Roll Map Coordinate Correction After Electrode Breakage
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Solution Overview
Problem
The mismatch between the coordinates of a roll map and the actual dimensions of an electrode occurs when the electrode is broken, leading to inaccurate data expression and potential errors in subsequent processes due to the lack of coordinate correction in consideration of the breakage length.
Innovation Solution
A system and method that includes an encoder, seam detection sensor, and reference point detector to determine the roll map correction direction, calculate the electrode breakage length, and correct the coordinates of the roll map by incorporating the breakage length, using a roll map coordinate corrector to align the simulated movement with the actual electrode dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode is broken and connected by a seam connection member, then the electrode can continue to be processed, but the length of the electrode becomes shorter leading to coordinate mismatch in the roll map
Solution Approach 1:
The system uses encoders on both the unwinder and rewinder to continuously monitor the actual position of the electrode, and feeds this information back to the roll map coordinate corrector. When a breakage is detected, the system calculates the coordinate adjustment amount based on the difference between unwinder and rewinder encoder values, and automatically corrects the roll map coordinates to maintain accuracy despite the electrode length change.
2Device complexity
If the roll map coordinates are not corrected after electrode breakage, then the system remains simple, but the coordinates of the roll map become different from the dimensions of the actual electrode leading to inaccurate data representation
Solution Approach 1:
The system installs encoders on both the unwinder and rewinder in advance, and establishes the coordinate correction mechanism before breakage occurs. When breakage is detected, the correction calculation is immediately performed using the pre-collected encoder data, allowing for rapid coordinate adjustment without adding complex real-time measurement systems.
3Loss of information
If the electrode breakage length is calculated and roll map coordinates are corrected, then data consistency is maintained, but additional sensors and calculation processes are required
Solution Approach 1:
The encoders installed on the unwinder and rewinder serve multiple functions: they monitor the electrode position during normal processing, detect breakage events, and provide data for coordinate correction calculations. This multi-functionality allows the system to maintain data consistency without adding dedicated sensors solely for breakage detection.
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.