Electrode Roll Defect Tracking With Datum Point Calibration
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Solution Overview
Problem
Existing secondary battery manufacturing processes lack effective methods for tracking and correcting defects in the electrode process, leading to inefficiencies and reduced yield.
Innovation Solution
A secondary battery manufacturing system and method that utilizes a roll map to store and calibrate defect and datum point data, enabling feedback and feedforward processes to improve quality and efficiency by precisely identifying and addressing defects in the electrode manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If defect data is stored without calibration, then data storage is simple, but measurement precision and manufacturing precision deteriorate due to coordinate offsets
Solution Approach 1:
The system performs preliminary calibration by storing datum point coordinates alongside defect data during the defect detection phase. This preliminary action establishes a reference framework that enables accurate position mapping without requiring complex real-time calculations during subsequent manufacturing processes.
Solution Approach 2:
The system implements feedback by comparing stored defect coordinate data with actual electrode sheet positions during manufacturing. The datum points serve as reference markers that provide continuous feedback on position accuracy, enabling the system to maintain precision throughout the manufacturing process.
2Reliability
If the entire electrode sheet is discarded when defects are detected, then product quality is improved, but productivity and yield worsen due to excessive material waste
Solution Approach 1:
The system segments the electrode sheet into discrete sections based on defect locations. By using defect coordinate data to identify specific problematic areas, the system can isolate and remove only the defective portions rather than discarding entire sheets, thereby maintaining productivity while ensuring quality.
Solution Approach 2:
The system applies local quality control by targeting specific defective regions identified through coordinate-based defect mapping. This approach ensures that quality improvements are achieved precisely where needed without unnecessarily affecting the quality or usability of defect-free portions of the electrode sheet.
3Manufacturing precision
If real-time defect tracking is implemented, then manufacturing precision is improved, but device complexity and measurement difficulty increase
Solution Approach 1:
The system introduces datum points as intermediary reference markers on the electrode sheet. These intermediaries simplify the measurement process by providing easily detectable reference positions that facilitate accurate coordinate mapping and defect tracking without requiring complex direct measurement systems.
Solution Approach 2:
The system creates a digital copy or map of defect positions and coordinates that mirrors the physical electrode sheet. This virtual representation simplifies tracking and analysis by allowing the system to work with data copies rather than requiring continuous complex physical measurements of the actual sheet.
Data Source
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AI summary
Example embodiments provide a secondary battery manufacturing system. The secondary battery manufacturing system includes a server configured to store a roll map including defect data indicating a defect of an electrode roll and datum point data indicating a datum point on the electrode roll, a controller configured to load the defect data and the datum point data from the server, and a datum point sensor configured to generate a datum point sensing signal by sensing the datum point on an electrode sheet unwound from the electrode roll, in which the controller is configured to generate datum point sensing data based on the datum point sensing signal and compare the datum point data with the datum point sensing data.