Method for manufacturing a secondary battery

Abstract

According to an exemplary embodiment of the present invention, there is provided a method for manufacturing a secondary battery, the method including the steps of collecting data from an electrode sheet undergoing an electrode process, calculating a production volume, which is the length of a portion of the electrode sheet undergoing the electrode process, and calculating a loss volume and a defective volume of the electrode sheet.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a secondary battery. This application claims the benefit of Korean Application No. 10-2023-0102897, 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 various wireless devices such as handsets, laptops, and wireless vacuum cleaners. In recent years, improvements in energy density and economies of scale have dramatically reduced the manufacturing cost per unit capacity of secondary batteries, and as the driving range of battery electric vehicles (BEVs) has increased to the same level as fuel-powered vehicles, the main use of secondary batteries is shifting 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 method for manufacturing a secondary battery using a roll map containing information about the quality and defects of the electrode manufacturing process. [Means for solving the problem]

[0005] According to an exemplary embodiment of the present invention, there is provided a method for manufacturing a secondary battery, the method including the steps of collecting data from an electrode sheet undergoing an electrode process, calculating a production volume, which is the length of a portion of the electrode sheet undergoing the electrode process, and calculating a loss volume and a defective volume of the electrode sheet.

[0006] The electrode process includes forming an upper coating on the upper surface of the electrode plate of the electrode sheet and a lower coating on the lower surface opposite the upper surface of the electrode plate, and portions of the electrode sheet spaced from each of the upper coating and the lower coating are excluded from the production volume.

[0007] The electrode process includes forming an upper coating on an upper surface of the electrode plate of the electrode sheet and a lower coating on a lower surface opposite the upper surface of the electrode plate, and the portion of the electrode sheet including either the upper coating or the lower coating is added to the production volume.

[0008] The electrode process includes forming an upper coating on an upper surface of the electrode plate of the electrode sheet and a lower coating on a lower surface opposite the upper surface of the electrode plate, and a first portion of the electrode sheet including the upper coating and spaced from the lower coating is added to the loss amount.

[0009] The electrode process includes forming an upper coating on the upper surface of the plate of the electrode sheet and a lower coating on the lower surface opposite the upper surface of the plate, and a second portion of the electrode sheet spaced from the upper coating and including the lower coating is added to the loss amount.

[0010] The defect amount is the length of the electrode sheet including the defect.

[0011] The defect amount is calculated based on compressed measurement data of the electrode sheet, and the compressed measurement data includes a judgment value calculated based on raw measurement data and coordinates matched to the judgment value.

[0012] The defect amount is calculated based on coordinate-related inspection data of the electrode sheet, and the coordinate-related inspection data includes a judgment value indicating a defect and coordinates that match the judgment value.

[0013] The method further includes a step of calculating a non-defective quantity, which is the length of a normal portion of the electrode sheet, based on the production quantity, the loss quantity, and the defective quantity of the electrode sheet.

[0014] The sum of the amount of non-defective products, the amount of losses, and the amount of defective products is the same as the production amount.

[0015] According to an exemplary embodiment, there is provided a method for manufacturing a secondary battery, the method including the steps of: collecting data from an electrode sheet undergoing a coating process in which an upper coating is formed on an upper surface of an electrode plate of the electrode sheet and a lower coating is formed on a lower surface of the electrode plate of the electrode sheet, the data including upper coating data indicative of the upper coating, lower coating data indicative of the lower coating, and coordinate-related inspection data of the electrode sheet; calculating a production amount based on the upper coating data and the lower coating data; calculating a rejection amount of the electrode sheet; and calculating a non-defective amount, which is the amount of a normal portion of the electrode sheet, based on the production amount and the rejection amount.

[0016] The portion of the electrode sheet that includes either the top coating or the bottom coating is counted toward the yield.

[0017] The portion of the electrode sheet that includes only one of the upper coating and the lower coating is counted toward the exclusion amount.

[0018] The coordinate-related inspection data includes a judgment value indicating a defect and coordinates that match the judgment value, and the defect amount, which is the length of the electrode sheet including the defect calculated based on the coordinate-related inspection data, is added to the exclusion amount. [Effects of the Invention]

[0019] According to an exemplary embodiment of the present invention, a method for manufacturing a secondary battery can be provided that allows feedback, feedforward, and tracking for electrode processes.

[0020] 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]

[0021] [Figure 1] 1 illustrates a secondary battery manufacturing system according to an exemplary embodiment. [Figure 2] FIG. 2 is a cross-sectional view of an electrode sheet. [Figure 3] The top and bottom surfaces of the electrode sheet are shown. [Figure 4] 1 is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment. [Figure 5] The screen displayed on the client device is shown. DETAILED DESCRIPTION OF THE INVENTION

[0022] 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.

[0023] 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.

[0024] 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.

[0025] Since the embodiments of the present invention are provided to more completely explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or shown in a schematic manner for clearer explanation. Therefore, the sizes and proportions of each component do not completely reflect the actual sizes and proportions.

[0026] (First embodiment) FIG. 1 shows a secondary battery manufacturing system 100 according to an exemplary embodiment.

[0027] FIG. 2 is a cross-sectional view of the electrode sheet ES.

[0028] FIG. 3 shows the upper surface EST and the lower surface ESB of the electrode sheet ES.

[0029] Referring to Figures 1 to 3, the secondary battery manufacturing system 100 may include an unwinder 111, a rewinder 113, die coaters 115T and 115B, a first rotary encoder 121, a second rotary encoder 123, a measuring instrument 131, an inspector 133, coating sensors 135T and 135B, a first controller 141, a second controller 143, an input device 150, servers 160 and 170, and a user device 180.

[0030] The unwinder 111 can be configured to unwind the electrode sheet ES from the electrode roll ER1. The rewinder 113 can be configured to wind the electrode sheet ES onto the electrode roll ER2. This allows the electrode sheet ES to move between the unwinder 111 and the rewinder 113.

[0031] A process for manufacturing a secondary battery (e.g., an electrode process) can be performed on the electrode sheet ES. The electrode process can be a roll-to-roll process because the electrode sheet ES is unwound from the electrode roll ER1 and wound around the electrode roll ER2.

[0032] A coating process may be performed on the electrode sheet ES. The coating process may be performed using die coaters 115T and 115B. The coating process is a process of applying a coating material, such as an electrode slurry, onto the electrode sheet ES. The electrode slurry may include an electrode active material, a conductive material, a binder, and a solvent. The electrode slurry may be prepared by dissolving the electrode active material, the conductive material, the binder, and the like in a solvent.

[0033] The die coater 115T can apply electrode slurry onto the upper surface EPT of the electrode plate EP, thereby forming a top coating TC on the upper surface EPT of the electrode plate EP. The electrode sheet ES can include a ground lane LT and an uncoated portion UCT. The ground lane LT can be a portion of the electrode plate EP to which the top coating TC has been applied or to which the top coating TC is scheduled to be applied. The uncoated portion UCT can be a portion of the electrode sheet ES that is free of the top coating TC (i.e., spaced apart from the top coating TC).

[0034] The die coater 115B can apply electrode slurry onto the lower surface EPB of the electrode plate EP, thereby forming a lower coating BC on the lower surface EPB of the electrode plate EP. The electrode sheet ES can include a ground lane LB and an uncoated portion UCB. The ground lane LB can be a portion of the electrode plate EP to which the lower coating BC has been applied or to which the lower coating BC is scheduled to be applied. The uncoated portion UCB can be a portion of the electrode sheet ES that is free of the lower coating BC (i.e., separated from the lower coating BC).

[0035] According to an exemplary embodiment, each of the ground lanes LT, LB and the uncoated portions UCT, UCB may extend in a running direction MD, which is the direction of movement (or longitudinal direction) of the electrode sheet ES. Each of the ground lanes LT, LB and the uncoated portions UCT, UCB may be divided into a lateral direction (or width direction) TD of the electrode sheet ES.

[0036] The first rotary encoder 121 may be configured to sense the amount of electrode sheet ES unwound from the electrode roll ER1 by the unwinder 111. Thus, the first rotary encoder 121 may be configured to generate an input amount signal UWAS indicating the unwound amount of electrode sheet ES. The first rotary encoder 121 may be configured to transmit the input amount signal UWAS to the first controller 141. The first controller 141 may be configured to collect input amount data based on the input amount signal UWAS of the electrode sheet ES. The input amount data may indicate the amount of material (i.e., electrode roll ER1) input into the secondary battery manufacturing system 100 to manufacture a secondary battery.

[0037] The second rotary encoder 123 may be configured to sense the amount of electrode sheet ES wound onto the electrode roll ER2 by the rewinder 113. Thus, the second rotary encoder 123 may be configured to generate a consumed amount signal WAS indicating the wound amount of electrode sheet ES. The second rotary encoder 123 may be configured to transmit the consumed amount signal WAS to the first controller 141. The first controller 141 may be configured to collect consumed amount data based on the consumed amount signal WAS of the electrode sheet ES. The consumed amount data may indicate the amount of electrode sheet ES wound by the rewinder 113.

[0038] A portion of the electrode sheet ES may be scrapped in some cases, and as a result, the amount of the electrode sheet ES unwound by the unwinder 111 may differ from the amount of the electrode sheet ES taken up by the rewinder 113. Furthermore, when the electrode sheet ES is stretched by pressure in a subsequent process such as a roll press, the amount of the electrode sheet ES taken up by the unwinder 111 may differ from the amount of the electrode sheet ES taken up by the rewinder 113.

[0039] As a non-limiting example, the first controller 141 and the second controller 143 may be programmable logic controllers (PLCs). A PLC is a specialized form of microprocessor-based controller that uses programmable memory to store instructions and implements functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. PLCs are easy to operate and program.

[0040] The first controller 141 and the second controller 143 may include a power supply, a CPU, an input interface, an output interface, a communication interface, and a memory device. The power supply may be configured to supply power to other elements of the first controller 141 and the second controller 143, such as the CPU, the input interface, the output interface, the communication interface, and the memory device, for operation of the first controller 141 and the second controller 143. The memory device may include a read-only memory (ROM) configured to store system programs such as an operating system, and a random access memory (RAM) configured to store user programs and data such as status information of input / output devices, timers, counters, and other internal device values. The CPU may be configured to implement logic and control communication between modules that convert input signals into output operating signals. The CPU may operate based on system programs and user programs stored in the memory device. The CPU may be configured to write or read inspection data and measurement data to or from the data area of ​​the memory device based on the system programs and user programs. Conditions and data of industrial equipment and production processes may be transmitted to the CPU via the input module. The results processed by the CPU may be transmitted to the actuator via the output module. The communication interface may be configured to transmit and receive data between the first controller 141 and the second controller 143, or between the second controller 143 and the server 160.

[0041] However, without being limited thereto, the first controller 141 and the second controller 143 may include any one of a simple controller, a complex processor such as a microprocessor, a CPU, or a GPU, a processor configured by software, dedicated hardware, and firmware. The first controller 141 and the second controller 143 may also be embodied by a general-purpose computer or application-specific hardware such as a DSP (Digital Signal Processor), an FPGA (Field Programmable Gate Array), and an ASIC (Application Specific Integrated Circuit).

[0042] The first controller 141 may be configured to collect coordinate data CD of the electrode sheet ES based on one of the input amount signal UWAS and the consumed amount signal WAS of the electrode sheet ES. For example, the first controller 141 may determine the movement distance of the electrode sheet ES based on the consumed amount signal WAS of the electrode sheet ES, thereby determining the position within the electrode sheet ES of the portion of the electrode sheet ES that is wound by the rewinder 113 at each point in time during the coating process. Hereinafter, the technical concept of the present invention will be described focusing on an embodiment in which the first controller 141 collects coordinate data CD based on the consumed amount signal WAS of the electrode sheet ES.

[0043] 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 may have coordinates. The coordinates may be one-dimensional quantities in the traveling direction MD (or the longitudinal direction of the electrode sheet ES), which is the direction of movement of the electrode sheet ES, but are not limited to this. The coordinates may also be two-dimensional quantities in the traveling direction MD and the lateral direction TD (or the width direction of the electrode sheet ES).

[0044] The measuring device 131 may be configured to measure the electrode sheet ES to collect measurement data of the electrode sheet ES. The measurement data may be raw data, and processing of the measurement data may determine an evaluation and a determination value of the portion of the electrode sheet ES from which the measurement data was collected. By way of non-limiting example, the measuring device 131 may be any one of a web gauge and a thickness gauge from Thermofisher Scientific.

[0045] The measuring device 131 can be configured to scan the electrode sheet ES. During scanning of the electrode sheet ES, the measuring device 131 can move along the lateral direction TD of the electrode sheet ES. During one scan, the sensing unit 131S of the measuring device 131 can move from one end of the lateral direction TD of the electrode sheet ES to the other end of the lateral direction TD of the electrode sheet ES.

[0046] While the measuring device 131 performs scanning in the lateral direction TD, the electrode sheet ES can be moved in the traveling direction MD by the unwinder 111 and the rewinder 113. This allows the portion of the electrode sheet ES measured by the measuring device 131 to have a zigzag shape.

[0047] The measurement data may include test results expressed as numerical values. The measurement data may include data on the amount of coating material loaded on the electrode sheet ES and data on the thickness of the coating material on 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 area density of the coating material.

[0048] The measuring instrument 131 may include a sensing unit 131S and a processor 131P. 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 sensing unit 131S 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.

[0049] The processor 131P may be configured to receive a measurement signal MS sensed by the sensing unit 131S to collect measurement data. The processor 131P may be configured to collect measurement data based on the measurement signal MS. The processor 131P may be connected to the sensing unit 131S via a wired or wireless connection. The processor 131P may be configured to calibrate the measurement data by adding an offset measurement amount to each of a plurality of measurement values ​​of the measurement data. Due to the progress of the process and aging of the equipment, the measurement values ​​of the measurement data may differ from the actual values. The processor 131P can improve the reliability of the measurement data by calibrating the measurement values ​​of the measurement data based on the offset measurement amount. The offset measurement amount may be determined based on known information about the equipment system by a method such as a sample test.

[0050] The inspector 133 may be configured to inspect the electrode sheet ES to collect inspection data ID. The inspector 133 may include any one of a color sensor, a seam sensor, a reference point sensor, and a vision machine.

[0051] The inspection data ID can include, for example, 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 the portions of the electrode sheet ES that have been sampled, data on the 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 the coating material and insulating layer 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. The inspection data ID can include a judgment value for the quality of the portions of the electrode sheet ES (for example, a value indicating the presence or absence of defects and the type of defect).

[0052] Here, the electrode sheet appearance data may include width data of the electrode sheet ES determined based on image-based inspection, width data of the insulating layer on the electrode sheet, overlay data indicating the overlap width between the coating material (i.e., electrode slurry) on the electrode sheet and the insulating layer, and mismatch data indicating misalignment between the land lane on the lower surface and the land lane on the upper surface of the electrode sheet ES. Reference points may also be formed at predetermined intervals on the electrode sheet ES, and the positions of other elements on the electrode sheet ES may be located based on the reference points. As a non-limiting example, the secondary battery manufacturing system 100 may include a separate server configured to store original inspection data (e.g., images of defective portions of the electrode sheet ES).

[0053] The inspection data ID may include width data of the ground lanes and unground lanes of the electrode sheet ES determined based on an image-based inspection of the electrode sheet ES, dimensional data such as the width of the insulating layer and the overlap width between the coating material and the insulating layer, and mismatch data between the ground lanes on the upper surface of the electrode sheet ES and the ground lanes on the lower surface of the electrode sheet ES.

[0054] The tester 133 may include a sensing unit 133S and a processor 133P. The sensing unit 133S may be configured to sense the electrode sheet ES to generate a test signal IS. For example, the sensing unit 133S may include any one of the sensors described above with respect to the sensing unit 131S.

[0055] The processor 133P may be configured to receive and process the raw test signal IS sensed by the sensing unit 133S to collect the test data ID. The processor 133P may include an algorithm for processing the image of the portion of the electrode sheet ES to determine a test value of the test data ID, or a model (e.g., an artificial neural network) trained to determine the test value based on the image of the portion of the electrode sheet ES.

[0056] The above-mentioned measurement data and test data IDs may be time-series data. The measurement data and test data IDs may be aligned in time. The measurement data and test data IDs may be indexed by time. The measurement data may include a measurement value and a time (or multiple times) matched to the measurement value. The test data ID may include a test value and a time (or multiple times) matched to the test value. That is, the measurement data and test data IDs may be stored based on the time at which the measurement and test were performed, and the measurement data and test data IDs may be associated with time. The time of the measurement data and test data ID may have, for example, but is not limited to, a timestamp format.

[0057] As an example, measurement data (e.g., loading amount data on the electrode sheet ES or thickness data of the electrode sheet ES) may have a series of measurement values ​​and a time associated with the series of measurement values. The measurement values ​​and the time may be matched one-to-one, but are not limited to this. The measurement values ​​may also be matched many-to-one with a single timestamp representing the start point of the measurement. As another example, defect data may have a value indicating a defect and a time associated with the value indicating a defect. Here, indicating a defect includes at least one of the presence or absence of a defect and the type of defect.

[0058] The coating sensor 135T may be configured to sense the upper ground lane LT on the upper surface EST of the electrode sheet ES. The coating sensor 135T may be configured to generate an upper coating sensing signal TCS that distinguishes between a portion of the upper ground lane LT that has an upper coating TC and a portion of the upper ground lane LT that does not have an upper coating TC. The coating sensor 135T may be configured to transmit the upper coating sensing signal TCS to the first controller 141.

[0059] The coating sensor 135B may be configured to sense the lower ground lane LB on the lower surface ESB of the electrode sheet ES. The coating sensor 135B may be configured to generate a lower coating sensing signal BCS that distinguishes between a portion of the lower ground lane LB that has a lower coating BC and a portion of the lower ground lane LB that does not have a lower coating BC. The coating sensor 135B may be configured to transmit the lower coating sensing signal BCS to the first controller 141.

[0060] The first controller 141 may be in operative communication with the first rotary encoder 121, the second rotary encoder 123, the measuring instrument 131, the inspection instrument 133, the additional measuring instrument, and the additional inspection instrument via a wired or wireless data network. The data network may be unidirectional or bidirectional. The data network may be implemented by a public network and / or a dedicated network using a physical channel, Wi-Fi, Bluetooth, and / or other frequency bands. The first rotary encoder 121, the second rotary encoder 123, the measuring instrument 131, the additional measuring instrument, and the additional inspection instrument may be configured to collect data or generate signals for collecting data from equipment, workpieces, semi-finished products, and finished products within the secondary battery manufacturing system 100. The first controller 141 may be configured to transmit coordinate data CD to the processor 131P.

[0061] The processor 131P can be configured to generate coordinate-related metrology data based on the coordinate data CD and the metrology data. The processor 131P can be configured to associate the metrology data with the coordinate data CD to generate the coordinate-related metrology data. Generally, the metrology data can be processed based on the trigger point. Examples of processing the metrology data can include storing the metrology data, manipulating the metrology data (e.g., generating the coordinate-related metrology data), and transmitting the metrology data.

[0062] 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 laterally, 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 partial completion of a scan.

[0063] The electrode sheet ES can be divided into a plurality of sections based on the scanning of the sensing unit 131S of the measuring instrument 131. That is, each of the plurality of sections can correspond to one scanning of the sensing unit 131S.

[0064] According to an exemplary embodiment, the processor 131P may be configured to calibrate the coordinate data CD based on the position of the sensing unit 131S. More specifically, the processor 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.

[0065] The measuring instrument 131 can collect measurement data of a portion of the electrode sheet ES that corresponds to (e.g., overlaps with) the sensing unit 131S, and the coordinate data CD is collected by the second rotary encoder 123 that is spaced apart from the sensing unit 131S as described above. As a result, the portion of the electrode sheet ES that corresponds to the coordinate data CD collected at the same time and the portion of the electrode sheet ES that corresponds to the measurement data may be different.

[0066] According to an exemplary embodiment, coordinate-related measurement data can be provided by calibrating 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 coordinate-related measurement data can include a measurement value, a time matched to the measurement value, and start and end coordinates. The time can be a timestamp indicating the date and time the measurement data was collected. The start and end coordinates can represent the start and end points of the portion of the electrode sheet ES from which the measurement data was collected. The start and end coordinates can be determined based on the calibrated coordinate data CD. The coordinate-related measurement data can include a measuring device ID for identifying the measuring device 131 and an equipment ID for identifying the secondary battery manufacturing system 100. The coordinate-related measurement data can be stored in the server 170 or a separate server provided for storing original data.

[0067] As another example, the sensing unit 131S may be directly connected to a position measuring device such as the first rotary encoder 121 and the second rotary encoder 123, or may be configured to sense a reference point of the electrode sheet ES. In this case, the processor 131P may be configured to collect coordinate-related measurement data based on the measurement signal MS transmitted from the sensing unit 131S.

[0068] A plurality of guide rolls for defining a movement path of the electrode sheet ES may be interposed between the sensing unit 131S and the rewinder 113. Thus, the offset length of the sensing unit 131S may be defined as the length of the electrode sheet ES interposed between the portion of the electrode sheet ES sensed by 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.

[0069] The processor 131P can be configured to generate compressed measurement data PMD based on the measurement data and the coordinate data CD. The compressed measurement data PMD can include a representative value of the measurement data for each of the multiple sections of the electrode sheet ES, a judgment value, and the start and end coordinates of each of the multiple sections of the electrode sheet ES. The compressed measurement data PMD can further include a timestamp indicating the date and time when the measurement data for the multiple sections was collected, a measuring instrument ID, and an equipment ID.

[0070] The processor 131P can be configured to calculate a representative value of the measurement data for each of the multiple sections of the electrode sheet ES. The representative value of the measurement data for each of the multiple sections of the electrode sheet ES can include at least one of the mean, standard deviation, median, maximum value, and minimum value of the measurement data for each of the multiple sections.

[0071] For example, if the coordinate-related measurement data has 1500 measurement values ​​corresponding to one scanning of the sensing unit 131S, the compressed measurement data PMD may include a single representative value calculated based on the 1500 measurement values. As a result, the size of the compressed measurement data PMD may be different from the size of the coordinate-related measurement data. The size of the compressed measurement data PMD may be even smaller than the size of the coordinate-related measurement data. The start and end coordinates of the compressed measurement data PMD are substantially the same as the start and end coordinates of the corresponding coordinate-related measurement data.

[0072] The server 170, which will be described later, performs various operations for managing the production of secondary batteries in addition to generating a roll map. According to an exemplary embodiment, the server 170 generates a roll map based on compressed measurement data PMD instead of coordinate-related measurement data having a size similar to that of raw measurement data, thereby reducing the resources of the server 170 allocated to generating and storing the roll map. This allows for continuous production management of the server 170 and improves the reliability of secondary battery production.

[0073] The measurement data is processed in a set manner to determine judgment values ​​for multiple sections of the electrode sheet ES. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is within a set range including an upper limit and a lower limit, the corresponding portion of the electrode sheet ES can be determined to be good. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is smaller than the lower limit or larger than the upper limit, the corresponding portion of the electrode sheet ES can be determined to be defective.

[0074] As another example, a measurement value (or representative value) within a first range can be determined to be normal, a measurement value (or representative value) within a second range even larger than the first range can be determined to be excessive, a measurement value (or representative value) within a third range even larger than the second range can be determined to be very excessive, a measurement value (or representative value) within a fourth range even smaller than the first range can be determined to be insufficient, and a measurement value (or representative value) within a fifth range even smaller than the fourth range can be determined to be very insufficient.

[0075] Here, if the lower limit of the second range is equal to or greater than the upper limit of the first range, the second range is greater than the first range. Similarly, if the upper limit of the fourth range is equal to or less than the lower limit of the first range, the fourth range is smaller than the first range.

[0076] The processor 131P may be configured to transmit the compressed measurement data PMD to the first controller 141. The processor 133P may be configured to transmit the inspection data ID to the first controller 141. The first controller 141 may be configured to generate (or collect) coordinate-related inspection data CID based on the inspection data ID and the coordinate data CD. As with the coordinate-related measurement data, the coordinate-related inspection data CID may be provided by calibrating the coordinate data CD based on the offset length and associating the calibrated coordinate data CD with the inspection data ID, but is not limited to this. For example, the first controller 141 may be configured to transmit the coordinate data CD to the processor 133P, and the processor 133P may generate (or collect) the coordinate-related inspection data CID.

[0077] Here, the offset length of the sensing unit 133S can be defined as the length of the electrode sheet ES interposed between the part of the electrode sheet ES sensed by the sensing unit 133S and the rewinder 113.

[0078] In another example, the processor 133P may receive the coordinate data CD from the first controller 141, and the coordinate-related inspection data CID may be generated by the processor 133P based on the coordinate data CD and the inspection data ID.

[0079] The first controller 141 may be configured to collect upper coating data TCD and lower coating data BCD. Due to reasons such as work interruptions, the upper coating TC and the lower coating BC may be formed discontinuously. For example, the ground lane LT may include a portion with the upper coating TC and a portion without the upper coating TC where the electrode plate EP is exposed. Similarly, the ground lane LB may include a portion with the lower coating BC and a portion without the lower coating BC where the electrode plate EP is exposed.

[0080] The upper coating data TCD can be collected based on the exhaustion amount signal WAS and the upper coating sensing signal TCS, and the lower coating data BCD can be collected based on the exhaustion amount signal WAS and the lower coating sensing signal BCS. Here, to collect the upper coating data TCD and the lower coating data BCD, the exhaustion amount signal WAS can be calibrated based on the offset length of the coating sensors 135T and 135B. The offset length of the coating sensors 135T and 135B can be defined as the length of the electrode sheet ES interposed between the portion of the electrode sheet ES sensed by the coating sensors 135T and 135B and the rewinder 113.

[0081] The upper coating data TCD may include values ​​representing the upper coatings TC and the start and end coordinates of the upper coatings TC matched thereto. As an example, the start and end coordinates of one of the upper coatings TC in FIG. 3 are X1 and X2. As a result, the upper coating data TCD may include coordinates X1 and X2 and values ​​representing the upper coatings TC matched thereto. As another example, the start and end coordinates of another of the upper coatings TC in FIG. 3 are X3 and X5. As a result, the upper coating data TCD may include coordinates X3 and X5 and values ​​representing the upper coatings TC matched thereto.

[0082] The top coating data TCD can include a value indicating the absence of a top coating TC and the start and end coordinates of a portion of the ground lane LT that does not have a matching top coating TC (i.e., a portion of the ground lane LT where the top surface EPT of the electrode plate EP is exposed). As an example, the start coordinate of one of the portions of the ground lane LT that does not have a top coating TC in FIG. 3 is X2, and the end coordinate is X3. As a result, the top coating data TCD can include the coordinates X2 and X3, and a value indicating the absence of a matching top coating TC. As another example, the start coordinate of one of the portions of the ground lane LT that does not have a top coating TC in FIG. 3 is X5, and the end coordinate is X6. As a result, the top coating data TCD can include the coordinates X5 and X6, and a value indicating the absence of a matching top coating TC.

[0083] The lower coating data BCD may include values ​​representing the lower coating BC and the start and end coordinates of the lower coating BC matched thereto. As an example, the start and end coordinates of one of the lower coatings BC in FIG. 3 are X1 and X2. As a result, the lower coating data BCD may include coordinates X1 and X2 and values ​​representing the lower coating BC matched thereto. As another example, the start and end coordinates of another of the lower coatings BC in FIG. 3 are X4 and X6. As a result, the lower coating data BCD may include coordinates X4 and X6 and values ​​representing the lower coating BC matched thereto.

[0084] The lower coating data BCD can include a value indicating that there is no lower coating BC, and the start and end coordinates of the portion of the ground lane LB where there is no lower coating BC (i.e., the portion of the ground lane LB where the underside EPB of the electrode plate EP is exposed). As an example, the start coordinate of the portion of the ground lane LB where there is no lower coating BC in Figure 3 is X2, and the end coordinate is X4. Thus, the lower coating data BCD can include coordinates X2 and X4, and values ​​indicating that there is no lower coating BC matched to them.

[0085] The first controller 141 may be configured to transmit the compressed measurement data PMD to the second controller 143. The second controller 143 may be configured to transmit the compressed measurement data PMD to the server 170. However, without being limited thereto, the first controller 141 may also transmit the compressed measurement data PMD directly to the server 170.

[0086] The second controller 143 can be configured to control the operation of the unwinder 111, the rewinder 113, and the coaters 115T, 115B. The second controller 143 can be configured to generate signals for operating and halting the operation of the unwinder 111, the rewinder 113, and the coaters 115T, 115B. The signals for operating and halting the operation of the unwinder 111, the rewinder 113, and the coaters 115T, 115B can be generated based on the electrode specification data, the compressed measurement data PMD, the coordinate-related inspection data CID, and the measurement signal MS.

[0087] The input device 150 can allow manual data input by an operator. For example, the input device 150 can include an HMI (Human Machine Interface). Alternatively, the input device 150 can allow operator data input using an input tool and computer-based input of manufacturing data, such as scraping an Excel file. The manual input data MID input by the input device 150 can include, for example, the length, start coordinates, and end coordinates of the electrode sheets ES cut by sample inspection of the electrode sheets ES, or the length, start coordinates, and end coordinates of the electrode sheets ES lost due to lot change (i.e., loading a new electrode roll ER1).

[0088] The compressed measurement data PMD, coordinate-related inspection data CID, upper coating data TCD, lower coating data BCD, and manual input data MID may be transmitted to server 170 via server 160. Server 160 may be, for example, a server for communication of a log database. Server 160 may be a program for communication between second controller 143 and server 170 for manufacturing management. Server 160 may also be embodied in hardware. The language and protocol of server 170 may be different from the language and protocol of second controller 143. For example, the language of server 170 may be SQL, and the language of second controller 143 may be ladder diagram.

[0089] The server 160 may be configured to convert the electrode specification data transmitted from the server 170 into a language of the second controller 143. The server 160 may also be configured to convert the compressed measurement data PMD, the coordinate-related inspection data CID, the upper coating data TCD, the lower coating data BCD, and the manually input data MID into a language of the server 170, and to record the compressed measurement data PMD, the coordinate-related inspection data CID, the upper coating data TCD, the lower coating data BCD, and the manually input data MID in a database of the server 170.

[0090] The electrode specification data may include model information and a recipe for the electrode sheet ES. The electrode specification data may include various items related to the processing of the electrode sheet ES, such as the number of lots processed in the current process, the number of land lanes 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.

[0091] In order to control the process, a communication line connecting the second controller 143 and the server 170 via the server 160 can be installed between the second controller 143 and the server 170. As a result, data transmission via the second controller 143 can save resources required for installing a communication line and can improve the efficiency of data processing and management compared to when the first rotary encoder 121, the second rotary encoder 123, and the measuring device 131 directly transmit the input amount signal UWAS, the consumed amount signal WAS, and the measurement signal MS to the first server 170, or when the first controller 141 directly transmits the compressed measurement data PMD to the server 170.

[0092] According to an exemplary embodiment, server 170 may be a data processing system that supports various activities required to manage the manufacturing of secondary batteries, such as work schedule management, work instructions, quality control, and work performance aggregation. Server 170 may be, for example, a manufacturing execution system (MES). Server 170 may be configured to input, process, output, and communicate data required for electrode manufacturing processes, such as a coating process, a roll pressing process, and a slitting process.

[0093] The server 170 can be configured to generate a roll map. The roll map can include data regarding lot specifications, such as the lot number, the length of the rolled electrode sheet ES, the width of the electrode sheet ES, and the materials and composition used in processing the electrode sheet ES.

[0094] The roll map can represent the electrode sheet ES based on coordinates indicating positions on the electrode sheet ES. As described above, processes for manufacturing a secondary battery can be performed on the electrode sheet ES. The roll map represents the history of processes performed on the electrode sheet ES and can include data related to the coordinates. This allows the roll map to enable feedback, feedforward, and tracking of the secondary battery manufacturing process, as described below.

[0095] The roll map can include event data representing events in the roll-to-roll process of the electrode sheet ES. Event data generally occurs as the process progresses, and is therefore time-series data. As a result, process event data can include a value representing the event and its corresponding time. Time-series data can be temporally ordered. Temporal ordering is a key characteristic of time-series data, which is the organization of 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., the time at which inspection and measurement were performed or a process action was taken), and events can be matched with time.

[0096] The manufacturing of secondary batteries involves a series of distinct processes, with leading processes affecting subsequent processes. Feedforward refers to correcting subsequent processes based on data generated according to the results of a previous process. In this case, if the time series data of a previous process is not directly matched with the real-world workpiece, semi-finished product, and finished product, it is difficult to reflect the time series data of the previous process in the subsequent process. Here, the term "workpiece" refers to an article provided as the result of each process, such as the electrode sheet ES after the coating process, roll pressing process, and slitting process shown in FIG. 1. The semi-finished product may refer to one of a separator, an electrode, or an assembly thereof cut by a notching process. The semi-finished product may also be a structure including a housing and an electrode assembly housed in the housing (in some cases, the structure may further include an electrolyte). The product refers to an article that has been processed to operate as a secondary battery through an activation process. The above definitions of workpiece, semi-finished product, and finished product relate to one aspect of each and do not exclude their usual definitions.

[0097] 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. In a roll map, time-series data such as measurement data can be associated with coordinate data CD based on the movement amount of the electrode sheet ES (i.e., either the input amount or the consumption amount). A roll map can associate 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. This allows the generation of a roll map and feedforward based on the roll map to achieve improved production efficiency and quality by quantifying and objectifying aspects of the process that previously depended on the discretion of the worker.

[0098] The roll map may be generated on a lot-by-lot basis. The electrode sheet ES is wound onto the second electrode roll ER2, and after reaching a target winding amount, the second electrode roll ER2 may be cut and separated from the electrode sheet ES connected to the first electrode roll ER1. A lot is a production unit in a roll-to-roll process, and the second electrode roll ER2 separated from the electrode sheet ES is an example of a lot. Accordingly, the server 170 may be configured to store a roll map of a previous process. The roll map of the previous process may correspond to the first electrode roll ER1. The server 170 may also be configured to generate and store a roll map of a current process. The roll map of the current process may correspond to the second electrode roll ER2.

[0099] 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.

[0100] Furthermore, roll maps are cumulatively generated for workpieces, components, 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 be matched to the 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 the roll map of the electrodes and separator included in the battery cell. As a result, if an event such as a quality issue occurs in a battery cell that has already been shipped, the collective data history of the manufacturing of the battery cell can be retrieved based on the cell ID.

[0101] The server 170 can provide manufacturing control based on roll map data such as compressed metrology data PMD, coordinate-related inspection data CID, top coating data TCD, bottom coating data BCD, and manual input data MID. The server 170 can be configured to determine or calculate, for example, the yield, non-defective, defective, and lost amounts of the coating process.

[0102] Here, the production volume of the coating process can be determined based on the actual execution of the coating process by the die coaters 115T and 115B. For example, if multiple defects (i.e., defects in the electrode sheet ES over a long length) occur during the coating process, the electrode sheet ES can be moved while the coating of the electrode sheet is interrupted. As a result, the ground lane LT can include a discontinuous upper coating TC, as shown on the upper surface EST and the lower surface ES B of the electrode sheet in FIG. 3, and the ground lane LB can include a discontinuous lower coating BC. The production volume can be the length of the electrode sheet ES on which the coating process has been performed on either the upper surface EPT or the lower surface EPB of the electrode plate EP.

[0103] For example, the electrode sheet ES between the start coordinate X1 and the end coordinate X2 can be added to the production volume because it includes an upper coating TC on the upper surface EPT of the electrode plate EP and a lower coating BC on the lower surface EPB of the electrode plate EP.

[0104] The electrode sheet ES between the start coordinate X2 and the end coordinate X3 does not include the upper coating TC, so that the upper surface EPT of the electrode plate EP is exposed, and does not include the lower coating BC, so that the lower surface EPB of the electrode plate EP is exposed, and therefore can be excluded from the production volume. This is because the coating process was not performed on the upper surface EPT and the lower surface EPB of the electrode plate EP.

[0105] The electrode sheet ES between the start coordinate X3 and the end coordinate X4 does not include the lower coating BC and the lower surface EPB of the electrode plate EP is exposed, but it includes the upper coating TC on the upper surface EPT of the electrode plate EP, so it can be added to the production volume.

[0106] For example, the electrode sheet ES between the start coordinate X4 and the end coordinate X5 can be added to the production volume because it includes an upper coating TC on the upper surface EPT of the electrode plate EP and a lower coating BC on the lower surface EPB of the electrode plate EP.

[0107] The electrode sheet ES between the start coordinate X5 and the end coordinate X6 does not include the upper coating TC and the upper surface EPT of the electrode plate EP is exposed, but it does include the lower coating BC on the lower surface EPB of the electrode plate EP, so it can be added to the production volume.

[0108] Thus, the production amount in the electrode sheet ES illustrated in FIG. 3 can be expressed as follows:

[0109] [Formula 1] Production volume = X6-X1-(X3-X2)

[0110] The amount of non-defective products can be calculated by subtracting the amount of defective products and the amount of loss from the amount of production. As a result, the relationship between the amount of production, the amount of non-defective products, the amount of defective products, and the amount of loss can be expressed by the following formula 2. As a result, the server 170 can be configured to automatically calculate the amount of non-defective products in the coating process, which is an example of production management based on a roll map.

[0111] [Formula 2] Production volume = quantity of good products + quantity of defective products + quantity of loss

[0112] The portions of the electrode sheet ES corresponding to the defective and lost amounts may be removed in a subsequent process or separated from the normal electrode sheet ES. The defective and lost amounts may be collectively referred to as the excluded amount. That is, the excluded amount may satisfy the following Equations 3 and 4:

[0113] [Formula 3] Exclusion amount = defective amount + loss amount

[0114] [Formula 4] Production volume - Rejection volume = Quality volume

[0115] In another example, according to an exemplary embodiment, server 170 may be a statistical process controller (SPC). Server 170 may manage the quality of the processing of electrode sheets ES by continuously monitoring the processing of electrode sheets ES based on original inspection data and / or measurement data. By collecting and analyzing production data in near real time, server 170 may identify problem conditions in a timely manner and provide an alarm to an operator before a potential problem occurs.

[0116] In another example, the server 170 may be a data warehouse configured to store roll map data such as compressed metrology data PMD, coordinate-related inspection data CID, top coating data TCD, bottom coating data BCD, and manually entered data MID for long periods of time.

[0117] The client device 180 may be configured to transmit an API request to the server 170 to inquire about role map information. The server 170 may be configured to transmit, in response to the API request from the client device 180, a uniform resource locator (URL) (or schema) including source code for displaying the role map on the client device 180 to the client device. The client device 180 may access the source code for visualizing and displaying the role map via the URL (or schema).

[0118] The client device 180 may be any device for communicating with the server 170, such as a workstation computer, a notebook computer, a laptop, a desktop computer, a tablet, a mobile device such as a smartphone, or a wearable device. The client device 180 may include an input tool for inputting API requests and a display device for displaying a role map.

[0119] The processing units 131P, 133P and the servers 160, 170 may be implemented using hardware, firmware, software, or a combination thereof. For example, the processing units 131P, 133P and the servers 160, 170 may include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processing units 131P, 133P and the servers 160, 170 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 and the servers 160, 170 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).

[0120] The servers 160 and 170 may include physical servers or cloud servers. The servers 160 and 170 may provide data and analysis results to operators through various frameworks. The frameworks may include protocols that support data transmission so that client devices can visualize data through a user interface and provide updated visualizations when new data is calculated by the server 170. The protocols that support data transmission may use HTML, JavaScript, and / or JSON.

[0121] The servers 160, 170 may include various APIs (Application Programming Interfaces) for storing data in databases and other data management tools. The APIs may also be used to retrieve data in the databases of the various data management systems. The data management systems may provide access to the databases, pull or retrieve data from the databases, and generate metrics, where metrics are tools for visualizing data. Metrics include measurements generated over time and may be used to monitor applications and generate status alerts.

[0122] In some embodiments, the operations of the processing units 131P, 133P and the servers 160, 170 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.

[0123] The processing units 131P, 133P and the servers 160, 170 may be configured with firmware, software, routines, and instructions for performing the operations described above or any of the steps described below. For example, the processing units 131P, 133P and the servers 160, 170 may be instantiated in memory.

[0124] However, this is for convenience of explanation, and the operations of the processing units 131P, 133P and servers 160, 170 described above may also be caused by a computing device, a distributed computing device, a processor, firmware, software, routines, instructions, or other device executing instructions.

[0125] The secondary battery manufacturing system 100 may implement a plug-in architecture together with an API for data acquisition to provide plug-and-play connections between the measuring instrument 131, the inspection instrument 133, and the coating sensors 135T and 135B, thereby allowing resources at a specific process step and a specific site to be easily transferred to other processes and other sites, or new resources to be easily introduced to each process step and site.

[0126] The data network between elements of the secondary battery manufacturing system 100 may include various types of communication channels, including unidirectional, bidirectional wired, and wireless communication. As an example, the data network may include industrial protocol networks such as OPC, Modbus, and ProfiNet. The communication channel may be a dedicated conduit communication such as USB (Universal Serial Bus), IEEE 802 (Ethernet), IEEE 1394 (FireWire), or other high-speed data communication standards.

[0127] The architecture configured to generate a roll map and an intermediate roll map can be implemented by adding only the first controller 141 to the essential elements of a modern process control system. That is, the system according to the exemplary embodiment can utilize resources already installed at the manufacturing site, thereby saving additional capital expenditures. Furthermore, by applying the same architecture as existing manufacturing facilities to newly constructed manufacturing facilities, it is possible to improve the reliability of secondary battery manufacturing, identify / improve problematic processes, and introduce new processes efficiently.

[0128] (Second embodiment) FIG. 4 is a flowchart illustrating a method for manufacturing a secondary battery according to an exemplary embodiment.

[0129] FIG. 5 shows the screen SCR displayed on the client device 180.

[0130] 1 and 4, data can be collected from the electrode sheet ES in P110. The data from the electrode sheet ES can be data for evaluating a coating process performed on the electrode sheet ES. The data from the electrode sheet ES can include coordinate-related data such as compressed measurement data PMD, coordinate-related inspection data CID, top coating data TCD, bottom coating data BCD, and manual input data MID. The data from the electrode sheet ES can be data for generating a roll map.

[0131] Next, a roll map can be generated in P120. Generating the roll map can include collectively storing, processing, modulating, and transmitting the compressed measurement data PMD, coordinate-related inspection data CID, upper coating data TCD, lower coating data BCD, and manually input data MID based on their coordinates, and generating a URL for accessing them. Collectively storing, processing, modulating, and transmitting the compressed measurement data PMD, coordinate-related inspection data CID, upper coating data TCD, lower coating data BCD, and manually input data MID can spatially (i.e., based on coordinates) sort the defect types. This prevents the lengths of portions of the electrode sheet ES corresponding to each defect from being overlapped and added together when calculating the defect amount.

[0132] 1, 4, and 5, the production volume of the electrode process (e.g., the coating process) can be calculated in P130. The calculation of the production volume of the coating process is substantially the same as that described with reference to FIGS.

[0133] Subsequently, in P140, the loss and defect amounts of the electrode process (eg, coating process) can be calculated.

[0134] The amount of loss of the electrode sheet ES may include a portion determined based on the manually input data MID and a portion determined based on the upper coating data TCD and the lower coating data BCD. For example, the amount of loss due to sample inspection and residual removal may be determined based on the manually input data MID.

[0135] Furthermore, if the coating process is not performed on each of the upper surface EPT and the lower surface EPB of the electrode plate EP, the energy density of the cut electrode sheet ES will decrease, and therefore the portion of the electrode sheet ES that includes only one of the upper coating TC and the lower coating BC may not be used in the actual product (i.e., electrode assembly). Therefore, the portion of the electrode sheet ES that includes only one of the upper coating TC and the lower coating BC may be added to the loss amount of the electrode sheet ES.

[0136] For example, the electrode sheet ES between the start coordinate X3 and the end coordinate X4 does not include the lower coating BC but does include the upper coating TC, so it can be added to the loss amount of the electrode sheet ES. For example, the electrode sheet ES between the start coordinate X5 and the end coordinate X6 does not include the upper coating TC but does include the lower coating BC, so it can be added to the loss amount of the electrode sheet ES.

[0137] Roll map data such as compressed measurement data PMD, coordinate-related inspection data CID, upper coating data TCD, lower coating data BCD, and manually input data MID can be visualized on the visualized upper surface VEST and visualized lower surface VESB of the electrode sheet ES displayed on the screen SCR.

[0138] The screen SCR may include a legend LG that represents elements of the visualized roll map. As shown in the legend LG in FIG. 5, color C1 indicates that the measured quantities (e.g., loading amount, thickness, etc.) on the electrode sheet ES are normal, color C2 indicates that the measured quantities (e.g., loading amount, thickness, etc.) on the electrode sheet ES are insufficient, and color C3 indicates that the measured quantities (e.g., loading amount, thickness, etc.) on the electrode sheet ES are excessive. Indicator I1 indicates a visual defect on the electrode sheet ES, and indicator I2 indicates a visual defect on the insulating layer of the electrode sheet ES.

[0139] Here, the visual defect may be a defect determined by an image-based inspection device such as a machine vision system, etc. Also, the insulating layer is an insulating material applied to the boundary of the land lane L1.

[0140] The defect amount can be determined from the portion of the electrode sheet ES that is not included in the loss amount calculation, i.e., the defect amount can be determined from the portion of the electrode sheet that includes each of the upper coating TC and the lower coating BC.

[0141] Some defects may overlap in the lateral direction TD. The defect amount is the substantial length of the part of the electrode sheet ES that includes the defects, so the defects may not be added together despite the overlap of the defects in the lateral direction TD.

[0142] In Figure 5, coordinates DX1 and DX2 are additionally displayed to explain the calculation of the defect amount. The portion of the electrode sheet ES between coordinates DX1 and X2 includes the upper coating TC and the lower coating BC, and includes defects due to excessive measurement amounts. This allows the portion of the electrode sheet ES between coordinates DX1 and X2 to be added to the calculation of the defect amount.

[0143] The portion of the electrode sheet ES between coordinates X3 and X4 includes the upper coating TC but not the lower coating BC, and therefore may not be included in the calculation of the defect amount. Similarly, the portion of the electrode sheet ES between coordinates X5 and X6 includes the lower coating BC but not the upper coating TC, and therefore may not be included in the calculation of the defect amount.

[0144] The portion of the electrode sheet ES between coordinates X4 and DX2 may include multiple defects that overlap in the lateral direction TD. Because the portion of the electrode sheet ES between coordinates X4 and DX2 includes an upper coating TC and a lower coating BC, the portion of the electrode sheet ES between coordinates X4 and DX2 can be added together to calculate the defect amount.

[0145] The portion of the electrode sheet ES between the coordinates X1 and DX2 and the portion of the electrode sheet ES between the coordinates DX2 and X5 are normal, and therefore may not be added together in calculating the amount of defects.

[0146] Next, in P150, the quantity of non-defective products in the electrode process (e.g., coating process) can be calculated. The quantity of non-defective products in the coating process can be calculated based on the production quantity, the loss quantity, and the defect quantity. More specifically, the quantity of non-defective products in the coating process can be calculated by subtracting the rejection quantity of the coating process (i.e., the sum of the loss quantity and the defect quantity) from the production quantity of the coating process.

[0147] As described above, based on the roll map data, the server 170 can be configured to determine the production volume, defective volume, and non-defective volume of the electrode sheet ES, and the production performance (i.e., non-defective volume) of the electrode sheet ES can be determined automatically and with high precision.

[0148] 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]

[0149] 100 Secondary battery manufacturing system 111 Unwinder 113 Rewinder 115B Die Coater 115T Die Coater 121 1st rotary encoder 123 Second rotary encoder 131 Measuring Instruments 131P processor, processing unit 131S Sensing unit 133 Inspection equipment 133P processor, processing unit 133S Sensing unit 135B Coating Sensor 135T Coating Sensor 141 First Controller 143 Second Controller 150 Input Device 160 servers 170 First Server 180 User equipment, client equipment BC Lower Coating BCD lower coating data BCS Lower Coating Detection Signal CD coordinate data CID coordinate related inspection data EP plate EPB bottom side EPT top surface ER1 First electrode roll ER2 Second electrode roll ES electrode sheet IS test signal LB lower land lane LT Upper Land Lane MD running direction MID Manual Input Data MS measurement signal PMD measurement data TC top coating TCD Top Coating Data TCS upper coating detection signal TD: Transverse (or width) direction UCB plain section UCT plain area UWAS direct input amount signal UWAS input amount signal WAS depletion signal

Claims

1. collecting data from the electrode sheet on which the electrode process is performed; Calculating a production volume, which is the length of the portion of the electrode sheet that has been subjected to the electrode process; and calculating the amount of loss and defect of the electrode sheet.

2. the electrode process includes forming an upper coating on an upper surface of a plate of the electrode sheet and a lower coating on a lower surface of the plate opposite the upper surface; The method for manufacturing a secondary battery according to claim 1 , wherein portions of the electrode sheet spaced apart from each of the upper coating and the lower coating are excluded from the production volume.

3. the electrode process includes forming an upper coating on an upper surface of a plate of the electrode sheet and a lower coating on a lower surface of the plate opposite the upper surface; The method of manufacturing a secondary battery according to claim 1 or 2, wherein a portion of the electrode sheet including either the upper coating or the lower coating is added to the production volume.

4. the electrode process includes forming an upper coating on an upper surface of a plate of the electrode sheet and a lower coating on a lower surface of the plate opposite the upper surface; The method for manufacturing a secondary battery according to claim 1 or 2, wherein the first portion of the electrode sheet including the upper coating and spaced apart from the lower coating is added to the loss amount.

5. the electrode process includes forming an upper coating on an upper surface of a plate of the electrode sheet and a lower coating on a lower surface of the plate opposite the upper surface; The method for manufacturing a secondary battery according to claim 1 or 2, wherein a second portion of the electrode sheet that is spaced apart from the upper coating and includes the lower coating is added to the loss amount.

6. The method for manufacturing a secondary battery according to claim 1 or 2, wherein the defect amount is a length of the electrode sheet including the defect.

7. the defect amount is calculated based on measurement data of the compressed electrode sheet, 3. The method for manufacturing a secondary battery according to claim 1, wherein the compressed measurement data includes a determination value calculated based on raw measurement data and coordinates matched to the determination value.

8. the defect amount is calculated based on coordinate-related inspection data of the electrode sheet; The method for manufacturing a secondary battery according to claim 1 or 2, wherein the coordinate-related inspection data includes a judgment value indicating a defect and coordinates that match the judgment value.

9. 3. The method for manufacturing a secondary battery according to claim 1, further comprising the step of calculating a non-defective quantity, which is the length of a normal portion of the electrode sheet, based on the production quantity, the loss quantity, and the defective quantity of the electrode sheet.

10. The method for manufacturing a secondary battery according to claim 9 , wherein the total of the amount of non-defective products, the amount of losses, and the amount of defective products is the same as the production amount.

11. collecting data from an electrode sheet undergoing a coating process in which an upper coating is formed on an upper surface of a plate of the electrode sheet and a lower coating is formed on a lower surface of the plate of the electrode sheet, the data including upper coating data indicative of the upper coating, lower coating data indicative of the lower coating, and coordinate-related inspection data of the electrode sheet; calculating a production amount based on the top coating data and the bottom coating data; Calculating an exclusion amount of the electrode sheet; and calculating a quantity of non-defective products, which is the quantity of normal portions of the electrode sheet, based on the production quantity and the rejected quantity.

12. The method of manufacturing a secondary battery according to claim 11 , wherein a portion of the electrode sheet including either the upper coating or the lower coating is added to the production volume.

13. The method of manufacturing a secondary battery according to claim 11 , wherein a portion of the electrode sheet including only one of the upper coating and the lower coating is added to the excluded amount.

14. the coordinate-related inspection data includes a judgment value indicating a defect and coordinates that match the judgment value; The method of manufacturing a secondary battery according to claim 11 , wherein a defect amount, which is a length of the electrode sheet including defects calculated based on the coordinate-related inspection data, is added to the exclusion amount.

Images