Battery Cell Dummy Feedback Control for Precise Process Settings

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Solution Overview

Problem

The performance and completion level of battery cells in manufacturing processes are highly dependent on process variables that are set based on technician experience, making it difficult to predict the impact of equipment changes or environmental variations on battery quality.

Innovation Solution

A battery manufacturing process management system using battery cell dummies equipped with sensors to measure and control process variables such as pressure, temperature, and deformation, and a controller to adjust these variables based on collected data, establishing a database for optimal settings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If process variables are set based on technician experience, then ease of operation is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveease of operationVSAvoidmanufacturing precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the manual, experience-based mechanical adjustment of process variables with an automated control system that uses sensors to detect actual process conditions and a controller to adjust variables accordingly. This substitution of human judgment with an automated sensing-controlling system resolves the contradiction by providing both ease of operation (automatic adjustment) and manufacturing precision (data-driven control).

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where sensors continuously monitor process variables and actual battery cell conditions, and this information is fed back to the controller which adjusts the process variables in real-time. This closed-loop feedback system ensures that manufacturing precision is maintained while eliminating the need for manual intervention, thus resolving the contradiction between ease of operation and manufacturing precision.

Inventive Principle:

Principle #23Feedback

2Productivity

If manufacturing equipment is replaced or equipment settings are changed, then productivity may be improved, but reliability deteriorates

Engineering Contradiction:

ImproveproductivityVSAvoidreliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The feedback mechanism continuously monitors the actual impact of equipment changes on battery cell quality. When equipment is replaced or settings are changed, the sensors detect any deviations in process conditions or product quality, and the controller automatically adjusts variables to maintain consistent output. This allows productivity improvements through equipment changes while maintaining reliability through real-time compensation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary detection and adjustment when equipment changes are made. By immediately monitoring process variables and product quality after equipment replacement or setting changes, and making preliminary adjustments to compensate for any negative effects, the system prevents reliability deterioration before it impacts production output.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If more sensors and control systems are added to monitor process variables, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvemanufacturing precisionVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs sensors and control systems that serve multiple functions: monitoring process variables, detecting battery cell conditions, providing feedback for adjustment, and ensuring quality control. By designing the sensing and control system to perform multiple functions simultaneously, the patent improves manufacturing precision without proportionally increasing device complexity, as each component serves several purposes in the manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Minimizes risks associated with equipment changes by optimizing process variables and providing real-time feedback, preventing performance degradation and defects in battery cells.

Implementation Method 1

a pressure sensor configured to measure the pressure applied to the battery cell dummy

Methodology Applied

Scientific EffectPressure sensing:

Implementation Method 2

a temperature sensor configured to sense the internal or external temperature of the battery cell dummy

Methodology Applied

Scientific EffectTemperature sensing:

Implementation Method 3

a gas volume sensor configured to measure the internal gas volume of the battery cell dummy

Methodology Applied

Scientific EffectGas volume sensing:

Implementation Method 4

a strain gauge configured to sense the deformation level of the battery cell dummy

Methodology Applied

Scientific EffectStrain measurement:

Data Source

PatentUS20260051525A1Battery manufacturing process management system and operating method thereof

Publication Date: 2026.02.19 LG ENERGY SOLUTION LTD

AI summary

A battery manufacturing process management system according to an embodiment includes a battery cell dummy configured to obtain data corresponding to a battery manufacturing process and a controller configured to control at least one process variable related to the battery manufacturing process based on the data corresponding to the battery manufacturing process that is obtained using the battery cell dummy.