Electrode Roll Mapping for Unit-Level Defect Origin Tracking
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Solution Overview
Problem
Current battery manufacturing processes cannot track the quality of electrode units before the notching process, leading to entire electrode rolls being discarded when defects are detected, as quality tracking is limited to post-notching stages.
Innovation Solution
A system that includes a notching controller, calculator, roll map generator, and mapping part to track the position of electrodes by storing pitch information, acquiring electrode coordinate data, and generating roll maps to determine the origin of unit electrodes during the electrode manufacturing process, allowing for defect analysis and quality tracking up to the electrode manufacturing stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If quality tracking is performed only after the notching process, then the tracking system is simple, but entire electrode rolls must be discarded when defects are detected
Solution Approach 1:
The patent divides the continuous electrode roll into individually trackable unit electrodes by introducing unique identifiers (cell IDs) to each unit. The tracking system segments the quality monitoring function into unit-level tracking, allowing defective units to be identified and isolated without discarding the entire roll. This segmentation enables precise defect localization while maintaining cost-effectiveness.
Solution Approach 2:
The patent applies preliminary action by marking unit electrodes with cell IDs during the electrode manufacturing process, before the notching process. This early identification enables traceability throughout subsequent manufacturing stages, allowing defects to be tracked back to their origin without requiring complex post-notching tracking systems.
2Reliability
If quality tracking is extended to the electrode manufacturing stage, then defect origin can be identified, but the tracking system becomes more complex
Solution Approach 1:
The patent implements a universal tracking system where cell IDs serve multiple functions: identifying unit electrodes during manufacturing, tracking their positions on the electrode roll, and enabling defect origin analysis. This multi-functional approach achieves high reliability without proportionally increasing system complexity, as the same identifier system serves multiple purposes throughout the manufacturing process.
Solution Approach 2:
The patent uses simple visual identifiers (cell IDs) that can be scanned and copied digitally throughout the manufacturing process. This copying mechanism allows the physical electrode to be tracked through digital representations, enabling complex tracking functionality through simple, replicable identification marks that don't significantly increase system complexity.
3Measurement precision
If cell ID coordinates are calculated and mapped to electrode positions, then precise defect localization is achieved, but data processing complexity increases
Solution Approach 1:
The patent replaces complex mechanical tracking systems with a digital coordinate mapping system. Instead of physically tracking electrode positions through mechanical means, the system uses mathematical coordinate transformations based on cell ID positions and pitch information. This substitution achieves high measurement precision through computational geometry while keeping the physical system relatively simple.
Solution Approach 2:
The patent introduces coordinate information as an intermediary between the physical electrode position and the defect detection system. The coordinate mapping serves as a mediator that translates physical positions into trackable data, enabling precise defect localization without requiring direct complex interaction between sensors and electrode positions.
Data Source
AI summary
A systems and methods for tracking a position of an electrode. The system may include: a notching controller configured to store pitch information of a unit electrode and to acquire electrode coordinate information of the electrode in a roll-to-roll state during a notching process and a cell identification (ID) of the unit electrode; a calculator configured to calculate coordinates of the cell ID from the pitch information and the cell ID; a roll map generator configured to generate a roll map based on the electrode coordinate information transmitted from the notching controller; and a mapping part configured to compare the coordinates of the roll map with the coordinates of the cell ID to derive an electrode position of the electrode during the electrode manufacturing process from which the unit electrode originates.