Roll map generation system and method for generating roll map

Abstract

According to exemplary embodiments, a method for generating a roll map is provided. The method comprises the steps of: cutting a cutting position of an electrode sheet that moves between an unwinder and a rewinder so as to provide a first lot; and identifying a correcting section of the electrode sheet, wherein the correcting section is between the cutting position of the electrode sheet and a portion of the electrode sheet sensed by a sensing unit at the time the electrode sheet is cut.

Description

Roll map generation system and method for generating roll maps

[0001] The present invention relates to a system configured to generate a roll map representing a lot, which is a unit of a rolled electrode sheet, and a method for generating the roll map. This application claims the benefit of Korean Application No. 10-2023-0092808, filed July 18, 2023, which is incorporated herein by reference in its entirety.

[0002] Unlike primary batteries, secondary batteries can be charged and discharged multiple times. They are widely used as a power source for various wireless devices, including handsets, laptops, and cordless vacuum cleaners. Recently, improved energy density and economies of scale have dramatically reduced the per-unit manufacturing cost of secondary batteries. Furthermore, as the range of battery electric vehicles (BEVs) has increased to match that of fuel-powered vehicles, the primary use of secondary batteries is shifting from mobile devices to mobility.

[0003] Secondary batteries are manufactured through electrode processes, assembly processes, and activation processes. Among these, the electrode process is the most critical process in determining the yield and performance of the battery cell. The electrode process may include a coating process, a roll-pressing process, and a slitting process. In the coating process, active and insulating materials may be applied to the surface of the current collector. In the roll-pressing process, the electrode may be pressed by pressure rolls. The roll-pressing process may determine the density, performance, and surface quality of the electrode. In the slitting process, the electrode may be cut into multiple electrodes depending on the battery cell design.

[0004] The technical idea of ​​the present invention is to provide a system configured to generate a roll map containing information on the quality and defects of an electrode manufacturing process.

[0005] According to exemplary embodiments of the present invention for solving the above-described problem, a method for generating a roll map is provided. The method comprises the steps of: cutting a cutting position of an electrode sheet moving between an unwinder and a rewinder to provide a first lot; and identifying a correction section of the electrode sheet, wherein the correction section is between a portion of the electrode sheet sensed by a sensing unit at the time of cutting the electrode sheet and the cutting position of the electrode sheet.

[0006] The lot ID of the data collected from the above correction section indicates the first lot.

[0007] The method further comprises the step of attributing data collected from the correction section to a roll map of a second lot subsequent to the first lot.

[0008] The step of attributing the data to the roll map of the second lot subsequent to the first lot sets the lot ID of the data so that the lot ID of the data indicates the second lot.

[0009] The method further includes a step of correcting coordinates of data collected from the correction section.

[0010] The lower limit of the coordinates of the data collected from the above correction section is the completed length of the first lot.

[0011] The above coordinates of the above data are corrected based on the above completion length.

[0012] The above coordinates of the above data are corrected based on the subtraction of the above completion length.

[0013] The upper limit of the coordinates of the above data is the sum of the completion length and the offset length, and the offset length is the length of the electrode sheet interposed between the sensing unit and the rewinder.

[0014] According to exemplary embodiments, a method of generating a roll map is provided. The method comprises the steps of: cutting a cutting position of an electrode sheet moving between an unwinder and a rewinder to provide a first lot; and identifying a correction section of the electrode sheet, wherein the correction section is between a portion of the electrode sheet processed by a processing device at the time the electrode sheet is cut and the cutting position of the electrode sheet.

[0015] The method further comprises the step of attributing the equipment data collected from the processing device to a roll map of a second lot subsequent to the first lot.

[0016] The method further includes a step of correcting coordinates of data collected from the correction section.

[0017] The lower limit of the coordinates of the data collected from the above correction section is the completed length of the first lot.

[0018] The above coordinates of the above data are corrected based on the above completion length.

[0019] The upper limit of the coordinates of the above data is the sum of the completion length and the offset length, and the offset length is the length of the electrode sheet interposed between the processing device and the rewinder.

[0020] According to exemplary embodiments of the present invention, a system may be provided for generating a roll map that enables feedback, feed forward, and tracking for an electrode process.

[0021] 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 skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects resulting from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0022] Figure 1 illustrates a roll map generation system according to exemplary embodiments.

[0023] FIG. 2 is a flowchart illustrating a roll map generation method according to exemplary embodiments.

[0024] FIG. 3 is a drawing for explaining a roll map generation method according to exemplary embodiments.

[0025] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0026] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0027] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0028] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0029]

[0030] (Example 1)

[0031] FIG. 1 illustrates a roll map generation system (100) according to exemplary embodiments.

[0032] Referring to FIG. 1, the roll map generation system (100) may include an unwinder (111), a rewinder (113), a processing mechanism (115), a completion knife (117), a first rotary encoder (121), a second rotary encoder (123), a measuring instrument (131), an inspector (133), a first controller (141), a second controller (143), a communication server (150), and a server (160).

[0033] The roll map generation system (100) may be configured to generate a roll map including data regarding an electrode sheet (ES). The roll map may represent the electrode sheet (ES) based on coordinates indicating a location on the electrode sheet (ES). A process for manufacturing a secondary battery may be performed on the electrode sheet (ES). The roll map may represent a history of the process performed on the electrode sheet (ES) and may include data associated with the coordinates. Accordingly, the roll map enables feedback, feed forwarding, and tracking of the manufacturing process of the secondary battery, which will be described later.

[0034] The first electrode roll (ER1) on which the previous process has been performed can be loaded onto the unwinder (111). The unwinder (111) can be configured to unwind the electrode sheet (ES) from the first electrode roll (ER1). The rewinder (113) can be configured to wind the electrode sheet (ES) to form a second electrode roll (ER2). Accordingly, the electrode sheet (ES) can move between the unwinder (111) and the rewinder (113). Since the electrode process is performed on the electrode sheet (ES) unwound from the first electrode roll (ER1) and wound onto the second electrode roll (ER2), the electrode process can be a roll-to-roll process.

[0035] The roll map can be generated on a lot basis. The electrode sheet (ES) is wound onto a second electrode roll (ER2), and after reaching a predetermined winding length, it can be cut and separated by a finishing knife (117). 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. Accordingly, the server (160) can be configured to store a roll map of a previous process. The roll map of the previous process can correspond to the first electrode roll (ER1). In addition, the server (160) can generate and store a roll map of a current process. The roll map of the current process can correspond to the second electrode roll (ER2).

[0036] Time series data organized over time (i.e., according to the progress of the process) in the roll map can be associated with coordinate data (CD) collected based on the amount of movement (i.e., either the amount of winding or the amount of unwinding) of the electrode sheet (ES).

[0037] The manufacturing of secondary batteries involves a series of distinct processes, with leading processes influencing subsequent processes. If the time-series data from leading processes do not directly align with real-world workpieces, semi-finished products, and finished goods, it can be difficult to incorporate these data into subsequent processes. Hereinafter, the correction of subsequent processes based on data generated from the results of leading processes is referred to as feedforward.

[0038] Here, the workpiece refers to an article provided as a result of each process, such as an electrode sheet (ES) that has undergone the coating process, roll pressing process, and slitting process illustrated in FIG. 1. A semi-finished product may refer to one of separators, electrodes, and assemblies thereof cut through a notching process. The semi-finished product may also be a structure including a housing and an electrode assembly embedded in the housing (in some cases, the structure further includes an electrolyte). A product refers to an article that has been processed to be operable as a secondary battery through an activation process. The above-described definitions of the workpiece, semi-finished product, and product are for one aspect thereof and do not exclude conventional definitions thereof.

[0039] For feedforwarding, the time-series data of the roll map must be associated with the positions of real-world workpieces, parts, semi-finished products, and finished products. The roll map can associate the time-series data with coordinate data, which includes coordinates representing the positions of real-world workpieces, parts, semi-finished products, and finished products. Based on the coordinate data, the roll map can provide a matching between the time-series data and real-world workpieces, parts, semi-finished products, and finished products. Accordingly, the creation of the roll map and feedforwarding based on the roll map can improve the productivity and quality of the secondary battery manufacturing process by quantifying and objectifying aspects of the process that were previously dependent on the arbitrary actions of the operator. Furthermore, the roll map of a preceding lot can be used to improve the process of a subsequent lot, an action referred to as process feedback. Process feedback using the roll map can include identifying process conditions and parameters that caused problems and defects based on the data contained in the roll map.

[0040] Furthermore, the roll map, as described below, is cumulatively generated for work-pieces, parts, semi-finished products, and finished products of unit processes, thereby allowing for tracking of the process history of shipped products (e.g., battery cells, battery modules, or battery packs). For example, a battery cell may include a cell ID formed on an electrode assembly or a case. The cell ID may include lot numbers and coordinate information of electrodes and separators included in the battery cell. In other words, the cell ID may be associated with a roll map of the electrodes and separators included in the battery cell. Accordingly, when an event such as a quality issue occurs in a battery cell that has already been shipped, historical data on the manufacturing of the corresponding battery cell may be retrieved based on the cell ID in order to identify the cause of the problem in the manufacturing process.

[0041] The electrode sheet (ES) can be processed by a processing device (115). For example, the processing device (115) may include a coater, and electrode slurry may be coated on the electrode sheet (ES). As another example, the processing device (115) may include an induction heating device and pressurized rolls, and a roll pressing process may be performed on the electrode sheet (ES) coated with the electrode slurry. As another example, the processing device (115) may include a splicing die and a scrap port, and a portion of the electrode sheet (ES) may be scraped. As another example, the processing device may include a slitting knife, and the electrode sheet (ES) may be separated into a plurality of electrode sheets.

[0042] The coating process involves applying a coating material, such as electrode slurry, onto an electrode sheet (ES). The electrode slurry may include an electrode active material, a conductive agent, a binder, and a solvent. The electrode slurry can be provided by dissolving the electrode active material, conductive agent, binder, etc. in a solvent.

[0043] The roll pressing process involves passing an electrode sheet (ES) coated with electrode slurry between opposing press rolls. The press rolls can smooth the electrode surface and enhance the bonding strength between the active material and the current collector.

[0044] To increase the production capacity (e.g., GWh) per line of a secondary battery production facility, a coating process and a roll pressing process are performed on wide electrode sheets (ES). Subsequently, in a slitting process, the wide electrode sheets (ES) can be cut to the specifications of the battery cell.

[0045] The first rotary encoder (121) may be configured to detect the amount of electrode sheet (ES) unwound from the first electrode roll (ER1) by the unwinder (111). Accordingly, the first rotary encoder (121) may be configured to generate an unwound amount signal (UWAS) indicating the unwound amount of the electrode sheet (ES). The first rotary encoder (121) may be configured to transmit the unwound amount signal (UWAS) to the first controller (141). The first controller (141) may be configured to collect unwound amount data based on the unwound amount signal (UWAS) of the electrode sheet (ES).

[0046] The second rotary encoder (123) may be configured to detect the amount of electrode sheet (ES) wound from the second electrode roll (ER2) by the rewinder (113). Accordingly, the second rotary encoder (123) may be configured to generate a winding amount signal (WAS) indicating the winding amount of the electrode sheet (ES). The second rotary encoder (123) may be configured to transmit the winding amount signal (WAS) to the first controller (141). The first controller (141) may be configured to collect winding amount data based on the winding amount signal (WAS) of the electrode sheet (ES).

[0047] A portion of the electrode sheet (ES) may be scrapped in some cases, and accordingly, the amount of the electrode sheet (ES) wound by the unwinder (111) may be different from the amount of the electrode sheet (ES) wound by the rewinder (113). In addition, when the electrode sheet (ES) is stretched by pressure in the roll pressing process, the amount of the electrode sheet (ES) wound by the unwinder (111) may be different from the amount of the electrode sheet (ES) wound by the rewinder (113).

[0048] The first controller (141) may be configured to collect coordinate data (CD) of the electrode sheet (ES) based on either a winding amount signal (WAS) or an unwinding amount signal (UWAS) of the electrode sheet (ES). For example, the first controller (141) may determine a movement distance of the electrode sheet (ES) in the current process step based on the winding amount signal of the electrode sheet (ES). Accordingly, coordinates indicating the relative positions of portions of the electrode sheet (ES) wound by the rewinder (113) within the electrode sheet (ES) at each point in time when roll-to-roll processing is performed on the electrode sheet (ES) may be determined. Furthermore, by correcting the coordinates using the offset lengths (OD1, OD2, OD3), the relative positions of each portion of the electrode sheet (ES) being processed or detected within the electrode sheet (ES) may be known. Hereinafter, the technical idea of ​​the present invention will be described with a focus on an embodiment in which the first controller (141) collects coordinate data (CD) based on the winding amount signal (WAS) of the electrode sheet (ES).

[0049] The coordinate data (CD) may include coordinates matching each portion of the electrode sheet (ES). That is, each arbitrary point on the electrode sheet (ES) may be matched with a coordinate. The coordinates may be a one-dimensional quantity in the machine direction (or longitudinal direction) of the electrode sheet (ES), but is not limited thereto. The coordinates may also be a two-dimensional quantity in the machine direction and the transverse direction (or width direction) of the electrode sheet (ES).

[0050] The sensing unit (131S) of the measuring device (131) may be configured to measure the electrode sheet (ES) to collect measurement data of the electrode sheet (ES). The sensing unit (131S) may measure the electrode sheet (ES) in a scanning manner. The sensing unit (131S) may be configured to scan the electrode sheet (ES) in a transverse direction (TD). While the measuring device (131) performs transverse scanning, the electrode sheet (ES) may be moved in the traveling direction by the unwinder (111) and the rewinder (113).

[0051] The measurement data may include a plurality of measurement values ​​expressed in numbers. 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 overlapping width between the coating material and the insulating material, mismatch data between the maintenance lanes on the upper surface of the electrode sheet (ES) and the maintenance lanes on the lower surface of the electrode sheet (ES), etc. Here, the loading amount represents the amount of the coating material loaded per unit area of ​​the electrode sheet (ES) and may be the areal density of the coating material.

[0052] The measuring device (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, and a Time of Flight (TOF) sensor. 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 a biosensor, a chemical sensor, a composition sensor, a current and / or power meter, an air quality sensor, a gas sensor, a Hall effect sensor, a brightness level sensor, and a light sensor. The measuring device (131) may include a pressure sensor, a temperature sensor, an ultrasonic sensor, a proximity sensor, a door status sensor, a motion tracking sensor, a humidity sensor, a visible light and infrared sensor, and a camera.

[0053] Hereinafter, as a non-limiting example, the technical idea of ​​the present invention will be described with reference to an embodiment in which the measuring device (131) is either a loading meter (e.g., a web gauge from Thermofisher Scientific) or a thickness meter configured to measure a loading amount of a coating layer on a sheet material (SM), and the measurement data includes either loading amount values ​​or thickness values. A person skilled in the art will readily arrive at an embodiment in which the measuring device includes either one of the above-described sensors and the measuring device is configured to detect either one of the above-described measurement quantities, based on the description herein.

[0054] The processor (131P) may be configured to collect measurement data based on a measurement signal (MS) sensed by the sensing unit (131S). The processor (131P) may be connected to the sensing unit (131S) by wire or wirelessly. The processor (131P) may be configured to correct 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 the aging of the equipment, the measurement values ​​of the measurement data may differ from the actual values. The processor (131P) may improve the reliability of the roll map generation system (100) and the method for generating the roll map by correcting the measurement values ​​of the measurement data based on the offset measurement amount. The offset measurement amount may be determined based on information known about the equipment system by a method such as a sample test.

[0055] The inspector (133) may be configured to inspect the electrode sheet (ES) to collect inspection data. For example, the inspector (133) may be, for example, a vision machine. The vision machine is an image-based inspection device that can capture an image of the electrode sheet (ES) and identify a defect on the electrode sheet (ES) based on the image of the electrode sheet (ES). As another example, the inspector (133) may be an Optical Character Reader (OCR) or an Optical Barcode Reader (OBR). The inspector (133) may be configured to collect data that is not characterized by a numerical value (e.g., defect data or an image of the electrode sheet (ES)), but is not limited thereto.

[0056] Inspection data may include judgments on the quality of a portion of an electrode sheet (ES) and process events. For example, the inspection data may include data on the appearance of the electrode sheet (ES) collected by an image-based inspection device such as a vision machine, data on open circuits and joints of the electrode sheet (ES), data on a portion of the electrode sheet (ES) on which sampling inspection has been performed, data on a portion of the electrode sheet (ES) scheduled for scrapping, data on a scrapped portion of the electrode sheet (ES), data on the quality of coating materials and insulating materials on the electrode sheet (ES), data on reference points indicating the position of the electrode sheet (ES), and defect data indicating the type and presence of defects such as pinhole defects, crater defects, line defects, crack defects, side ring defects, island defects, fold defects, wrinkle defects, dent defects, and imprint defects. The reference points may be formed at predetermined intervals on the electrode sheet (ES), and the positions of other elements on the electrode sheet (ES) may be located based on the reference points. The inspector can be any one of a color sensor, a seam sensor, a fiducial sensor, and a vision machine.

[0057] The tester (133) may include a sensing unit (133S) and a processor (133P). The sensing unit (133S) may include any of the sensors exemplified in relation to the sensing unit (133S). The sensing unit (133S) may be configured to test the electrode sheet (ES) to generate a test signal (IS). The processor (133P) may be configured to collect test data based on the test signal (IS) sensed by the sensing unit (133S). The processor (133P) may be connected to the sensing unit (133S) by wire or wirelessly.

[0058] Measurement data and inspection data can be time-series data. Measurement data and inspection data can be temporally ordered. Temporal ordering is a key characteristic of time-series data, organizing events in the order in which they occur and arrive for processing. That is, measurement data and inspection data can be stored based on the time at which the measurement and inspection were performed, and can be associated with time. Accordingly, each measurement value of the measurement data can be time-matched, and each evaluation value of the inspection data can be time-matched.

[0059] For example, measurement data may have a series of measurement values ​​and time values ​​associated with the series of measurement values. The measurement values ​​and time values ​​may be matched one-to-one, but are not limited thereto. As another example, inspection data, such as defect data, may have a judgment value (e.g., a value indicating a defect) and a time value associated with the value indicating the defect. Here, indicating a defect means including information about at least one of the presence or absence of a defect and the type of defect.

[0060] The first controller (141) may be in operative communication with the first and second rotary encoders (121, 123), the measuring instrument (131), and the inspector (133) 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 specialized network using a physical channel, WiFi, Bluetooth, and / or other frequency bands. The first and second rotary encoders (121, 123), the measuring instrument (131), and additional measuring instruments and inspectors may be configured to collect data from equipment, workpieces, semi-finished products, and products within the roll map generation system (100), or to generate signals for collecting data.

[0061] The first controller (141) may be configured to transmit coordinate data (CD) to the processor (131P). The processor (131P) may be configured to associate measurement data with the coordinate data (CD) to generate coordinate-related measurement data (CMD). Typically, the measurement data may be processed based on a trigger point.

[0062] As a non-limiting example, the trigger point for processing measurement data may be the completion of scanning. For example, the sensing unit (131S) may scan the electrode sheet (ES) in the width direction of the electrode sheet (ES), and measurement data may be stored, processed, modulated, and transmitted for each scan. In another example, the trigger point may be the completion of multiple scans or the completion of a portion of a scan. Examples of processing measurement data may include storing measurement data, manipulating measurement data (e.g., generating coordinate-associated measurement data (CMD)), and transmitting measurement data.

[0063] According to exemplary embodiments, the measuring device (131) may be configured to calibrate the coordinate data (CD) based on the position of the sensing unit (131S) of the measuring device (131). More specifically, the measuring device (131) may be configured to calibrate the coordinate data (CD) based on an offset length (OD2), thereby associating the coordinates of the coordinate data (CD) with the measurement values ​​of the measurement data.

[0064] The measuring device (131) can collect measurement data of a portion corresponding to (e.g., overlapping) the sensing unit (131S), and the coordinate data (CD) is collected by a second rotary encoder (123) spaced apart from the sensing unit (131S) as described above, so that the portion of the electrode sheet (ES) corresponding to the winding amount signal (UWAS) generated at the same time and the portion of the electrode sheet (ES) corresponding to the measurement signal (MS) may be different.

[0065] The processor (131P) may be configured to collect coordinate-related measurement data (CMD) based on the measurement data and the coordinate data (CD). The coordinate-related measurement data (CMD) may include a representative value and representative coordinates (e.g., a start coordinate and an end coordinate). The representative value may include at least one of an average, a standard deviation, a median, a maximum value, and a minimum value of the measurement data of a portion of the electrode sheet (ES) inspected by one scanning of the sensing unit (131S). The representative coordinates (e.g., a start coordinate and an end coordinate) may indicate a start point and an end point of a portion of the electrode sheet (ES) inspected by one scanning of the sensing unit (131S).

[0066] According to exemplary embodiments, the processor (131P) may be configured to correct coordinate data (CD) collected at the same time as the measurement data based on an offset length (OD2) to collect coordinate-related measurement data (CMD), and to associate representative coordinates (e.g., start coordinates and end coordinates) of the corrected coordinate data (CD) with representative values ​​of the measurement data. Accordingly, the measurement values ​​of the measurement data may be matched with times, and the representative values ​​of the coordinate-related measurement data (CMD) may be matched with the representative coordinates (e.g., start coordinates and end coordinates).

[0067] A plurality of guide rolls may be interposed between the sensing unit (131S) and the rewinder (113) to define the movement path of the electrode sheet (ES). Accordingly, the offset length (OD2) may be defined as the length of the electrode sheet (ES) between the sensing unit (131S) and the rewinder (113) according to the movement path of the electrode sheet (ES). The offset length (OD2) may be equal to the straight-line distance between the sensing unit (131S) and the rewinder (113), or may be greater than the straight-line distance between the sensing unit (131S) and the rewinder (113).

[0068] The processor (131P) may be configured to generate evaluation data based on coordinate-related measurement data (CMD). The evaluation data may include a judgment value of a process of each of a plurality of sections of the electrode sheet (ES). The judgment value of a process of each of a plurality of sections of the electrode sheet (ES) may be determined based on a comparison of a set range and the measurement values ​​(or a representative value of the measurement values).

[0069] For example, a representative value within a first range may be determined as normal, a representative value within a second range that is greater than the first range may be determined as excessive, a representative value within a third range that is greater than the second range may be determined as very excessive, a representative value within a fourth range that is smaller than the first range may be determined as insufficient, and a representative value within a fifth range that is smaller than the fourth range may be determined as very insufficient.

[0070] Here, if the lower limit of the second range is greater than or equal to 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 less than or equal to the lower limit of the first range, the fourth range is less than the first range.

[0071] The processor (131P) may be configured to transmit coordinate-related measurement data (CMD) to the first controller (141). The coordinate-related measurement data (CMD) transmitted to the second controller (143) may be transmitted to the server (160) via the communication server (150). The second controller (143) and the communication server (150) may relay communication of data including the coordinate-related measurement data (CMD) between the server (160) and the first controller (141). However, the present invention is not limited thereto. The first controller (141) may also directly transmit the coordinate-related measurement data (CMD) to the server (160).

[0072] The first controller (141) may be configured to transmit coordinate data (CD) to the processor (133P). The processor (133P) may be configured to associate inspection data with the coordinate data (CD) to generate coordinate-related inspection data (CID).

[0073] According to exemplary embodiments, the tester (133) may be configured to calibrate the coordinate data (CD) based on the position of the tester (133). More specifically, the tester (133) may be configured to correlate the coordinates of the coordinate data (CD) with the evaluation values ​​of the test data by calibrating the coordinate data (CD) based on an offset length (OD3). The offset length (OD3) may be equal to a straight-line distance between the sensing unit (133S) and the rewinder (113), or may be greater than the straight-line distance between the sensing unit (133S) and the rewinder (113).

[0074] The processor (133P) may be configured to collect coordinate-related inspection data (CID) based on inspection data and coordinate data (CD). The coordinate-related inspection data (CID) may include evaluation values ​​(e.g., values ​​indicating the presence or absence of a defect, the order of the defect, the presence or absence of a reference point, and the order of the reference point, etc.) and representative coordinates (e.g., a start coordinate and an end coordinate).

[0075] According to exemplary embodiments, the processor (133P) may be configured to correct coordinate data (CD) collected at the same time as the inspection data based on an offset length (OD3) to collect coordinate-associated inspection data (CID), and to associate coordinates of the corrected coordinate data (CD) with evaluation values ​​of the inspection data. Accordingly, evaluation values ​​of the inspection data may be matched with times, and evaluation values ​​of the coordinate-associated inspection data (CID) may be matched with coordinates. Consecutive evaluation values ​​of the inspection data (CID) (e.g., values ​​representing consecutive defects) may be matched with representative coordinates (e.g., start coordinates and end coordinates) of a section of the electrode sheet (ES) in which the evaluation values ​​are consecutive.

[0076] The first controller (141) may be configured to receive an equipment signal (ESS) from the processing device (115). The first controller (141) may be configured to collect equipment data (ED) based on the equipment signal (ESS). The equipment signal (ESS) may include operating information of the processing device (115).

[0077] For example, the equipment signal (ESS) may include information on the gap of the coating die, the pressure, speed, and supply amount of the slurry pump, and the level of the slurry supply tank. As another example, the equipment signal (ESS) may include information on the temperature of the induction heating device, the pressure of the pressurizing rolls, and the position of the pressurizing rolls. As another example, the equipment signal (ESS) may include information on the speed of the slitting knife. As another example, the equipment signal (ESS) may also include information on the movement speed, tension, and friction of the electrode sheet (ES) by the unwinder (111) and the rewinder (113).

[0078] The first controller (141) can be configured to transmit equipment data (ED), coordinate-related measurement data (CMD), coordinate-related inspection data (CID), and winding amount signal (WAS) to the second controller (143).

[0079] The second controller (143) may be configured to control the operation of the unwinder (111), the rewinder (113), the processing mechanism (115), and the finishing knife (117). The second controller (143) may be configured to generate signals for operation and stop of the unwinder (111), the rewinder (113), the processing mechanism (115), and the finishing knife (117). The signals for operation and stop of the unwinder (111), the rewinder (113), the processing mechanism (115), and the finishing knife (117) may be generated based on the recipe of the electrode sheet (ES).

[0080] In order to control the process, a communication line may be installed between the second controller (143) and the server (160) via a communication server (150) to connect the second controller (143) and the server (160). Accordingly, data transmission through the second controller (143) can reduce resources required for installation of the communication line and improve data processing and management efficiency compared to the case where the first and second rotary encoders (121, 123) and the measuring device (131) directly transmit the unwinding amount signal (UWS), the winding amount signal (WS) and the measurement signal (MS) to the server (160) and the case where the first controller (141) directly transmits the coordinate-related measurement data (CMD) and the evaluation data to the server (160).

[0081] The communication server (150) may include a program for communication between the second controller (143) of the manufacturing facility and the server (160). The communication server (150) may be implemented in hardware as described below. The language and protocol of the server (160) may be different from those of the second controller (143). For example, the language of the server (160) may be SQL, and the language of the second controller (143) may be a ladder diagram.

[0082] The communication server (150) may be configured to convert the product ID and recipe of the electrode sheet (ES) transmitted from the server (160) into the language of the second controller (143). In addition, the communication server (150) may be configured to convert equipment data (ED), coordinate-related measurement data (CMD), and coordinate-related inspection data (CID) into the language of the server (160) and record the coordinate-related measurement data (CMD) in the database of the server (160).

[0083] The server (160) may be configured to generate a roll map based on equipment data (ED), coordinate-related measurement data (CMD), and coordinate-related inspection data (CID). The roll map may be generated on a lot-by-lot basis. The roll map may include data regarding specifications of the lot. Specifications of the lot may include, for example, a lot number, a length of a rolled electrode sheet (ES), a width of the electrode sheet (ES), and materials and compositions used in processing the electrode sheet (ES).

[0084] According to exemplary embodiments, the server (160) may be a data processing system that supports various activities necessary for managing the manufacturing of secondary batteries, such as work schedule management, work instructions, quality control, and work performance aggregation. The server (160) may be, for example, MES (Manufacturing Execution System) software. The server (160) may be configured to input, process, output, and communicate data necessary for electrode manufacturing, such as coating processes, press processes, and manufacturing processes.

[0085] In another example, the server (160) may be configured to store and process measurement data of a raw electrode sheet (ES). The server (160) may be configured to continuously monitor the processing of the electrode sheet (ES) based on the measurement data, thereby managing the quality of the processing of the electrode sheet (ES). The server (160) may be a Statistical Process Controller (SPC). By collecting and analyzing manufacturing data in near real time, the server (160) can promptly identify problem conditions and provide alerts to operators before potential problems occur.

[0086] In another example, the server (160) may be a solution that manages all information and processes at all stages of the product or service lifecycle across the global supply chain. The server (160) may be, for example, a Product Lifecycle Management (PLM) system. The server (160) may store data such as items, parts, products, documentation, requirements, engineering change orders, quality, and workflows. The server (160) may be configured to generate and store electrode specification data (ESD).

[0087] The processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may be implemented by hardware, firmware, software, and combinations thereof. For example, the processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may include any one of simple controllers, complex processors such as microprocessors, CPUs, GPUs, processors configured by software, dedicated hardware, and firmware. The processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may be implemented by, for example, 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).

[0088] The server (160) may include a physical server or a cloud server. The server (160) may provide data and analysis results to the operator via various frameworks. The framework may include a protocol that supports data transmission, allowing the display device to visualize data through a user interface and provide updated visualizations when new data is calculated by the server (160). The protocol that supports the data transmission may use HTML, JavaScript, and / or JSON.

[0089] The server (160) may include various Application Programming Interfaces (APIs) for storing data in databases and other data management tools. The APIs may also be used to retrieve data from databases in various data management systems. The data management systems may provide access to the databases, pull data from the databases, retrieve data, and generate metrics. Metrics are tools for visualizing data. Metrics include time-series measurements and can be used for monitoring applications and generating status alerts.

[0090] The roll map generation system (100) can implement a plug-in architecture with an API for data acquisition to provide plug-and-play connectivity for the instrument (131), the tester (133), additional instruments, and additional testers. This allows resources from a specific process step and site to be easily transferred to other processes and sites, or new resources to be easily introduced to each process step and site.

[0091] The data network between elements of the roll map generation system (100) may include various types of communication channels, including unidirectional, bidirectional wired, and wireless communications. For example, the data network may include an industrial protocol network such as OPC, Modbus, ProfiNet, etc. The communication channel may be a dedicated conduit communication such as Universal Serial Bus (USB), IEEE 802 (Ethernet), IEEE 1394 (FireWire), or other high-speed data communication standards.

[0092] In some embodiments, the roll map generation system (100) may further include a manual input system that allows a worker to input manufacturing data. The roll map generation system (100) may also allow for a worker to input data using an input tool, or computer-based input of manufacturing data, such as scraping an Excel file.

[0093] According to some embodiments, the operations of the processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may be implemented as instructions stored on a machine-readable medium that can be read and executed by one or more processors. Here, the 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, the machine-readable medium may include a Read Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk storage medium, an optical storage medium, a flash memory, an electrical, optical, acoustical, or other form of radio signal (e.g., a carrier wave, an infrared signal, a digital signal, etc.), and any other signal.

[0094] The processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may be configured with firmware, software, routines, and instructions for performing the operations described above or any process described below. For example, the processor (131P), the processor (133P), the first controller (141), the second controller (143), the communication server (150), and the server (160) may be instantiated in memory.

[0095] The first and second controllers (141, 143) may be, for example, a Programmable Logic Controller (PLC). A PLC is a specialized type of microprocessor-based controller that uses programmable memory to store commands and implement functions such as logic, sequencing, timing, counting, and arithmetic to control machines and processes. PLCs are easy to operate and program.

[0096] The first and second controllers (141, 143) may include a power supply, a central processing unit (CPU), an input interface, an output interface, a communication interface, and first and second memory devices. The power supply may be configured to supply operating power to the CPU, the input module, the output module, the communication interface, and the first and second memory devices. The first memory device may be configured to store a system program of the PLC. The first memory device may be, for example, a read-only memory (ROM) and may be configured to permanently store data for the operating system of the second controller (143). The second memory device may be configured to store a user program and data. The user program may be a program set by a user to cause the CPU to perform a specific function. The data may include the aforementioned coordinate-related measurement data (CMD) and coordinate data (CD). The second memory device may further store status information of input and output devices, timers, counters, and values ​​of other internal devices. The second memory device may be, for example, a random access memory (RAM).

[0097] The CPU may be configured to implement logic and control communication between modules that convert input signals into output operation signals. The CPU may operate based on a system program stored in the first memory device. The CPU may be configured to manipulate data based on a user program stored in the memory device.

[0098] When a PLC is operating, the CPU can scan current input conditions and data and store them in a memory device. The CPU can then be configured to read and execute the user program step by step, and then transmit the results to one of the output modules, communication modules, or memory devices.

[0099] The input and output modules perform isolation and signal conditioning, allowing sensors and actuators to be connected directly to the input and output modules without additional circuitry. The input and output modules can be configured to transfer data between the CPU and external devices.

[0100] Conditions and data of industrial devices and production processes can be transmitted to the CPU via an input module. The results processed by the CPU can be transmitted to an actuator via an output module. The input module may include, for example, digital and analog devices such as mechanical switches for position detection, proximity switches, photoelectric switches, encoders, temperature and pressure switches, potentiometers, linear variable differential transformers, strain gauges, thermistors, thermal transistors, and thermocouples with AC or DC. The input module may provide an interface between the input device and the CPU, which operates based on low DC voltage. Some input devices can generate analog signals with a high voltage range. The input module may be configured to convert the signals generated by the input device into voltages within a range acceptable to the CPU.

[0101] The output module may be configured to generate signals for controlling the operation of the actuator. The output module may include a relay, a transistor, and a triac. The output module may include a relay, a contactor, a solenoid valve, and a motor.

[0102] However, this is for convenience of explanation, and the operations of the processor (131P), processor (133P), first controller (141), second controller (143), communication server (150) and server (160) described above may also be caused by other devices that execute computing devices, distributed computing devices, processors, firmware, software, routines and instructions, etc.

[0103] The architecture configured to generate a roll map can be implemented by adding only the first controller (141) to the second controller (143), the communication server (150), and the server (160), which are essential elements in a modern process management system. That is, the roll map generation system (100) according to exemplary embodiments can utilize the resources of an existing manufacturing site and reduce additional capital expenditure. In addition, by applying the same architecture as the existing manufacturing facility to a newly constructed manufacturing facility, the reliability of secondary battery manufacturing, the discovery / improvement of problematic processes, and the introduction of new processes can be improved. A person skilled in the art will easily arrive at a roll map generation system including an integrated PLC that performs the functions of the first controller (141) and the second controller (143) respectively, based on what is described herein.

[0104]

[0105] (Example 2)

[0106] FIG. 2 is a flowchart illustrating a roll map generation method according to exemplary embodiments.

[0107] FIG. 3 is a drawing for explaining a roll map generation method according to exemplary embodiments.

[0108] Referring to FIGS. 1 to 3, an electrode sheet (ES) may be cut at P110. By cutting the electrode sheet (ES), an electrode roll may be completed, and a first lot (L1) may be provided. The electrode sheet (ES) may be cut based on a winding amount signal (WAS). According to exemplary embodiments, the second controller (143) may be configured to generate a signal for controlling the operation of the completion knife (117) based on the winding amount signal (WAS). After the winding amount target of the electrode roll (ER2) is achieved, the electrode roll (ER2) may be separated by cutting the electrode sheet (ES), and thus a completed first lot (L1) may be provided. The completed first lot (L1) may be unloaded from the rewinder (113) as indicated by an arrow in FIG. 3.

[0109] Next, in P120, the electrode sheet (ES) calibration section can be identified. The identification of the calibration section can be performed by the server (160). The calibration section of the electrode sheet (ES) can be different for each data. Here, the data can include equipment data (ED), coordinate-related measurement data (CMD), and coordinate-related inspection data (CID). More specifically, the calibration section (CR1) of the equipment data (ED), the calibration section (CR2) of the coordinate-related measurement data (CMD), and the calibration section (CR3) of the coordinate-related inspection data (CID) can be different from each other.

[0110] The calibration section may be between the data collection position of the electrode sheet (ES) and the cutting position of the electrode sheet (ES). For example, the calibration section (CR1) of the equipment data (ED) may be collected from the electrode sheet (ES) between the portion of the electrode sheet (ES) processed by the processing device (115) at the time of separation of the first lot (L1) by the completion knife (117) and the cutting position of the electrode sheet (ES) by the completion knife (117). As another example, the calibration section (CR2) of the coordinate-related measurement data (CMD) may be collected from the electrode sheet (ES) between the portion of the electrode sheet (ES) detected by the sensing unit (131S) at the time of separation of the first lot (L1) by the completion knife (117) and the cutting position of the electrode sheet (ES) by the completion knife (117). As another example, the correction section (CR3) of the coordinate-related inspection data (CID) can be collected from the electrode sheet (ES) between the portion of the electrode sheet (ES) detected by the sensing unit (133S) at the time of separation of the first lot (L1) by the completion knife (117) and the cutting position of the electrode sheet (ES) by the completion knife (117).

[0111] Next, in P130, the data collected from the calibration section can be attributed to the roll map of the subsequent lot. The equipment data (ED) collected from the calibration section (CR1), the coordinate-related measurement data (CMD) collected from the calibration section (CR2), and the coordinate-related inspection data (CID) collected from the calibration section (CR3) are collected before the completion of the first lot (L1). Accordingly, the lot ID of the equipment data (ED) collected from the calibration section (CR1), the coordinate-related measurement data (CMD) collected from the calibration section (CR2), and the coordinate-related inspection data (CID) collected from the calibration section (CR3) can indicate the first lot (L1), as shown in Table 1 below.

[0112] In Table 1, the first column represents the lot IDs before data correction, the second column represents the coordinates before data correction, the third column represents the lot IDs after data correction, and the fourth column represents the coordinates after data correction.

[0113] Lot ID Coordinates (au) Corrected Lot ID Corrected Coordinates (au) 1st Lot 1398 1st Lot 1398 1st Lot 1399 1st Lot 1399 1st Lot 1400 2nd Lot 0 1st Lot 1401 2nd Lot 1 1st Lot 1402 2nd Lot 2 1st Lot (omitted) 2nd Lot (omitted) 1st Lot 1465 2nd Lot 65 1st Lot 1466 2nd Lot 66 1st Lot 1467 2nd Lot 67 1st Lot 1468 2nd Lot 68 1st Lot 1469 2nd Lot 69 2nd Lot 70 2nd Lot 70 2nd Lot 71 2nd Lot 71 2nd Lot 72 2nd Lot 72 2 Lot 73 No. 2 Lot 73 No. 2 Lot Omitted Lot 2 Omitted

[0114] A lot subsequent to the first lot (L1) may be referred to as a second lot. Assigning data collected from a calibration section to a roll map of the subsequent lot may include setting a lot ID such that the lot ID of the data collected from the calibration section indicates the second lot. The lot IDs of the equipment data (ED) collected from the calibration section (CR1), the coordinate-related measurement data (CMD) collected from the calibration section (CR2), and the coordinate-related inspection data (CID) collected from the calibration section (CR3) may be corrected to indicate the second lot. Accordingly, when the roll map of the second lot is retrieved based on the lot ID, the data collected from the calibration section may be retrieved. Subsequently, at P140, the coordinates of the data collected from the calibration section may be corrected. The lower limit of the coordinates of the data collected from the calibration section may be a completed length. Here, the completed length is a target winding length of the electrode roll (ER2), and may be determined according to a product recipe. The upper limit of the coordinates of the data collected from the calibration section may be the sum of the corresponding ones among the completion length and the offset lengths (OD1, OD2, OD3). The coordinates of the data collected from the calibration section may be corrected based on the completion length of the first lot (L1). The coordinates of the data collected from the calibration section may be corrected based on the subtraction of the completion length of the first lot (L1). In Table 1, an exemplary completion length is 1400 (arbitrary unit, hereinafter referred to as au), and an exemplary offset length is 69 (au). Accordingly, the lower limit of the coordinates of the data collected from the calibration section is 1400 (au), and the upper limit of the coordinates is 1469 (au). Accordingly, in Table 1, the coordinates of the data collected from the calibration section in the range of 1400 (au) to 1469 (au) may be corrected to be in the range of 0 (au) to 69 (au).

[0115] The present invention has been described in more detail through drawings and examples. However, the configurations described in the drawings or examples described in this specification are merely embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as of the time of this application.

Claims

1. A step of cutting the cutting position of the electrode sheet moving between the unwinder and the rewinder to provide the first lot; and Including a step of identifying a calibration section of the above electrode sheet, A method for generating a roll map, wherein the correction section is between a portion of the electrode sheet sensed by the sensing unit at the time the electrode sheet is cut and the cutting position of the electrode sheet.

2. In paragraph 1, A method for generating a roll map, wherein the lot ID of the data collected from the above correction section indicates the first lot.

3. In paragraph 1, A method for generating a roll map, further comprising the step of attributing data collected from the above correction section to a roll map of a second lot subsequent to the first lot.

4. In paragraph 3, A method for generating a roll map, wherein the step of attributing the data to the roll map of the second lot subsequent to the first lot comprises setting the lot ID of the data so that the lot ID of the data indicates the second lot.

5. In paragraph 1, A method for generating a roll map, characterized in that it further comprises a step of correcting coordinates of data collected from the above correction section.

6. In paragraph 1, A method for generating a roll map, characterized in that the lower limit of the coordinates of the data collected from the above correction section is the completed length of the first lot.

7. In paragraph 6, A method for generating a roll map, characterized in that the coordinates of the above data are corrected based on the completion length.

8. In paragraph 6, A method for generating a roll map, characterized in that the coordinates of the above data are corrected based on the subtraction of the completion length.

9. In paragraph 6, The upper limit of the coordinates of the above data is the sum of the completion length and the offset length, and A method for generating a roll map, wherein the offset length is the length of the electrode sheet interposed between the sensing unit and the rewinder.

10. A step of cutting the cutting position of the electrode sheet moving between the unwinder and the rewinder to provide the first lot; and Including a step of identifying a calibration section of the above electrode sheet, A method for generating a roll map, characterized in that the correction section is between the portion of the electrode sheet processed by the processing device at the time the electrode sheet is cut and the cutting position of the electrode sheet.

11. In paragraph 10, A method for generating a roll map, further comprising the step of attributing the equipment data collected from the processing device to the roll map of a second lot subsequent to the first lot.

12. In paragraph 10, A method for generating a roll map, characterized in that it further comprises a step of correcting coordinates of data collected from the above correction section.

13. In paragraph 10, A method for generating a roll map, wherein the lower limit of the coordinates of the data collected from the above correction section is the completed length of the first lot.

14. In paragraph 13, A method for generating a roll map, characterized in that the coordinates of the above data are corrected based on the completion length.

15. In paragraph 13, The upper limit of the coordinates of the above data is the sum of the completion length and the offset length, and A method for generating a roll map, wherein the offset length is the length of the electrode sheet interposed between the processing device and the rewinder.

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