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GullySystem
Manufacturing · Software for eV charger manufacturers

Record the firmware, power module and test result inside every charger you ship.

This software suits EV charger makers and assembly plants. It holds variants by connector and power rating and tracks power modules and boards by lot. End-of-line tests are saved with the firmware loaded, and each charger keeps its service history.

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At a glance

A charger order names an output power, a connector type, a cable length, a metering option and a communication stack. AC wallboxes and DC cabinets differ widely. Parts lists differ too. A DC unit may use several power modules, a cooling system, a contactor set, a payment terminal and a screen. You order modules, boards, enclosures and cable assemblies against both. One long lead part can stop a whole batch.

Assembly starts with the enclosure and ends with an end-of-line test. Firmware is loaded, the communication link to the back office is checked, the energy meter is read against a reference, and insulation and earth leakage are measured. The unit goes out with a serial and a firmware version. Both matter a year later. When a charger on a customer’s car park trips, the support team needs to know which board, which module lot and which software it carries.

How the work runs today

The firmware engineer pushes a new build on Tuesday. By Wednesday the loading station is still writing the old one onto half a batch, and nobody has noticed the mismatch yet. The purchase desk is chasing a power module that has slipped by three weeks.

A distributor calls to ask when twenty wallboxes will ship. The answer depends on a connector shipment, a label reprint and a test slot. No date is truly firm. Three people, three dates.

Where it breaks

What goes wrong for eV charger manufacturers without a proper system.

Firmware versions drift across a batch

Units on the same pallet may carry different builds because the loading station was updated mid-run. Support cannot tell which charger runs which software without connecting to each one on a customer’s car park. Checking is slow and tedious.

Power modules and boards arrive in lots

Rectifier modules, control boards and meters come from suppliers in lots with their own data sheets. When a module type shows early failures, the affected chargers cannot be named from the shop record.

End-of-line results sit on the bench PC

Insulation, earth leakage, meter accuracy and communication checks are saved to a file on the test PC. The serial plate and the delivery note are written separately.

Variants multiply with connectors and options

Cable length, connector type, meter, display, payment terminal and enclosure colour combine into many builds. The parts list for each is rebuilt by hand. Errors follow.

Field faults return with no build history

A charger sent back from a car park has a serial but no list of boards, modules or firmware. The repair team opens it to find out.

What the software does

What we would build for eV charger manufacturers.

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

Charger models and options

Hold each power rating, connector, meter and enclosure option with its own parts list, so an order for a seven kilowatt wallbox and one for a cabinet start from different sheets.

Module and board stock

Receive power modules, control boards, meters and cables by lot with the supplier reference, and issue them to builds so that each serial names the lots inside it.

Assembly and wiring jobs

Follow each unit from enclosure through wiring, module fit and cable gland to final close.

Firmware and end-of-line test

Record the firmware loaded and every test reading against the unit serial, so the delivery note can list the build each charger carries when it leaves the dock.

Serials and labels

Print rating plates and serial labels from the stored unit record.

Dispatch and installation handover

Release units against customer orders with serial lists, manuals and commissioning notes.

Returns and field faults

Log returned chargers against their build record and the lots inside.

Before you talk to a supplier

A requirements checklist for eV charger manufacturers.

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

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Ready product

A product already built for eV charger manufacturers.

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

EV Charger Manufacturer Management Software

Charger models and options, module and board lots, assembly jobs, firmware flashing and end-of-line test records, serial labels and returns for EV charger makers.

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Solutions inside

The business modules eV charger manufacturers use most.

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

Services

The services behind it.

IoT and Edge Computing

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

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Business Process Automation

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

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ERP, CRM and Business Software Implementation

One record of stock, orders, customers and accounts, set up so your team opens it every day.

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Data Migration and Moving Off Spreadsheets

Data migration and spreadsheet replacement covers auditing existing files, cleaning and deduplicating records, loading them into a new system and reconciling the loaded result against known totals. Both systems then run side by side before cutover. Originals stay untouched.

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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 eV charger manufacturers ask before they call.

Can a charger serial show its firmware and module lot?

Yes. The unit record stores the firmware version loaded at the end of the line, the power module lot and the control board lot. Support can read them before anyone opens a ticket, and before a technician is sent to a car park to find out.

Does this software connect to the chargers themselves?

No. It is a factory and service system, not a charging network back office. Firmware version and test readings are entered or imported at the end-of-line step, from the loading tool and the bench, and then stay with the unit.

How are option combinations handled?

A base model carries optional parts such as meter, screen, payment terminal and cable length. The chosen combination becomes the parts list for that order, with each optional line priced.

Where do we start?

A short walk-through uses one of your models and its test sheet. Pricing follows in a written proposal that depends on users and modules chosen.

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.

Share your requirements