Method for manufacturing secondary battery

Abstract

Provided, according to exemplary embodiments, is a method for manufacturing a secondary battery. The method comprises the steps of: performing a coating process of providing an upper coating, an upper insulating coating, a lower coating, and a lower insulating coating on an electrode sheet unwound from a first electrode roll and wound around a second electrode roll; collecting coordinate-related inspection data and compressed measurement data from the electrode sheet on which the coating process is performed; generating a roll map including a spatially aligned process event of the second electrode roll on the basis of the coordinate-related inspection data and the compressed measurement data; and determining suspension of the second electrode roll on the basis of the roll map.

Description

Method of manufacturing a secondary battery

[0001] The present invention relates to a method for manufacturing a secondary battery. This application claims the benefit of Korean Application No. 10-2023-0119253, filed September 7, 2023, and Korean Application No. 10-2024-0097743, filed July 24, 2024, which are incorporated herein by reference in their 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 method for manufacturing a secondary battery using a roll map including 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 manufacturing a secondary battery is provided. The method comprises the steps of collecting coordinate-related inspection data and compressed measurement data from an electrode sheet on which a coating process has been performed, wherein an upper coating, an upper insulating coating, a lower coating, and a lower insulating coating are provided on the electrode sheet in the coating process; generating a roll map including spatially aligned process events of an electrode roll based on the coordinate-related inspection data and the compressed measurement data, wherein the electrode sheet is wound onto the electrode roll; and determining a hold of the electrode roll based on the roll map.

[0006] The holding of the electrode sheet is determined based on the hold reference data and the roll map, and if any one of the coordinate-related inspection data and the compressed measurement data of the roll map includes a portion that satisfies the hold reference data, the electrode roll is determined to be the holding.

[0007] If each of the coordinate-related inspection data and the compressed measurement data of the above roll map does not include a portion that satisfies the hold reference data, the electrode roll is put into a subsequent process.

[0008] The defective portion of the electrode roll determined to be on hold is scrapped at the rewinding stage.

[0009] A sample inspection is performed on the electrode roll determined as the above-mentioned hold.

[0010] The above hold reference data includes misalignment between the upper insulating coating and the lower insulating coating.

[0011] If the above coordinate-related inspection data indicates misalignment of the upper insulating coating and the lower insulating coating, the electrode roll is determined to be on hold.

[0012] The above hold reference data includes surface defects of the upper insulating coating and the lower insulating coating.

[0013] If the above coordinate-related inspection data indicates a line defect of a size exceeding the critical width of either the upper insulating coating or the lower insulating coating, the electrode roll is determined to be on hold.

[0014] If the above coordinate-related inspection data indicates a pinhole defect of a size exceeding the critical diameter of either the upper insulating coating or the lower insulating coating, the electrode roll is determined to be on hold.

[0015] The above hold reference data includes misalignment between the upper coating and the lower coating.

[0016] If the length of the section of the electrode roll defined by the coordinates that match the judgment value indicating misalignment between the upper coating and the lower coating exceeds the critical length, the electrode roll is determined to be on hold.

[0017] The above hold reference data includes surface defects between the upper coating and the lower coating.

[0018] If the above coordinate-related inspection data indicates a line defect in either the upper coating or the lower coating exposing the electrode plate of the electrode sheet, the electrode roll is determined to be on hold.

[0019] If the above coordinate-related inspection data indicates a line defect exceeding the critical length of either the upper coating or the lower coating, the electrode roll is determined to be on hold.

[0020] If the above coordinate-related inspection data indicates a critical number or more of pinhole defects in either the upper coating or the lower coating, the electrode roll is determined to be on hold.

[0021] If the above coordinate-related inspection data indicates a critical number or more of crater defects in either the upper coating or the lower coating, the electrode roll is determined to be on hold.

[0022] If the above coordinate-related inspection data indicates a crater defect of a size exceeding the critical diameter of either the upper coating or the lower coating, the electrode roll is determined to be withheld.

[0023] If the above coordinate-related inspection data indicates island defects greater than a critical frequency in either the upper coating or the lower coating, the electrode roll is determined to be withheld.

[0024] The above hold reference data includes insufficient or excessive loading of the upper coating and the lower coating.

[0025] If the compressed measurement data above indicates that the loading amount of either the upper coating or the lower coating is excessive or insufficient, the electrode roll is determined to be on hold.

[0026] Figure 1 illustrates a secondary battery manufacturing system according to exemplary embodiments.

[0027] Figure 2 is a cross-sectional view of an electrode sheet.

[0028] Figure 3 shows the upper and lower surfaces of the electrode sheet.

[0029] Figure 4 is a flowchart for explaining a method for manufacturing a secondary battery according to exemplary embodiments.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034]

[0035] (Example 1)

[0036] FIG. 1 illustrates a secondary battery manufacturing system (100) according to exemplary embodiments.

[0037] Figure 2 is a cross-sectional view of an electrode sheet (ES).

[0038] Figure 3 shows the upper surface (EST) and lower surface (ESB) of the electrode sheet (ES).

[0039] Referring to FIGS. 1 to 3, the secondary battery manufacturing system (100) may include an unwinder (111), a rewinder (113), die coaters (115T, 115B), die coaters (117T, 117B), a first rotary encoder (121), a second rotary encoder (123), a measuring instrument (131), an inspector (133), coating sensors (135T, 135B), a first controller (141), a second controller (143), and servers (160, 170).

[0040] The unwinder (111) may be configured to unwind the electrode sheet (ES) from the electrode roll (ER1). The rewinder (113) may be configured to wind the electrode sheet (ES) onto the electrode roll (ER2). Accordingly, the electrode sheet (ES) can move between the unwinder (111) and the rewinder (113).

[0041] A process (e.g., an electrode process) for manufacturing a secondary battery can be performed on an electrode sheet (ES). The electrode process is performed on an electrode sheet (ES) that is unwound from an electrode roll (ER1) and rolled onto an electrode roll (ER2), and the electrode process may be a roll-to-roll process.

[0042] A coating process may be performed on the electrode sheet (ES). The coating process may be performed by die coaters (115T, 115B). The coating process is a process of applying a coating material, such as electrode slurry, onto the electrode sheet (ES). The electrode slurry may include an electrode active material, a conductive agent, a binder, and a solvent. The electrode slurry may be provided by dissolving the electrode active material, the conductive agent, the binder, and the like in a solvent.

[0043] A die coater (115T) can provide electrode slurry onto an upper surface (EPT) of an electrode plate (EP), thereby forming a top coating (TC) on the upper surface (EPT) of the electrode plate (EP). The electrode sheet (ES) can include a holding portion lane (LT) and a non-coating portion (UCT). The holding portion lane (LT) can be a portion of the electrode plate (EP) to which the top coating (TC) has been applied or to which the top coating (TC) is scheduled to be applied. The non-coating portion (UCT) can be a portion of the electrode sheet (ES) to which the top coating (TC) is not applied (i.e., spaced apart from the top coating (TC).

[0044] The die coater (115B) can provide electrode slurry onto the lower surface (EPB) of the electrode plate (EP), thereby forming a lower coating (BC) on the lower surface (EPB) of the electrode plate (EP). The electrode sheet (ES) can include a holding portion lane (LB) and a non-coating portion (UCB). The holding portion lane (LB) can be a portion of the electrode plate (EP) to which the lower coating (BC) has been applied or to which the lower coating (BC) is scheduled to be applied. The non-coating portion (UCB) can be a portion of the electrode sheet (ES) to which the lower coating (BC) is not applied (i.e., spaced apart from the lower coating (BC).

[0045] According to exemplary embodiments, each of the maintenance lanes (LT, LB) and the uncoated portions (UCT, UCB) may extend in the travel direction, which is the movement direction (or longitudinal direction) of the electrode sheet (ES). Each of the maintenance lanes (LT, LB) and the uncoated portions (UCT, UCB) may be separated in the transverse direction (or width direction) of the electrode sheet (ES).

[0046] A die coater (117T) can provide an insulating material on the upper surface (EPT) of the electrode plate (EP). Accordingly, an upper insulating coating (ICT) can be formed on the upper surface (EPT) of the electrode plate (EP). The upper insulating coating (ICT) can include an overlay portion (ILTO) that overlaps with the upper coating (TC) and an edge portion (ILTE) that does not overlap with the upper coating (TC) (i.e., covers the uncoated portion (UCT).

[0047] A die coater (117B) can provide an insulating material on the lower surface (EPB) of the electrode plate (EP). Accordingly, a lower insulating coating (ICB) can be formed on the lower surface (EPB) of the electrode plate (EP). The lower insulating coating (ICB) can include an overlay portion (ILBO) that overlaps with the upper coating (BC) and an edge portion (ILBE) that does not overlap with the lower coating (BC) (i.e., covers the uncoated portion (UCB).

[0048] The first rotary encoder (121) may be configured to sense the amount of electrode sheets (ES) unwound from the electrode roll (ER1) by the unwinder (111). Accordingly, the first rotary encoder (121) may be configured to generate an input amount signal (UWAS) indicating the output amount of the electrode sheets (ES). The first rotary encoder (121) may be configured to transmit the input amount signal (UWAS) to the first controller (141). The first controller (141) may be configured to collect input amount data based on the input amount signal (UWAS) of the electrode sheets (ES). The input amount data may indicate the amount of material (i.e., the electrode roll (ER1)) input into the secondary battery manufacturing system (100) to manufacture the secondary battery.

[0049] The second rotary encoder (123) may be configured to sense the amount of the electrode sheet (ES) wound onto the electrode roll (ER2) by the rewinder (113). Accordingly, the second rotary encoder (123) may be configured to generate a consumption amount signal (WAS) indicating the winding amount of the electrode sheet (ES). The second rotary encoder (123) may be configured to transmit the consumption amount signal (WAS) to the first controller (141). The first controller (141) may be configured to collect consumption amount data based on the consumption amount signal (WAS) of the electrode sheet (ES). The consumption amount data may indicate the amount of the electrode sheet (ES) wound by the rewinder (113).

[0050] 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 a subsequent process such as a roll press, 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).

[0051] As a non-limiting example, the first controller (141) and the second controller (143) may be 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.

[0052] The first and second controllers (141, 143) may include a power supply, a CPU, an input interface, an output interface, a communication interface, and memory devices. The power supply may be configured to supply power to other elements of the first and second controllers (141, 143), such as the CPU, the input interface, the output interface, the communication interface, and the memory devices, for the operation of the first and second controllers (141, 143). The memory devices may include a Read Only Memory (ROM) configured to store a system program, such as an operating system, and a Random Access Memory (RAM) configured to store data, such as user programs and status information of input and output devices, timers, counters, and other internal device values. The CPU may be configured to implement logic and control communication between modules that convert input signals into output operation signals. The CPU may operate based on the system program and user programs stored in the memory devices. The CPU may be configured to write or read inspection data and measurement data to the data areas of memory devices based on system programs and user programs. Conditions or data of industrial devices and production processes may be transmitted to the CPU via an input module. Results processed by the CPU may be transmitted to an actuator via an output module. The communication interface may be configured to transmit and receive data between the first and second controllers (141, 143) or between the second controller (143) and the server (150).

[0053] However, the present invention is not limited thereto, and the first and second controllers (141, 143) may include any one of a simple controller, a complex processor such as a microprocessor, a CPU, a GPU, a processor configured by software, dedicated hardware, and firmware. The first and second controllers (141, 143) may also 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).

[0054] The first controller (141) may be configured to collect coordinate data (CD) of the electrode sheet (ES) based on either an input amount signal (UWAS) or a depletion amount signal (WAS) of the electrode sheet (ES). For example, the first controller (141) may determine a movement distance of the electrode sheet (ES) based on the depletion amount signal (WAS) of the electrode sheet (ES), and accordingly, a position of a portion of the electrode sheet (ES) wound by the rewinder (113) at each point in time during which the coating process is performed may be determined within the electrode sheet (ES). Hereinafter, the technical idea of ​​the present invention will be described with reference to an embodiment in which the first controller (141) collects coordinate data (CD) based on the depletion amount signal (WAS) of the electrode sheet (ES).

[0055] The coordinate data (CD) may include coordinates matching each part of the electrode sheet (ES). That is, each arbitrary point on the electrode sheet (ES) may have a coordinate. The coordinate may be a one-dimensional quantity in the driving direction (or the longitudinal direction of the electrode sheet (ES)), which is the moving direction of the electrode sheet (ES), but is not limited thereto. The coordinate may also be a two-dimensional quantity in the driving direction and the transverse direction of the electrode sheet (ES) (or the width direction of the electrode sheet (ES)).

[0056] The measuring device (131) may be configured to measure the electrode sheet (ES) to collect measurement data of the electrode sheet (ES). The measurement data is circular data, and evaluation and judgment values ​​of the portion of the electrode sheet (ES) from which the measurement data was collected may be determined by processing the measurement data. As a non-limiting example, the measuring device (131) may be any one of a web gauge and a thickness gauge from Thermofisher Scientific.

[0057] The measuring device (131) may be configured to scan the electrode sheet (ES). During scanning of the electrode sheet (ES), the measuring device (131) may move along the transverse direction of the electrode sheet (ES). During one scan, the sensing unit (131S) of the measuring device (131) may move from one transverse end of the electrode sheet (ES) to the other transverse end of the electrode sheet (ES).

[0058] While the measuring device (131) performs transverse scanning, the electrode sheet (ES) can be moved in the traveling direction by the unwinder (111) and the rewinder (113). Accordingly, the portion of the electrode sheet (ES) measured by the measuring device (131) can have a zigzag shape.

[0059] Measurement data may include test results expressed in numerical values. Measurement data may include data on the loading amount of the coating material on the electrode sheet (ES) and data on the thickness of the coating material on the electrode sheet (ES). Here, the loading amount indicates 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.

[0060] 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 sensing unit (131S) 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.

[0061] The processor (131P) may be configured to receive a measurement signal (MS) sensed by the sensing unit (131S) to collect measurement data. The processor (131P) may be configured to collect measurement data based on the measurement signal (MS). The processor (131P) may be connected to the sensing unit (131S) 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 measurement data 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 through a method such as a sample test.

[0062] The inspector (133) may be configured to inspect the electrode sheet (ES) to collect inspection data (ID). The inspector (133) may include any one of a color sensor, a seam sensor, a reference point sensor, and a vision machine.

[0063] The inspection data (ID) may include, for example, external dimension data of the electrode sheet (ES) collected by an image-based inspection device such as a vision machine, data on short 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 to be scrapped, data on a scrapped portion of the electrode sheet (ES), data on the quality of coating materials and insulating layers 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 data (ID) may include a judgment value for the quality of a portion of the electrode sheet (ES) (for example, a value indicating the presence or absence of a defect and the type of defect).

[0064] Here, the data collected by the image base inspection device may include external dimension data of the electrode sheet (ES), width data of each of the electrode sheet (ES), the retention lanes (LT, LB) and the uncoated portions (UCT, UCB), width data of each of the edge portion (ILTE) of the upper insulating coating (ICT) and the edge portion (ILBE) of the lower insulating coating (ICB), insulation mismatch data indicating misalignment between the upper insulating coating (ICT) and the lower insulating coating (ICB), overlay width data indicating the width of the overlay portion (ILTO) of the upper insulating coating (ICT) and the overlay portion (ILBO) of the lower insulating coating (ICB), and mismatch data indicating misalignment of the retention lane (LB) on the lower surface (EPB) of the electrode plate (EP) and the retention lane (LT) on the upper surface (EPT).

[0065] Additionally, reference points may be formed at predetermined intervals on the electrode sheet (ES), and the locations of other elements on the electrode sheet (ES) may be located based on the reference points. As a non-limiting example, the secondary battery manufacturing system may include a separate server configured to store original inspection data (e.g., an image of a defective portion of the electrode sheet (ES).

[0066] The tester (133) may include a sensing unit (133S) and a processor (133P). The sensing unit (133S) may be configured to detect the electrode sheet (ES) to generate a test signal (IS). For example, the sensing unit (133S) may include any of the sensors described above with respect to the sensing unit (131S).

[0067] The processor (133P) may be configured to receive and process a circular inspection signal (IS) sensed by the sensing unit (131S) to collect inspection data (ID). The processor (133P) may include an algorithm for processing an image of a portion of the electrode sheet (ES) to determine an inspection value of the inspection data (ID) or a model (e.g., an artificial neural network) trained to determine an inspection value based on an image of a portion of the electrode sheet (ES).

[0068] The above-described measurement data and inspection data (ID) may be time-series data. The measurement data and inspection data (ID) may be temporally aligned. The measurement data and inspection data (ID) may be time-indexed. The measurement data may include measurement values ​​and times (or times) matching the measurement values. The inspection data (ID) may include inspection values ​​and times (or times) matching the inspection values. That is, the measurement data and inspection data (ID) may be stored based on the time at which the measurement and inspection were performed, and the measurement data and inspection data (ID) may be associated with time. The times of the measurement data and inspection data (ID) may, for example, have a timestamp format, but are not limited thereto.

[0069] For example, measurement data (e.g., loading amount data on an electrode sheet (ES) or thickness data of the electrode sheet (ES)) may have a series of measurement values ​​and times associated with the series of measurement values. The measurement values ​​and times may be matched one-to-one, but are not limited thereto. The measurement values ​​may also be matched many-to-one with a single timestamp indicating the start point of the measurement. As another example, defect data may have a value indicating a defect and a time associated with the value indicating the defect. Here, indicating a defect includes at least one of the presence or absence of a defect and the type of defect.

[0070] The coating sensor (135T) may be configured to detect the upper maintenance lane (LT) of the upper surface (EST) of the electrode sheet (ES). The coating sensor (135T) may be configured to generate an upper coating detection signal (TCS) that distinguishes between a portion of the upper maintenance lane (LT) having an upper coating (TC) and a portion of the upper maintenance lane (LT) without an upper coating (TC). The coating sensor (135T) may be configured to transmit the upper coating detection signal (TCS) to the first controller (141).

[0071] The coating sensor (135B) may be configured to detect the lower support lane (LB) of the lower surface (ESB) of the electrode sheet (ES). The coating sensor (135B) may be configured to generate a lower coating detection signal (BCS) that distinguishes between a portion of the lower support lane (LB) having a lower coating (BC) and a portion of the lower support lane (LB) without a lower coating (BC). The coating sensor (135B) may be configured to transmit the lower coating detection signal (BCS) to the first controller (141).

[0072] The first controller (141) may be in operative communication with the first and second rotary encoders (121), the measuring device (131), the tester (133) and additional measuring devices and testers 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), the measuring device (131) and additional measuring devices and testers may be configured to collect data from equipment, workpieces, semi-finished products and products within the secondary battery manufacturing system (100), or to generate signals for collecting data. The first controller (141) may be configured to transmit coordinate data (CD) to the processor (131P).

[0073] The processor (131P) may be configured to generate coordinate-related measurement data based on coordinate data (CD) and measurement data. The processor (131P) may be configured to associate the measurement data with the coordinate data (CD) to generate coordinate-related measurement data. Generally, the measurement data may be processed based on a trigger point. Examples of processing the measurement data may include storing the measurement data, manipulating the measurement data (e.g., generating coordinate-related measurement data), and transmitting the measurement data.

[0074] As a non-limiting example, the trigger point for processing measurement data may be the completion of a scan. For example, the sensing unit (131S) may scan the electrode sheet (ES) in a transverse direction, 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.

[0075] The electrode sheet (ES) can be divided into a plurality of sections based on scanning of the sensing unit (131S) of the measuring device (131). That is, each of the plurality of sections can correspond to one scanning of the sensing unit (131S).

[0076] According to exemplary embodiments, the processor (131P) may be configured to calibrate the coordinate data (CD) based on the position of the sensing unit (131S). More specifically, the processor (131P) may be configured to calibrate the coordinate data (CD) based on an offset length, thereby associating the coordinates of the coordinate data (CD) with the measurement values ​​of the measurement data.

[0077] The measuring device (131) can collect measurement data of a portion of the electrode sheet (ES) corresponding to (e.g., overlapping) the sensing unit (131S), and coordinate data (CD) is collected by a second rotary encoder (123) spaced apart from the sensing unit (131S) as described above. Accordingly, a portion of the electrode sheet (ES) corresponding to coordinate data (CD) collected at the same point in time and a portion of the electrode sheet (ES) corresponding to measurement data may be different.

[0078] According to exemplary embodiments, coordinate-associated measurement data may be provided by correcting coordinate data (CD) collected at the same time as measurement data based on an offset length and associating the corrected coordinate data (CD) with the measurement data. The coordinate-associated measurement data may include measurement values, times matched to the measurement values, and start and end coordinates. The time may be a timestamp indicating the time at which the measurement data was collected. The start and end coordinates may indicate a start and end point of a portion of the electrode sheet (ES) from which the measurement data was collected. The start and end coordinates may be determined based on the corrected coordinate data (CD). The coordinate-associated measurement data may include a measurement device ID for identifying the measurement device (131) and a facility ID for identifying the secondary battery manufacturing system (100). The coordinate-associated measurement data may be stored in the server (160) or may be stored in a separate server provided for storing original data.

[0079] As another example, the sensing unit (131S) may be directly connected to a position measuring device such as the first and second rotary encoders (121, 123), or may be configured to sense a reference point of the electrode sheet (ES). In this case, the processor (131P) may be configured to collect coordinate-related measurement data based on the measurement signal (MS) transmitted from the sensing unit (131S).

[0080] The offset length of the sensing unit (131S) can be defined as the length of the electrode sheet (ES) interposed between the portion of the electrode sheet (ES) detected by the sensing unit (131S) and the rewinder (113). 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 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).

[0081] The processor (131P) may be configured to generate compressed measurement data (PMD) based on the measurement data and coordinate data (CD). The compressed measurement data (PMD) may include a representative value of the measurement data of each of the plurality of sections of the electrode sheet (ES), a judgment value, and a start coordinate and an end coordinate of each of the plurality of sections of the electrode sheet (ES). The compressed measurement data (PMD) may further include a time stamp indicating the collection date and time of the measurement data of the plurality of sections, a measuring device ID, and a facility ID.

[0082] The processor (131P) may be configured to calculate a representative value of each measurement data of a plurality of sections of the electrode sheet (ES). The representative value of each measurement data of each of the plurality of sections of the electrode sheet (ES) may include at least one of an average, a standard deviation, a median, a maximum value, and a minimum value of each measurement data of the plurality of sections.

[0083] For example, if the coordinate-associated measurement data has 1500 measurement values ​​corresponding to one scanning of the sensing unit (131S), the compressed measurement data (PMD) may include a single representative value calculated based on the 1500 measurement values. Accordingly, the size of the compressed measurement data (PMD) may be different from the size of the coordinate-associated measurement data. The size of the compressed measurement data (PMD) may be smaller than the size of the coordinate-associated measurement data. The start coordinate and the end coordinate of the compressed measurement data (PMD) are substantially the same as the start coordinate and the end coordinate of the corresponding coordinate-associated measurement data.

[0084] The server (160) described below performs various tasks for managing the production of secondary batteries in addition to generating a roll map. According to exemplary embodiments, the server (160) generates a roll map based on compressed measurement data (PMD) instead of coordinate-related measurement data having a size similar to that of the original measurement data, thereby reducing the resources of the server (160) allocated to the generation and storage of the roll map. Accordingly, continuous manufacturing management of the server (160) can be provided, and the reliability of secondary battery manufacturing can be enhanced.

[0085] Measurement data can be processed in a set manner so that judgment values ​​of multiple sections of the electrode sheet (ES) can be determined. When a measured amount of a coating material on the electrode sheet (ES) (e.g., a loading amount on the electrode sheet (ES) or a thickness of the electrode sheet (ES)) is within a set range including an upper limit and a lower limit, a corresponding portion of the electrode sheet (ES) can be determined as a good product. When a measured amount of a coating material on the electrode sheet (ES) (e.g., a loading amount on the electrode sheet (ES) or a thickness of the electrode sheet (ES)) is less than the lower limit or greater than the upper limit, a corresponding portion of the electrode sheet (ES) can be determined as a defective product.

[0086] As another example, a measurement value (or representative value) within a first range may be determined as normal, a measurement value (or representative value) within a second range that is greater than the first range may be determined as excessive, a measurement value (or representative value) within a third range that is greater than the second range may be determined as very excessive, a measurement value (or representative value) within a fourth range that is smaller than the first range may be determined as insufficient, and a measurement value (or representative value) within a fifth range that is smaller than the fourth range may be determined as very insufficient.

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

[0088] The processor (131P) may be configured to transmit compressed measurement data (PMD) to the first controller (141). The processor (133P) may be configured to transmit inspection data (ID) to the first controller (141).

[0089] The first controller (141) may be configured to generate (or collect) coordinate-related inspection data (CID) based on inspection data (ID) and coordinate data (CD). Similar to coordinate-related measurement data, coordinate-related inspection data (CID) may be provided by correcting coordinate data (CD) based on an offset length and associating the corrected coordinate data (CD) with inspection data (ID), but is not limited thereto.

[0090] For example, the first controller (141) may be configured to transmit coordinate data (CD) to the processor (133P), and the processor (133P) may generate (or collect) coordinate-related inspection data (CID). In another example, the processor (143P) may receive coordinate data (CD) and inspection data (ID) from the controller (141), and the coordinate-related inspection data (CID) may be generated by the processor (143P) based on the coordinate data (CD) and the inspection data (ID). Here, the offset length of the sensing unit (133S) may be defined as the length of the electrode sheet (ES) interposed between the portion of the electrode sheet (ES) detected by the sensing unit (133S) and the rewinder (113).

[0091] The first controller (141) may be configured to collect upper coating data (TCD) and lower coating data (BCD). Due to interruptions in operations, etc., the upper coating (TC) and lower coating (BC) may be formed discontinuously. For example, the maintenance lane (LT) may include a portion with an upper coating (TC) and a portion without an upper coating (TC) and an exposed electrode plate (EP). Similarly, the maintenance lane (LB) may include a portion with an undercoat (BC) and a portion without an undercoat (BC) and an exposed electrode plate (EP).

[0092] The upper coating data (TCD) can be collected based on the exhaustion signal (WAS) and the upper coating detection signal (TCS), and the lower coating data (BCD) can be collected based on the exhaustion signal (WAS) and the lower coating detection signal (BCS). Here, for the collection of the upper coating data (TCD) and the lower coating data (BCD), the exhaustion signal (WAS) can be corrected based on the offset length of the coating sensors (135T, 135B). The offset length of the coating sensors (135T, 135B) can be defined as the length of the electrode sheet (ES) interposed between the portion of the electrode sheet (ES) detected by the coating sensors (135T, 135B) and the rewinder (113).

[0093] The top coating data (TCD) may include a value representing a top coating (TC) and the start and end coordinates of the top coating (TC) that are matched thereto. The top coating data (TCD) may include a value representing the absence of a top coating (TC) and the start and end coordinates of a portion of the retainer lane (LT) that is free of a top coating (TC) that is matched thereto (i.e., a portion of the retainer lane (LT) where the upper surface (EPT) of the electrode plate (EP) is exposed).

[0094] The bottom coating data (BCD) may include a value representing the bottom coating (BC) and the start and end coordinates of the bottom coating (BC) that match it. The bottom coating data (BCD) may include a value representing the absence of the bottom coating (BC) and the start and end coordinates of a portion of the maintenance lane (LB) without the bottom coating (BC) (i.e., a portion of the maintenance lane (LB) where the upper surface (EPB) of the electrode plate (EP) is exposed).

[0095] The first controller (141) may be configured to transmit compressed measurement data (PMD) to the second controller (143). The second controller (143) may be configured to transmit the compressed measurement data (PMD) to the server (160). However, this is not limited thereto, and the first controller (141) may also transmit the compressed measurement data (PMD) directly to the server (160).

[0096] The second controller (143) may be configured to control the operation of the unwinder (111), the rewinder (113), the die coaters (115T, 115B), and the die coaters (117T, 117B). The second controller (143) may be configured to generate signals for operation and stop of the unwinder (111), the rewinder (113), the die coaters (115T, 115B), and the die coaters (117T, 117B). The signals for operation and stop of the unwinder (111), the rewinder (113), the die coaters (115T, 115B), and the die coaters (117T, 117B) may be generated based on electrode specification data, compressed measurement data (PMD), coordinate-associated inspection data (CID), and measurement signals.

[0097] The secondary battery manufacturing system (100) may include an input device that allows manual data entry by a worker. The input device may include, for example, a Human Machine Interface (HMI). Alternatively, the input device may allow computer-based input of manufacturing data, such as data entry by a worker using an input tool or scraping of an Excel file. The manually input data (MID) entered by the input device may include, for example, the length, start coordinates, and end coordinates of an electrode sheet (ES) cut by a sample inspection of the electrode sheet (ES), or the length, start coordinates, and end coordinates of an electrode sheet (ES) lost in a lot replacement (i.e., loading a new electrode roll (ER1)).

[0098] Compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manual input data (MID) can be transmitted to the server (160) via the server (150). The server (150) can be, for example, a server for communication based on log data. The server (150) can be a program for communication between the second controller (143) and the server (160) for manufacturing management. The server (150) can also be implemented in hardware. The language and protocol of the server (160) can be different from the language and protocol of the controller (143). For example, the language of the server (160) can be SQL, and the language of the controller (143) can be a ladder diagram.

[0099] The server (150) may be configured to convert electrode specification data transmitted from the server (160) into the language of the second controller (143). In addition, the server (150) may be configured to convert compressed measurement data (PMD), coordinate-related inspection data (CID), upper coating data (TCD), lower coating data (BCD), and manual input data (MID) into the language of the server (160), and record the compressed measurement data (PMD), coordinate-related inspection data (CID), upper coating data (TCD), lower coating data (BCD), and manual input data (MID) in a database of the server (160).

[0100] Electrode specification data may include model information and recipe of the electrode sheet (ES). The electrode specification data may include all matters related to processing of the electrode sheet (ES), such as the number of lots being processed in the current process, the number of maintenance lanes formed on the electrode sheet (ES), process conditions including temperature, humidity, and pressure, the moving speed of the electrode sheet (ES), the discharge amount of the coating die, and the pressure of the pressurizing rolls.

[0101] A communication line connecting the second and server (160) may be installed to control the process. Accordingly, data transmission through the second controller (143) can reduce resources required for installation of the communication line compared to the case where the first and second rotary encoders (121, 123) and the measuring device (130) directly transmit the input signal (UWS), the exhaustion signal (WS) and the measurement signal (MS) to the first server (160) and the case where the first controller (141) directly transmits the compressed measurement data (PMD) to the server (160), and can improve the efficiency of data processing and management of the second controller (143) via the server (150) between the controller (143) and the server (160).

[0102] 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, a Manufacturing Execution System (MES). The server (160) may be configured to input, process, output, and communicate data necessary for electrode manufacturing processes, such as a coating process, a roll pressing process, and a slitting process.

[0103] The server (160) may be configured to generate a roll map. The roll map may be generated based on compressed measurement data (PMD), coordinate-associated inspection data (CID), top coating data (TCD), and bottom coating data (BCD).

[0104] The roll map may further include data regarding the specifications of the lot. The specifications of the lot may include, for example, the lot number, the length of the rolled electrode sheet (ES), the width of the electrode sheet (ES), and the materials and compositions used in processing the electrode sheet (ES).

[0105] The roll map can represent the electrode sheet (ES) based on coordinates indicating the location on the electrode sheet (ES). A process for manufacturing a secondary battery can be performed on the electrode sheet (ES), as described above. The roll map can represent the history of the process performed on the electrode sheet (ES) and include data associated with the coordinates. Accordingly, the roll map enables feedback, feedforward, and tracking of the secondary battery manufacturing process, as described below.

[0106] A roll map may include event data representing events in a roll-to-roll process of an electrode sheet (ES). Event data typically occurs as the process progresses, and thus is time-series data. Accordingly, data on process events may include values ​​representing the events and corresponding times. Time-series data may be temporally ordered. Temporal ordering, a key characteristic of time-series data, organizes events in the order in which they occur and arrive for processing. In other words, time-series data may be stored based on the time at which an event occurs (i.e., when inspection and measurement are performed, or when process actions are performed), and events may be associated with times.

[0107] The manufacturing of secondary batteries involves a series of different processes, with the leading process influencing the following process. Feedforward refers to the correction of the following process based on data generated from the results of the preceding process. However, if the time series data of the preceding process does not directly match the real-world workpieces, semi-finished products, and finished products, it is difficult to reflect the time series data of the preceding process in the following process. Here, the workpiece refers to an article provided as a result of each process, such as the electrode sheet (ES) that has undergone the coating process, roll pressing process, and slitting process illustrated in Fig. 1. The semi-finished product may refer to one of separators, electrodes, and their assemblies 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). The product refers to an article that has been processed to be operable as a secondary battery through an activation process. The definitions of work-pieces, semi-finished products and finished products set forth above are only one aspect of these and do not exclude the usual definitions of these.

[0108] For feedforward, time-series data must be associated with the actual locations of workpieces, parts, semi-finished products, and finished products in the real world. In a roll map, time-series data, such as measurement data, can be associated with coordinate data (CD) based on the movement amount (i.e., either input or output) of the electrode sheet (ES). The roll map can associate time-series data with coordinate data, which includes coordinates representing the actual locations of workpieces, parts, semi-finished products, and finished products in the real world. Accordingly, the creation of a roll map and feedforward based on the roll map can quantify and objectify aspects of the process previously dependent on the operator's discretion, thereby improving production efficiency and quality.

[0109] The roll map can be generated on a lot basis. The electrode sheet (ES) is wound onto the second electrode roll (ER2), and after reaching the winding amount target, the second electrode roll (ER2) can be cut and separated from the electrode sheet (ES) connected to the first electrode roll (ER1). A lot is a production unit of a roll-to-roll process, and the second electrode roll (ER2) separated from the electrode sheet (ES) is an example of a lot. Accordingly, the server (160) can be configured to store the roll map of the previous process. The roll map of the previous process can correspond to the first electrode roll (ER1). In addition, the server (160) can be configured to generate and store a roll map of the current process. The roll map of the current process can correspond to the second electrode roll (ER2).

[0110] 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.

[0111] Furthermore, the roll map 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 case. The cell ID may be matched to the lot number and coordinate information of the electrodes and separator included in the battery cell. In other words, the cell ID may be associated with the roll map of the electrodes and separator included in the battery cell. Accordingly, if an event such as a quality issue occurs in a battery cell that has already been shipped, the history of collective data of the manufacturing of the corresponding battery cell can be retrieved based on the cell ID.

[0112] The server (160) can provide production management based on data from the roll map, such as compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manual input data (MID). The server (160) can be configured to determine or calculate, for example, the production volume, good quantity, defective quantity, and loss quantity of the coating process.

[0113] Here, the production volume of the coating process can be determined based on the actual performance of the coating process by the die coaters (115T, 115B). For example, if a number of defects (i.e., defects in the electrode sheet (ES) over a long length) occur during the coating process, the electrode sheet (ES) can be moved while the coating of the electrode sheet is stopped. Accordingly, the holding lane (LT) can include a discontinuous upper coating (TC) such as the upper surface (EST) and the lower surface (ESB) of the electrode sheet in FIG. 3, and the holding lane (LB) can include a discontinuous lower coating (BC). The production volume can be the length of the electrode sheet (ES) on which the coating process is performed on either the upper surface (EPT) or the lower surface (EPB) of the electrode plate (EP).

[0114] The quantity of good products can be calculated by subtracting the quantity of defective products and losses from the quantity of production. Accordingly, the relationship between the quantity of production, quantity of good products, quantity of defective products, and quantity of losses can be expressed as Equation 1 below. Accordingly, the server (160) can be configured to automatically calculate the quantity of good products in the coating process, as an example of production management based on a roll map.

[0115] [Formula 1]

[0116] Production = Amount of good products + Amount of defective products + Amount of loss

[0117] The portion of the electrode sheet (ES) corresponding to the defective amount and the loss amount can be removed in a subsequent process or separated from the normal electrode sheet (ES). The defective amount and the loss amount can be collectively referred to as the exclusion amount. That is, the exclusion amount can satisfy the following equations 2 and 3.

[0118] [Formula 2]

[0119] Exclusion amount = defective amount + loss amount

[0120] [Formula 3]

[0121] Production volume - exclusion volume = quality volume

[0122] In another example, according to exemplary embodiments, the server (160) may be a Statistical Process Controller (SPC). The server (160) can continuously monitor the processing of the electrode sheet (ES) based on original inspection data and / or measurement data, thereby managing the quality of the processing of the electrode sheet (ES). 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.

[0123] In another example, the server (160) may be a data warehouse configured to store data of the roll map for long periods of time, such as compressed measurement data (PMD), coordinate-associated inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manual input data (MID).

[0124] The client device may be configured to transmit an API request to the server (160) to retrieve information about the roll map. The server (160) may be configured to transmit, in response to the API request from the client device, a Uniform Resource Locator (URL) (or schema) containing source code for displaying the roll map on the client device. The client device may access the source code for visualizing and displaying the roll map through the URL (or schema).

[0125] A client device may be any device capable of communicating with a server (160), such as a workstation computer, a laptop, a desktop computer, a tablet, a mobile device such as a smart phone, or a wearable device. The client device may include input tools for entering API requests and a display device for displaying a roll map.

[0126] The processing units (131P, 133P) and the servers (160, 170) may be implemented by hardware, firmware, software, or a combination thereof. For example, the processing units (131P, 133P) and the servers (160, 170) may include computing devices such as workstation computers, desktop computers, laptop computers, and tablet computers. The processing units (131P, 133P) and the servers (160, 170) may also include any one of simple controllers, complex processors such as microprocessors, CPUs, and GPUs, processors configured by software, dedicated hardware, and firmware. The processing units (131P, 133P) and the servers (160, 170) may be implemented by, for example, general-purpose computers or application-specific hardware such as digital signal processors (DSPs), field programmable gate arrays (FPGAs), and application specific integrated circuits (ASICs).

[0127] The servers (160, 170) may include physical servers or cloud servers. The servers (160, 170) may provide data and analysis results to workers via various frameworks. The frameworks may include protocols that support data transfer, allowing client devices to visualize data through a user interface and provide updated visualizations when new data is calculated by the server (160). The protocols that support data transfer may use HTML, JavaScript, and / or JSON.

[0128] The servers (160, 170) 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.

[0129] According to some embodiments, the operations of the processing units (131P, 133P) and the servers (160, 170) 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.

[0130] The processing units (131P, 133P) and servers (160, 170) 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 processing units (131P, 133P) and servers (160, 170) may be instantiated within memory.

[0131] However, this is for convenience of explanation, and the operations of the above-described processing units (131P, 133P) and servers (160, 170) may also be caused by other devices that execute computing devices, distributed computing devices, processors, firmware, software, routines, and instructions.

[0132] The secondary battery manufacturing system (100) can implement a plug-in architecture with an API for data acquisition to provide plug-and-play connectivity for measuring instruments (131), inspection instruments (133), and coating sensors (135T, 135B). Accordingly, resources from a specific process step and site can be easily transferred to other processes and sites, or new resources can be easily introduced to each process step and site.

[0133] The data network between elements of the secondary battery manufacturing system (100) may include various types of communication channels, including unidirectional, bidirectional wired, and wireless 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.

[0134] The architecture configured to generate roll maps and intermediate roll maps can be implemented by simply adding a controller (141) to the essential elements of a modern process management system. That is, the system according to exemplary embodiments can utilize resources of existing manufacturing sites and reduce additional capital expenditures. Furthermore, by applying the same architecture to newly constructed manufacturing facilities as to existing manufacturing facilities, the reliability of secondary battery manufacturing, the discovery / improvement of problematic processes, and the introduction of new processes can be improved.

[0135]

[0136] (Example 2)

[0137] Figure 4 is a flowchart for explaining a method for manufacturing a secondary battery according to exemplary embodiments.

[0138] Referring to FIGS. 1 and 4, electrode sheet (ES) data can be collected at P110. The data of the electrode sheet (ES) may be data for evaluating a coating process performed on the electrode sheet (ES). The data of the electrode sheet (ES) may include coordinate-related data, such as compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manual input data (MID). The data of the electrode sheet (ES) may be data for generating a roll map.

[0139] Next, in P120, a roll map can be generated. The generation of the roll map can include collectively storing, processing, modifying, and transmitting the compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manually entered data (MID) based on their coordinates, and generating a URL (or schema) for accessing them. By collectively storing, processing, modifying, and transmitting the compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manually entered data (MID), process events, such as occurrence of defects and types of defects, can be spatially (i.e., based on coordinates). That is, the roll map can be indexed by the coordinates of the process events, and thus, the process events can be retrieved based on their coordinates.

[0140] Accordingly, the length of the portion corresponding to each defect in the electrode sheet (ES) can be prevented from being repeatedly added when calculating the amount of defects. For example, if the compressed measurement data (PMD) corresponding to the first portion of the electrode sheet (ES) indicates an excessive or insufficient loading amount and the coordinate-related inspection data (CID) corresponding to the first portion of the electrode sheet (ES) indicates the presence of a pinhole in the upper coating (TC), the first portion can be prevented from being repeatedly added when calculating the amount of defects.

[0141] Because the compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manually entered data (MID) contain coordinates, the compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manually entered data (MID) can be aligned by coordinates. The compressed measurement data (PMD), coordinate-related inspection data (CID), top coating data (TCD), bottom coating data (BCD), and manually entered data (MID) can be collectively referred to as coordinate-related data.

[0142] Next, referring to FIGS. 1, 4, and 5, at P130, the holding of the completed second electrode roll (ER2) can be determined based on the hold reference data (MCD) and the roll map. The hold reference data (MCD) can be stored in the server (160), or can be transmitted to the server (160) from an external server (e.g., a quality control server).

[0143] The server (160) may be configured to compare coordinate-related data of the roll map with hold reference data (MCD). The hold reference data (MCD) may include conditions for determining whether to hold the second electrode roll (ER2). Here, holding the second electrode roll (ER2) means not putting the second electrode roll (ER2) into a subsequent process.

[0144] If a completed electrode roll (ER2) has a serious potential quality issue, the completed electrode roll (ER2) may be placed on hold. The placed electrode roll (ER2) may be stored in a buffer or warehouse. A series of processes may be performed on the placed electrode roll (ER2) to resolve the quality issue. For example, defective portions of the second electrode roll (ER2) may be scrapped at the rewinding stage, or sample inspection may be performed on the second electrode roll (ER2).

[0145] If the compressed measurement data (PMD) and coordinate-related inspection data (CID) of the completed electrode roll (ER2) include a portion that satisfies the hold reference data (MCD), the server (160) may determine that the completed electrode roll (ER2) is on hold and may not be input into a subsequent process. If the compressed measurement data (PMD) and coordinate-related inspection data (CID) of the completed electrode roll (ER2) do not include a portion that satisfies the hold reference data (MCD), the server (160) may determine that the completed electrode roll (ER2) may be input into a subsequent process (e.g., a roll pressing process).

[0146] For example, the hold reference data (MCD) may include a misalignment between the upper insulating coating (ICT) and the lower insulating coating (ICB). The coordinate-associated inspection data (CID) may include a judgment value indicating the alignment (or misalignment) of the upper insulating coating (ICT) and the lower insulating coating (ICB) and a coordinate associated with the judgment value. If the judgment value of the coordinate-associated inspection data (CID) of the roll map indicates that the upper insulating coating (ICT) and the lower insulating coating (ICB) are misaligned, the second electrode roll (ER2) corresponding to the roll map may be determined to be held.

[0147] As another example, the hold reference data (MCD) may include surface defects of the upper insulating coating (ICT) and the lower insulating coating (ICB). More specifically, the hold reference data (MCD) may include line defects exceeding a critical width of the upper insulating coating (ICT) and the lower insulating coating (ICB) and pinhole defects exceeding a critical diameter. The coordinate-associated inspection data (CID) may include judgment values ​​indicating the presence or absence and type of defects on the surfaces of the upper insulating coating (ICT) and the lower insulating coating (ICB) and coordinates associated therewith. When the judgment values ​​of the coordinate-associated inspection data (CID) of the roll map indicate that there are line defects exceeding a critical width (e.g., 0.5 mm) and / or pinhole defects exceeding a critical diameter (e.g., 0.5 mm) in the upper insulating coating (ICT) and the lower insulating coating (ICB), the second electrode roll (ER2) corresponding to the roll map may be determined to be held.

[0148] As another example, the hold reference data (MCD) may include a misalignment between the upper coating (TC) and the lower coating (BC). More specifically, the hold reference data (MCD) may include a misalignment between the upper coating (TC) and the lower coating (BC) that exceeds a critical length (e.g., a length in the direction of travel). The coordinate-associated inspection data (CID) may include a judgment value indicating the misalignment of the upper coating (TC) and the lower coating (BC) and a coordinate associated with the judgment value. If the length of the section defined by the coordinates matching the judgment value indicating the misalignment of the upper coating (TC) and the lower coating (BC) of the coordinate-associated inspection data (CID) of the roll map is greater than or equal to the critical length (e.g., 50 m), the second electrode roll (ER2) corresponding to the roll map may be determined to be held.

[0149] As another example, the hold criteria data (MCD) may include surface defects of the top coating (TC) and the bottom coating (BC). More specifically, the hold criteria data (MCD) may include line defects that expose the electrode plate (EP) of either the top coating (TC) or the bottom coating (BC), line defects exceeding a critical length, pinhole defects exceeding a critical number, crater defects exceeding a critical number, crater defects exceeding a critical diameter, and island defects exceeding a critical frequency. The coordinate-associated inspection data (CID) may include a judgment value indicating the presence or absence and type of defects on the surfaces of the top insulating coating (ICT) and the bottom insulating coating (ICB), and a coordinate associated with the judgment value. When the coordinate-related inspection data (CID) of the roll map indicates a line defect exposing one of the electrode plates (EP) of the upper coating (TC) and the lower coating (BC), a line defect exceeding a critical length, a pinhole defect exceeding a critical number, a crater defect exceeding a critical number, a crater defect exceeding a critical diameter, or an island defect exceeding a critical frequency, the second electrode roll (ER2) corresponding to the roll map may be determined to be on hold.

[0150] As another example, the hold reference data (MCD) may include the loading amounts of the top coating (TC) and the bottom coating (BC). The compressed measurement data (PMD) may include representative values ​​of the loading amounts of the top coating (TC) and the bottom coating (BC) and start and end coordinates associated with the representative values. If the compressed measurement data (PMD) of the roll map indicates that the loading amount of either the top coating (TC) or the bottom coating (BC) is excessive or insufficient, the second electrode roll (ER2) corresponding to the roll map may be determined to be held.

[0151]

[0152] 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 collecting coordinate-related inspection data and compressed measurement data from an electrode sheet; A step of generating a roll map including spatially aligned process events of an electrode roll based on coordinate-associated inspection data and compressed measurement data, wherein the electrode sheet is wound onto the electrode roll; and A method for manufacturing a secondary battery, comprising a step of determining the retention of the electrode roll based on the roll map.

2. In paragraph 1, The above holding of the electrode sheet is determined based on the hold reference data and the roll map, and A method for manufacturing a secondary battery, characterized in that the electrode roll is determined to be held if any one of the coordinate-related inspection data and the compressed measurement data of the roll map includes a portion that satisfies the hold reference data.

3. In paragraph 2, A method for manufacturing a secondary battery, characterized in that if each of the coordinate-related inspection data and the compressed measurement data of the roll map does not include a portion that satisfies the hold reference data, the electrode roll is put into a subsequent process.

4. In paragraph 2, A method for manufacturing a secondary battery, characterized in that the defective portion of the electrode roll determined to be on hold is scrapped in a rewinding stage.

5. In paragraph 2, A method for manufacturing a secondary battery, characterized in that a sample inspection is performed on the electrode roll determined as the above-mentioned reservation.

6. In paragraph 2, A method for manufacturing a secondary battery, characterized in that the electrode sheet comprises a plate, an upper coating on an upper surface of the plate, an upper insulating coating on the upper surface, a lower coating on a lower surface opposite to the upper surface of the plate, and a lower insulating coating on the lower surface.

7. In paragraph 6, A method for manufacturing a secondary battery, wherein the hold reference data includes misalignment between the upper insulating coating and the lower insulating coating.

8. In paragraph 7, A method for manufacturing a secondary battery, characterized in that when the coordinate-related inspection data indicates misalignment of the upper insulating coating and the lower insulating coating, the electrode roll is determined to be on hold.

9. In paragraph 6, A method for manufacturing a secondary battery, wherein the above hold reference data includes surface defects of the upper insulating coating and the lower insulating coating.

10. In paragraph 9, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a line defect of a size exceeding a critical width of either the upper insulating coating or the lower insulating coating, the electrode roll is determined to be on hold.

11. In paragraph 9, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a pinhole defect of a size exceeding a critical diameter of either the upper insulating coating or the lower insulating coating, the electrode roll is determined to be on hold.

12. In paragraph 6, A method for manufacturing a secondary battery, wherein the hold reference data includes misalignment between the upper coating and the lower coating.

13. In paragraph 12, A method for manufacturing a secondary battery, characterized in that when the length of a section of the electrode roll defined by coordinates that match the judgment value indicating misalignment between the upper coating and the lower coating in the coordinate-related inspection data exceeds a critical length, the electrode roll is determined to be on hold.

14. In paragraph 6, A method for manufacturing a secondary battery, wherein the hold reference data includes surface defects between the upper coating and the lower coating.

15. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a line defect in any one of the upper coating and the lower coating exposing the electrode plate of the electrode sheet, the electrode roll is determined to be on hold.

16. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a line defect exceeding a critical length of either the upper coating or the lower coating, the electrode roll is determined to be on hold.

17. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a pinhole defect of a critical number or more in either the upper coating or the lower coating, the electrode roll is determined to be on hold.

18. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates a critical number or more of crater defects in either the upper coating or the lower coating, the electrode roll is determined to be on hold.

19. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the above coordinate-related inspection data indicates a crater defect of a size exceeding a critical diameter of either the upper coating or the lower coating, the electrode roll is determined to be on hold.

20. In paragraph 14, A method for manufacturing a secondary battery, characterized in that if the coordinate-related inspection data indicates an island defect of more than a critical frequency in either the upper coating or the lower coating, the electrode roll is determined to be on hold.

21. In paragraph 6, A method for manufacturing a secondary battery, wherein the above hold reference data includes insufficient or excessive loading of the upper coating and the lower coating.

22. In paragraph 21, A method for manufacturing a secondary battery, characterized in that if the compressed measurement data indicates that the loading amount of either the upper coating or the lower coating is excessive or insufficient, the electrode roll is determined to be on hold.

Images