Manufacturing · Energy Storage System Manufacturer Management Software

Cell grades, welds, firmware and test curves per serial.

Manage cell lots, capacity grading, module and rack builds, battery management unit firmware, end-of-line tests, container configuration and shipment in one system. Each module and rack carries the cell lots, busbar welds and test curves that went into it, so a field fault starts at the serial number. Open the build. Trace it to the cell tray.

Share your requirements

Grading limits, module layouts and rack bills of parts are entered as your engineers define them, before the first cell tray reaches the grading rack.
Open orders, cell stock and serial history are migrated from your workbooks, so a rack built last year can still be traced to its cell lot.
When buyers ask for a different test report layout, GullySystem staff adjust it for you on request, and your test engineers keep their rig routine.

GullySystem gives makers of battery modules, racks, cabinets and containers one place for cell receipt, grading, module builds, BMS firmware loading and end-of-line tests. Every pack serial shows its cell lots, weld results, busbar torque and test curves, so a service call is answered from the file.

Where it breaks today

What goes wrong before the software.

Cell grades never reach the stacking bench

Capacity and internal resistance are measured at grading, yet trays reach the stacking bench without the numbers, so unmatched prismatic or pouch cells land in one module. Balance faults follow. They surface late.

A cell lot cannot be searched later

When one supplier lot proves weak, the maker must find every module built from it, but with no link from lot to serial the list comes from memory. It takes days.

Firmware on a rack is a guess

Management units are flashed from a shared folder, and which release a rack carries is known only to the person who loaded it. Nobody wrote it down. Then a CAN bus fault arrives from a site.

Weld and torque checks leave no record

A laser weld schedule or busbar bolt torque is written on a paper traveller, and once the lid is closed nobody can confirm either value without cutting the case. The traveller is lost.

Test curves live on the test rig

Cycle curves and hipot readings sit in files on the rig PC, so the report for one serial needs a walk to the test bay and a date search. File names rarely match serials.

Containers ship with gaps

Cooling units, smoke detectors and switchgear arrive from separate suppliers, so a container can be booked for transport while the fire panel is still on order. The truck waits at the gate.

How it runs

How the work flows through it, step by step.

1
Cell receipt
Trays arrive with a lot code. Receiving staff record the datasheet capacity and nominal voltage, the chemistry, LFP or NMC, the cell format and the count received against the delivery note.
2
Grading
Each cell is measured for capacity, open-circuit voltage and DC internal resistance on the grading rack, then given a grade, while rejects are quarantined for return to the supplier. Trays carry the grade label.
3
Module build
Matched cells are stacked, busbars are welded or bolted, and sensing harnesses are fitted, after which the finished module receives a serial linked to every cell lot used. Welds are logged at the station.
4
Rack assembly
Modules, fuses, contactors and the management unit go into the rack frame, and the technician who loads the firmware signs it in by name. The release number is stored on that entry.
5
End-of-line test
High-voltage insulation (hipot) and insulation resistance, cell balance and one full charge and discharge cycle are checked, and the curves are saved to the serial. Failed units go to rework. The failed test stays attached.
6
Container and shipment
Cooling, detection and switchgear are checked against the bill of parts, and the packing list and handling notes are printed for the carrier. A missing contactor or fire panel stops the release.

Modules

What is inside.

Every module can be switched on, left out or changed to match how your team already works.

Cell lot receipt

Log tray deliveries by supplier lot code, with datasheet values and quantities, then quarantine any lot that fails an incoming voltage or resistance check and hold it from grading.

Cell grading station

Capture capacity, voltage and internal resistance for each cell and assign a grade, then send cells to the module line in matched sets with a label on every tray.

Module build cards

Open a card per module listing the matched cells, busbar weld schedule and torque values, then close it with a serial that points back to every cell lot used.

Busbar and harness records

Record laser weld settings, bolt torque readings and sensing harness continuity at the station, so a closed module keeps its build evidence on file after the lid goes on.

Rack bills and management units

Hold the bill of parts for each rack type, with fuses, contactors, busbar links, pre-charge resistor and management unit, and see shortages before the build starts on the frame.

Firmware register

Store the release loaded onto each management unit with the date and the technician, and when a release is withdrawn, list every serial running that version in one search.

End-of-line test results

Store insulation, balance and cycle-curve results against the serial, mark failures, and send them down a rework route with the name of the test that failed on the card.

Container configuration

Define cooling, fire detection, switchgear and cable sets for each container and track which items are received, so shipment stays blocked until the whole list is complete.

Dangerous goods handling notes

Keep the packing and handling notes your safety staff set for each shipment type, including the UN 38.3 test summary a carrier asks for, with the packing list.

Field fault tracing

Open a rack by serial when a customer reports a fault, then drill down through its modules to the cell lots, weld records and test curves behind each one.

Solutions inside

The business modules it is built from.

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

Batch and Serial Tracking
A closed module receives a serial that points back to every cell lot and grade used, so lot searches reach finished racks without opening any pack.
Goods Receipt (GRN)
Tray deliveries are checked against the order and lot code, and a failed incoming voltage check places the whole lot in quarantine away from the grading rack.
Quality Control
Hipot, balance and cycle-curve readings are stored against the serial, and a failed rack is routed to rework with the failing test named instead of shipping.
Bill of Materials
Each rack type lists its modules, fuses, contactors and management unit, and shortages are shown before the build is released onto the frame.
Work Order Management
Station steps for welding, torque and sensing harnesses are completed in order, and the laser settings and bolt readings stay with the module serial.
Barcodes and Labels
Pack and rack labels print the serial, grade and the handling note your safety staff entered, so crates and trays are identified at a single scan.
Production Planning
Planners see cell stock by grade and the container builds waiting on parts, then sequence module work around the missing cooling units or fire panels.
Stock Tracking and Alerts
Stock of cooling units, smoke detectors and switchgear is watched against a set level, and purchasing is alerted before a container build stalls at the dock.

Services

How we would put it in.

Setup, data migration, integrations and anything built on top.

Who uses it

One system, each person sees their part.

For cell grading staff

Measure incoming cells, assign grades and release matched sets to the module line, while each tray keeps its grade label and rejected cells wait in quarantine for return.

For module and rack assemblers

Open the card, log welds and torque, fit the management unit and record the firmware loaded, because the serial closes only when every step on the bench is done.

For test engineers

Run the end-of-line checks and enter hipot, balance and cycle results, and send failed units back for rework with the failing test named on the card.

For production planners

See cell stock by grade, plan module builds and watch which containers are waiting on parts, so the line is sequenced around real shortages instead of guesses.

For service engineers

Search a serial in the field and read its cell lots, firmware release and last test curve, then plan the visit with the right spares loaded in the van.

Reports

The numbers the owner asks for.

Cells received, graded and rejected by lot
Module builds by grade and status
Racks by firmware release
End-of-line failures by test type
Containers waiting on parts
Cell lots used per rack serial
Field faults by cell lot and rack

Good fit

Who this is built for.

Makers of battery modules and packs
Builders of rack-mounted storage cabinets
Assemblers of containerised storage systems
Makers of home and commercial storage units
Integrators building packs around bought-in prismatic or pouch cells

Honest answer

When it is not the right choice.

A solar installer who fits panels and inverters on roofs is better served by Solar Installer Management Software, since cell grading and rack builds are not part of that job.
A counter shop selling batteries to walk-in buyers needs the wholesale ordering product instead, because it builds no modules and tests no cells.

Made to fit

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.

Grading rules

Grade limits for capacity and resistance and the matching rules for each module come from your engineers’ own criteria, so the grading rack sorts cells as your design expects.

Rack and container bills

Standard rack types and container builds are loaded with their parts lists, from fuse and contactor ratings to the cooling unit and the fire panel.

Test report layouts

Reports follow the layout that buyers and your test staff expect, whether the buyer wants a hipot summary, a cell balance table or the full cycle curve.

Records migrated

Cell lots, serials and test files are copied in from your workbooks and from the folders beside the test rigs, so history does not start at zero.

Messages and documents

Packing lists and test reports go by email, with short notices over messaging when a container is released or a rack fails its balance check.

Works alongside

Email
Accounting export
Barcode and label printing
SMS
WhatsApp

Common questions

Questions owners ask before a demo.

How is a cell lot linked to a rack?

Each module serial stores the lots and grades of its cells, and each rack serial stores its modules, so one lot code search lists every rack holding such cells.

Can the system store test curves?

Yes. Insulation readings and charge-cycle curves sit under the serial and print as a report, and the layout is agreed with your test staff before the first rack runs.

What if a firmware release is withdrawn?

Search the register for the release and list every rack that carries it, then book the reload for a named technician and log it when done. Nothing relies on memory.

Can we quarantine a weak cell lot?

Yes. The lot is flagged, and any module that would draw on it is blocked until a decision is entered by a named person, with the reason.

Does it handle racks of different sizes?

Yes. Every rack type carries its own bill of parts and module count, and the serial records which type was built, so mixed frames can share one test bay.

Can the container build be tracked by supplier part?

Yes. Cooling units, detectors and switchgear are received against the container build, and each shortage is visible well before the truck is booked for the gate.

Does it set safety or transport rules?

No. Handling notes are plain fields that your safety officer fills in, and the software prints whatever was entered and nothing more, leaving safety decisions with your own people.

How do you quote this?

The figure depends on line logins and test layouts. Your module design goes into a sample first, and only after that does a cost appear in the written offer.

Wondering what it would cost? Share your requirements and an engineer will come back with a scope.

Industries

Businesses that use this.

Energy storage system manufacturers

Related products.

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