Electrode Roll Map Alignment for Length-Change Traceability
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Solution Overview
Problem
Existing battery manufacturing processes face challenges in accurately tracing the origin of defects in electrode rolls due to changes in length during the roll-to-roll process, which complicates identifying the source of issues in semi-finished or finished batteries.
Innovation Solution
A roll map creation system that includes an inspection measurement device and a roll map creation device, which uses correction data to align coordinates and match inspection and measurement data across varying electrode roll lengths, ensuring accurate cell traceability by creating an overlay roll map.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode roll length changes during the roll-to-roll process, then the manufacturing process can be completed, but accurate cell traceability becomes difficult to achieve
Solution Approach 1:
The system creates a first roll map during the electrode coating process that records the initial position and length of the electrode roll. This preliminary mapping allows for later correction when the roll length changes during subsequent roll-to-roll processes, ensuring traceability is maintained throughout the manufacturing sequence.
Solution Approach 2:
The system detects changes in electrode roll length parameters during the roll-to-roll process and automatically generates correction data to adjust the coordinates. By dynamically updating the length parameter and recalculating corresponding positions, the system maintains accurate traceability despite physical changes in the electrode roll.
2Measurement precision
If correction data is generated to account for length differences, then coordinate accuracy is improved, but system complexity increases
Solution Approach 1:
The system incorporates feedback mechanisms where the detected length differences between the first roll map and subsequent roll maps automatically trigger correction data generation. This closed-loop approach ensures coordinate accuracy is maintained without requiring manual intervention, balancing precision with automated complexity management.
Solution Approach 2:
The roll map creation device acts as an intermediary that automatically processes and generates correction data between the inspection measurement device and the roll-to-roll manufacturing process. This intermediary function simplifies the overall system by centralizing the coordinate correction logic in a dedicated component.
3Difficulty of detecting and measuring
If overlay roll map is created by matching coordinates, then defect identification capability is improved, but data processing time increases
Solution Approach 1:
The system creates and stores the first roll map with complete coordinate information during the electrode coating process, before the roll-to-roll process begins. This preliminary preparation of reference data allows for rapid overlay and comparison during defect identification, reducing processing time while maintaining detection capability.
Data Source
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AI summary
A roll map creation system includes an inspection measurement device for moving electrodes represented by the first roll map created in the preceding process from the unwinder to the rewinder and inspecting the electrodes to obtain inspection and/or measurement data; and a roll map creation device for creating a second roll map by assigning coordinates to the electrodes, and matching the inspection and/or measurement data according to the coordinates of the electrodes, where the roll map creation device is configured to create correction data of the difference in lengths when the first roll map length (A) and the second roll map length (B) differ.