EV & Battery Manufacturing
Cell, module and pack lines where traceability and safety are the same requirement.
- Scope
- Ground to Cloud
- Approach
- Retrofit first
- Base
- Bangalore, India
The brief
What this sector asks of a control system
Battery lines carry automotive takt pressure with process-industry consequences. We build control and traceability for cell handling, module assembly and pack finishing — where a cell that fails later has to be traceable to its formation data, and where a thermal event is a safety case rather than a quality one.
Every engagement starts the same way: we walk the floor, read the existing drawings, and write down what is actually installed before anyone proposes a platform. The sector decides the priorities — the plant decides the design.
Constraints we engineer around
What we bring
Disciplines we lead with in ev & battery manufacturing
The same engineering team carries the work from the panel to the dashboard, so nothing is lost at a handover between vendors.
In detail
What shapes the work here
The constraints that decide how a system for this sector gets engineered.
Traceability down to the cell
A pack is only as traceable as its weakest join. Cell serials have to survive sorting, stacking, welding and enclosure, and attach to the module and pack that eventually carry them — because a field failure is investigated at cell level, not pack level.
Marking and reading strategy is decided early for that reason. Cells that were never individually identified cannot be retrofitted into a genealogy afterwards.
Safety interlocks that are not advisory
Cell handling introduces hazards most assembly lines do not have: stored energy in every part, thermal runaway as a credible fault, and electrolyte handling in the upstream steps. Interlocks here are engineered as safety functions with defined performance levels, not as PLC logic that happens to stop a conveyor.
We design the safety architecture with your EHS team and keep it separate from process logic, so a production change cannot quietly weaken it.
Ramping a line that is still changing
Battery plants commission while the product design is still moving. Control that hard-codes a cell format or a stacking count becomes an obstacle by the second variant.
We keep format-dependent values in recipe data and parameterise the station logic, so a design change is a data change and a requalification rather than a rewrite.
Typical scope
What we are brought in to do
- Cell sorting, stacking and module assembly station control
- Serial genealogy from cell through module to finished pack
- Welding and joining parameter capture tied to unit serials
- Dry-room and environmental monitoring with excursion records
- End-of-line test data capture and pass/fail attribution
Engineering constraints
- Traceability
- Cell-level genealogy through the pack
- Safety
- Rated safety functions, kept separate
- Change
- Format handled as recipe data
Common questions
- Can you work to our cell supplier's marking scheme?
- Yes. The reading strategy is designed around whatever marking already exists; where cells arrive unmarked, we design the first identification point and are clear about what it costs in cycle time.
- Do you handle the safety case?
- We engineer the safety functions and provide the documentation for them. The safety case itself belongs with your EHS and certification route, and we work into it rather than around it.
- Our line design is not frozen yet — is that a problem?
- It is normal. It changes how the logic is written, not whether we can start: format-dependent values live in data from day one.
Elsewhere
