiment) FIG. 9 is a block diagram illustrating another exemplary controller 143'.

[0105] Referring to FIG. 9, the controller 143′ may include a power supply 1431, a central processing unit (CPU) 1432, an input interface 1433, an output interface 1434, a communication interface 1435, and memory devices 1436, 1437, 1438.

[0106] The power supply 1431, CPU (Central Process Unit) 1432, input interface 1433, output interface 1434, communication interface 1435, and memory devices 1436, 1437 are substantially the same as those described with reference to Figures 1 and 2, so duplicate descriptions thereof will be omitted.

[0107] The memory device 1438 may be configured to store the copied first data D1 and second data D2 (see FIG. 8). The memory device 1438 may be a memory chip or a memory module separate from the memory device 1437. That is, the memory device 1438 may be an element separate from the memory device 1437. According to an exemplary embodiment, the controller 143′ may include a separate memory device 1438 for storing data that should be stored for a relatively long period of time, such as the first data D1 and the second data D2 (see FIG. 8).

[0108] Thus, memory device 1437 can include a first memory area 1437R1 and a third memory area 1437R3 (see FIG. 8) used to collect data, and memory device 1438 can include memory areas used to copy and store data, as well as a second memory area 1437R2 and a fourth memory area 1437R4 (see FIG. 8).

[0109] The memory device 1438 may be a different type of memory from the memory device 1437. For example, the memory device 1437 may be any one of a static RAM (SRAM) and a dynamic RAM (DRAM), and the memory device 1438 may be any one of a NAND flash memory, a ferroelectric RAM (FRAM), a magnetic RAM (MRAM), a phase-change RAM (PRAM), and a resistive RAM (ReRAM).

[0110] The present invention has been described in more detail above with reference to the drawings and embodiments, etc. However, the configurations shown 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]

[0111] 100 Role Map Generation System 111 Unwinder 113 Rewinder 115 Processing equipment 121 1st rotary encoder 125 Second rotary encoder 131 Measuring Instruments 131P Processing section 131S Sensing unit 133 Inspection equipment 133P Processing section 133S Sensing unit 141 Controller 143, 143' Controller 1431 Power Supply 1432 CPU 1433 Input interface, input module 1434 Output Interface, Output Module 1435 Communication Interface 1436 Memory Device 1437 Memory Device 1437R1 First Memory Area 1437R2 Second Memory Area 1437R3 Third Memory Area 1437R4 4th Memory Area 1438 Memory Device 145 servers 150 servers

Claims

1. collecting first data in a first memory area representing a first event of the electroded sheet undergoing roll-to-roll processing; copying the first data to a second memory area.

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

3. The method for generating a role map of claim 1 , further comprising the steps of reading the first data from the second memory area and recording the first data on a server.

4. The first data is collected based on a work order transmitted from the server to a controller; and The method of generating a roll map of claim 3 , wherein the controller is configured to control the roll-to-roll process based on the work order.

5. collecting second data representative of a second event of the roll-to-roll process in a third memory area; 2. The method of claim 1, further comprising the step of: copying the second data to a fourth memory area.

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

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

8. The method for generating a role map of claim 5 , further comprising the steps of reading the second data from the fourth memory area and recording the second data on a server.

9. The method of generating a roll map of claim 7 further comprising generating a roll map representing the roll-to-roll process based on the first data and the second data.

10. a memory device including a first memory area and a second memory area; a central processing unit (CPU) configured to access the first memory area and the second memory area; The process controller is configured such that the CPU collects start data indicating the start of a roll-to-roll process of the electrode sheet in the first memory area and copies the start data in the first memory area to the second memory area.

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

12. a controller configured to control a roll-to-roll process of the electrode sheet; a server configured to access the controller; The controller a memory device including a first memory area and a second memory area; a CPU configured to access the first memory area and the second memory area; The CPU is configured to collect start data indicating the start of the roll-to-roll process of the electrode sheet in the first memory area and copy the start data in the first memory area to the second memory area.

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

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

15. 15. The role map generation system of claim 14, wherein the server is configured to read the start data in the second memory area and the completion data in the fourth memory area, and the server is configured to record the start data and the completion data.

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