Battery Electrode Roll Mapping for Precise Defect Localization
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Solution Overview
Problem
Current methods for manufacturing lithium secondary batteries face challenges in accurately marking and tracking defects during the electrode manufacturing process, making it difficult to identify the cause of defects and anomalies in finished products, which can lead to safety issues and product failures.
Innovation Solution
A system and method for generating a roll map that includes an inspection and measurement device to acquire data on electrode dimensions, coating mismatches, slurry loading, and defects, along with a position measurement device to track the electrode's position, allowing for the creation of a simulated electrode map that displays inspected and measured data, enabling precise tracking and analysis of manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual marking or tagging is used to identify defects on electrodes, then defect identification is possible, but the exact location of defects becomes difficult to determine and track
Solution Approach 1:
The patent creates a virtual copy of the electrode in the form of a roll map that digitally represents the physical electrode's defect locations. Instead of relying on physical markings that can be removed or misplaced, the system generates a digital twin containing precise coordinate information of all defects, enabling accurate tracking throughout the manufacturing process without compromising the actual electrode integrity.
Solution Approach 2:
The patent transitions from two-dimensional physical markings on the electrode surface to a comprehensive digital representation that adds the dimension of precise coordinate data and manufacturing history. The roll map captures defect locations with exact coordinates (position, width, length) and links them to manufacturing parameters, creating a multi-dimensional information structure that enables precise defect tracking and analysis.
2Loss of information
If physical markings are placed on electrodes to track defects, then defect history can be recorded, but the markings may be removed or disappear during manufacturing processes
Solution Approach 1:
The system creates a persistent digital copy of defect information in the roll map that remains intact throughout the manufacturing process. Unlike physical markings that can be removed during coating, rolling, or slitting operations, the digital defect records are stored and maintained in the manufacturing execution system, ensuring continuous availability of defect history information for quality analysis and traceability.
Solution Approach 2:
The roll map serves as an intermediary between the physical electrode and the defect tracking system. Rather than directly marking the electrode, the system uses the roll map as a digital mediator that records, stores, and transmits defect information through various manufacturing stages, preventing information loss without interfering with the physical electrode processing.
3Measurement precision
If traditional marking methods are used on finished battery products, then defect identification is possible, but detailed manufacturing history information cannot be determined
Solution Approach 1:
The patent enriches the basic defect location information by adding multiple dimensions of manufacturing history data to the roll map. Beyond simple coordinates, the system records manufacturing parameters (slurry loading, coating thickness, rolling pressure), process timestamps, equipment used, and quality metrics, creating a comprehensive digital record that enables both precise defect localization and detailed manufacturing traceability.
Solution Approach 2:
The system performs preliminary recording of defect information and manufacturing parameters at the time of defect detection, rather than attempting to retrieve or infer this information later. By capturing and storing complete defect and process data in the roll map during the electrode manufacturing stage, the system ensures that all manufacturing history information is preserved before subsequent processing steps may alter or remove the physical electrode.
4Manufacturing precision
If comprehensive inspection and tracking systems are implemented, then manufacturing quality control is improved, but system complexity increases
Solution Approach 1:
The roll map serves multiple functions within a single integrated system: it records defect locations, tracks manufacturing history, stores process parameters, enables quality analysis, and provides traceability. By consolidating these diverse functions into a universal digital platform, the system achieves comprehensive quality control without proportionally increasing complexity, as the same infrastructure supports multiple manufacturing and quality assurance needs.
Data Source
AI summary
Methods and systems for executing tracking and monitoring manufacturing data of a battery are disclosed. One method includes: receiving, by a server system, sensing data of the battery from a sensing system; generating, by the server system, mapping data based on the sensing data; generating, by the server system, identification data of the battery based on the sensing data; generating, by the server system, monitoring data of the battery based on the sensing data, the identification data, and the mapping data; and generating, by the server system, display data for displaying a simulated electrode of the battery on a graphical user interface based on the monitoring data of the battery.