Battery Systems

Diagnostics & Health Assessment

Every service engagement starts with a precision state-of-health assessment. Using impedance spectroscopy, capacity profiling, and real-time telemetry, we build a complete performance baseline for each battery pack — identifying degradation patterns before they impact fleet uptime.

• Full pack impedance profiling and capacity benchmarking
• State-of-charge and state-of-health verification against rated specifications
• Degradation trend analysis from historical fault and cycle data
• Thermal imaging to detect hotspots and uneven cell ageing

Pack Repair & Reconditioning

When performance drops below rated capacity, targeted reconditioning restores it. We perform module-level and cell-level interventions that bring packs back to specification — maximizing longevity and avoiding premature replacement.

• Defective cell identification and precision replacement
• Bus bar, interconnect, and weld integrity restoration
• Enclosure resealing with IP rating revalidation
• Post-reconditioning capacity verification and performance sign-off

BMS Calibration & Firmware

The BMS governs every charge cycle, discharge limit, and safety threshold. Miscalibration leads to range loss, premature cutoffs, and accelerated cell wear. We recalibrate and update BMS parameters to ensure the pack performs as designed — end to end.

• SOC/SOH algorithm tuning for accurate range and capacity reporting
• Firmware updates aligned with OEM and field performance data
• Cell balancing circuit diagnostics and threshold configuration
• Communication protocol validation across CAN, SPI, and SMBus interfaces

Thermal Management Servicing

Sustained performance depends on thermal stability. We service both liquid-cooled and air-cooled battery thermal systems to keep cells operating within their rated temperature window — critical for longevity across India's varied climate conditions.

• Coolant loop flush, pressure testing, and refill to OEM specification
• Thermal interface material inspection and replacement
• Heat exchanger and chiller unit performance restoration
• Temperature sensor calibration and wiring harness validation

Cell-Level Analysis & Balancing

Cell imbalance is the primary driver of premature capacity loss. We test every cell individually and perform active and passive balancing to restore uniform voltage and capacity across the entire series string — extending the pack's productive life.

• Individual cell voltage, impedance, and capacity characterization
• Active and passive balancing to equalize cell performance
• Weak cell isolation and precision replacement
• Full pack requalification and rated capacity verification

Second-Life Assessment

Batteries that no longer meet vehicle-grade performance requirements often retain significant capacity for second-life applications. We grade and certify retired packs based on residual performance, enabling responsible reuse in stationary storage and lower-demand platforms.

• Residual capacity measurement and remaining cycle-life projection
• Safety and compliance grading for repurposed deployment
• Module sorting, matching, and configuration for new applications
• Full traceability documentation for downstream partners