Roll press apparatus and method for determining deterioration of roll press apparatus

Abstract

To provide a roll press device that can determine the deterioration state of the rolls. [Solution] The roll press apparatus 4 comprises a plurality of rolls 41U, 41L and a measuring device 44 for measuring the surface state of the plurality of rolls. The plurality of rolls have a roll body 410U, 410L, a first layer 411U, 411L located on the surface of the roll body, and a second layer 412U, 412L located on the surface of the first layer and having physical properties that differ from the first layer by a predetermined value or more. The measuring device measures the state of the second layer as the surface state of the roll.

Description

Technical Field

[0001] The present invention relates to a roll press device and a method for determining deterioration of the roll press device.

Background Art

[0002] For example, in order to manufacture a sheet-like member such as an electrode of a lithium-ion battery, a roll press device that presses a material with a plurality of rolls is used (Patent Documents 1-3). Especially when manufacturing the electrodes of a battery, since a high-strength material is pressed, the plating layer applied to the surface of the roll may peel off during use. When the state of the roll surface deteriorates, it is necessary to stop the production line and replace the roll.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0004] Since it is difficult to accurately detect the surface state of a roll rotating at high speed, it takes time to determine the deterioration state of the roll, and it is difficult to appropriately judge the replacement timing. Since it takes time to replace the roll, the more frequent the replacement, the longer the downtime of the production line, and the higher the cost of manufacturing a sheet-like product with the roll press device.

[0005] The present disclosure has been made in view of the above problems, and provides a roll press device capable of determining the deterioration state of a roll.

Means for Solving the Problems

[0006] To solve the above problems, a roll press apparatus according to the present invention comprises a plurality of rolls and a measuring device for measuring the surface state of the plurality of rolls. The plurality of rolls have a roll body, a first layer located on the surface of the roll body, and a second layer located on the surface of the first layer, the second layer having physical properties that differ from the first layer by a predetermined value or more. The measuring device measures the state of the second layer as the surface state of the roll. [Effects of the Invention]

[0007] According to the present invention, when the measuring device detects the first layer, it can be determined that the second layer has deteriorated. [Brief explanation of the drawing]

[0008] [Figure 1] Overall diagram of a manufacturing line with a roll press device. [Figure 2] A schematic cross-sectional view of a lithium-ion battery manufactured on a production line. [Figure 3] Manufacturing process diagram for lithium-ion batteries. [Figure 4] An explanatory diagram showing the configuration of a roll press device. [Figure 5] A flowchart showing the process for determining roll deterioration. [Figure 6] An explanatory diagram showing a state where part of the second layer is missing, exposing the first layer. [Figure 7] An explanatory diagram showing a state in which the second layer is missing beyond a predetermined range, exposing the first layer. [Figure 8] An explanatory diagram showing an example where the physical properties of the first layer and the physical properties of the second layer differ by more than a predetermined value. [Figure 9] An explanatory diagram showing the configuration of a roll press apparatus according to Example 2. [Figure 10] An overall diagram of a manufacturing line having a roll press device, relating to Example 3. [Figure 11] An overall diagram of a manufacturing line having a roll press device, relating to Example 4. [Figure 12] A flowchart illustrating the roll press control process. [Figure 13] Flowchart showing the roll press control process according to Example 5. [Figure 14] Overall configuration diagram of a manufacturing line having a roll press device according to Example 6.

Mode for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present invention will be described based on the drawings. The roll press device of the present embodiment is used, for example, in the manufacture of products having sheet-like members such as lithium-ion batteries, nickel-hydrogen batteries, fuel cells, films, sheets, separators, and ion exchange membranes.

[0010] In the present embodiment, in order to accurately and promptly detect the deterioration of the second layer exposed on the surface of the roll, a first layer having physical properties different from the second layer by a predetermined value or more is provided between the roll body and the second layer. In the normal state where the second layer is not deteriorated, the measuring device detects the second layer. On the other hand, when the first layer is partially exposed or the presence of the first layer can be seen through, it can be determined that the second layer is deteriorated. When the deterioration of the second layer is determined, the replacement timing of the roll can be estimated from the determination timing and the degree of deterioration.

Example

[0011] The first embodiment will be described with reference to FIGS. 1 to 8. FIG. 1 is an overall configuration diagram showing an overview of a manufacturing line 1 for manufacturing electrodes of a lithium-ion battery.

[0012] The manufacturing line 1 includes, in order from the upstream side, for example, a mixing device 2, a sheet-forming device 3, a roll material supply device 6, a current collector foil supply device 7, a roll press device 4, and a cutting device 5. Further, on the downstream side of the manufacturing line 1, for example, a laminating device, a liquid injection device, an inspection device, etc. are arranged (to be described later in FIG. 3). The manufacturing line 1 is controlled by an overall controller 11.

[0013] The mixing device 2 is, for example, a device that mixes active material, conductive material, binder, etc. to manufacture electrode materials. The electrode materials manufactured by the mixing device 2 are fed into the sheet-forming device 3. The sheet-forming device 3 presses the electrode materials between work rolls to manufacture a sheet-shaped electrode 91. The sheet-shaped electrode 91 is wound into a roll and sent to the roll material supply device 6.

[0014] The roll material supply device 6 supplies the roll-shaped sheet-shaped electrode 91 to the roll press device 4. The roll material supply device 6 continuously feeds out the roll-shaped sheet-shaped electrode 91 so that the supply of the sheet-shaped electrode 91 to the roll press device 4 is not interrupted. Note that the roll material supply device 6 may be omitted, and the sheet-shaped electrode 91 may be directly supplied from the sheet-forming device 3 to the roll press device 4.

[0015] The current collector foil supply device 7 supplies the current collector foil 92 to be laminated on the sheet-shaped electrode to the roll press device 4.

[0016] The roll press device 4 forms an electrode by pressing a sheet-shaped workpiece 93 composed of the sheet-shaped electrode 91 and the current collector foil 92, and supplies it to the cutting device 5.

[0017] The cutting device 5 cuts the electrode supplied from the roll press device 4 into a predetermined shape. The positive electrode or the negative electrode is manufactured by the above process.

[0018] Figure 2 shows the schematic structure of the lithium-ion battery 200. The lithium-ion battery 200 includes, for example, a casing 201, a positive electrode 210, a negative electrode 220, and a separator 230 provided between the positive electrode 210 and the negative electrode 220. A terminal 211 extending to the casing 201 is provided on the positive electrode 210. Similarly, a terminal 221 extending outside the casing 201 is also provided on the negative electrode 220.

[0019] Figure 3 shows the manufacturing process for lithium-ion batteries. The manufacturing processes for the positive electrode and the negative electrode include, for example, a mixing process, a sheeting process, a pressing process, and a cutting process. The positive and negative electrodes manufactured in this way are then sent to the cell manufacturing process.

[0020] The cell manufacturing process includes, for example, a lamination process, an electrolyte injection process, and an inspection process. In the lamination process, a sheet-shaped positive electrode, a separator, and a sheet-shaped negative electrode are layered and pressed together. These multilayer structures are then inserted into a casing, which serves as the outer casing. In the electrolyte injection process, electrolyte is injected into the casing. After the electrolyte is injected, the casing is sealed to prevent leakage of the electrolyte.

[0021] In the inspection process, the manufactured cells are charged and tested to ensure that their electrical characteristics, such as capacity and internal resistance, are within the standard range. Furthermore, the external appearance, including the presence of scratches and dents, is inspected before shipment.

[0022] Figure 4 shows the configuration of the roll press device 4. The roll press device 4 includes, for example, a plurality of work rolls (hereinafter referred to as rolls) 41U, 41L, a press controller 42, sensors 43U, 43L, and a measuring device 44. In the figure, the upper component is denoted by the letter "U", and the lower component is denoted by the letter "L".

[0023] Multiple rolls 41U and 41L are spaced apart vertically and rotate in opposite directions by a motor (not shown). In the illustrated example, the upper roll 41U rotates counterclockwise while being pressed downwards, and the lower roll 41L rotates clockwise while being pressed upwards. As a result, the sheet-like workpiece 93 inserted between the upper roll 41U and the lower roll 41L is pressed from both above and below.

[0024] The upper roll 41U comprises, for example, a roll body 410U, a first plating layer 411U as a "first layer" uniformly formed on the outer surface (surface; the same applies hereinafter) of the roll body 410U, and a second plating layer 412U as a "second layer" uniformly formed on the outer surface of the first plating layer 411U.

[0025] The lower roll 41L, like the upper roll 41U, comprises, for example, a roll body 410L, a first plating layer 411L as a "first layer" uniformly formed on the outer surface of the roll body 410L, and a second plating layer 412L as a "second layer" uniformly formed on the outer surface of the first plating layer 411L. Hereafter, when upper and lower are not distinguished, rolls 41U and 41L may be referred to as roll 41, the first plating layers 411U and 411L as first plating layer 411, and the second plating layers 412U and 412L as second plating layer 412.

[0026] Sensor 43 detects the surface condition of the roll 41 (i.e., the second plating layer 412) and transmits the detection signal to the measuring device 44. Sensor 43U detects the surface condition of the upper roll 41U. The lower sensor 43L detects the surface condition of the lower roll 41L. When not distinguished, sensors 43U and 43L are referred to as sensor 43.

[0027] The measuring device 44 receives signals detected by each sensor 43 and transmits these detection signals to the press controller 42 either as they are or after processing. When the measuring device 44 detects the first plating layer 411, it determines that the second plating layer 412 is deteriorated. Deterioration can occur, for example, when the second plating layer 412 is worn down and thinned, allowing the underlying first plating layer 411 to show through, or when the second plating layer is partially worn down and disappears (missing).

[0028] When the measuring device 44 detects the first plating layer 411 on the surface of the roll 41 in an area greater than a predetermined range, it can determine that the second plating layer 412 is degraded.

[0029] In this embodiment, in order to accurately determine the deterioration of the second plating layer 412, at least one of the physical properties of the first plating layer 411 or the second plating layer 412 is set such that the difference between the physical properties of the first plating layer 411 and the physical properties of the second plating layer 412 is large.

[0030] Physical properties include mechanical properties, thermal properties, electrical properties, magnetic properties, and optical properties. As will be described later in Figure 8, the physical properties of the first plating layer 411 and the second plating layer 412 are set so that the first plating layer 411 located below the second plating layer 412 can be clearly detected. The physical properties of the first plating layer and the second plating layer may be of different types or of the same type. For example, if the roll body 410 is black, the first plating layer 411 is white, and the second plating layer 412 is brown or black, then if part of the second plating layer 412 is missing or thinned, that area will turn white, and the first plating layer 411 will be detected.

[0031] Sensor 43 is a device that detects differences in physical properties. For example, if the reflectivity of visible light differs between the first plating layer 411 and the second plating layer 412, a two-dimensional camera capable of capturing normal visible light can be used as sensor 43. Not limited to two-dimensional cameras, line scan cameras, 3D cameras, ToF (Time of Flight) cameras, cameras capable of detecting infrared light, multispectral cameras, etc., can also be used.

[0032] A so-called AI-equipped camera or smart camera, which has a machine learning model built into the sensor 43, may also be used.

[0033] The press controller 42 is a device that includes, for example, a processor 401, a memory 402, and various interfaces 403. The various interfaces 403 include, for example, at least one of a communication interface, an input / output interface, and a user interface.

[0034] Processor 401 is not limited to a CPU (Central Processing Unit), but may also include a GPU (Graphics Processing Unit) or an ASIC (Application Specific Integrated Circuit), etc.

[0035] The processor 401 reads and executes a predetermined computer program 420 stored in memory 402, thereby realizing the notification unit 421, the control unit 422, and the signal acquisition unit 423. The signal acquisition unit 423 acquires signals from the measuring device 44. The control unit 422 outputs control signals to control the rotation of each roll 41, etc.

[0036] The notification unit 421 sends a predetermined message to the user of the roll press device 4. The predetermined message includes, for example, a notification that deterioration of the roll 41 (specifically, deterioration of the second plating layer 412) has been detected, along with the time of detection. The predetermined message may also include data showing the detection result of the sensor 43 (for example, image data of the surface of the roll 41). Upon receiving this predetermined message, the user can, for example, set a replacement time for the roll 41 and arrange for a new roll.

[0037] The press controller 42 is connectable to a storage medium MM. The storage medium MM is, for example, a memory device, a hard disk drive, an optical disk drive, a magneto-optical disk drive, or a magnetic tape drive, and stores computer programs and data non-temporarily. The storage medium MM can store computer programs and data by transferring them to the memory 402 of the press controller 42. It is also possible to transfer computer programs and data from the memory 402 to the storage medium MM for storage. By storing a computer program 420 that realizes the functions of the press controller 42 in the storage medium MM, connecting the storage medium MM to another computer, and installing the computer program 420 stored in the storage medium MM on the other computer, the other computer can be made to function as the press controller 42.

[0038] The measuring device 44 and the sensor 43 described above may be integrated. That is, the signal measured by the sensor 43 may be processed within the sensor 43, and the processing result may be output to the press controller 42. Alternatively, the measuring device 44 may be provided within the press controller 42. The measuring device 44 may also be provided in the overall controller 11.

[0039] The mounting position and angle of the sensor 43 are not specified. The sensor 43 should be mounted in a position and at an angle that allows it to detect the presence of the first plating layer 411 based on the difference between the physical properties of the first plating layer 411 and the physical properties of the second plating layer 412. A light-shielding member or the like may be provided around the sensor 43 to prevent the incidence of ambient light.

[0040] If the physical properties of the first plating layer 411 and the second plating layer 412 are not optical properties, a sensor suitable for the physical properties to be detected is selected and positioned at a mounting position and angle suitable for detecting the physical properties to be detected.

[0041] Sensor 43 is preferably a non-contact sensor. However, a contact sensor can also be used depending on the situation.

[0042] The process of determining the deterioration of the roll 41 (S10) will be explained using the flowchart in Figure 5. The measuring device 44 periodically or irregularly acquires signals from the sensor 43 (S11) and determines whether a change has been detected on the surface of the roll 41 (S12). The measuring device 44 executes step S11 until a change is detected on the roll surface (S12:NO).

[0043] When the measuring device 44 detects a change on the roll surface (S12:YES), it determines whether the change is greater than or equal to a predetermined range (S13). When the measuring device 44 detects a change greater than or equal to a predetermined range on the roll surface (S13:YES), it determines that the roll 41 has deteriorated and sends a message to the user (S14).

[0044] The measuring device 44 may issue a warning to the user if the detected change is below a predetermined range (S13: NO) (S15).

[0045] Figure 6 shows the partial detection of the first plating layer 411 on the surface of the second plating layer 412, which serves as the roll surface. Figure 6 shows a state in which, for example, the second plating layer 412 is worn away in a minute area 413 on the surface of the second plating layer 412, and the first plating layer 411 located beneath the second plating layer 412 is exposed. Even if the second plating layer 412 in the minute area 413 does not completely disappear, if the second plating layer 412 is worn away and becomes thin, the first plating layer 411 underneath may become visible. In the state shown in Figure 6, it cannot be said that a change beyond a predetermined range has been detected on the roll surface.

[0046] Figure 7 shows the first plating layer 411 being detected beyond a predetermined range on the surface of the second plating layer 412, which serves as the roll surface. Figure 7 shows the case where the second plating layer 412 is worn over a wide area due to aging or other factors, and the first plating layer 411 is exposed in a region 414 that is larger than the predetermined range. A size (area) larger than the predetermined range is a size in which the second plating layer 412 is worn down and may have an impact on the pressing of the sheet-like workpiece 93 in the near future.

[0047] Even if the first plating layer 411 is exposed in the second plating layer 412 in an area 414 exceeding a predetermined range, there is no problem with pressing the sheet-shaped workpiece 93. However, if the roll press device 4 continues to operate with the first plating layer 411 exposed in an area 414 exceeding a predetermined range, a large portion of the second plating layer 412 will eventually peel off, and eventually the first plating layer 411 will also wear down, potentially affecting the pressing of the sheet-shaped workpiece 93.

[0048] Therefore, in this embodiment, the first plating layer 411 is used as a warning display layer to inform the user of the replacement timing, and the physical properties of at least one of the first plating layer 411 or the second plating layer 412 are set so that the first plating layer 411 and the second plating layer 412 can be clearly distinguished.

[0049] Figure 8 shows an example where the physical properties of the first plating layer 411 and the second plating layer 412 differ by a predetermined value or more. At least one of the following properties is selected for the physical properties of the first plating layer 411 and the second plating layer 412: mechanical properties, thermal properties, electrical properties, magnetic properties, and optical properties. Figure 8 illustrates several clearer examples.

[0050] One of the differences between the physical properties of the first plating layer 411 and the second plating layer 412 is the difference in materials. For example, the first plating layer 411 may be formed from chromium and the second plating layer 412 from tungsten carbide. Conversely, the first plating layer 411 may be formed from tungsten carbide and the second plating layer 412 from chromium. In addition to the combination of chromium and tungsten carbide, materials such as diamond-like carbon can also be used.

[0051] Another difference between the physical properties of the first plating layer 411 and the second plating layer 412 is the difference in color. For example, the first plating layer 411 can be made a light color such as white, and the second plating layer 412 can be made a dark color such as black. By emphasizing the differences in hue, brightness, etc., between the color of the first plating layer 411 and the color of the second plating layer 412, the degradation of a minute region 413 can be accurately detected using a visible light camera as a sensor 43.

[0052] One difference between the physical properties of the first plating layer 411 and the second plating layer 412 is the degree of surface roughness. The surface of the first plating layer 411 can be formed rough, and the surface of the second plating layer 412 can be formed smooth. Conversely, the surface of the first plating layer 411 can be formed smooth, and the surface of the second plating layer 412 can be formed rough. The difference in surface roughness can be measured, for example, with a laser displacement meter.

[0053] One of the differences between the physical properties of the first plating layer 411 and the second plating layer 412 is the difference in their electrical properties. Differences in electrical properties include, for example, differences in surface resistance and differences in induced current.

[0054] In this embodiment, each of the multiple rolls 41 has a roll body 410, a first plating layer 411 located on the surface of the roll body 410, and a second plating layer 412 located on the surface of the first plating layer 411, the second plating layer 412 having physical properties that differ from the first plating layer 411 by a predetermined value or more. The measuring device 44 measures the state of the second plating layer 412 as the surface state of the roll 41. Therefore, in this embodiment, if the second plating layer 412 wears down due to aging or other reasons, and the underlying first plating layer 411 is partially exposed, the presence of the partially exposed first plating layer 411 can be detected.

[0055] In this embodiment, when the measuring device 44 detects the first plating layer 411, it is determined that the second plating layer 412 is degraded, thus enabling early detection of the degradation of the second plating layer 412.

[0056] In this embodiment, when the measuring device 44 detects the first plating layer 411 beyond a predetermined range on the surface of the roll 41, it is determined that the second plating layer 412 is degraded. Therefore, it is possible to prevent the replacement of the roll 41 due to slight degradation in a minute region 413 as shown in Figure 6, thereby preventing unnecessary roll replacements.

[0057] In this embodiment, the physical properties of at least one of the physical properties of the first plating layer 411 or the second plating layer 412 are set such that the difference between the physical properties of the first plating layer 411 and the physical properties of the second plating layer 412 is greater than the difference between the physical properties of the second plating layer 412 and the physical properties of the roll body 410. This makes it possible to accurately determine the deterioration of the roll by increasing the difference between the physical properties of the first plating layer 411 and the physical properties of the second plating layer 412.

[0058] In this embodiment, the difference between the physical properties of the first plating layer 411 and the second plating layer 412 is a difference between similar physical properties, so the first plating layer 411 and the second plating layer 412 can be distinguished and detected using a common sensor 43.

[0059] In this embodiment, since the first and second layers are plating layers, it is possible to determine the deterioration of the roll having the plating layer.

[0060] In this embodiment, the difference between the physical properties of the first plating layer 411 and the second plating layer 412 is detected by a camera, which is an example of a sensor 43, thus enabling the improvement of the functionality of the roll press device 4 at a relatively low cost. In addition, the mounting position and angle of the camera are adjusted to suppress ambient light from entering the camera lens.

[0061] In this embodiment, if it is determined that the second plating layer 412 formed on any one of the rolls 41 is deteriorating, information regarding the replacement timing of the rolls 41 is output. Therefore, the user of the roll press device 4 can properly maintain the roll press device 4 and reduce maintenance costs.

[0062] In this embodiment, since the roll press device 4 can be used for manufacturing electrodes of lithium-ion batteries, the number of times deteriorated rolls 41 (worn rolls 41) need to be replaced and the time required for replacement can be reduced, thereby improving the throughput of lithium-ion battery manufacturing and lowering manufacturing costs. In other words, in this embodiment, since rolls can be replaced at the appropriate time, the cost of preparing new rolls can be reduced and the downtime of manufacturing associated with roll replacement can be shortened.

[0063] In this embodiment, the sensor 43 and measuring device 44 can be installed on the roll press device 4 as an add-on, making it possible to improve the functionality of the existing roll press device 4 at a relatively low cost.

[0064] The roll body 410 may be provided with three or more plating layers, not limited to the two plating layers, the first plating layer 411 and the second plating layer 412. In that case as well, the physical properties of the outermost plating layer and the physical properties of the plating layer immediately below the outermost plating layer should be set so that deterioration (such as peeling) of the outermost plating layer can be clearly detected. [Examples]

[0065] Example 2 will be explained using Figure 9. In the following examples, including this one, the differences from Example 1 will be described in particular.

[0066] The roll press apparatus 4A of this embodiment measures the surface condition of multiple rolls 41U, 41L using multiple measuring devices 44U, 44L, each having a different measurement method. The surface condition of the upper roll 41U is measured by the measuring device 44U for the upper roll and transmitted to the press controller 42. The surface condition of the lower roll 41L is measured by the measuring device 44L for the lower roll and transmitted to the press controller 42.

[0067] The measuring device 44U for the upper roll measures the surface condition of the upper roll 41U based on a first measurement method. The measuring device 44L for the lower roll measures the surface condition of the lower roll 41L based on a second measurement method. The first and second measurement methods may be completely different or the same. If the first and second measurement methods are the same, measurement parameters such as detection thresholds may be different for the first and second measurement methods.

[0068] For example, if the upper roll 41U is illuminated by factory ceiling lighting, the measuring device 44U for the upper roll can use a camera less affected by ambient light as its sensor 43U, or it can be equipped with an optical filter on the sensor 43U. If ambient light is not easily incident on the lower roll 41L, the measuring device 44L for the lower roll can use a standard visible light camera as its sensor 43L. In addition, for example, the color, wavelength, and illuminance of the inspection lighting can be changed for the measuring device 44U for the upper roll and the measuring device 44L for the lower roll.

[0069] If deterioration of the roll surface (deterioration of the second plating layer 412) is detected by at least one of the measuring devices 44U for the upper roll and 44L for the lower roll, it may be determined that both of the rolls 41U and 41L should be replaced. Alternatively, if deterioration of the roll surface is detected by both the measuring device 44U for the upper roll and 44L for the lower roll, it may be determined that both of the rolls 41U and 41L should be replaced.

[0070] Of the rolls 41U and 41L, only the one showing deterioration in its surface condition may be replaced. However, since multiple rolls 41U and 41L are used simultaneously for extended periods and similarly deteriorate over time, they will need to be replaced alternately at short intervals. Therefore, if deterioration is detected in either roll 41U or 41L, replacing both rolls 41U and 41L simultaneously will reduce the time and labor required for roll replacement.

[0071] This embodiment, configured in this way, also provides the same effects as Embodiment 1. Furthermore, the roll press apparatus 4A of this embodiment measures the surface condition of multiple rolls 41U, 41L using multiple measuring devices 44U, 44L with different measurement methods, so that it can measure the deterioration of the roll surface appropriately according to the installation conditions of the rolls 41U, 41L and the surrounding environment. [Examples]

[0072] Example 3 will be explained using Figure 10. In the manufacturing line 1B of this example, the overall controller 11B controls the roll press device 4B.

[0073] The overall controller 11B includes, for example, a processor 101, memory 102, and various interfaces 103. By executing a predetermined computer program stored in memory 102, the processor 101 controls the roll press machine 4B and the entire production line 1B. The processor 101, memory 102, and various interfaces 103 are the same as those described in Figure 4.

[0074] The overall controller 11B includes, for example, a signal acquisition unit 110, a control unit 120, and a notification unit 120. These signal acquisition unit 110, control unit 120, and notification unit 120 have the same functions as the signal acquisition unit 423, control unit 422, and notification unit 421 described in Figure 4. In addition to controlling the roll press device 4B, the control unit 120 can also control the other devices 2, 3, 5, 6, and 7 in the other processes.

[0075] This embodiment, configured in this way, also provides the same effects and advantages as Embodiment 1. Furthermore, in this embodiment, the roll press device 4B is also controlled by the overall controller 11B, thus simplifying the control structure.

[0076] This embodiment can be combined with either Embodiment 1 or Embodiment 2. [Examples]

[0077] Embodiment 4 will be described using Figures 11 and 12. In this embodiment, the overall controller 11C controls the manufacturing speed of the roll press device 4C based on the speed of the manufacturing line 1C. The roll press device 4C determines the deterioration of the surface condition of the roll 41 when the speed of the manufacturing line 1C changes, or before the speed of the manufacturing line 1C changes.

[0078] As shown in Figure 11, the overall controller 11C includes an adjustment timing detection unit 140, a control condition adjustment unit 150, and a quality information storage unit 160.

[0079] The adjustment timing detection unit 140 has the function of detecting whether a predetermined adjustment timing has arrived. The adjustment timing is the timing for adjusting the control conditions of the roll press device 4C. Examples of adjustment timings include the switching of roll material by the roll material supply device 6 (also called switching of electrode rods), and when the manufacturing speed of other devices 2, 3, 5, and 7 decreases.

[0080] When the control condition adjustment unit 150 detects the arrival of a predetermined adjustment timing, it transmits information to the press controller 42 of the roll press device 4C based on the quality information stored in the quality information storage unit 160, causing the control conditions of the roll press device 4C to be adjusted.

[0081] The quality information storage unit 160 stores quality information acquired from the pre-processing steps (mixing step, sheeting step) of the roll press device 4C and quality information acquired from the post-processing steps (cutting step) of the roll press device 4C. Quality information acquired from the pre-processing steps of the roll press includes, for example, the quality of the electrode slurry and the quality of the sheet-shaped electrode 91. Quality information acquired from the post-processing steps of the roll press includes, for example, quality information when the electrodes are cut and information indicating the results of quality inspections of the manufactured cells.

[0082] The roll press control process will be explained using the flowchart in Figure 12. First, before full-scale operation of production line 1C, the roll press device 4C is test-run to determine the deterioration of the rolls (S10). Details of the deterioration determination process are as described in Figure 5.

[0083] After completing the deterioration assessment process during trial operation (S10), the roll press device 4C performs roll pressing (S20). The sheet-like workpiece 93 pressed by the roll press device 4C is sent to the cutting device 5 for cutting. The cut workpiece is then sent to the cell manufacturing process (lamination, liquid injection, inspection).

[0084] The overall controller 11C controls the operation of each device 2, 3, 6, 7, 4, 5, etc., and adjusts the control conditions of the roll press device 4C at predetermined adjustment timings (S30).

[0085] The quality information storage unit 160 of the overall controller 11C acquires and stores quality information from the pre-roll press process and the post-roll press process, respectively (S31). The adjustment timing detection unit 140 detects the arrival of a predetermined adjustment timing (S32). When the predetermined adjustment timing is detected, the control condition adjustment unit 150 adjusts the control conditions of the roll press device 4C based on the quality information stored in the quality information storage unit 160 (S34).

[0086] In other words, the control condition adjustment unit 150 resets the parameters used to control the roll press based on quality information and transmits the reset parameters to the press controller 42 of the roll press device 4C. The control conditions are press conditions, such as the press pressure value and the rotation speed of the roll 41.

[0087] Once the adjustment of the control conditions is complete (S30), normal pressing operations are resumed, and the deterioration determination process (S10) and the roll pressing execution process (S20) are repeatedly performed. During normal pressing operations, quality information is collected from the processes preceding and following the roll pressing process and stored in the quality information storage unit 160.

[0088] If the predetermined adjustment timing is detected again and new quality information is stored in the quality information storage unit 160, the process of adjusting the control conditions is executed (S30). New quality information refers to quality information that has not been reflected in the adjustment of the control conditions.

[0089] In this embodiment, the deterioration of the surface condition of each roll 41 can be determined, and the control conditions of the roll press device 4C can be adjusted. Therefore, this embodiment provides the same effects as in Embodiment 1, while maintaining or improving the manufacturing quality of the roll press device 4C.

[0090] In other words, the roll press apparatus 4C of this embodiment can reduce the maintenance cost of each roll 41 by determining the deterioration of the surface condition of each roll 41, and furthermore, by adjusting the control conditions of the roll press apparatus 4C according to the operating state of the production line 1C, it is possible to maintain or improve product quality (for example, electrode quality of lithium-ion batteries) while the production line 1C is in operation.

[0091] In this embodiment, by combining the determination of deterioration of the surface condition of the roll 41 with the adjustment of control conditions, it is possible to achieve both a reduction in manufacturing costs and the maintenance or improvement of product quality.

[0092] This embodiment can be expressed, for example, as follows:

[0093] "A roll press apparatus 4C comprising a plurality of rolls 41, a measuring device 44 for measuring the surface state of the plurality of rolls, and a control device 42, wherein the plurality of rolls 41 have a roll body 410, a first layer 412 located on the surface of the roll body, and a second layer 412 located on the surface of the first layer and having physical properties that differ from the first layer by a predetermined value or more, the measuring device measures the state of the second layer as the surface state of the roll, and the control device controls the operation of the plurality of rolls based on the adjusted control conditions when a predetermined adjustment timing is detected and the control conditions are adjusted." This embodiment can also be expressed, for example, as follows:

[0094] "A method for determining when to replace multiple rolls 41 of a roll press device 4C, wherein each roll has a roll body 410, a first layer 411 located on the surface of the roll body, and a second layer 412 located on the surface of the first layer, and comprises a measuring device 44 for measuring the surfaces of the multiple rolls, and a control device 42 for acquiring the measurement results of the measuring device, wherein when the measuring device detects the first layer, it is determined that the second layer is deteriorated, and when a predetermined adjustment timing is detected and the control conditions are adjusted, the control device controls the operation of the multiple rolls based on the adjusted control conditions." This embodiment can be combined with any of Embodiments 1-3. The overall controller 11C may control the operation of the roll press device 4C. This embodiment can also be combined with any combination of any two of Embodiments 1-3. [Examples]

[0095] Embodiment 5 will be explained using Figure 13. In this embodiment, when adjusting the control conditions of the roll press device 4, deterioration of the surface condition of the roll 41 is determined. The roll press control process in this embodiment may be performed by the overall controller 11C as described in Figure 11, or by the press controller 42 as described in Figure 4. The roll press control process in this embodiment may be performed in cooperation between the overall controller 11C and the press controller 42.

[0096] Here, the roll press device 4 (or roll press device 4C; the same applies hereafter) will be described as the main component of the operation. When the start switch is turned on, the roll press device 4 performs the roll press process (S20).

[0097] The roll press device 4 continues the roll press process and adjusts the control conditions and determines the deterioration of the rolls at the appropriate timing (S30D). In step S30D, quality information from the previous process and quality information from the next process are acquired and stored (S31), a predetermined timing for adjusting the control conditions is detected (S32), the deterioration of the surface condition of the rolls is determined (S33), and the control conditions of the roll press device are adjusted (S34). The deterioration determination process (S33) is the same as the process (S10) described in Figure 5.

[0098] This embodiment, configured in this way, also achieves the same effects as Embodiment 4. Furthermore, in this embodiment, when the speed of the production line decreases to a predetermined adjustment timing, deterioration of the surface condition of the roll is determined, and the control conditions of the roll press device are adjusted. Therefore, in this embodiment, when a predetermined adjustment timing slower than the normal line speed is detected during the pressing operation, deterioration of the surface condition of the roll and adjustment of the control conditions can be performed. Because the deterioration of the surface condition of the roll is determined at a speed slower than the normal line speed (i.e., the normal pressing speed), the determination accuracy can be made higher than in Embodiment 1. In contrast, in Embodiment 1, deterioration of the surface condition of the roll can be determined almost constantly, so deterioration can be detected earlier than in this embodiment.

[0099] This embodiment can be expressed, for example, as follows:

[0100] "A roll press apparatus 4C comprising a plurality of rolls 41, a measuring device 44 for measuring the surface state of the plurality of rolls, and a control device 42, wherein the plurality of rolls 41 have a roll body 410, a first layer 412 located on the surface of the roll body, and a second layer 412 located on the surface of the first layer and having physical properties that differ from the first layer by a predetermined value or more, and when a predetermined adjustment timing is detected, the measuring device measures the state of the second layer as the surface state of the roll, and the control device controls the operation of the plurality of rolls based on the adjusted control conditions." This embodiment can also be expressed, for example, as follows:

[0101] "A method for determining when to replace multiple rolls 41 of a roll press device 4C, wherein each roll has a roll body 410, a first layer 411 located on the surface of the roll body, and a second layer 412 located on the surface of the first layer, and comprises a measuring device 44 for measuring the surfaces of the multiple rolls and a control device 42 for acquiring the measurement results of the measuring device, wherein when a predetermined adjustment timing is detected, if the measuring device detects the first layer, it is determined that the second layer is deteriorated, and the control device controls the operation of the multiple rolls based on the adjusted control conditions, thus determining deterioration of the roll press device." This embodiment can also be combined with any one of Examples 1-3, or with a combination of several of Examples 1-3. [Examples]

[0102] Example 6 will be explained using Figure 14. In the manufacturing line 1E of this example, the press controller 42E of the roll press device 4E controls the operation of each device 2, 3, 6, 7, and 5 of the manufacturing line 1E.

[0103] Each device 2, 3, 6, 7, 4, and 5 in the manufacturing line 1E is interconnected via a communication network 111. The press controller 42E performs roll pressing and roll surface condition deterioration detection. Furthermore, the press controller 42E can adjust the control conditions of the roll press device 4E.

[0104] This embodiment, configured in this way, also provides the same effects and advantages as Embodiment 1. In this embodiment, since an overall controller is not provided, the control structure can be simplified, and the cost of the manufacturing line can be reduced.

[0105] It should be noted that the present invention is not limited to the embodiments described above. Those skilled in the art can make various additions and modifications within the scope of the present invention. The embodiments described above are not limited to the configuration examples shown in the accompanying drawings. The configuration and processing methods of the embodiments can be appropriately modified within the scope of achieving the objectives of the present invention.

[0106] Furthermore, each component of the present invention can be arbitrarily selected, and an invention comprising the selected components is also included in the present invention. Moreover, the components described in the claims can be combined in combinations other than those explicitly stated in the claims. It is possible to replace a part of the configuration of one embodiment with a part of the configuration of another embodiment, and it is also possible to add a part of the configuration of one embodiment to a part of the configuration of another embodiment. In addition, it is possible to add, delete, or replace parts of the configuration of each embodiment with other components.

[0107] In each embodiment, only those control lines and information lines deemed necessary for illustrative purposes are shown, and not all control lines and information lines are necessarily shown in the actual product. In practice, it can be assumed that almost all components are interconnected. Furthermore, each embodiment can be used in combination as appropriate.

[0108] The above-described embodiment includes an invention that can be expressed as follows:

[0109] (Note 1) A roll press apparatus comprising a plurality of rolls and a measuring device for measuring the surface state of the plurality of rolls, wherein the plurality of rolls have a roll body, a first layer located on the surface of the roll body, and a second layer located on the surface of the first layer and having physical properties that differ from the first layer by a predetermined value or more, and the measuring device measures the state of the second layer as the surface state of the roll.

[0110] (Note 2) The roll press apparatus according to Note 1, wherein when the measuring device detects the first layer, it is determined that the second layer is deteriorated.

[0111] (Note 3) The roll press apparatus according to either Note 1 or 2, wherein when the measuring device detects the first layer in a predetermined range or more on the surface of the roll, it is determined that the second layer is deteriorated.

[0112] (Note 4) A roll press apparatus according to any one of Notes 1-3, wherein the physical properties of the first layer or the second layer are set such that the difference between the physical properties of the first layer and the second layer is greater than the difference between the physical properties of the second layer and the physical properties of the roll body.

[0113] (Note 5) The roll press apparatus according to any one of Notes 1-4, wherein the physical property is at least one of the mechanical properties, thermal properties, electrical properties, magnetic properties, or optical properties.

[0114] (Note 6) The roll press apparatus according to any one of Notes 1-5, wherein the first layer and the second layer are plating layers.

[0115] (Note 7) The roll press apparatus according to any one of Notes 1-6, wherein the difference between the physical properties of the first layer and the physical properties of the second layer can be detected by the camera of the measuring device.

[0116] (Note 8) A roll press apparatus according to any one of Notes 1-7, wherein if it is determined that the second layer formed on any one of the plurality of rolls is deteriorated, information regarding the replacement timing of the plurality of rolls is output.

[0117] (Note 9) A roll press apparatus according to any one of Notes 1-8, wherein the electrodes of a battery are inserted between the plurality of rolls.

[0118] (Note 10) A roll press apparatus according to any one of Notes 1-9, wherein the rotational speed of the plurality of rolls is reduced when the line speed decreases in at least one of the upstream or downstream processes, and the condition of the plurality of rolls is measured by the measuring device.

[0119] (Note 11) A method for determining when to replace multiple rolls of a roll press device, wherein each roll has a roll body, a first layer located on the surface of the roll body, and a second layer located on the surface of the first layer, and comprises a measuring device for measuring the surfaces of the multiple rolls, and a control device for acquiring the measurement results of the measuring device, wherein when the measuring device detects the first layer, it is determined that the second layer is deteriorated.

[0120] (Note 12) The method for determining deterioration of a roll press apparatus according to Note 11, wherein the measuring device detects the first layer based on the difference between the physical properties of the first layer and the physical properties of the second layer, and when the measuring device detects the first layer in a predetermined range or more on the surface of the roll, it is determined that the second layer is deteriorated.

[0121] (Note 13) The properties of the first layer are set such that the difference between the properties of the first layer and the second layer is greater than the difference between the properties of the second layer and the roll body. A method for determining the deterioration of a roll press device as described in either Appendix 11 or 12. [Explanation of symbols]

[0122] 1,1B,1C,1E: Manufacturing line; 4,4A,4B,4C,4E: Roll press equipment; 41U,41L: Roll; 42,42E: Press controller; 43U,43L: Sensor; 44,44U,44L: Measuring device; 410U,410L: Roll body; 411U,411L: First plating layer; 412U,412L: Second plating layer

Claims

1. A roll press device, Multiple roles, A measuring device for measuring the surface state of the plurality of rolls Equipped with, Each of the aforementioned rolls comprises a roll body, a first layer located on the surface of the roll body, and a second layer located on the surface of the first layer, the second layer having physical properties that differ from the first layer by a predetermined value or more. The measuring device measures the state of the second layer as the surface state of the roll. Roll press machine.

2. When the measuring device detects the first layer, it is determined that the second layer is deteriorated. The roll press apparatus according to claim 1.

3. When the measuring device detects the first layer in a predetermined range or more on the surface of the roll, it is determined that the second layer is deteriorated. The roll press apparatus according to claim 2.

4. The properties of the first layer or the second layer are set such that the difference between the properties of the first layer and the second layer is greater than the difference between the properties of the second layer and the roll body. The roll press apparatus according to claim 3.

5. The aforementioned physical properties are at least one of the following: mechanical properties, thermal properties, electrical properties, magnetic properties, and optical properties. The roll press apparatus according to claim 4.

6. The first and second layers are plating layers. The roll press apparatus according to claim 5.

7. The difference between the physical properties of the first layer and the physical properties of the second layer can be detected by the camera of the measuring device. The roll press apparatus according to claim 6.

8. If it is determined that the second layer formed on any one of the rolls is deteriorated, information regarding the replacement timing of the rolls is output. The roll press apparatus according to claim 7.

9. The electrodes of the battery are inserted between the aforementioned multiple rolls. The roll press apparatus according to claim 8.

10. If the line speed decreases in at least one of the upstream or downstream processes, the rotational speed of the plurality of rolls is reduced, and the state of the plurality of rolls is measured by the measuring device. The roll press apparatus according to claim 4.

11. A method for determining when to replace multiple rolls in a roll press machine, The roll comprises a roll body, a first layer located on the surface of the roll body, and a second layer located on the surface of the first layer. The system comprises a measuring device for measuring the surfaces of the plurality of rolls, and a control device for acquiring the measurement results of the measuring device. When the measuring device detects the first layer, it is determined that the second layer is deteriorated. A method for determining the deterioration of a roll press machine.

12. The measuring device detects the first layer based on the difference between the physical properties of the first layer and the physical properties of the second layer. When the measuring device detects the first layer in a predetermined range or more on the surface of the roll, it is determined that the second layer is deteriorated. A method for determining deterioration of a roll press apparatus according to claim 11.

13. The properties of the first layer are set such that the difference between the properties of the first layer and the second layer is greater than the difference between the properties of the second layer and the roll body. A method for determining deterioration of a roll press apparatus according to claim 12.

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