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GullySystem
Manufacturing · Software for battery pack manufacturers

Match every cell to its grade, every pack to its serial and every test to its cycle log.

A battery pack maker takes in 18650 and prismatic cells, grades them on a sorter and welds them into modules. A battery management system (BMS) board and housing follow, then each pack is cycled on a charger channel before it ships. The software tracks cell lots, grading results, BMS firmware, cycle tests and serial numbers, so a returned pack can be traced to the cells inside it.

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At a glance

Cells in one string must be matched. A cell with higher internal resistance or lower capacity than its neighbours ages faster and drags the whole series group down. Matching is done before any nickel strip meets a spot welder. Sorting early decides how the pack ages.

Production software for pack makers holds the grading result for every cell, the module it joined and the pack it ended up in. The charge curve and the firmware version are filed under the same serial. Nothing gets retyped by hand. Start with your incoming cell carton.

How the work runs today

Cell cartons arrive with a supplier lot code and a certificate of analysis. Each cell is measured for open-circuit voltage, capacity and AC internal resistance, then dropped into a grade bin. Cells of one grade are arranged into a module with nickel strip, spot welded or bus-barred, and fitted with a thermistor and balance leads for the management board.

The BMS board gets firmware and cell-count parameters. Modules go into a housing with a fuse, a contactor, connectors and a rating label. Then the pack cycles on a test channel. Its serial collects capacity, curve and trips. Packs that pass are boxed against the customer’s order.

Where it breaks

What goes wrong for battery pack manufacturers without a proper system.

Cell grading data lives in a file on the grader

Capacity and resistance readings for thousands of cells sit in CSV files on the sorter’s laptop. No one links a cell to its pack. The trail ends at the bin.

Mixed grades enter the same module

A tray of mid-grade cells is set beside a tray of top-grade cells at the welding bench. The pack is built, and its cell imbalance shows only months later, when a scooter owner complains about range.

Weld quality is checked by eye

Spot weld counts, electrode wear and pull-test samples are not written down. A cold joint shows up on the road.

BMS firmware and parameters differ by pack

A board is flashed with last month’s hex file for the wrong series count, and nothing on the record says which packs carry which setting. Support guesses from photographs.

Returned packs lose their history

A pack comes back with a swollen pouch cell. Without cell lots, grades and cycle logs, a bad cell supplier’s lot cannot be told apart from a poor weld or a charger fault.

What the software does

What we would build for battery pack manufacturers.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Cell lot receiving and grading

Log each cell carton against its supplier lot code and save voltage, capacity and AC resistance per cell, with the grade bin assigned.

Module build and weld records

Record which graded cells joined which module, the welder, the spot weld current setting and pull-test samples taken on nickel strip.

BMS firmware and parameters

Store the hex file and parameter set flashed onto each board, with the cell count and the serial of the pack it joined.

Charge and discharge cycle tests

Save capacity, voltage curve and over-current or over-temperature trips per pack, with the cycler channel and date.

Pack serials and labels

Assign a pack serial, print the rating label and carton label with its barcode, and tie the pack to its customer order.

Returns and failure analysis

Log a returned pack with the fault description, the cell found failing and whether the supplier lot is suspect, then link it to its build history.

Before you talk to a supplier

A requirements checklist for battery pack manufacturers.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for battery pack manufacturers.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Battery Pack Manufacturer Management Software

Cell lots and grading, module and weld records, BMS firmware, cycle tests, pack serials and returns for battery pack manufacturers.

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Solutions inside

The business modules battery pack manufacturers use most.

Each one is also available on its own, or inside a system built for you.

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

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IoT and Edge Computing

Machines, meters and sensors feeding the same system your office uses, even when the network drops.

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Data Engineering and Business Intelligence

Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.

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How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

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Common questions

Questions battery pack manufacturers ask before they call.

Can it store grading data for every cell?

Yes. Capacity, resistance and voltage readings are saved per cell, and a file import from the sorter can be set up as extra work.

Does it tell us which cells are in which pack?

Yes. Each module lists its cells by grade and lot, and each pack lists its modules, so one serial opens the cell trail.

Can we hold different chemistries?

Yes. Each pack type has its own cell type, grading limits and cycler profile, so lithium iron phosphate and nickel manganese cobalt packs run side by side.

Is shipping paperwork covered?

Dangerous goods papers for cells and packs stay with your safety officer, who knows the UN number and the carrier. The software supplies the packing lists and serials those papers quote.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

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