Merge-Wound Electrode Roll Mapping for Seam-Level Defect Tracking
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Solution Overview
Problem
Existing technologies fail to accurately track the quality of merge-wound electrodes due to a lack of detailed coordinate information, making it difficult to determine the cause of defects in subsequent processes and final products.
Innovation Solution
An apparatus that includes a position measurement device, input device, seam detector, and reference point detector to generate a roll map of merge-wound electrodes, accurately reflecting coordinate information and seam positions, allowing for precise tracking of electrode quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple electrodes are merged and wound to maintain productivity, then electrode utilization is improved, but quality tracking capability deteriorates
Solution Approach 1:
The patent divides the merged electrode into distinct segments by recording the coordinate positions where individual electrodes are connected. Each electrode's coordinate information is separately tracked and stored, allowing the system to identify which specific electrode segment a defect originates from, even though the electrodes are physically merged into a single continuous structure.
Solution Approach 2:
The patent creates a virtual copy of the coordinate information for each electrode by using an encoder to record and store the position data of connection points. This digital replica of the physical electrode arrangement enables quality tracking without requiring physical separation of the merged electrodes.
2Device complexity
If only total length is measured by encoder, then measurement simplicity is improved, but defect location accuracy deteriorates
Solution Approach 1:
The patent performs preliminary measurement by recording the coordinate positions of connection points between electrodes during the merging process. This advance recording of position data enables precise defect location tracking later without requiring additional measurement devices or complex operations during quality inspection.
3Ease of manufacture
If electrode coordinate values are not managed, then process simplicity is improved, but quality analysis capability deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the encoder continuously monitors and records the coordinate positions of electrodes during the merging process. This recorded coordinate information is then used to trace defects back to their source electrodes, creating a closed-loop quality tracking system that maintains process simplicity while enabling reliable defect analysis.
Data Source
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AI summary
An apparatus for generating a roll map of a merge-wound electrode according to one embodiment of the present invention includes a position measurement device configured to acquire, when an electrode moves in a roll-to-roll state between an unwinder and a rewinder, coordinate value data for a longitudinal position of the electrode according to an amount of rotation of the rewinder, an input device configured to input, when two or more old electrodes that are each marked with a plurality of reference points at certain intervals are connected to be merged and wound into one new electrode, an input signal indicating a start of merge-winding or an end of merge-winding, a seam detector configured to detect a seam, which is an old electrode connection portion of the new electrode that is merge-wound, and acquire electrode coordinate values of the seam in conjunction with the position measurement device, a reference point detector configured to detect reference points of the merge-wound new electrode and acquire electrode coordinate values of the reference points in conjunction with the position measurement device, and a roll map generator configured to generate a roll map for simulating the new electrode moving in a roll-to-roll state based on the input signal of the input device and display longitudinal coordinate values of the electrode, the electrode coordinate values of the seam, and the electrode coordinate values of the reference points on the roll map in conjunction with the position measurement device, the seam detector, and the reference point detector.