Continuous Web Production Tracking for Defect Traceability
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Solution Overview
Problem
The battery cell production industry faces high scrap rates due to challenges in tracking defects or deviations upstream and downstream the production line, making it difficult to identify faulty cells or cell components and recall production history, especially for electrode materials, which is time-consuming and complex.
Innovation Solution
A method and system for computer-implemented tracking of production history on a continuous web, using sensors and measuring devices to obtain and process time-stamped measured data and movement information, enabling precise mapping of production-relevant features and allowing for early identification of anomalies and root cause analysis, with improved positioning resolution and reduced marker invasiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If space indices are introduced for tracking production information, then production history can be tracked, but the process becomes time-consuming and complex
Solution Approach 1:
The patent creates a virtual copy of the continuous web (virtual electrode web representation) that mirrors the physical web's production history. Instead of tracking the physical web through complex space indices, a digital twin is maintained that contains all production-relevant features and measurements, simplifying the tracking process while preserving complete production history information.
Solution Approach 2:
The patent replaces the mechanical/physical tracking system (space indices, physical markers on the web) with an information-based system. Production history is tracked through data structures and computational models rather than physical tagging systems, reducing complexity while maintaining traceability.
2Measurement precision
If markers are applied on the continuous web for position indication, then positioning accuracy is improved, but the markers are invasive and may affect production
Solution Approach 1:
Instead of applying physical markers to the continuous web, the patent uses a virtual representation that captures position information through non-invasive sensing and computational mapping. The virtual electrode web representation records position data without requiring physical alterations to the material being processed.
Solution Approach 2:
The patent introduces an intermediary computational layer that translates sensor measurements into position information without requiring direct physical markers on the web. The virtual representation acts as a mediator between the physical web and the tracking system, eliminating the need for invasive marking.
Data Source
AI summary
A method for computer-implemented tracking of production history of a continuous web is provided, which is-processed in a production system, including a sub-system applied to perform specific operation(s). The web is transported along a curved given path through the production system by winding/unwinding from/onto a coil. The following are performed:obtaining measured data of the web while being transported along the path, the measured data being current time-stamped measured data acquired a sensor or a measuring device installed at the production system along the path, where a spatial position of each sensor and measuring device with respect to the given path determined by a one-time reference calibration;obtaining movement information of the web;determining production-relevant features of the web by processing the time-stamped measured data and the movement information of the web by mapping the time-stamped measured data to physical points of regions of the web.