Electrode Roll Map Coordinate Correction After Breakage Seaming
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Solution Overview
Problem
In the electrode manufacturing process for lithium secondary batteries, electrode breakage during roll-to-roll processes leads to mismatched coordinates between the roll map and actual electrode dimensions, causing inaccuracies in defect detection and process alignment.
Innovation Solution
A roll map coordinate correction system and method that utilizes encoders, seam detection sensors, and reference point detectors to determine the breakage length and correct roll map coordinates by comparing encoder values and reference points before and after seam connection, ensuring alignment with actual electrode dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrode breakage occurs and broken electrodes are connected by seam connection member, then electrode continuity is restored, but electrode length becomes shorter causing coordinate mismatch in roll map
Solution Approach 1:
The system performs preliminary detection of seam connection members using sensors during the electrode manufacturing process. By detecting the presence and position of seam connection members before they cause coordinate mismatches in subsequent processes, the system can pre-calculate correction values and adjust roll map coordinates proactively, ensuring continuous accurate tracking despite electrode breakages and connections
Solution Approach 2:
The system implements a feedback mechanism where encoder values and sensor detections are continuously monitored. When a seam connection member is detected or electrode breakage is identified, the system calculates the actual electrode length change and feeds this information back to correct the roll map coordinates in real-time, maintaining coordinate accuracy throughout the manufacturing process
2Productivity
If roll map coordinates are not corrected after electrode breakage, then processing continues without interruption, but defect detection accuracy deteriorates due to coordinate mismatch
Solution Approach 1:
The system replaces manual coordinate correction methods with an automated electronic correction system. Encoders, sensors, and a controller work together to automatically detect electrode breakages, calculate length changes, and adjust roll map coordinates without stopping production, thereby maintaining both productivity and measurement precision simultaneously
Data Source
AI summary
A roll map coordinate correction system simulating an electrode moving in a roll-to-roll state between an unwinder and a rewinder includes a position expressed as a coordinate in a length direction of the simulated electrode, an encoder configured to derive the position of the electrode according to rotation amounts of the unwinder and the rewinder, and a seam detection sensor configured to detect a seam connection member and acquire a coordinate of the seam connection member in conjunction with the encoder. The system includes a reference point detector configured to detect a plurality of reference points marked on the electrode and acquire coordinates of the reference points in conjunction with the encoder, and a roll map coordinate corrector wherein, the roll map coordinate corrector determines a roll map correction direction by comparing encoder values, calculates an electrode breakage length by comparing coordinates and corrects the coordinates of the roll map.