Electrode Seam Cause Tracking With Roll Map Correlation
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Solution Overview
Problem
Existing electrode manufacturing processes struggle to accurately identify the cause of seam formation in electrodes, which complicates quality tracing and defect analysis in secondary batteries.
Innovation Solution
A system that includes a position measuring instrument, signal generator, seam detector, and determination unit to determine the cause of electrode connections by generating a roll map that displays the seam's position and cause, using rotary encoders and tension sensors to track electrode movement and detect seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only seam position detection is implemented using conventional seam detectors, then the device complexity is low, but the measurement precision of connection cause identification is insufficient
Solution Approach 1:
The determination system divides the connection cause identification into multiple independent detection components: seam position detector, connection advance notice signal generator, and cause determiner. Each component performs a specific function, allowing the system to achieve high measurement precision while maintaining manageable device complexity through modular architecture.
Solution Approach 2:
The system generates connection advance notice signals before the seam is actually detected, based on predetermined distances from the unwinder and rewinder. This preliminary action allows the cause determiner to identify potential connection causes in advance, improving measurement precision by analyzing data before the actual connection event occurs.
2Loss of information
If comprehensive connection cause determination is implemented, then the loss of information is reduced, but the difficulty of detecting and measuring increases
Solution Approach 1:
The determination system continuously monitors seam positions and compares them against predetermined distances from the unwinder and rewinder. When a seam is detected within these predetermined distances, the system generates connection advance notice signals and determines the corresponding cause. This feedback mechanism ensures complete information capture about connection causes while automating the detection and measurement process to reduce complexity.
3Reliability
If multiple sensors and determination units are added to identify connection causes, then the reliability of quality tracing is improved, but the device complexity increases
Solution Approach 1:
The determination system is designed to handle multiple connection causes (unwinder-side issues, rewinder-side issues, and other causes) using a unified detection and determination framework. The same seam detector and determination unit work together for all types of connection cause identification, achieving high reliability for quality tracing while avoiding the need for separate specialized systems for each cause type.
Data Source
AI summary
An electrode connection cause determination system includes a position measuring instrument. The position measuring instrument is configured to, when an electrode moves between an unwinder and a rewinder in a roll-to-roll state, acquire coordinate value data based on a longitudinal position of the electrode determined according to a rotation amount of the rewinder. The system includes a signal generator configured to generate a connection advance notice signal if the electrode includes a connecting portion corresponding to a cause event, a seam detector configured to detect a seam attached onto the electrode after the connection advance notice signal is generated, and a determination unit configured to, when the seam is detected within a predetermined distance from a first coordinate value of the electrode after the connection advance notice signal is generated, determine that a connection cause of an electrode connection by the seam corresponds to the cause event.