Electrode Roll Mapping for Defect Tracking in Battery Manufacturing
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Solution Overview
Problem
Existing secondary battery manufacturing systems lack effective methods for generating and utilizing roll maps that include information about quality and defects in the electrode manufacturing process, leading to inefficiencies and losses in the production process.
Innovation Solution
A secondary battery manufacturing system that includes a first encoder to sense the length of an electrode sheet unwound from a roll, a controller to collect and transmit data, and a server to store and generate roll maps, enabling feedback and feedforward control to manage defects and losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manufacturing tracking methods are used, then system complexity is reduced, but defect tracking precision and inter-process loss management deteriorate
Solution Approach 1:
The patent creates a virtual copy of the physical electrode roll through the roll map data structure. The roll map contains defect position data, scrap data, and process data that replicate the essential information of the physical electrode sheet without requiring complex physical tracking infrastructure. This digital copying approach enables precise defect tracking while avoiding the need for sophisticated material handling and tracking hardware.
Solution Approach 2:
The roll map serves as an intermediary data structure between the physical electrode manufacturing process and the quality control system. It mediates the tracking of defects and scrap by providing a standardized data format that can be processed by the server without requiring direct complex interaction with the physical manufacturing equipment, thus reducing system complexity while maintaining tracking precision.
2Manufacturing precision
If comprehensive defect data collection is implemented, then manufacturing precision is improved, but loss of time in data processing increases
Solution Approach 1:
The system performs preliminary actions by collecting and storing defect position data, scrap data, and process data in the roll map during the manufacturing process itself. This preliminary data collection and organization enables rapid retrieval and analysis when quality control decisions are needed, reducing the time required for data processing while maintaining comprehensive defect tracking for improved manufacturing precision.
Solution Approach 2:
The patent transforms physical defect characteristics into standardized data parameters within the roll map structure. By converting defect positions, scrap lengths, and process variables into uniform digital parameters, the system enables efficient data processing through standardized formats that can be quickly analyzed without the time-consuming overhead of handling raw, unstructured manufacturing data.
3Loss of information
If roll map data storage is implemented, then information about defects is preserved, but loss of substance in the form of scrap electrode material increases
Solution Approach 1:
The roll map provides feedback by storing defect position data and scrap data that can be analyzed to identify patterns and causes of defects. This feedback mechanism enables continuous improvement of the manufacturing process, reducing the occurrence of defects and subsequent scrap generation. By preserving defect information systematically, the system transforms what would be pure loss into learning opportunities that reduce future material waste.
Solution Approach 2:
The patent implements a systematic approach to discarding and recovering by precisely tracking scrap electrode material through the roll map. By recording the position and characteristics of scrapped portions, the system enables targeted recovery efforts and prevents unnecessary scrapping of good material. The detailed defect position data allows for precise identification of only the defective portions that need to be discarded, maximizing the recovery and utilization of sound electrode material.
Data Source
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AI summary
Example embodiments of the present technology provide a battery cell formation device. The apparatus includes: a driving part including a driving plate and driving rods configured to move the driving plate in a first direction; and a support part including a support plate and elastic elements connected to the support plate, in which the support plate is spaced apart from the driving plate in the first direction and includes steps protruding in the first direction.