Cell grades, module builds, BMS firmware and cycle tests tied to each pack serial.
Each pack serial opens its own build. Cell lots, grading bins, spot weld records, module builds, battery management board firmware and charge curves sit in one system. Under that serial sit the 18650 or prismatic cells with their grades, the welder energy and the cycler curve, and a returned pack opens its build history. Quality staff compare a suspect cell lot with every pack that used it.
- Pack types, cell grades, string layouts and test profiles keyed in as work proceeds
- Open orders and cell stock loaded from the spreadsheets you use now
- Grading limit and test field changes made by GullySystem staff when asked
Battery pack makers keep cell lots and grading, module builds, spot weld settings, BMS firmware, cycler tests, serials and returns together. Every pack lists the graded cells inside it and its capacity curve. A suspect cell lot returns every pack that used it, with customers and dispatch dates.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and pack type
Start from the order. A buyer’s order names the pack type, nominal voltage, capacity and quantity, and the bill of materials lists cells, nickel strip, busbars, BMS board, housing, fuse and sense harness.
- 2
Cell receiving and grading
Grade every cell. Cells arrive by supplier lot with the datasheet and certificate, each one is measured for capacity and resistance and sorted into a bin, and the result is saved against the lot.
- 3
Module building
Cells of one grade are arranged in the series and parallel layout and then welded. The module record names the cells, the welder, the energy settings and the strip lot behind each joint.
- 4
Pack assembly
A BMS board is fitted and flashed with firmware and cell count parameters. Modules then go into the housing with fuses, balance leads and connectors, and the version loaded is logged.
- 5
Charge and discharge
Cycle each pack. Charge and discharge run on a cycler channel, and the capacity, voltage curve and protection trips are saved against the serial, while any pack outside its limits is held.
- 6
Labelling and dispatch
Passing packs receive a serial label and are packed against the order. Your safety officer prepares the transport paperwork from the packing list, using the weights and serials it carries.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Bill of Materials
Each pack type lists its cell format, series and parallel layout, BMS board, housing and fuses, and a change is saved as a new revision.
- Batch and Serial Tracking
Cells are received by supplier lot and graded one by one, so a pack serial can name the lot and the bin behind every cell.
- Quality Control
Spot weld energy and pull-test samples are saved per module, and a result outside its limit holds the module before it reaches a pack.
- Work Order Management
A work order releases a kit of modules, BMS boards and housings for a stated number of packs, and shows any shortfall to the stores.
- Production Planning
Cycler channels are scheduled from open work orders, and a channel that falls free is offered to the next pack waiting in the queue.
- Ticket Management
A returned pack opens a ticket with its fault and the failing cell, and the same record shows the pack’s whole build history.
- Barcodes and Labels
Pack serials and carton labels print from the record, and scanning them at dispatch confirms that the right pack goes against the right order.
- Order Management
Customer orders hold pack type and quantity, and the open balance falls as packed serials are dispatched against them from the line.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For the plant head
Read cells graded, packs on the cyclers, returns and orders due from one screen, with lots on hold listed beside them.
For grading and welding teams
Record cell grades, bin trays and weld settings for each module. Welders see which tray feeds which module, so a mismatched bin never reaches the bench during a rushed shift.
For test engineers
Maintain firmware, grading limits and cycle profiles, then review results by serial. A pack run twice gives two records, and neither overwrites the other.
For quality staff
Hold suspect lots, review returns and trace packs back to the cells inside them. Weld pull-test results sit one click away from the pack record.
For stores and dispatch
Cell lots come in against the supplier certificate, and modules, BMS boards and housings go out to each work order in the quantity it needs. Finished packs leave against the customer order.
The numbers the owner asks for.
- Cells graded by lot and grade
- Modules built by welder and strip lot
- Capacity results by pack type and channel
- Packs held or reworked, by reason
- Returns by cell lot and failure type
- Firmware version per pack serial
- Packing lists and delivery notes by customer
Who this is built for.
- Makers of lithium-ion packs for electric two-wheelers and three-wheelers
- Assemblers of energy storage packs for solar and backup systems
- Makers of tool and appliance battery packs
- Makers of industrial and forklift battery modules
- Contract pack assemblers who build to a customer’s bill of materials
When it is not the right choice.
- Plants that coat electrodes and fill cells need process control this product does not offer.
- Makers of vehicle components generally may find EV Component Manufacturer Management Software closer.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- SMS
- WhatsApp or other messaging
- Cell grader file import
- Cycle tester file import
- Label printer
- Accounting export
Questions owners ask before a demo.
How does a pack serial link to its cells?
Module records list the graded cells used, and the pack record lists its modules, so one serial opens the cells, their supplier lots and their grades behind it.
Can the grader’s files be imported?
A file import from the grader can be built as extra work. The column layout is agreed with your test engineer in the first workshop, before any file is loaded.
What happens to a cell lot placed on hold?
It is blocked from issue, and the packs that already used it are listed so quality staff can decide what happens next.
Can different chemistries run together?
Yes. Lithium iron phosphate and nickel manganese cobalt types each keep their own cell, grading limits and test profile. They sit in one system without mixing.
Are cycle test curves stored?
Capacity, voltage curve and protection trips are saved against the serial. A retest on another channel is added as a new run and never overwrites the first result.
How are weld checks recorded?
Spot weld settings, strip lot and pull-test samples are saved per module, with the welder and the date, so a weak joint traces to a shift and a machine.
Does it cover transport documents?
It holds the packing lists, serials and gross weights that such documents need. What the hazard class and the carrier demand is for your safety officer to decide.
Can a customer ask for a build report?
A serial report shows cells, grades, firmware and test results. Whether it meets a customer’s own requirements is for your quality staff to confirm.
Who owns the pack data?
You do. Before work starts, the proposal states how build and test records can be taken out of the system.
What does it cost?
No price is published, since it depends on cycler channels, lines and users. A demo using a pack type of your own comes first.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Battery Pack Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- 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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