Battery manufacturing system

Abstract

Provided is a battery manufacturing system comprising: an electrode process device for performing an electrode process; and a roll map creation device for creating a roll map including coordinate data, which indicates the positions of electrodes, and measurement and inspection data which is generated according to the progress of the electrode process performed on the electrodes and is matched with the coordinate data, wherein the electrode process device includes: an unwinder for unwinding the electrodes from a first electrode roll; a rewinder for winding the electrodes on a second electrode roll; an inspection measurement instrument for collecting inspection measurement data of the electrodes to be transferred; and a first encoder which is provided on one side of the electrodes to be transferred and which detects the moving speed of the electrodes by emitting a laser beam at the electrodes, the first encoder is a contactless encoder, the roll map creation device receives a defective position of the electrodes so as to create an electrode removal section corresponding to the defective position, and the electrode removal section is created on the basis of data detected from the first encoder.

Description

Battery manufacturing system

[0001] The present invention relates to a battery manufacturing system, and more particularly, to a battery manufacturing system capable of improving the traceability of battery products by accurately counting the amount of discarded defective electrodes.

[0002] This application claims the benefit of priority from Korean Patent Application No. 10-2023-0101921, filed August 4, 2023, the entire disclosure of which is incorporated herein by reference.

[0003] With technological developments and growing demand for electric vehicles, demand for secondary batteries is also rapidly increasing. Lithium secondary batteries, with their high energy density, high operating voltage, and excellent storage and lifespan characteristics, are widely used as a power source for various mobile devices and other electronic products.

[0004] In the battery manufacturing process, which includes electrode manufacturing and assembly, if a defect or other issue arises in a semi-finished or finished battery, it may be necessary to trace the entire process back. In other words, it is necessary to determine the origin of each component of the battery cell being traced.

[0005] To more easily identify the causes of defects, there is a need for methods that can enhance the reliability of production-related data while ensuring cell traceability in the complex battery manufacturing process.

[0006] The first technical task to be achieved by the present invention is to provide a battery manufacturing system capable of improving the traceability of battery products by accurately counting the amount of discarded defective electrodes.

[0007] The second technical task to be achieved by the present invention is to provide a battery manufacturing method capable of improving the traceability of battery products by accurately counting the amount of discarded defective electrodes.

[0008] The present invention provides a battery manufacturing system, comprising: an electrode process device for performing an electrode process; and a roll map creation device for creating a roll map including coordinate data indicating the position of an electrode and measurement and inspection data generated according to the progress of an electrode process performed on the electrode and matching the coordinate data, wherein the electrode process device includes: an unwinder configured to unwind an electrode from a first electrode roll; a rewinder configured to wind the electrode onto a second electrode roll; and an inspection measuring device for collecting inspection measurement data of the electrode being transported; a first encoder provided on one side of the electrode being transported and configured to detect a moving speed of the electrode by irradiating a laser to the electrode, wherein the first encoder is a non-contact encoder; and the roll map creation device is configured to receive a defective position of the electrode and create an electrode removal section corresponding to the defective position, and the electrode removal section is created based on data detected from the first encoder.

[0009] In some embodiments, the roll map creation device may be configured to generate tag coordinates of a tag corresponding to the defective location to create an electrode removal section.

[0010] In some embodiments, the roll map creation device may be configured to define a preceding removal reference coordinate preceding the tag coordinate and a succeeding removal reference coordinate following the tag coordinate based on the tag coordinate, and to define an interval between the preceding removal reference coordinate and the succeeding removal reference coordinate as an electrode removal interval.

[0011] In some embodiments, the first encoder may be provided on the unwinder.

[0012] In some embodiments, the battery manufacturing system may further include a second encoder, which is a contact encoder, on the rewinder.

[0013] In some embodiments, the first encoder may be configured to transmit a roll amount signal to the roll map creation device based on the linear velocity of the electrode.

[0014] In some embodiments, the roll map creation device may be configured to calculate a waste amount due to a defect in the electrode based on the discharge amount signal.

[0015] In some embodiments, the first encoder comprises: a first light source configured to irradiate a first laser beam to the electrode; and a second light source configured to irradiate a second laser beam non-parallel to the first laser beam to the electrode, wherein the first encoder is configured to receive the first laser beam and the second laser beam reflected from the electrode, and is configured to detect a moving speed of the electrode by analyzing the reflected first laser beam and the second laser beam.

[0016] In some embodiments, the first encoder may be configured to analyze the reflected laser beam using an interference pattern of Doppler shifted light scattered from the electrode surface.

[0017] In some embodiments, the battery manufacturing system may further include a reference point sensor configured to detect a reference point of the electrode to generate a reference point detection signal.

[0018] Another aspect of the present invention provides a battery manufacturing system comprising: an unwinder configured to unwind an electrode sheet from a first electrode roll; a rewinder configured to wind the electrode sheet onto a second electrode roll; a non-contact first encoder configured to detect a length of the electrode sheet unwound by the unwinder to generate an unwinding amount signal; a second encoder configured to detect a length of the electrode sheet wound by the rewinder to generate a winding amount signal; and a programmable logic controller (PLC) configured to collect coordinate data indicating a position on the electrode sheet based on the winding amount signal.

[0019] In some embodiments, the PLC may be configured to collect scrap data representing the length of a discarded portion of the electrode sheet based on the release amount signal and the take-up amount signal.

[0020] In some embodiments, the battery manufacturing system may further include a scrap port configured to discard defective portions of the electrode sheet.

[0021] In some embodiments, the battery manufacturing system further comprises a failure detection sensor configured to generate a failure detection signal, and the PLC may be configured to collect failure detection data by associating the failure detection signal with the coordinate data.

[0022] In some embodiments, the first encoder comprises: a first light source configured to irradiate a first laser beam to the electrode sheet; and a second light source configured to irradiate a second laser beam non-parallel to the first laser beam to the electrode sheet, wherein the first encoder is configured to receive the first laser beam and the second laser beam reflected from the electrode, and is configured to detect a moving speed of the electrode sheet by analyzing an interference pattern of the reflected first laser beam and the second laser beam.

[0023] The present invention provides a battery manufacturing method, which comprises the steps of: unwinding an electrode from a first electrode roll of an unwinder; detecting a moving speed of the electrode with a first encoder, which is a non-contact encoder provided on the unwinder; winding the electrode with a second electrode roll of a rewinder; and creating a roll map including coordinate data indicating a position of the electrode and measurement and inspection data generated according to the progress of an electrode process performed on the electrode and matching the coordinate data, in order to achieve the second technical task, wherein the step of creating the roll map includes the step of receiving a defective position of the electrode and creating an electrode removal section corresponding to the defective position, and wherein the electrode removal section is created based on data detected from the first encoder.

[0024] In some embodiments, the step of creating the roll map is performed by a roll map creation device, and the roll map creation device may be configured to create tag coordinates of a tag corresponding to the defective location to create an electrode removal section.

[0025] In some embodiments, the device may further include a step of detecting a length of the electrode wound by the rewinder using a second encoder, which is a contact-type encoder provided on the rewinder, and the roll map creation device may be configured to: detect the wound length of the electrode using the first encoder, generate an unwinding amount signal; and detect the wound length of the electrode using the second encoder, generate an unwinding amount signal, and calculate a scrap amount due to a defect in the electrode.

[0026] The battery manufacturing system of the present invention has the effect of improving the traceability of battery products by accurately counting the amount of waste of defective electrodes generated during the electrode manufacturing process.

[0027] 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.

[0028] Figure 1 is a conceptual perspective drawing schematically showing the state of an electrode undergoing an electrode manufacturing process.

[0029] Figure 2 conceptually illustrates a roll map created in an electrode manufacturing process according to one embodiment of the present invention.

[0030] FIG. 3 illustrates a battery manufacturing system according to exemplary embodiments of the present invention.

[0031] FIG. 4 is a block diagram illustrating a battery manufacturing system according to exemplary embodiments.

[0032] Figure 5 is a block diagram conceptually illustrating the configuration of the first encoder.

[0033] Figure 6 is a conceptual diagram illustrating a method for defining a defective portion of an electrode sheet based on a defective tag.

[0034] Figure 7 is a schematic diagram showing a battery manufacturing system (11) according to another embodiment of the present invention.

[0035] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the embodiments of the present invention may be modified in various different forms, and the scope of the present invention should not be construed as being limited by the embodiments described below. It is preferable to interpret that the embodiments of the present invention are provided to more completely explain the present invention to those of ordinary skill in the art. Like numbers refer to like elements throughout. Furthermore, various elements and areas in the drawings are schematically drawn. Therefore, the present invention is not limited by the relative sizes or intervals depicted in the accompanying drawings.

[0036] While terms like "first" and "second" may be used to describe various components, these components are not limited by these terms. These terms are used solely to distinguish one component from another. For example, a first component could be referred to as a "second component," and vice versa, without departing from the scope of the present invention.

[0037] The terminology used in this application is only used to describe specific embodiments and is not intended to limit the inventive concept. The singular expression includes the plural expression unless the context clearly indicates otherwise. In this application, it should be understood that the expressions "comprises" or "has" indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the specification, but do not preclude the possibility of the presence or addition of one or more other features, numbers, operations, components, parts, or combinations thereof.

[0038] Unless otherwise defined, all terms used herein, including technical and scientific terms, have the same meaning as commonly understood by those of ordinary skill in the art to which the present invention pertains. Furthermore, it is to be understood that commonly used terms, such as those defined in dictionaries, should be interpreted to have a meaning consistent with their meaning within the relevant technical context, and should not be interpreted in an overly formal sense unless explicitly defined herein.

[0039] In some embodiments, where implementations are otherwise feasible, specific process sequences may be performed in a different order than described. For example, two processes described in succession may be performed substantially simultaneously, or in a reverse order from the described order.

[0040] In the accompanying drawings, variations in the shapes depicted may be expected, for example, depending on manufacturing techniques and / or tolerances. Therefore, embodiments of the present invention should not be construed as being limited to the specific shapes of the regions depicted herein, but should include, for example, changes in shapes resulting from the manufacturing process. All terms "and / or" used herein include each and every combination of one or more of the mentioned components. In addition, the term "substrate" used herein may mean the substrate itself, or a laminated structure including the substrate and a predetermined layer or film formed on the surface thereof. In addition, the "surface of the substrate" in this specification may mean the exposed surface of the substrate itself, or the outer surface of a predetermined layer or film formed on the substrate.

[0041]

[0042] (Example 1)

[0043] Figure 1 is a conceptual perspective drawing schematically showing the state of an electrode undergoing an electrode manufacturing process.

[0044] Referring to Fig. 1, a coated electrode (1) is manufactured by coating an active material on a current collector in a coater (C) to form a coated portion (1a). A reference point may be marked on an uncoated portion (1b) on which the active material is not coated. In some embodiments, the active material may be coated on both the upper and lower surfaces of the electrode (1). The coated electrode (1) may be pressed by a press roll in a roll press process and cut along the length direction of the electrode (1) by a slitter in a slitting process.

[0045] Afterwards, in the notching process, electrode tabs (2) can be formed by punching with a press or the like. In the notching process, the electrode tabs (2) are formed for each unit electrode so that they can be cut for each unit electrode to be manufactured into a battery cell or cut in a subsequent process. The width of the unit electrode corresponds to the pitch (P) processed by the press.

[0046] This electrode manufacturing process is performed through a series of roll-to-roll processes in which the electrode unwound from the unwinder is moved and wound on the rewinder in a sequential and repeated manner. That is, the electrode is coated as it moves from the unwinder of the coating process to the rewinder, and the electrode is wound on the rewinder, thereby completing the electrode roll of the coating process. Next, the electrode roll is placed on the unwinder of the roll press process and moved to the rewinder of the roll press process. The electrode roll is wound on the rewinder of the roll press process, thereby completing the electrode roll of the roll press process. Thereafter, the electrode roll is unwound from the unwinder of a subsequent process (e.g., a second roll press process, a slitting process, a notching process, etc.), and after going through a predetermined process, is wound on the rewinder of the subsequent process again, thereby completing the electrode roll of the subsequent process. In this way, the electrode manufacturing process may include a series of roll-to-roll processes in which the electrode released from the unwinder is moved and wound in the rewinder (so-called roll-to-roll process) is sequentially repeated.

[0047] Figure 2 conceptually illustrates a roll map created in an electrode manufacturing process according to one embodiment of the present invention.

[0048] As described above, electrodes are processed in a roll-to-roll manner in coating processes, roll press processes, slitting processes, etc. The roll map is a bar-shaped representation of the progress of the electrode, and the longitudinal and transverse positions of the electrode are depicted as coordinates on the roll map. That is, the roll map is defined on a coordinate plane having two coordinate axes, the longitudinal axis and the transverse axis of the electrode, and each position of the electrode on the coordinate plane can be represented by a coordinate value on the coordinate plane. This roll map stores information on defects, quality, electrode breakage, etc. that occur in the electrode manufacturing process together with the coordinates, so that data related to quality or defects in the electrode manufacturing process can be easily and visually grasped at a glance.

[0049] Referring to Figure 2, external defect information, such as pinhole defects (f1) and line defects (f2), are visualized and displayed at the coordinates where the defects occurred. Furthermore, mismatches between the coated and uncoated portions (f3) are also displayed. Other loading defects are also displayed, as well as areas where electrodes are discarded at the outermost edge.

[0050] In addition, reference points (K1, K2, K3) can be marked and displayed at predetermined intervals on the electrode (1). When a fracture occurs in the electrode (1) and it is connected with a joint connecting member, the length of the electrode is reduced by the fractured length. As described above, the points where appearance defects occur can also be removed and connected by the worker. The roll map can also simulate such a situation and modify the coordinates on the roll map. Referring to Fig. 2, the coordinates that do not reflect the above-described electrode removal portion and the coordinates that reflect it are shown together on one roll map. The former is called the absolute coordinate (x), and the latter is called the relative coordinate (y). As shown in Fig. 2, the relative coordinate (y) and the absolute coordinate (x) can be displayed together on one roll map, but can also be displayed separately. The roll map indicated by the relative coordinate (y) shows the state of the actual electrode.

[0051] Such roll maps can be created for each of the individual processes described above. However, since the roll-to-roll process unwinds the electrode wound in the preceding process in the subsequent process, the end of the roll map representing the electrode roll of the preceding process becomes the beginning of the roll map representing the electrode roll of the subsequent process, and so on, and the start and end of the electrode are reversed during the roll-to-roll process. In addition, in the case of a double-sided electrode in which the electrode active material is coated on both sides of the electrode, the electrode surface may be reversed, such as the top electrode in the preceding process becoming the back electrode in the subsequent process. In other words, depending on the winding direction of the electrode in the preceding process and the unwinding direction of the electrode in the subsequent process, the start and end of the electrode may be reversed. Since the roll maps of each process are created based on these reversed electrodes, the coordinates of the roll maps of each process are also reversed. Furthermore, as the electrode is cut and connected multiple times in the longitudinal direction to remove defective or broken sections, and so on, during a series of roll-to-roll processes, the length of the electrode changes. Since the roll map of each process reflects these inversions and length changes, the coordinate values ​​may be different for each.

[0052] In the final stage of the electrode manufacturing process, only the remaining electrodes (survival electrodes) remain, excluding the electrode parts removed in the previous stages. Since batteries are manufactured using these survival electrodes, if a problem occurs in a finished or semi-finished battery, the cause of the problem can be traced by referring to the roll map of the final electrode. Furthermore, the roll maps for each process described above can be used to trace the electrode part that caused the problem. Thus, the roll map is a useful tool for quality monitoring, as well as for assessing quality and defects.

[0053]

[0054] Figure 3 illustrates a battery manufacturing system (10) according to exemplary embodiments of the present invention.

[0055] Referring to FIG. 3, the battery manufacturing system (10) may include a coating device (200), a roll pressing device (300), a slitting device (400), a notching device (500), and rewinding stages (600).

[0056] The electrode sheet unwound from the inserted electrode roll can be processed by any one of the die coater of the coating device (200), the pressure rolls of the roll pressing device (300), and the slitting knife of the slitting device (400), and the processed electrode sheet can be wound onto an electrode roll. Accordingly, the processing of the coating device (200), the roll pressing device (300), and the slitting device (400) for producing the electrode of the battery can be referred to as a roll-to-roll process.

[0057] The coating device (200) can perform a coating process on an electrode sheet. The coating process is a process of applying a coating material, such as electrode slurry, onto the electrode sheet. 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, the conductive agent, the binder, and the like in a solvent.

[0058] The roll pressing device (300) can perform a roll pressing process on an electrode sheet. The roll pressing process is a process of passing an electrode sheet coated with electrode slurry between opposing pressure rolls. The roll pressing process can flatten the surface of the electrode sheet and enhance the bonding strength between the active material of the electrode sheet and the current collector.

[0059] A slitting device (400) can perform a slitting process on an electrode sheet. Through the slitting process, the electrode sheet can be separated into a plurality of electrode sheets.

[0060] The notching device (500) can cut the electrode sheet drawn from the electrode roll into the electrode shape of a battery cell. Accordingly, unit electrodes can be formed in the notching device (500). The notching device (500) can further perform a drying process on either the electrode sheet or the unit electrodes.

[0061] If the electrode sheet contains a defect, the defect in the electrode sheet can be removed. The defect in the electrode sheet can be removed in either the roll pressing device (300) or the rewinding stages (600).

[0062] In each of the rewinding stages (600), no actual process may be performed on the electrode sheet. Each of the rewinding stages (600) may change the winding direction of the electrode sheet. Each of the rewinding stages (600) may unwind the electrode roll, remove defects from the electrode sheet unwound from the electrode roll, and rewind the electrode sheet from which the defects have been removed. Accordingly, in addition to removing defects from the electrode roll, the outer portion of the input electrode roll may be wound on the inner portion of the completed electrode roll. Similarly, the inner portion of the input electrode roll may be wound on the outer portion of the completed electrode roll.

[0063] Defects in the electrode sheet can be removed while the roll pressing device (300) performs the roll pressing process. Alternatively, only the defects in the electrode sheet can be removed without performing the roll pressing process. The operation mode of the roll pressing device (300) that removes only the defective portions of the electrode sheet without performing the roll pressing process is referred to as the rewinding mode. In the rewinding mode, each of the pressure rolls can be moved to a different position separate from the position where the electrode sheet was located.

[0064] As the electrode roll is sequentially processed by the coating device (200), the roll pressing device (300), the slitting device (400), and the notching device (500), unit electrodes can be provided. In the case of long unit electrodes, after the roll pressing process is performed in the roll pressing device (300), they can be directly transferred to the notching device (500) without slitting in the slitting device (400).

[0065] If the defects in the electrode roll processed by the coating device (200) and fed into the roll pressing device (300) are excessive, the defects in the electrode roll can be removed in the roll pressing device (300). The excessive defects in the electrode roll processed by the coating device (200) may include, for example, a large number of tab folds, ring defects, etc.

[0066] If the defects in the electrode roll processed by the roll pressing device (300) are excessive, the defects in the electrode roll can be removed in either the roll pressing device (300) operating in the rewinding mode or the rewinding stage (600). Subsequently, the electrode roll with reduced defects (or no defects) can be input to the slitting device (400). The excessive defects in the electrode roll processed by the roll pressing device (300) can include winding slippage and exceeding the upper limit of the number of defective tags.

[0067] If the number of defects in the electrode roll processed by the slitting device (400) is excessive, the defects in the electrode roll can be removed in the rewinding stage (600). Then, the electrode roll with reduced defects (or no defects) can be fed into the notching device (500). The excessive number of defects in the electrode roll processed by the slitting device (400) can include exceeding the upper limit of the number of defect tags.

[0068] Here, each of the rewinding stages (600) can be online. Each of the rewinding stages (600) can be configured to discard defective electrode rolls and collect scrap data indicating the discarded length. Accordingly, the length of the discarded electrodes in the rewinding stages (600) can be updated, thereby improving the traceability of the battery manufacturing process.

[0069]

[0070] FIG. 4 is a block diagram illustrating a battery manufacturing system (10) according to exemplary embodiments.

[0071] Referring to FIG. 4, the battery manufacturing system (10) may include an electrode process device (100), an EIF (1010), a server (1020), and a visualization device (1030). The electrode process device (100) may be one or more of a coating device (200), a roll pressing device (300), a slitting device (400), a notching device (500), and rewinding stages (600).

[0072] The electrode process device (100) may include an unwinder (111), a rewinder (113), a first encoder (121), a second encoder (123), a reference point sensor (135), a roll map PLC (Programmable Logic Controller) (141), and a process PLC (143). In some embodiments, the electrode process device (100) may further include a splicing table (115) and / or a scrap port (117).

[0073] The battery manufacturing system (10) 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 coordinate values ​​indicating locations on the electrode sheet (ES). A process for manufacturing a battery may be performed on the electrode sheet (ES), as described below. The roll map may represent events of the process performed on the electrode sheet (ES) and include data associated with the coordinate values. Accordingly, the roll map enables feedback, feed forwarding, and battery manufacturing process tracking, as described below.

[0074] 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) onto the second electrode roll (ER2). The electrode sheet (ES) can be wound onto the second electrode roll (ER2) and, after reaching a predetermined winding length, cut and separated. Accordingly, the electrode sheet (ES) can be moved between the unwinder (111) and the rewinder (113).

[0075] The roll map can be generated in units of lots. 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. Similarly, the first electrode roll (ER1) newly loaded into the unwinder (111) is also an example of a lot. Accordingly, the server (1020) can store the first roll map of a previous process (e.g., a coating process, a roll pressing process, or a slitting process). The first roll map may correspond to the first electrode roll (ER1). In addition, the server (1020) can be configured to generate a second roll map of the second electrode roll (ER2) based on the processing of the electrode process device (100). The second roll map may correspond to the second electrode roll (ER2).

[0076] As a non-limiting example, the second roll map may be generated by updating the first roll map. Alternatively, the second roll map may be generated based on data generated in the electrode process device (100) without loading the first roll map.

[0077] Time series data organized over time in the roll map (i.e., according to the progress of the process) can be associated with coordinate data collected based on the movement amount of the electrode sheet (ES) (i.e., either the exhaustion amount or the input amount).

[0078] Battery manufacturing involves a series of different processes, with leading processes influencing subsequent processes. If the time-series data from leading processes do not directly match the actual workpieces, intermediate products, and finished products, it can be difficult to reflect the time-series data from leading processes in subsequent processes. Hereinafter, the correction of subsequent processes based on data generated from the results of leading processes is referred to as "feed forward."

[0079] 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. 3. 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 comprising 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 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.

[0080] The battery electrode process involves a series of roll-to-roll processes. For feedforwarding, time-series data needs to be associated with the positions of real-world workpieces, components, semi-finished products, and finished products. Here, feedforwarding may include controlling the processing of an electrode sheet (ES) based on a roll map of a first electrode roll (ER1) generated in a previous process. For example, the roll map of a first electrode roll (ER1) processed in a current process may include defective data (DD), and in an electrode process device (100), an electrode sheet (ES) unwound from the first electrode roll (ER1) may be discarded based on the defective data (DD).

[0081] Roll maps can link time-series data to coordinate data, which contains coordinate values ​​representing the positions of actual workpieces, parts, semi-finished products, and finished products. Based on these coordinate data, roll maps can provide a match between time-series data and real-world workpieces, parts, semi-finished products, and finished products. Accordingly, roll map creation and feed forwarding based on roll maps can quantify and objectify aspects of a process previously dependent on operator discretion, thereby improving productivity and quality.

[0082] Additionally, the roll map of a preceding lot can be used to improve the process for subsequent lots, an action referred to as process feedback. Process feedback using a roll map can include identifying process conditions and parameters that caused problems and defects based on the data contained in the roll map.

[0083] Furthermore, the roll map, as described below, is cumulatively generated for work-pieces, parts, semi-finished products, and finished products of unit processes, thereby enabling 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 number and coordinate information of the electrodes and separator included in the battery cell. In other words, the cell ID may be associated with a roll map of the electrodes and separator included in the battery cell. Accordingly, if 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 can be retrieved based on the cell ID.

[0084] The first encoder (121) may be configured to sense the amount of electrode sheet (ES) unwound from the first electrode roll (ER1) by the unwinder (111). Accordingly, the first encoder (121) may generate an unwinding amount signal (UWAS) indicating the length of the electrode sheet (ES) unwound by the unwinder (111). The first encoder (121) may be configured to transmit the unwinding amount signal (UWAS) to the roll map PLC (141).

[0085] The first encoder (121) may be a non-contact encoder. The first encoder (121) may be provided on the unwinder (111). In some embodiments, the first encoder (121) may be a non-contact encoder configured to measure the linear speed of the electrode sheet (ES) using a laser beam. Fig. 5 is a block diagram conceptually illustrating the configuration of the first encoder (121).

[0086] Referring to FIG. 5, the first encoder (121) includes a first light source (1215a) configured to irradiate a first laser beam (L1) to an electrode sheet (ES) and a second light source (1215b) configured to irradiate a second laser beam (L2) to the electrode sheet (ES).

[0087] A laser beam can be generated from a laser generating device (1211) and split into two directions by a beam splitter (1213). Thereafter, the split laser beam can be irradiated to a first light source (1215a) and a second light source (1215b) through a prism (1212).

[0088] The first laser beam (L1) irradiated from the first light source (1215a) and the second laser beam (L2) irradiated from the second light source (1215b) can be directed to be irradiated at substantially the same position on the electrode sheet (ES). Since the first laser beam (L1) and the second laser beam (L2) are not parallel, they can be directed to a desired position through an appropriate optical system. The first light source (1215a) and the second light source (1215b) can include an optical system that directs the first laser beam (L1) and the second laser beam (L2) to a specific position.

[0089] The first encoder (121) may further include a light receiving unit (1217). The light receiving unit (1217) is configured to receive a first laser beam (L1) and a second laser beam (L2) reflected from the surface of the electrode sheet (ES). When the first laser beam (L1) and the second laser beam (L2) are reflected at substantially the same position on the electrode sheet (ES), an interference pattern is generated due to Doppler shift light scattered from the surface of the electrode sheet (ES), and the light receiving unit (1217) obtains the interference pattern and transmits it to the controller (1219). The controller (1219) can analyze the interference pattern to determine the linear speed of the electrode sheet (ES).

[0090] Referring again to FIG. 4, the second encoder (123) may be configured to sense the amount of electrode sheet (ES) wound onto the second electrode roll (ER2) by the rewinder (113). Accordingly, the second encoder (123) may generate a winding amount signal (WAS) indicating the length of the electrode sheet (ES) wound by the rewinder (113). The second encoder (123) may be configured to transmit the winding amount signal (WAS) to the roll map PLC (141).

[0091] The second encoder (123) may be a contact-type encoder. In some embodiments, the second encoder (123) may be an encoder configured to measure the length of the electrode sheet (ES) conveyed by bringing a rotating wheel into contact with the electrode sheet (ES). The second encoder (123) may be provided on the rewinder (113).

[0092] In the first encoder (123), defects such as uncoated portions have not yet been removed from the first electrode roll (ER1). If the first encoder (123) is a contact-type, when the electrode sheet (ES) is unwound from the unwinder (111), the portion where defects such as uncoated portions exist may slip beyond a tolerance, thereby increasing the measurement error. Therefore, by employing a non-contact encoder for the first encoder (123), the measurement error can be minimized.

[0093] In addition, as described below, after the defective portion of the electrode sheet (ES) is removed, it is wound in the rewinder (113). Accordingly, the electrode sheet (ES) with the defective portion removed is wound in the second encoder (123) to form the second electrode roll (ER2). Since the defective portion has already been removed, there is relatively little concern about measurement errors due to slippage, and even when a relatively inexpensive contact-type rotary encoder is used, it is possible to produce electrode products with an error within the allowable range.

[0094] Defective portions of the electrode sheet (ES) can be discarded as described below. Accordingly, the length of the electrode sheet (ES) unwound from the unwinder (111) may be different from the length of the electrode sheet (ES) wound by the rewinder (113). Since the length of the unwound electrode sheet (ES) is measured by a non-contact first encoder (121), it can be measured with high precision.

[0095] The roll map PLC (141) may be configured to collect coordinate data of the electrode sheet (ES) based on the unwinding amount signal (UWAS) and / or the winding amount signal (WAS) of the electrode sheet (ES). For example, the roll map PLC (141) may determine the movement distance of the electrode sheet (ES) based on the unwinding amount signal (UWAS) of the electrode sheet (ES), and accordingly, the roll map PLC (141) may be configured to determine the position within the electrode sheet (ES) of a portion of the electrode sheet (ES) unwound by the unwinder (111) at each point in time when an event occurs in the electrode sheet (ES). As another example, the roll map PLC (141) can determine the movement distance of the electrode sheet (ES) based on the winding amount signal (WAS) of the electrode sheet (ES), and accordingly, the roll map PLC (141) can be configured to determine the position within the electrode sheet (ES) of a portion of the electrode sheet (ES) that is wound by the rewinder (113) at each time an event occurs in the electrode sheet (ES). As another example, the roll map PLC (141) can also determine the movement distance of the electrode sheet (ES) based on each of the winding amount signal (UWAS) and the winding amount signal (WAS).

[0096] Here, the event may include various processing, inspection, and measurement that occur on the electrode sheet (ES) in the electrode process device (100), such as cutting of the electrode sheet (ES), joining of the electrode sheet (ES), sensing of a datum point on the electrode sheet (ES), and sensing of a defective tag on the electrode sheet (ES). Hereinafter, the technical idea of ​​the present invention is explained with reference to an embodiment in which a roll map PLC (141) collects coordinate data based on a winding amount signal (WAS) of the electrode sheet (ES), as a non-limiting example.

[0097] The coordinate data may include coordinate values ​​that match each part of the electrode sheet (ES). That is, each arbitrary point on the electrode sheet (ES) may be matched with a coordinate value. The coordinate value may be a one-dimensional quantity in the longitudinal direction of the electrode sheet (ES), but is not limited thereto. The coordinate value may also be a two-dimensional quantity in the Y direction in the longitudinal direction and the width direction of the electrode sheet (ES).

[0098] The defect detection sensor (131) may be configured to sense either a defect mark or a defect tag on the electrode sheet (ES). The defect mark may be formed, for example, by an inkjet printer or the like, and may include information on the location and type of the defect. The defect tag may be attached to the electrode sheet (ES) by a worker or a defect tag attaching device. The defect tag may indicate the location of the defect in the electrode sheet (ES). As a non-limiting example, the defect detection sensor (131) may be either a color sensor or a vision machine. The defect detection sensor (131) may be configured to generate a defect detection signal (NSS). The defect detection sensor (131) may be configured to transmit the defect detection signal (NSS) to the roll map PLC (141).

[0099] Figure 6 is a conceptual diagram illustrating a method for defining a defective portion (DES) of an electrode sheet (ES) based on a defective tag (T).

[0100] Referring to Fig. 6, when a defect (F) is detected on the electrode sheet (ES), a defect tag (T) is assigned to a corresponding location. As described above, the defect (F) of the electrode sheet (ES) can be identified by a defect detection sensor (131) (see Fig. 4), and the roll map creation device can store tag coordinates corresponding to the location where the defect (F) on the electrode sheet (ES) is identified.

[0101] The portion of the electrode sheet (ES) where the defect (F) occurs needs to be removed. When the portion where the defect (F) occurs is removed, the overall length of the electrode sheet (ES) is correspondingly shortened.

[0102] Based on the tag coordinates indicating the location where a defect (F) occurs in the electrode sheet (ES), a preceding removal reference coordinate (C1) preceding the tag coordinates and a subsequent removal reference coordinate (C2) following the tag coordinates can be defined. In addition, the section between the preceding removal reference coordinate (C1) and the subsequent removal reference coordinate (C2) can be defined as a defective portion (DES) of the electrode sheet (ES).

[0103] The preceding removal reference coordinate (C1) may be a coordinate preceding the tag coordinate by a predetermined length a. In some embodiments, the succeeding removal reference coordinate (C2) may be a coordinate following the tag coordinate by a predetermined length a. In some embodiments, the length of the defective portion (DES) may be 2a, which is twice the predetermined length a.

[0104] By excluding the defective portion (DES) from the electrode sheet (ES), a roll map of the survival electrode (S) can be created. The electrode sheet (i.e., the defective portion (DES)) between the preceding removal reference coordinate (C1) and the succeeding removal reference coordinate (C2) in the actual electrode can be cut off and discarded, and the end of the preceding removal reference coordinate (C1) and the end of the succeeding removal reference coordinate (C2) can be joined to each other.

[0105] Referring again to FIG. 4, the rollmap PLC (141) may be configured to collect defect detection data (NSD) based on the defect detection signal (NSS). The rollmap PLC (141) may be configured to associate the defect detection signal (NSS) with coordinate data to collect the defect detection data (NSD). The defect detection data (NSD) may include, for example, a defect value indicating the presence or absence of a defect and the nature of the defect, and coordinate values ​​matched to the defect value.

[0106] To collect the non-defect detection data (NSD), the coordinate data can be calibrated based on the offset length (OL1). The calibration of the coordinate data compensates for the difference between the portion of the electrode sheet (ES) sensed by the first encoder (121), i.e., the portion of the electrode sheet (ES) wound by the rewinder (113), and the portion of the electrode sheet (ES) sensed by the non-defect detection sensor (131).

[0107] According to exemplary embodiments, the rollmap PLC (141) can correct coordinate data collected at the same time as the bad detection signal (NSS) based on an offset length (OL1) to collect bad detection data (NSD), and associate the corrected coordinate data with the bad detection signal (NSS).

[0108] The offset length (OL1) is the length of the electrode sheet (ES) between the defect detection sensor (131) and the rewinder (113) along the movement path of the electrode sheet (ES). The offset length (OL1) may be equal to the straight-line distance between the defect detection sensor (131) and the rewinder (113).

[0109] The process PLC (143) may be configured to control the operation of the unwinder (111), the rewinder (113), the scrap port (117), and the processing mechanism (119). The process PLC (143) may be configured to generate signals for operation and interruption of the unwinder (111), the rewinder (113), the scrap port (117), and the processing mechanism (119).

[0110] The process PLC (143) may be configured to receive defective detection data (NSD) from the roll map PLC (141). The process PLC (143) may be configured to receive defective data (DD) from the server (1020). The defective data (DD) may be loaded into the process PLC (143) via the EIF (1010). Here, the defective data (DD) may indicate the location of a defect on the first electrode roll (ER1). The defective data (DD) may be included in the first roll map of the first electrode roll (ER1).

[0111] The process PLC (143) may be configured to generate signals for operation and stop of the unwinder (111), the rewinder (113), the scrap port (117), and the processing mechanism (119) based on the defective detection data (NSD) and the defective data (DD). When a defect on the electrode sheet (ES) identified by the defective data (DD) and the defective detection data (NSD) approaches the splicing table (115), the process PLC (143) may be configured to generate a signal for slowing down the moving speed of the electrode sheet (ES) or stopping the winding and unwinding of the unwinder (111) and the rewinder (113).

[0112] After cutting the starting position of the defect (or, considering the process margin, a position adjacent to the starting position of the defect) on the splicing table (115), the scrap port (117) can be configured to wind up the defective portion (DES) of the electrode sheet (ES), as indicated by the bold dashed line. After the defective portion (DES) of the electrode sheet (ES) is sufficiently wound by the scrap port (117), the electrode sheet (ES) connected to the scrap port (117) and the electrode sheet (ES) connected to the unwinder (111) can be separated. Subsequently, the current process can be continued by connecting the portion of the electrode sheet (ES) connected to the unwinder (111) and the portion of the electrode sheet (ES) connected to the rewinder (113). The portion of the electrode sheet (ES) connected to the unwinder (111) and the portion of the electrode sheet (ES) connected to the rewinder (113) can be connected on a splicing table (115).

[0113] In some embodiments, after the unwinder (111) and the rewinder (113) are stopped for scrapping the defective portion (DES) of the electrode sheet (ES), the defective portion (DES) of the electrode sheet (ES) can be moved to the scrap port by driving the unwinder (111) without driving the rewinder (113). In some embodiments, the roll map PLC (141) can be configured to collect scrap data (SD) based on the unwind amount signal (UWAS) after the start of scrapping the defective portion (DES) of the electrode sheet (ES). In some embodiments, for collecting the scrap data (SD), the roll map PLC (141) can also receive a signal for controlling the operation of the unwinder (111) and the rewinder (113) from the process PLC (143). As another example, the roll map PLC (141) may be configured to collect scrap data (SD) based on the amount of rotation of the drive roll of the scrap port (117). As another example, the roll map PLC (141) may be configured to collect scrap data (SD) based on a change in the distance between reference points on the electrode sheet (ES) and a distance between a seam on the electrode sheet (ES) and the reference point.

[0114] The roll map PLC (141) may be configured to collect scrap data (SD) indicating the length of electrode sheets (ES) discarded due to defects from the electrode roll for the electrode process device (100). Accordingly, the length of discarded electrodes in the rewinding stages (600) can be updated, and the traceability of the battery manufacturing process can be improved.

[0115] In some embodiments, the roll map PLC (141) may be configured to calculate the length of the discarded electrode sheet from the unwinding amount signal (UWAS) and the winding amount signal (WAS). In some embodiments, the roll map PLC (141) may be configured to check whether the difference between the unwinding amount and the winding amount calculated from the unwinding amount signal (UWAS) and the winding amount signal (WAS) matches the scrap data (SD). In some embodiments, the roll map PLC (141) may be configured to determine the scrap data (SD) as the discarded amount of the electrode sheet if the difference between the unwinding amount and the winding amount matches the scrap data (SD).

[0116] The seam sensor (133) may be configured to sense a seam on the electrode sheet (ES) to generate a seam detection signal (JSS). The seam may be a portion where both ends of the electrode sheet (ES) are joined after a defective portion (DES) of the electrode sheet (ES) is removed. As a non-limiting example, the seam sensor (133) may be any one of a color sensor and a vision machine. The seam sensor (133) may be configured to transmit the seam detection signal (JSS) to the roll map PLC (141).

[0117] The roll map PLC (141) may be configured to collect joint detection data (JSD) based on the joint detection signal (JSS). The roll map PLC (141) may be configured to collect joint detection data (JSD) by associating the joint detection signal (JSS) with coordinate data.

[0118] According to exemplary embodiments, the rollmap PLC (141) can correct coordinate data collected at the same time as the seam detection signal (JSS) based on an offset length (OL2) to collect seam detection data (JSD) and associate the corrected coordinate seam detection signal (JSS).

[0119] The offset length (OL2) is the length of the electrode sheet (ES) between the seam sensor (133) and the rewinder (113) along the movement path of the electrode sheet (ES). The offset length (OL2) may be equal to the straight-line distance between the seam sensor (133) and the rewinder (113).

[0120] The reference point sensor (135) may be configured to sense reference points of the electrode sheet (ES) to generate a reference point detection signal (DSS). The reference points may be formed at set intervals on the electrode sheet (ES) to indicate a position on the electrode sheet (ES). Each of the reference points may be, for example, a two-dimensional barcode including information on the direction of the reference point and the sequence number of the reference point. Accordingly, the reference point detection signal (DSS) may include a time value corresponding to sensing of the reference point and a sequence number value of the reference point. The reference point sensor (135) may be configured to transmit the reference point detection signal (DSS) to the roll map PLC (141).

[0121] The roll map PLC (141) may be configured to collect reference point detection data (DSD) based on a reference point detection signal (DSS). The roll map PLC (141) may be configured to collect reference point detection data (DSD) by associating the reference point detection signal (DSS) with coordinate data.

[0122] According to exemplary embodiments, the rollmap PLC (141) can correct coordinate data collected at the same time as the reference point detection signal (DSS) based on an offset length (OL3) to collect reference point detection data (DSD), and associate the corrected coordinate data with the reference point detection signal (DSS).

[0123] The offset length (OL3) is the length of the electrode sheet (ES) between the reference point sensor (135) and the rewinder (113) along the movement path of the electrode sheet (ES). The offset length (OL3) may be equal to the straight-line distance between the reference point sensor (135) and the rewinder (113).

[0124] According to exemplary embodiments, any data generated based on events of scrap data (SD), bad detection data (NSD) and electrode sheet (ES) can be corrected based on baseline detection data (DSD).

[0125] The electrode process device (100) may further include an additional inspection measuring instrument. Here, the inspection measuring instrument is a term encompassing devices capable of performing only inspection, devices capable of performing only measurement, and devices capable of performing both inspection and measurement. If any of these three applies, it is referred to as an inspection measuring instrument. The inspection measuring instrument may include a sensing unit and a processing unit.

[0126] The above inspection measuring instrument may be configured to collect or generate inspection measurement data. Here, the term "inspection measurement data" encompasses both inspection data and measurement data, and if either of these two applies, it is referred to as inspection measurement data. The processing unit of the inspection measuring instrument may be connected to the sensing unit via wired or wireless means.

[0127] The above 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.

[0128] The above inspection data may include judgments on the quality of a portion of the 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 breaks and seams 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 disposal, data on a discarded 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 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 inspection device may be any one of a color sensor, a seam sensor, a reference point sensor, and a vision machine.

[0129] The inspection measurement data described above may be time-series data. The inspection measurement data may be temporally ordered. Temporal ordering is a key characteristic of time-series data, which organizes events in the order in which they occur and arrive for processing. That is, the inspection measurement data may be stored based on the time at which the inspection and / or measurement was performed, and the inspection measurement data may be temporally associated. Accordingly, each measurement value and each inspection value of the inspection measurement data may be time-matched.

[0130] The rollmap PLC (141) can be in operative communication with the first encoder (121), the second encoder (123), the defect detection sensor (131), the seam sensor (133), the reference point sensor (135) and additional measuring instruments and inspectors via a wired or wireless data network. The data network can be unidirectional or bidirectional. The data network can be implemented by a public network and / or a specialized network using a physical channel, WiFi, Bluetooth and / or other frequency bands. The first encoder (121), the second encoder (123), the defect detection sensor (131), the seam sensor (133), the reference point sensor (135) and additional measuring instruments and inspectors can be configured to collect data from equipment, workpieces, semi-finished products and products within the electrode process device (100), or to generate signals for collecting data.

[0131] The roll map PLC (141) can be configured to transmit defective detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD) to the process PLC (143). The defective detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD) can be transmitted to the first server (1020) via the process PLC (143) and the EIF (1010). The process PLC (143) and the EIF (1010) can relay communication of data including the defective detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD) between the first server (1020) and the roll map PLC (141). However, it is not limited thereto, and the rollmap PLC (141) may also directly transmit defective detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD) to the server (1020).

[0132] In order to control the process, a communication line may be installed between the process PLC (143) and the server (1020) via the EIF (1010) to connect the process PLC (143) and the server (1020). Accordingly, data transmission through the process PLC (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 encoders (121, 123) and the reference point sensor (135) directly transmit the unwinding amount signal (UWAS), the winding amount signal (WAS) and the measurement signal to the server (1020) and the case where the roll map PLC (141) directly transmits the defect detection data (NSD), the joint detection data (JSD), the scrap data (SD) and the reference point detection data (DSD) to the server (1020).

[0133] EIF (1010) may be a device for communication between a process PLC (143) of a manufacturing facility and a server (1020), which is an upper server.

[0134] In some embodiments, the server (1020) may include a roll map creation unit configured to create a roll map. The roll map may be a simulation of process data of the electrode sheet (ES) on a plane that simulates the electrode sheet (ES) moving between the unwinder (111) and the rewinder (113). In this case, the server (1020) may function as a roll map creation device.

[0135] In some embodiments, the roll map PLC (141) may include a roll map creation unit configured to create the roll map. In this case, the roll map PLC (141) may function as a roll map creation device. Hereinafter, a case in which the server (1020) creates the roll map will be described. However, the roll map PLC (141) may also be configured to create the roll map in a manner identical, equivalent, or similar to the configuration related to creating the roll map by the server (1020).

[0136] The server (1020) may be configured to generate a roll map based on defect detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD). The roll map may be generated on a lot-by-lot basis. The roll map may include data regarding specifications of the lot. The specifications of the lot may include, for example, a lot number, a length of a wound electrode sheet (ES), a width of the electrode sheet (ES), and materials and compositions used in processing the electrode sheet (ES).

[0137] According to exemplary embodiments, the server (1020) 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 (1020) may be, for example, a Manufacturing Execution System (MES). The server (1020) may be configured to input, process, output, and communicate data necessary for electrode manufacturing, such as a coating process, a press process, and a manufacturing process.

[0138] According to other exemplary embodiments, the server (1020) may be configured to store and process raw measurement data. The server (1020) may 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). According to exemplary embodiments, the server (1020) may further include a Statistical Process Controller (SPC). By collecting and analyzing manufacturing data in near real-time, the server (1020) may timely identify problem conditions and provide alerts to operators before potential problems occur.

[0139] According to other exemplary embodiments, the server (1020) may further include, for example, a data warehouse, and may store defect detection data (NSD), scrap data (SD), and coordinate data for a long period of time based on the quality assurance period of the product, etc.

[0140] According to other exemplary embodiments, the server (1020) may perform all of the functions of MES, SPC, and data warehouse, or may be provided separately from MES, SPC, and data warehouse for roll map creation.

[0141] The rollmap PLC (141), the process PLC (143), the EIF (1010), and the server (1020) can be implemented by hardware, firmware, software, and combinations thereof. For example, the rollmap PLC (141), the process PLC (143), the EIF (1010), and the server (1020) can include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The rollmap PLC (141), the process PLC (143), the EIF (1010), and the server (1020) can also include any one of simple controllers, complex processors such as microprocessors, CPUs, GPUs, processors configured by software, dedicated hardware, and firmware. The roll map PLC (141), process PLC (143), EIF (1010) and server (1020) 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).

[0142] The server (1020) may include a physical server or a cloud server. The server (1020) may provide data and analysis results to the operator via various frameworks. The framework may include a protocol supporting data transmission, allowing the display device (1030) to visualize data through a user interface and provide updated visualizations when new data is calculated by the server (1020). The protocol supporting the data transmission may use HTML, JavaScript, and / or JSON.

[0143] The server (1020) 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.

[0144] The server (1020) can transmit a visualization command (VC) to the display device (1030), and the display device (1030) can visualize the roll map and display the visualized roll map.

[0145] The electrode process device (100) can implement a plug-in architecture with an API for data acquisition to provide plug-and-play connectivity for measuring instruments and 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.

[0146] The data network between elements of the battery manufacturing system (10) 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.

[0147] In some embodiments, the battery manufacturing system (10) may further include a manual input system that allows an operator to input manufacturing data. The battery manufacturing system (10) may allow for operator data entry using an input tool and computer-based input of manufacturing data, such as scraping an Excel file. The manual input system may be, for example, a Human-Machine Interface (HMI) of a Supervisory Control And Data Acquisition (SCADA) system. SCADA typically includes a combination of software and hardware, such as a PLC and a Remote Terminal Unit (RTU). The HMI is a key component of the SCADA system, serving as a screen that supports communication between the operator and the SCADA system. For example, manual input via the HMI may include selecting a defect type and reflecting performance upon completion.

[0148] According to some embodiments, the operations of the Rollmap PLC (141), the Process PLC (143), the EIF (1010), and the Server (1020) 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.

[0149] The roll map PLC (141), process PLC (143), EIF (1010), and server (1020) may be configured with firmware, software, routines, and instructions for performing the operations described above or any of the processes described below. For example, the roll map PLC (141), process PLC (143), EIF (1010), and server (1020) may be instantiated in memory.

[0150] The roll map PLC (141) can be implemented by software configured to receive an unwinding amount signal (UWAS), a winding amount signal (WAS), a defect detection signal (NSS), a joint detection signal (JSS), and a reference point detection signal (DSS), collect coordinate data, defect detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD), and transmit the defect detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD).

[0151] The process PLC (143) can be implemented by software configured to generate control signals for controlling the unwinder (111), the rewinder (113), the scrap port (117) and the processing mechanism (119) based on the product ID, the product recipe, the defective data (DD) and the defective detection signal (NSS), receive the defective detection data (NSD), the joint detection data (JSD), the scrap data (SD) and the reference point detection data (DSD), and transmit the defective detection data (NSD), the joint detection data (JSD), the scrap data (SD) and the reference point detection data (DSD).

[0152] EIF (1010) may be implemented by software for relaying the transmission of data and information between the process PLC (143) and the server (1020). More specifically, EIF (1010) may be implemented by software configured to perform flow control, error control, synchronization, order control, addressing, multiplexing, routing, and format conversion of communication between the process PLC (143) and the server (1020).

[0153] The server (1020) may be implemented by software configured to transmit, for example, a product ID and a product recipe to a process PLC (143) and generate a roll map based on defect detection data (NSD), joint detection data (JSD), scrap data (SD), and reference point detection data (DSD).

[0154] However, this is for convenience of explanation, and the operations of the above-described roll map PLC (141), process PLC (143), EIF (1010) and server (1020) may also be caused by other devices executing computing devices, distributed computing devices, processors, firmware, software, routines and instructions, etc.

[0155] The architecture of a battery manufacturing system (10) configured to generate a roll map can be implemented by adding only a roll map PLC (141) to the processing unit, process PLC (143), EIF (1010), and server (1020), which are essential elements in a modern process management system. That is, the system 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 an existing manufacturing facility to a newly constructed manufacturing facility, the reliability of battery manufacturing, the discovery / improvement of problematic processes, and the introduction of new processes can be improved.

[0156]

[0157] (Example 2)

[0158] Figure 7 is a schematic diagram showing a battery manufacturing system (11) according to another embodiment of the present invention.

[0159] Referring to FIG. 7, the battery manufacturing system (11) may include an electrode process device (101), an EIF (1010), a server (1020), and a visualization device (1030).

[0160] The EIF (1010), server (1020) and visualization device (1030) are substantially the same as those described with reference to FIG. 4.

[0161] The electrode process device (101) may include an unwinder (111), a rewinder (113), a splicing table (115), a scrap port (117), a first encoder (121), a second encoder (123), a reference point sensor (135), and an integrated PLC (140).

[0162] The unwinder (111), the rewinder (113), the splicing table (115), the scrap port (117), the first encoder (121), the second encoder (123), the reference point sensor (135), the EIF (1010), the server (1020), and the display device (1030) are substantially the same as those described with reference to FIG. 4, so a duplicate description thereof is omitted.

[0163] The integrated PLC (140) can be configured to perform the functions of the roll map PLC (141) and the process PLC (143) of FIG. 4. Accordingly, the integrated PLC (140) can be implemented by software configured to receive an unwinding amount signal (UWAS), a winding amount signal (WAS), a defect detection signal (NSS), a seam detection signal (JSS), and a reference point detection signal (DSS), collect coordinate data, defect detection data (NSD), seam detection data (JSD), scrap data (SD), and reference point detection data (DSD), transmit the defect detection data (NSD), seam detection data (JSD), scrap data (SD), and reference point detection data (DSD), and generate control signals for controlling the unwinder (111), the rewinder (113), the scrap port (117), and the processing mechanism (119) based on the product ID, the product recipe, the defect data (DD), and the defect detection data (NSD).

[0164] While the embodiments of the present invention have been described in detail above, those skilled in the art will appreciate that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, modifications to future embodiments of the present invention will not depart from the scope of the invention.

[0165] [Explanation of symbols]

[0166] 10, 11: Battery manufacturing system

[0167] 100, 101: Electrode process equipment

[0168] 111: Unwinder

[0169] 113: Rewinder

[0170] 115; Splicing Table

[0171] 117: Scrap Port

[0172] 119: Processing device,

[0173] 121: 1st encoder

[0174] 123: Second encoder

[0175] 131: Defect detection sensor

[0176] 133: Seam sensor

[0177] 135: Reference point sensor

[0178] 140, 141, 143: PLC (Programmable Logic Controller)

[0179] 145: EIF (Equipment Interface)

[0180] 150: Server

[0181] 160: Display device

Claims

1. An electrode process device that performs an electrode process; and A roll map creation device that creates a roll map including coordinate data indicating the position of an electrode and measurement and inspection data generated according to the progress of an electrode process performed on the electrode and matching the coordinate data; Including, The above electrode process device: An unwinder configured to unwind an electrode from a first electrode roll; A rewinder configured to wind the electrode onto a second electrode roll; and An inspection measuring instrument for collecting inspection measurement data of the electrode being transported; A first encoder provided on one side of the electrode being transported and configured to detect the moving speed of the electrode by irradiating the electrode with a laser; Including, The above first encoder is a non-contact encoder, A battery manufacturing system in which the roll map creation device is configured to receive a defective location of the electrode and create an electrode removal section corresponding to the defective location, and the electrode removal section is created based on data detected from the first encoder.

2. In paragraph 1, A battery manufacturing system characterized in that the roll map creation device is configured to create tag coordinates of a tag corresponding to the defective location in order to create an electrode removal section.

3. In paragraph 2, A battery manufacturing system characterized in that the roll map creation device is configured to define a preceding removal reference coordinate preceding the tag coordinate and a succeeding removal reference coordinate following the tag coordinate based on the tag coordinate, and to define a section between the preceding removal reference coordinate and the succeeding removal reference coordinate as an electrode removal section.

4. In paragraph 2, A battery manufacturing system, characterized in that the first encoder is provided on the unwinder.

5. In paragraph 4, A battery manufacturing system characterized in that it further comprises a second encoder which is a contact encoder on the rewinder.

6. In paragraph 4, A battery manufacturing system, characterized in that the first encoder is configured to transmit a discharge amount signal to the roll map creation device based on the linear speed of the electrode.

7. In paragraph 6, A battery manufacturing system characterized in that the roll map creation device is configured to calculate the amount of waste due to defects in the electrode based on the discharge amount signal.

8. In paragraph 1, The above first encoder: a first light source configured to irradiate a first laser beam to the electrode; and A second light source configured to irradiate a second laser beam non-parallel to the first laser beam onto the electrode; Including, A battery manufacturing system, characterized in that the first encoder is configured to receive the first laser beam and the second laser beam reflected from the electrode, and is configured to detect the moving speed of the electrode by analyzing the reflected first laser beam and the second laser beam.

9. In paragraph 8, A battery manufacturing system, characterized in that the first encoder is configured to analyze the reflected laser beam using an interference pattern of Doppler shift light scattered from an electrode surface.

10. In paragraph 1, A reference point sensor configured to detect a reference point of the electrode to generate a reference point detection signal; A battery manufacturing system characterized by further including:

11. An unwinder configured to unwind an electrode sheet from a first electrode roll; A rewinder configured to wind the electrode sheet onto a second electrode roll; A non-contact first encoder configured to detect the length of the electrode sheet unwound by the unwinder to generate an unwinding amount signal; a second encoder configured to detect the length of the electrode sheet wound by the rewinder to generate a winding amount signal; and A programmable logic controller (PLC) configured to collect coordinate data indicating a position on the electrode sheet based on the winding amount signal; A battery manufacturing system comprising:

12. In paragraph 11, A battery manufacturing system characterized in that the PLC is configured to collect scrap data indicating the length of a discarded portion of the electrode sheet based on the discharge amount signal and the winding amount signal.

13. In paragraph 12, A battery manufacturing system further comprising a scrap port configured to discard defective portions of the electrode sheet.

14. In paragraph 11, Further comprising a failure detection sensor configured to generate a failure detection signal, A battery manufacturing system characterized in that the PLC is configured to collect defect detection data by associating the defect detection signal with the coordinate data.

15. In paragraph 11, The above first encoder: a first light source configured to irradiate a first laser beam onto the electrode sheet; and A second light source configured to irradiate a second laser beam non-parallel to the first laser beam onto the electrode sheet; Including, A battery manufacturing system, characterized in that the first encoder is configured to receive the first laser beam and the second laser beam reflected from the electrode, and is configured to detect the moving speed of the electrode sheet by analyzing an interference pattern of the reflected first laser beam and the second laser beam.

16. Step of unwinding the electrode from the first electrode roll of the unwinder; A step of detecting the moving speed of the electrode using a first encoder, which is a non-contact encoder provided on the unwinder; A step of winding the second electrode roll of the rewinder of the above electrode; and A step of creating a roll map including coordinate data indicating the position of the electrode and measurement and inspection data generated according to the progress of an electrode process performed on the electrode and matching the coordinate data; Including, The step of creating the above roll map includes the step of receiving a defective location of the electrode and creating an electrode removal section corresponding to the defective location, A battery manufacturing method in which the above electrode removal section is created based on data detected from the first encoder.

17. In paragraph 16, The step of creating the above roll map is performed by a roll map creation device, A battery manufacturing method characterized in that the roll map creation device is configured to create tag coordinates of a tag corresponding to the defective location in order to create an electrode removal section.

18. In paragraph 17, Further comprising a step of detecting the length of the electrode wound by the rewinder by a second encoder which is a contact-type encoder provided on the rewinder, The above roll map creation device: A release amount signal generated by detecting the release length of the electrode with the first encoder; and A winding amount signal generated by detecting the winding length of the electrode with the second encoder; A battery manufacturing method characterized in that it is configured to calculate the amount of waste due to defects in the electrode.

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