A role map generation system and a method for generating role maps.

Abstract

According to exemplary embodiments of the present invention, a method for generating a roll map is provided. The method includes the steps of collecting coordinate data and measurement data of an electrode sheet, and generating compressed measurement data based on the measurement data, wherein the measurement data is collected by scanning sections of the electrode sheet.

Description

Technical Field

[0001] The present invention relates to a system configured to generate a roll map representing a lot, which is a unit of a wound electrode sheet, and a method for generating a roll map. This application claims the benefit of Korean Application No. 10-2023-0102299, filed on Aug. 4, 2023, which is hereby incorporated by reference in its entirety.

Background Art

[0002] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. Secondary batteries are widely used as an energy source for various cordless devices such as handsets, notebook computers, and cordless vacuum cleaners. In recent years, due to improvements in energy density and economies of scale, the manufacturing cost per unit capacity of secondary batteries has decreased dramatically, and as the cruising range of battery electric vehicles (BEVs) has increased to a level comparable to that of fuel vehicles, the main application of secondary batteries has shifted from mobile devices to mobility.

[0003] Secondary batteries are manufactured through an electrode process, an assembly process, and an activation process. Among them, the electrode process is the most crucial process for determining the yield and performance of battery cells. The electrode process can include a coating process, a roll pressing process, and a slitting process. In the coating process, an active material and an insulating material can be applied onto the surface of a current collector. In the roll pressing process, the electrode can be pressed by a pressure roll. The roll pressing process can determine the density, performance, and surface quality of the electrode. In the slitting process, the electrode can be cut into a plurality of electrodes according to the design of the battery cell.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The technical concept of this invention aims to solve is to provide a system configured to generate a roll map containing information on the quality and defects of the electrode manufacturing process. [Means for solving the problem]

[0005] According to an exemplary embodiment of the present invention for solving the above-mentioned problems, a method for generating a roll map is provided. The method includes the steps of collecting coordinate data of an electrode sheet and measurement data of the electrode sheet, and generating compressed measurement data based on the measurement data, wherein the measurement data is collected by scanning sections of the electrode sheet.

[0006] The above measurement data includes either the loading amount data of the coating material on the electrode sheet or the thickness data of the electrode sheet.

[0007] The compressed measurement data described above includes the average of the measurement data for the above section of the electrode sheet.

[0008] The above average is calculated from a portion of the measurement data.

[0009] The electrode sheet described above includes a coated portion to which the coating substance described above is applied, and the average is calculated from a portion of the measurement data corresponding to the coated portion.

[0010] The process further includes a step of calibrating the above measurement data by adding an offset measurement to each of the measured values ​​in the above measurement data.

[0011] The step further includes determining the start and end coordinates of the above section of the electrode sheet.

[0012] The above-mentioned section of the electrode sheet includes an extra-electrode region in which the sensing unit of a measuring instrument configured to collect the above-mentioned measurement data senses a portion horizontally separated from the electrode.

[0013] The above-mentioned section of the electrode sheet includes a turnaround region in which the sensing unit changes the scanning direction.

[0014] According to an exemplary embodiment, a method for generating a roll map is provided. The method includes the steps of: collecting first coordinate data and first measurement data of a first section of an electrode sheet; and determining a first mean of a portion of the first measurement data, a first start coordinate of the first section, and a first end coordinate of the first section based on the first coordinate data and the first measurement data, wherein the first measurement data is collected by scanning the first section.

[0015] The above method further includes the steps of: collecting second coordinate data and second measurement data of a second section connected to the first section of the electrode sheet; and determining a second average of the portion of the second measurement data, a second start coordinate of the second section, and a first end coordinate of the second section based on the second coordinate data and the second measurement data.

[0016] The second measurement data described above is collected by scanning the second section described above.

[0017] The second starting coordinates mentioned above are the same as the first ending coordinates mentioned above.

[0018] According to an exemplary embodiment, a roll map generation system is provided. The system includes a roll map PLC (Programmable Logic Controller) configured to collect coordinate data of an electrode sheet based on a winding amount signal of the electrode sheet generated by a rotary encoder, wherein the rotary encoder is configured to sense the length of the electrode sheet wound by a rewinder to generate the winding amount signal, and the coordinate data indicates a position on the electrode sheet; and a measuring instrument including a sensing unit and a processing unit, wherein the sensing unit is configured to scan each of a plurality of sections of the electrode sheet to collect measurement data of the electrode sheet, and the processing unit is configured to collect the measurement data based on a measurement signal generated by the sensing unit, wherein the processing unit is configured to generate compressed measurement data based on the measurement data, and the size of the compressed measurement data is even smaller than the size of the measurement data.

[0019] The compressed measurement data described above includes the average of the portion of the measurement data for each of the multiple sections of the electrode sheet described above.

[0020] The processing unit described above is configured to determine the start and end coordinates of each of the multiple sections of the electrode sheet. [Effects of the Invention]

[0021] According to exemplary embodiments of the present invention, a system can be provided for generating a roll map that enables feedback, feedforward, and tracking of an electrode process.

[0022] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by those having ordinary knowledge in the technical field to which the exemplary embodiments of the present disclosure belong from the following description. That is, unintended effects associated with implementing the exemplary embodiments of the present disclosure can also be derived by those having ordinary knowledge in the technical field from the exemplary embodiments of the present disclosure.

Brief Description of the Drawings

[0023] [Figure 1] Shows a roll map generation system according to an exemplary embodiment. [Figure 2] It is a flowchart showing a method for generating a roll map according to an exemplary embodiment. [Figure 3] Shows the measurement of an electrode sheet by a measuring instrument. [Figure 4] Shows sections of an electrode sheet. [Figure 5] Shows measurement data generated from the sections. [Figure 6] Shows a visualized roll map. [Figure 7] Shows sections of an electrode sheet.

Mode for Carrying Out the Invention

[0024] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Before that, terms and words used in this specification and the claims should not be construed as being limited to their ordinary or dictionary meanings, but should be construed as meanings and concepts consistent with the technical idea of the present invention based on the principle that the inventor can appropriately define the concept of the terms in order to explain his own invention in the best way.

[0025] Therefore, the embodiments described herein and the configurations shown in the drawings represent only one of the most preferred embodiments of the present invention and do not represent the entire technical concept of the present invention; there may be a variety of equivalents and modifications that can substitute for them at the time of filing.

[0026] Furthermore, in describing the present invention, if it is determined that a specific description of a related known configuration or function would likely obscure the gist of the invention, such detailed description will be omitted.

[0027] Embodiments of the present invention are provided to give a more complete explanation to an ordinary person of the art; therefore, the shapes and sizes of components in the drawings may be exaggerated, omitted, or shown schematically for the sake of clarity. Accordingly, the sizes and proportions of each component do not fully reflect their actual sizes and proportions.

[0028] (First embodiment: apparatus, Second embodiment: method) Figure 1 shows a secondary battery manufacturing system 10 according to an exemplary embodiment.

[0029] Figure 2 is a flowchart showing a method for generating a role map according to an exemplary embodiment.

[0030] Figure 3 shows the measurement of the electrode sheet ES by the measuring instrument 130.

[0031] Figure 4 shows section S1 of the electrode sheet ES.

[0032] Figure 5 shows the measurement data MD generated from interval S1.

[0033] Referring to Figures 1 to 5, the secondary battery manufacturing system 10 may include an unwinder 111, a rewinder 113, a processing device 115, a first rotary encoder 121, a second rotary encoder 123, a measuring instrument 130, a first controller 141, a second controller 143, a server 210, a server 220, and a user device 300.

[0034] The secondary battery manufacturing system 10 can be configured to generate a roll map containing data about the electrode sheet ES. The roll map can represent the electrode sheet ES based on coordinate values ​​indicating its position on the electrode sheet ES. Processes for manufacturing a secondary battery can be performed on the electrode sheet ES. The roll map can represent the history of processes performed on the electrode sheet ES and may include data related to coordinates. This allows the roll map to enable feedback, feedforwarding, and tracking of the secondary battery manufacturing process, as described later.

[0035] The first electrode roll ER1, which has undergone a previous process, can be loaded onto the unwinder 111. The unwinder 111 can unwind the electrode sheet ES from the first electrode roll ER1. The rewinder 113 can wind the electrode sheet ES to form the second electrode roll ER2. This allows the electrode sheet ES to move between the unwinder 111 and the rewinder 113. Since the electrode process is performed on the electrode sheet ES that is unwound from the first electrode roll ER1 and wound onto the second electrode roll ER2, the electrode process can also be called a roll-to-roll process.

[0036] Roll maps can be generated in lot units. The electrode sheet ES can be wound onto the second electrode roll ER2 and cut and separated after reaching a predetermined winding length. A lot is a production unit of a roll-to-roll process, and the separated second electrode roll ER2 is an example of a lot. This allows the server 220 to save the roll map of the previous process. The roll map of the previous process can correspond to the first electrode roll ER1. The server 220 can also generate and save the roll map of the current process. The roll map of the current process can correspond to the second electrode roll ER2.

[0037] Time-series data, structured according to the flow of time in the roll map (i.e., according to the progress of the process), can be associated with coordinate data CD collected based on the amount of movement of the electrode sheet ES (i.e., either the winding amount or the unwinding amount).

[0038] The manufacturing of secondary batteries involves a series of distinct processes, where the leading process influences the following process. In this context, it is difficult to reflect the time-series data of the leading process in the following process if it does not directly match the actual workpieces, semi-finished products, and finished products in the real world. Below, we will refer to the correction of the following process based on data generated according to the results of the leading process as feedforward.

[0039] Here, "workpiece" refers to an article provided as a result of each process, such as an electrode sheet ES, which has undergone the coating, roll pressing, and slitting processes shown in Figure 1. "Semi-finished product" can refer to one of the following: a separation membrane cut by the notching process, an electrode, or an assembly thereof. A semi-finished product may also be a structure including a housing and an electrode assembly housed within the housing (in some cases, the structure further includes an electrolyte). "Product" refers to an article processed by the activation process to be operational as a secondary battery. The above definitions of workpiece, semi-finished product, and product relate to one aspect of them and do not preclude the usual definitions of them.

[0040] The electrode manufacturing process for secondary batteries involves a series of roll-to-roll processes. For feedforwarding, time-series data needs to be associated with the locations of real-world workpieces, parts, semi-finished products, and finished products. A roll map can associate time-series data with coordinate data that includes coordinate values ​​indicating the locations of real-world workpieces, parts, semi-finished products, and finished products. Based on the coordinate data, the roll map can provide a matching between time-series data and real-world workpieces, parts, semi-finished products, and finished products. Thus, the generation of roll maps and feedforwarding based on roll maps can improve the productivity and quality of secondary battery manufacturing processes by quantifying and objectifying aspects of the process that were previously dependent on the arbitrary actions of the workers. Furthermore, roll maps of preceding lots can also be used to improve processes for subsequent lots, and such operation can be called process feedback. Process feedback using roll maps can include identifying process conditions and process parameters that cause problems and defects based on the data contained in the roll maps.

[0041] Furthermore, as described later, roll maps are generated cumulatively for the workpieces, parts, semi-finished products, and finished products of each unit process, allowing for the tracking of process history for shipped products (e.g., battery cells, battery modules, or battery packs). For example, a battery cell may include a cell ID formed on the electrode assembly or case. The cell ID may include lot numbers and coordinate information for the electrodes and separators contained in the battery cell. In other words, the cell ID can be associated with a roll map of the electrodes and separators contained in the battery cell. This allows historical data of the manufacturing of a battery cell to be retrieved based on the cell ID in order to find the cause of a problem in the manufacturing process if an event such as a quality issue occurs in a battery cell that has already been shipped.

[0042] The electrode sheet ES can be processed by a processing device 115. For example, the processing device 115 may include a coater, which can coat the electrode sheet ES with electrode slurry. Alternatively, the processing device 115 may include a pressure roll, which can perform a roll pressing process on the electrode sheet ES coated with electrode slurry. Another example is the processing device 115, which may include a splicing die and a scrap port, which can scrap portions of the electrode sheet ES. Finally, the processing device may include a slitting knife, which can separate the electrode sheet ES into multiple electrode sheets.

[0043] The coating process involves applying a coating material, such as an electrode slurry, onto an electrode sheet ES. The electrode slurry can include an electrode active material, a conductive material, a binder, and a solvent. An electrode slurry can be provided by dissolving the electrode active material, conductive material, binder, etc., in a solvent.

[0044] The roll pressing process involves passing electrode sheets ES coated with electrode slurry between two opposing pressure rolls. The pressure rolls flatten the electrode surface, increasing the bonding force between the active material and the current collector.

[0045] To increase the production volume per line (e.g., GWh) of a secondary battery production facility, a coating process and a roll pressing process are performed on the wide electrode sheet ES. In a subsequent slitting process, the wide electrode sheet ES can be cut according to the specifications of the battery cell.

[0046] At P110, coordinate data CD and measurement data can be collected. Coordinate data CD can be collected by the roll map PLC141.

[0047] The first rotary encoder 121 can be configured to sense the amount of electrode sheet ES unwound from the first electrode roll ER1 by the unwinder 111. This allows the first rotary encoder 121 to generate an unwound amount signal UWAS indicating the amount of electrode sheet ES unwound. The first rotary encoder 121 can be configured to transmit the unwound amount signal UWAS to the roll map PLC 141. The roll map PLC 141 can be configured to collect unwound amount data based on the electrode sheet ES unwound amount signal UWAS.

[0048] The second rotary encoder 123 can be configured to sense the amount of electrode sheet ES wound onto the second electrode roll ER2 by the rewinder 113. This allows the second rotary encoder 123 to generate a winding amount signal WAS indicating the amount of electrode sheet ES wound. The second rotary encoder 123 can be configured to transmit the winding amount signal WAS to the roll map PLC 141. The roll map PLC 141 can be configured to collect winding amount data based on the winding amount signal WAS of the electrode sheet ES.

[0049] The electrode sheet ES may be scrapped in some cases, which may result in the amount of electrode sheet ES wound up by the unwinder 111 being different from the amount of electrode sheet ES wound up by the rewinder 113. Also, if the electrode sheet ES is stretched by pressure during the roll pressing process, the amount of electrode sheet ES wound up by the unwinder 111 may be different from the amount of electrode sheet ES wound up by the rewinder 113.

[0050] The roll map PLC141 can be configured to collect coordinate data CD of the electrode sheet ES based on either the winding amount signal WAS or the unwinding amount signal UWAS of the electrode sheet ES. For example, the roll map PLC141 can determine the distance the electrode sheet ES traveled in the current process step based on the winding amount signal of the electrode sheet ES. This allows for the determination of coordinate values ​​indicating the relative position within the electrode sheet ES of the portion of the electrode sheet ES being wound by the rewinder 113 at each point in time during the coating process. The technical concept of the present invention will be described below, focusing on an embodiment in which the roll map PLC141 collects coordinate data CD based on the winding amount signal WAS of the electrode sheet ES.

[0051] The coordinate data CD may include coordinate values ​​that match each part of the electrode sheet ES. That is, each of any points on the electrode sheet ES can be matched with a coordinate value. The coordinate value may be, but is not limited to, a one-dimensional quantity in the X direction, which is the direction of travel of the electrode sheet ES (or the longitudinal direction of the electrode sheet ES). The coordinate value may also be a two-dimensional quantity in the X direction and the Y direction, which is the lateral direction (or the width direction of the electrode sheet ES).

[0052] To describe the movement of the electrode sheet ES and the movement of the sensing part of the measuring instrument 130, we define the +X, -X, +Y, and -Y directions. The +X and -X directions are opposite to each other, and the +Y and -Y directions are opposite to each other. Each of the ±X directions may be substantially perpendicular to each of the ±Y directions. The ±X directions may also be simply called the X directions, and the ±Y directions may also be simply called the Y directions.

[0053] The measuring instrument 130 can be configured to measure the electrode sheet ES in order to collect measurement data of the electrode sheet ES. The measuring instrument 130 can measure the electrode sheet ES in a scanning manner. During scanning by the measuring instrument 130, the measuring instrument 130 can be moved in the ±Y direction. While the measuring instrument 130 is scanning in the ±Y direction, the electrode sheet ES can be moved in the +X direction by the unwinder 111 and the rewinder 113.

[0054] During a single scan, the sensing unit 131 of the measuring instrument 130 can move in the -Y direction from one end to the other of the electrode sheet ES, or in the +Y direction from the other end to one end of the electrode sheet ES. Due to the movement of the electrode sheet ES, the sensing unit 131 of the measuring instrument 130 can move in the -X direction relative to the electrode sheet ES.

[0055] The arrows AR1, AR2, and AR3 in Figures 3 and 4 indicate the relative movement of the sensing unit 131 of the measuring instrument 130 with respect to the electrode sheet ES. Arrow AR1 corresponds to the -Y direction scanning of the sensing unit 131, and arrow AR2 corresponds to the +Y direction scanning of the sensing unit 131. After each scanning is completed, a set time is allowed for the sensing unit 131 to change its direction of movement. Arrow AR3 indicates the relative movement of the sensing unit 131 due to the movement of the electrode sheet ES while the sensing unit 131 is changing direction.

[0056] The measurement data may include multiple numerically represented measurement values. For example, the measurement data may include dimensional data of the electrode sheet ES such as thickness and width, loading amount data of the coating material on the electrode sheet ES, dimensional data such as the width of the insulating material provided on the coating material and the overlap width between the coating material and the insulating material, and mismatch data between the coating lane on the upper surface of the electrode sheet ES and the coating lane on the lower surface of the electrode sheet ES. Here, the loading amount represents the amount of coating material loaded per unit area of ​​the electrode sheet ES and may be the area density of the coating material.

[0057] The measurement data is processed according to a set method to determine whether the measured portion of the electrode sheet ES is good or bad. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is within a set range including upper and lower limits, the corresponding portion of the electrode sheet ES can be determined to be good. If the measured amount of coating material on the electrode sheet ES (e.g., the loading amount on the electrode sheet ES or the thickness of the electrode sheet ES) is less than the lower limit or greater than the upper limit, the corresponding portion of the electrode sheet ES can be determined to be defective.

[0058] The measuring instrument 130 may include a sensing unit 131 and a processing unit 133. The sensing unit 131 may be configured to sense a physical quantity of an electrode sheet ES to generate a measurement signal MS. For example, the sensing unit 131 may include a TDI (Time Delay and Integration) camera, a CMOS (Complementary Metal Oxide Semiconductor) image sensor, and a TOF (Time of Flight) sensor. The sensing unit 131 may also include an emitter and receiver configured to perform measurements using non-destructive signals such as ultrasound, microwaves, terahertz waves, and infrared rays. The sensing unit 131 may also include analog and / or digital sensors such as biosensors, chemical sensors, composition sensors, current and / or power meters, air quality sensors, gas sensors, Hall effect sensors, brightness level sensors, and light sensors. The measuring instrument 130 may also include pressure sensors, temperature sensors, ultrasonic sensors, proximity sensors, door condition sensors, motion tracking sensors, humidity sensors, visible light sensors, infrared sensors, and cameras.

[0059] The technical concept of the present invention will be described below in non-limiting examples, focusing on embodiments in which the instrument 130 is a loading amount measuring instrument (e.g., a web gauge from Thermo Fisher Scientific) configured to measure the loading amount of a coating layer on a sheet material SM, and embodiments in which the instrument 130 is a thickness measuring instrument configured to measure the thickness of the sheet material SM. Based on what has been described herein, ordinary articulators of the art will readily arrive at embodiments in which the instrument includes any one of the sensors described above and the instrument is configured to sense any one of the quantities described above.

[0060] The secondary battery manufacturing system 10 may further include an inspector configured to inspect the electrode sheet ES to collect inspection data. The inspection data may include quality judgments and process events related to parts of the electrode sheet ES. For example, the inspection data may include appearance data of the electrode sheet ES collected by an image-based inspection device such as a vision machine, data on breaks and seams of the electrode sheet ES, data on parts of the electrode sheet ES that have been sampled, data on parts of the electrode sheet ES that are scheduled to be scrapped, data on scrapped parts of the electrode sheet ES, data on the quality of the coating and insulating materials on the electrode sheet ES, data on reference points indicating the location 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, puncture defects, and indentation defects. Reference points may be formed at predetermined intervals on the electrode sheet ES, and the location of other elements on the electrode sheet ES may be known based on the reference points. The inspector may be any one of a color sensor, a seam sensor, a reference point sensor, and a vision machine.

[0061] The measuring instrument 130 may be configured to collect two or more types of data. For example, the measuring instrument 130 may be configured to measure the thickness of the electrode sheet ES and the 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). Alternatively, the measuring instrument 130 may be configured to sense a reference point on the electrode sheet in addition to measuring the mismatch of the electrode sheet ES.

[0062] The measurement and inspection data described above may be time-series data. Temporal ordering is a key characteristic of time-series data, where events are organized in the order in which they occur and arrive for processing. That is, measurement and inspection data can be stored based on the time at which the measurement and inspection were performed, and thus can be associated with time. This allows each measurement value in the measurement data to be time-matched, and each inspection value in the inspection data to be time-matched.

[0063] As an example, measurement data (e.g., loading amount on electrode sheet ES or thickness of electrode sheet ES) may have a series of measurement values ​​(e.g., loading amount on electrode sheet ES or thickness of electrode sheet ES) and time values ​​associated with the series of loading value values. The loading value and time value can, but are not limited to, a one-to-one matching. As another example, defect data may have a value indicating a defect and time values ​​associated with the value indicating a defect. Here, indicating a defect means including information about at least one of the following: the presence or absence of a defect and the type of defect.

[0064] The processing unit 133 can be configured to collect the measurement signal MS sensed by the sensing unit 131 in order to generate measurement data. The processing unit 133 can be connected to the sensing unit 131 by wire or wireless connection. The processing unit 133 can be configured to calibrate the measurement data by adding an offset measurement to each of the multiple measurement values ​​of the measurement data. Due to process progression and equipment aging, the measurement values ​​of the measurement data may differ from the actual values. By calibrating the measurement data based on the offset measurement, the processing unit 133 can improve the reliability of the system 10 and the method for generating the roll map. The offset measurement can be determined based on known information about the equipment system by methods such as sample testing.

[0065] The rollmap PLC 141 may be in operative communication with the first rotary encoder 121, the second rotary encoder 123, the measuring instrument 130, additional measuring instruments, and additional testers via a wired or wireless data network. The data network may be unidirectional or bidirectional. The data network may be embodied by a public network and / or specialized network using a physical channel, WiFi, Bluetooth®, and / or other frequency bands. The first rotary encoder 121, the second rotary encoder 123, the measuring instrument 130, additional measuring instruments, and additional testers may be configured to collect data from equipment, workpieces, semi-finished products, and finished products within the secondary battery manufacturing system 10, or to generate signals for data collection.

[0066] The roll map PLC 141 can be configured to transmit coordinate data CD to the processing unit 133. The processing unit 133 can be configured to associate measurement data with the coordinate data CD to generate coordinate-related measurement data. Generally, measurement data can be processed based on trigger points. Examples of measurement data processing may include saving the measurement data, manipulating the measurement data (e.g., generating coordinate-related measurement data), and transmitting the measurement data.

[0067] As an unrestrictive example, the trigger point for processing measurement data may be the completion of scanning. For example, the sensing unit 131 can scan the electrode sheet ES in the width direction, and the measurement data can be saved, processed, modulated, and transmitted after each scan. In other examples, the trigger point may be the completion of multiple scans, or the completion of a portion of a scan.

[0068] The electrode sheet ES can be divided into multiple sections S1, S2, S3, S4, S5, and S6 based on scanning by the sensing unit 131 of the measuring instrument 130. Each of the multiple sections S1, S2, S3, S4, S5, and S6 can correspond to one scan by the sensing unit 131. The dashed lines in Figure 3 are virtual boundaries between the multiple sections S1, S2, S3, S4, S5, and S6.

[0069] As shown in Figure 4, the first section S1 may include a turnaround region (TAR), an extraelectrode region (EER), and an electrode region (ER).

[0070] The electrode region ER corresponds to the electrode sheet ES that was actually scanned within section S1. The turnaround region TAR corresponds to the portion of the electrode sheet ES that passed through the sensing unit 131 in the +X direction during the direction change of the sensing unit 131.

[0071] The stroke width SW, which is the distance the sensing unit 131 moves during a single scan, may be wider than the width EW of the electrode sheet ES. This allows the sensing unit 131 to measure the outside of the electrode sheet ES for a predetermined time interval after each scan. The electrode outer region EER corresponds to the portion of the electrode sheet ES that the sensing unit 131 passes through in the +X direction while the sensing unit 131 is outside the electrode sheet ES.

[0072] Here, the statement that the sensing unit 131 is outside the electrode sheet ES means that the sensing unit 131 is separated from the electrode sheet ES horizontally (for example, in the ±Y direction) and that the sensing unit 131 and the electrode sheet ES do not overlap in a direction perpendicular to the electrode sheet ES.

[0073] Sections S2, S3, S4, S5, and S6, like section S1, may include a turnaround region (TAR), an extra-electrode region (EER), and an electrode region (ER).

[0074] According to an exemplary embodiment, the measuring instrument 130 may be configured to calibrate the coordinate data CD based on the position of the measuring instrument 130. More specifically, the measuring instrument 130 may be configured to associate the coordinate values ​​of the coordinate data CD with the measured values ​​of the measurement data by calibrating the coordinate data CD based on the offset length OD.

[0075] The measuring instrument 130 can collect measurement data for the portion corresponding to (for example, overlapping) the sensing unit 131, and the coordinate data CD is collected by the second rotary encoder 123 which is separated from the sensing unit 131 as described above. Therefore, the portion of the electrode sheet ES corresponding to the coordinate data CD and the portion of the electrode sheet ES corresponding to the measurement data may be different at the same time.

[0076] In P120, compressed measurement data PMD can be generated. The compressed measurement data PMD can be generated by the processing unit 133.

[0077] According to an exemplary embodiment, the processing unit 133 can calculate representative values ​​of the measured values ​​of the measurement data to collect compressed measurement data PMD, calibrate coordinate data CD collected at the same time as the measurement data based on the offset length OD, and associate the calibrated coordinate data CD with the representative values ​​of the measurement data. The measured values ​​of the measurement data can be matched with time, and representative values ​​(e.g., averages) of the compressed measurement data PMD can be matched with calibrated coordinate values ​​(e.g., start coordinates and end coordinates).

[0078] As another example, the sensing unit 131 may be directly connected to position measuring instruments such as a first rotary encoder 121 and a second rotary encoder 123, and may be configured to sense a reference point on the electrode sheet ES. In this case, the sensing unit 131 may collect coordinate data CD in addition to measurement data. In this case, the processing unit 133 may be configured to collect coordinate-related measurement data based on the measurement data and coordinate data CD transmitted from the sensing unit 131.

[0079] Multiple guide rolls can be interposed between the sensing unit 131 and the rewinder 113 to define the movement path of the electrode sheet ES. This allows the offset length OD to be defined as the length of the electrode sheet ES between the sensing unit 131 and the rewinder 113, corresponding to the movement path of the electrode sheet ES. The offset length OD may be the same as the straight-line distance between the sensing unit 131 and the rewinder 113, or it may be longer than the straight-line distance between the sensing unit 131 and the rewinder 113.

[0080] The size (i.e., capacity) of the compressed measurement data PMD may differ from the size (i.e., capacity) of the measurement data. The size (i.e., capacity) of the compressed measurement data PMD may even be smaller than the size (i.e., capacity) of the measurement data. This helps prevent overloading of server 210.

[0081] The representative values ​​of the compressed measurement data PMD may include at least one of the mean, standard deviation, median, maximum, and minimum values ​​of the measurement data for each of the multiple intervals S1, S2, S3, S4, S5, and S6. The mean, standard deviation, median, maximum, and minimum values ​​can be calculated from portions of the measurement data.

[0082] More specifically, the measurement data may include portions P1, P2, P3, P4, and P5. Portions P1 and P5 are measurement data generated from the uncoated portion (i.e., the uncoated area) of the electrode sheet ES and can be excluded from the generation of the compressed measurement data PMD. Portions P2 and P4 may be measurement data generated from the boundary between the uncoated and coated portions (i.e., the coated area). As a result, the data from portions P2 and P4 may be excluded from the generation of the compressed measurement data PMD because it may distort the compressed measurement data PMD. Portions P1 and P5 may each be called the first exclusion portion, and portions P2 and P4 may be called the second exclusion portion.

[0083] The compressed measurement data PMD can be generated based on portion P3 of the measurement data MD. Therefore, portion P3 of the measurement data MD may also be called the effective region.

[0084] If a set number of consecutive data points in the measurement data exceed a threshold value, the data points following these points can be classified as coated areas. Similarly, if a set number of consecutive data points below a threshold value in the measurement data can be classified as uncoated areas.

[0085] The compressed measurement data PMD may further include judgment values. These judgment values ​​can be determined by the processing unit 133. The judgment values ​​can be determined separately for each of the multiple intervals S1, S2, S3, S4, S5, and S6. The judgment values ​​for each of the multiple intervals S1, S2, S3, S4, S5, and S6 of the electrode sheet ES can be determined based on a comparison between a set range and the measured value (or average).

[0086] For example, a measurement (or average) within the first range can be determined to be normal, a measurement (or average) within the second range (larger than the first range) can be determined to be excessive, a measurement (or average) within the third range (larger than the second range) can be determined to be very excessive, a measurement (or average) within the fourth range (smaller than the first range) can be determined to be insufficient, and a measurement (or average) within the fifth range (smaller than the fourth range) can be determined to be very insufficient.

[0087] Here, if the lower limit of the second range is greater than or equal to the upper limit of the first range, then the second range is greater than the first range. Similarly, if the upper limit of the fourth range is less than or equal to the lower limit of the first range, then the fourth range is less than the first range.

[0088] The compressed measurement data PMD can include start and end coordinates. It can also include start and end coordinates for multiple sections S1, S2, S3, S4, S5, and S6 of the electrode sheet ES. The processing unit 133 can be configured to determine the start and end coordinates for each of the multiple sections S1, S2, S3, S4, S5, and S6. The multiple sections S1, S2, S3, S4, S5, and S6 can be sequentially arranged and connected to each other.

[0089] According to an exemplary embodiment, the start and end coordinates of each of the multiple sections S1, S2, S3, S4, S5, and S6 can be determined based on scanning by the sensing unit. More specifically, the end coordinates of each of the multiple sections S1, S2, S3, S4, S5, and S6 may be the position of the sensing unit 131 relative to the electrode sheet ES at the end of scanning by the sensing unit 131. The end coordinates of the preceding section among the multiple sections S1, S2, S3, S4, S5, and S6 may be the start coordinates of the subsequent section.

[0090] For example, X1 could be the starting coordinate of interval S1. X2 could be the ending coordinate of interval S1 and could be the starting coordinate of interval S2. X3 could be the ending coordinate of interval S2 and could be the starting coordinate of interval S3. X4 could be the ending coordinate of interval S3 and could be the starting coordinate of interval S4. X5 could be the ending coordinate of interval S4 and could be the starting coordinate of interval S5. X6 could be the ending coordinate of interval S5 and could be the starting coordinate of interval S6. X7 could be the ending coordinate of interval S6 and could be the starting coordinate of interval S7.

[0091] Unlike the above, where each of the multiple sections S1, S2, S3, S4, S5, and S6 of the electrode sheet ES corresponds to one scan of the sensing unit 131, each of the multiple sections of the electrode sheet ES may correspond to multiple scans of the sensing unit 131, or it may correspond to a portion of a single scan of the sensing unit 131.

[0092] At P130, a transmission command SCD can be generated. The transmission command SCD can be generated by the processing unit. The processing unit 133 can be configured to generate the transmission command SCD and transmit the transmission command SCD to the roll map PLC 141. The processing unit 133 can be configured to transmit compressed measurement data PMD to the roll map PLC 141.

[0093] The roll map PLC141, upon receiving the transmission command SCD, can be configured to transmit the compressed measurement data PMD to the second controller 143.

[0094] The compressed measurement data PMD transmitted to the second controller 143 can be transmitted to the server 220 via the second controller 143 and the server 210. The second controller 143 and the server 210 can relay the communication of the compressed measurement data PMD between the server 220 and the rollmap PLC 141. However, it is not limited to this, and the rollmap PLC 141 can also transmit the compressed measurement data PMD directly to the server 220.

[0095] The second controller 143 can be configured to control the operation of the unwinder 111, the rewinder 113, and the processing device 115. The second controller 143 can be configured to generate signals for the operation and interruption of the unwinder 111, the rewinder 113, and the processing device 115. The signals for the operation and interruption of the unwinder 111, the rewinder 113, and the processing device 115 can be generated based on a body containing product ID and manufacturing recipe details.

[0096] For process control, a communication line can be installed between the second controller 143 and the server 220 via the server 210. This allows for data transmission via the second controller 143 to save resources required for installing a communication line and streamline data processing and management compared to the case where the first rotary encoder 121, the second rotary encoder 123, and the measuring instrument 130 directly transmit the unwind amount signal UWAS, the winding amount signal WAS, and the measurement signal MS to the server 220, compared to the case where the first controller 141 directly transmits compressed measurement data PMD to the server 220.

[0097] As an unrestrictive example, the first controller 141 and the second controller 143 could be PLCs (Programmable Logic Controllers). A PLC is a special form of microprocessor-based controller that uses programmable memory to store instructions and controls machines and processes by embodying functions such as logic, sequencing, timing, counting, and arithmetic. PLCs are easy to operate and program.

[0098] 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 the CPU, input interface, output interface, communication interface, and other components of the first controller 141 and the second controller 143, such as the memory device. The memory device may include a ROM (Read Only Memory) configured to store system programs such as an operating system, and a RAM (Random Access Memory) 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 control communication between modules that embody logic and convert input signals into output operation signals. The CPU may operate based on system programs and user programs stored in the memory device. The CPU may be configured to write or read inspection data and measurement data to or from the data area of ​​the memory device based on system programs and user programs. Conditions and data of industrial equipment and production processes may be transmitted to the CPU via input modules. The results processed by the CPU can be transmitted to the actuator via the output module. The communication interface can be configured to send and receive data between the first controller 141 and the second controller 143, or between the second controller 143 and the server 210.

[0099] However, the first controller 141 and the second controller 143 may also include any one of the following: a simple controller, a microprocessor, a complex processor such as a CPU or GPU, a processor composed of software, dedicated hardware, and firmware. The first controller 141 and the second controller 143 can be embodied, for example, by a general-purpose computer or application-specific hardware such as a DSP (Digital Signal Processor), FPGA (Field Programmable Gate Array), and ASIC (Application Specific Integrated Circuit).

[0100] The compressed measurement data PMD can be transmitted to server 220 via server 210. Server 210 may be a communication server. Server 210 may, for example, be a server for communication of a log database, but is not limited to this. Server 210 may be a program for communication between the second controller 143 of the manufacturing equipment and server 220 for manufacturing management. Server 210 may also be implemented in hardware, as described later. The language and protocol of server 220 may differ from the language and protocol of the second controller 143. For example, the language of server 220 may be SQL, and the language of the second controller 143 may be a ladder diagram.

[0101] Server 210 can be configured to convert electrode specification data ESD transmitted from Server 220 into the language of the second controller 143. Server 210 can also be configured to convert compressed measurement data PMD into the language of Server 220 and record the compressed measurement data PMD in Server 220's database.

[0102] The electrode specification data ESD can include model information and recipes related to the processing of the electrode sheet ES. The electrode specification data ESD can include various details related to the processing of the electrode sheet ES, such as the number of lots processed in the current process, the number of coating lines formed on the electrode sheet ES, process conditions including temperature, humidity and pressure, and process parameters including the movement speed of the electrode sheet ES, the discharge rate of the coating die and the pressure of the pressure roll.

[0103] For process control, a communication line can be installed between the second controller 143 and the server 220 via the server 210. This allows for data transmission via the second controller 143 to save resources required for installing a communication line and streamline data processing and management compared to the case where the first rotary encoder 121, the second rotary encoder 123, and the measuring instrument 130 directly transmit the unwind amount signal UWAS, the winding amount signal WAS, and the measurement signal MS to the server 220, compared to the case where the first controller 141 directly transmits compressed measurement data PMD to the server 220.

[0104] Server 220 can be configured to generate roll maps. Roll maps can be generated on a lot basis. Roll maps can include data regarding lot specifications. Lot specifications may include, for example, lot number, length of wound electrode sheet ES, width of electrode sheet ES, and material and composition used to process electrode sheet ES.

[0105] According to an exemplary embodiment, the server 220 may be a data processing system that supports various activities necessary to manage the manufacturing of secondary batteries, such as work schedule management, work instructions, quality control, and work performance aggregation. The server 220 may be, for example, a Manufacturing Execution System (MES). The server 220 may be configured to input, process, output, and communicate data necessary for electrode manufacturing, such as coating processes, pressing processes, and manufacturing processes.

[0106] In another example, server 220 could be a Statistical Process Controller (SPC). Server 220 can be configured to store and process inspection data of electrode sheets ES. Server 220 can manage the quality of electrode sheet ES processing by continuously monitoring the processing of electrode sheet ES based on the inspection data. By collecting and analyzing manufacturing data in near real-time, server 220 can identify problem conditions in a timely manner and provide alarms to operators before potential problems occur.

[0107] If server 220 is an MES or SPC, it may be unsuitable for long-term storage of compressed measurement data PMD. Server 220 could, for example, be a data warehouse and be able to store compressed measurement data PMD for long periods based on the product's quality assurance period, etc.

[0108] According to other exemplary embodiments, the server 220 may perform all the functions of the MES, SPC, and data warehouse, or it may be provided separately from the MES, SPC, and data warehouse to create a role map.

[0109] Figure 6 shows the visualized role map VRM.

[0110] Referring to Figures 1 and 6, the server 220 can be configured to transmit role map data to the user device 300. The user device may include a display device for displaying the role map VRM visualized based on the role map data D1.

[0111] The visualized roll map VRM can include multiple visualization intervals VS1, VS2, VS3, VS4, VS5, VS6 corresponding to multiple sections S1, S2, S3, S4, S5, S6 (see Figure 3) of the electrode sheet ES. Each of the multiple visualization intervals VS1, VS2, VS3, VS4, VS5, VS6 can include a start coordinate, an end coordinate, and a color.

[0112] The starting coordinate of visualization interval VS1 can be X1, and the ending coordinate can be X2. The starting coordinate of visualization interval VS2 can be X2, and the ending coordinate can be X3. The starting coordinate of visualization interval VS3 can be X3, and the ending coordinate can be X4. The starting coordinate of visualization interval VS4 can be X4, and the ending coordinate can be X5. The starting coordinate of visualization interval VS5 can be X5, and the ending coordinate can be X6. The starting coordinate of visualization interval VS6 can be X6, and the ending coordinate can be X7.

[0113] The judgment values ​​for visualization intervals VS1, VS2, VS4, and VS6 can be displayed in color C1, the judgment value for visualization interval VS3 can be displayed in color C2, and the judgment value for visualization interval VS5 can be displayed in color C3.

[0114] Color C1 indicates that the judgment values ​​for visualization intervals VS1, VS2, VS4, and VS6 are normal; color C2 indicates that the judgment value for visualization interval VS3 is excessive; and color C3 indicates that the judgment value for visualization interval VS3 is very excessive. Color C4 indicates that the judgment value is insufficient; and color C5 indicates that the judgment value is very insufficient.

[0115] Here, a visualized roll map (VRM) displaying compressed measurement data (PMD) is shown for illustrative purposes only and does not limit the technical concept of the present invention in any way. The visualized roll map can further display additional data such as inspection data, equipment data, and process parameter data generated by the inspection equipment. Such additional data can be associated with coordinates, and the specific method of association between the additional data and coordinates may differ from that of the compressed measurement data (PMD). For example, pinch hole defect data, which is one of the inspection data, can be matched with a single coordinate value indicating the location of the pinch hole, rather than with start and end coordinates.

[0116] The processing unit 133 can be configured to transmit measurement data to the second server 220. According to an exemplary embodiment, the measurement data can be transmitted to the second server 180 via server 210. Server 210 may be a device for communication between the processing unit 133 and server 220.

[0117] The processing unit 133 and servers 210, 220 can be embodied in hardware, firmware, software, or a combination thereof. For example, the processing unit 133 and servers 210, 220 can include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processing unit 133 and servers 210, 220 can also include any one of the following: a simple controller, a microprocessor, a complex processor such as a CPU or GPU, a processor composed of software, dedicated hardware, and firmware. The processing unit 133 and servers 210, 220 can be embodied, for example, in a general-purpose computer or in application-specific hardware such as a DSP (Digital Signal Process), FPGA (Field Programmable Gate Array), and ASIC (Application Specific Integrated Circuit).

[0118] Servers 210 and 220 may include physical servers or cloud servers. Servers 210 and 220 can provide data and analysis results to workers through various frameworks. The framework may include protocols to support data transmission so that user devices 300 can visualize data through a user interface and provide updated visualizations when new data is calculated by servers 210 and 220. The protocols supporting the above data transmission may use HTML, JavaScript, and / or JSON.

[0119] Servers 210 and 220 can include a variety of APIs (Application Programming Interfaces) for storing data in databases and other data management tools. These APIs can also be used to retrieve data in the databases of various data management systems. The data management systems can provide access to the database, pull data from it, retrieve data, and generate metrics. Here, metrics are tools for visualizing data. Metrics include time-series generated measurements and can be used for application monitoring and generating status alerts.

[0120] The secondary battery manufacturing system 10 can embody a plug-in architecture with an API for data acquisition to provide plug-and-play connectivity for measuring instruments 130, additional measuring instruments, and additional inspection instruments. This allows resources at specific process steps and sites to be easily transferred to other processes and sites, or new resources to be easily introduced at each process step and site.

[0121] The data network between elements of the secondary battery manufacturing system 10 can include a variety of communication channels, including unidirectional, bidirectional wired, and wireless communication. For example, the data network can include industrial protocol networks such as OPC, Modbus, and ProfiNet. The communication channel may be dedicated conduit communication such as USB (Universal Serial Bus), IEEE 802 (Ethernet), IEEE 1394 (FireWire), or other high-speed data communication standards.

[0122] In some embodiments, the secondary battery manufacturing system 10 may further include a manual input system that allows an operator to input manufacturing data. The secondary battery manufacturing system 10 may also allow operator data input using input tools and computer-based input of manufacturing data, such as Excel file scraping.

[0123] According to some embodiments, the operation of the processing unit 133, the first controller 141, the second controller 143, the servers 210 and 220 can be embodied as instructions stored on a machine-readable medium that can be read and executed by one or more processors. Here, the machine-readable medium can include any mechanism for storing and / or transmitting information in a form readable by a machine (e.g., a computing device). For example, the machine-readable medium can include ROM (Read Only Memory), RAM (Random Access Memory), magnetic disk storage medium, optical storage medium, flash memory, electrical, optical, acoustic or other forms of radio signals (e.g., carrier waves, infrared signals, digital signals, etc.) and any other signals.

[0124] The processing unit 133 and servers 210, 220 may consist of firmware, software, routines, and instructions for performing the operations described above or any of the processes described below. For example, the processing unit 133 and servers 210, 220 may be instantiated in memory.

[0125] However, this is for illustrative purposes only, and the operation of the processing unit 133 and servers 210, 220 described above can also be triggered by other devices that execute computing devices, distributed computing devices, processors, firmware, software, routines, and instructions, etc.

[0126] An architecture configured to generate role maps and intermediate role maps can be realized by adding only a first controller 141 to the essential elements of a modern process control system. In other words, the system according to the exemplary embodiment can leverage resources already installed in the manufacturing site and save additional capital expenditures. Furthermore, by applying the same architecture to newly constructed manufacturing facilities as to existing manufacturing facilities, it is possible to streamline the reliability of secondary battery manufacturing, the identification and improvement of problematic processes, and the introduction of new processes.

[0127] A typical engineer in this industry can easily arrive at a system that includes an integrated PLC performing the respective functions of the first controller 141 and the second controller 143, based on what is described herein.

[0128] (Third embodiment) Figure 7 shows section S1' of the electrode sheet ES.

[0129] Referring to Figures 1 and 7, the section S1' of the electrode sheet ES can be defined differently from section S1 in Figure 4. More specifically, the start coordinate of section S1' may be the position in the X direction where scanning of the sensing unit 131 begins. The end coordinate of section S1' may be the same as the start coordinate of the subsequent section. In this case, the trigger for the transmission of the compressed measurement data PMD, evaluation data ED, start coordinate, and end coordinate of section S1' may be the start of scanning of the subsequent section.

[0130] The present invention has been described in more detail above with reference to the drawings and embodiments. However, the configurations described in the drawings or embodiments described herein are merely one embodiment of the present invention and do not represent the entire technical concept of the present invention. Therefore, there may be various equivalents and modifications that can be substituted for them at the time of filing. [Explanation of symbols]

[0131] 10. Secondary battery manufacturing system 111 Unwinder 113 Rewinder 115 Processing equipment 121 First Rotary Encoder 123 Second Rotary Encoder 130 Measuring Instruments 131 Sensing Unit 133 Processing Unit 141 First Controller 143 Second Controller 210 servers 220 servers 300 user devices

Claims

1. A step of collecting coordinate data of the electrode sheet and measurement data of the electrode sheet, The step of generating compressed measurement data based on the aforementioned measurement data includes, A method for generating a roll map, wherein the measurement data is collected by scanning the section of the electrode sheet.

2. A method for generating a roll map according to claim 1, wherein the measurement data includes one of the loading amount data of the coating material on the electrode sheet and the thickness data of the electrode sheet.

3. A method for generating a roll map according to claim 1, wherein the compressed measurement data includes the average of the measurement data for the section of the electrode sheet.

4. The method for generating a role map according to claim 3, wherein the average is calculated from a portion of the measurement data.

5. The electrode sheet includes a coated portion to which a coating substance is applied, and The method for generating a roll map according to claim 3, wherein the average is calculated from a portion of the measurement data corresponding to the coated area.

6. A method for generating a roll map according to claim 1, wherein the measurement data is calibrated based on the offset measurement amount.

7. A method for generating a roll map according to claim 1, further comprising the step of determining the start and end coordinates of the section of the electrode sheet.

8. A method for generating a roll map according to claim 1, wherein the section of the electrode sheet includes an extra-electrode region where a sensing unit of a measuring instrument configured to collect the measurement data senses a portion horizontally separated from the electrode.

9. The method for generating a roll map according to claim 8, wherein the section of the electrode sheet includes a turnaround region in which the sensing unit changes the scanning direction.

10. A step of collecting first coordinate data and first measurement data of the first section of the electrode sheet, The process includes the step of determining a first average of a portion of the first measurement data, a first start coordinate of the first section, and a first end coordinate of the first section, based on the first coordinate data and the first measurement data. The first measurement data is collected by scanning the first section, and the method for generating a roll map is also provided.

11. The steps include collecting second coordinate data and second measurement data of the second section connected to the first section of the electrode sheet, The method further includes the step of determining a second mean of a portion of the second measurement data, a second start coordinate of the second interval, and a first end coordinate of the second interval, based on the second coordinate data and the second measurement data. The method for generating a roll map according to claim 10, wherein the second measurement data is collected by scanning the second section.

12. A method for generating a roll map according to claim 11, wherein the second starting coordinate is the same as the first ending coordinate.

13. A controller configured to collect coordinate data of an electrode sheet based on an electrode sheet winding amount signal generated by an encoder, wherein the encoder is configured to sense the length of the electrode sheet wound by a rewinder to generate the winding amount signal, and the coordinate data indicates the position on the electrode sheet, and the controller A measuring instrument comprising a sensing unit and a processing unit, wherein the sensing unit is configured to scan each of a plurality of sections of the electrode sheet to collect measurement data of the electrode sheet, and the processing unit is configured to collect the measurement data based on the measurement signals generated by the sensing unit, The processing unit is configured to generate compressed measurement data based on the measurement data, and A roll map generation system in which the size of the compressed measurement data is even smaller than the size of the measurement data.

14. The roll map generation system according to claim 13, wherein the compressed measurement data includes the average of the portion of the measurement data for each of the plurality of sections of the electrode sheet.

15. The roll map generation system according to claim 13, wherein the processing unit is configured to determine the start coordinates and end coordinates of each of the plurality of sections of the electrode sheet.

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