Our Assembly and Testing Solutions for Rotors
The path from rotor design to series production requires expertise in both assembly and testing. We develop solutions that enable stable and economically efficient industrialization.
For over 15 years, we have been a partner in electromobility, delivering solutions that combine technological excellence with hands-on experience. As a full-service provider, we support you in the industrialization process, contributing our extensive expertise in rotor assembly and testing. Together with you, we develop customized rotor assembly systems and rotor test systems for electric motors, precisely tailored to your requirements – flexible, precise and future-proof. Our solutions enable reliable rotor assembly and testing in series production.
Rotor assembly systems and rotor test systems for electric motors
Rotor assembly and testing in series production
Modular rotor assembly for different rotor types
Development expertise and R&D capabilities
Virtual commissioning to validate concepts
Solutions from prototype development to series production
15 years of experience
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Josef Stöbig and Paul Birkeneder: “Let’s talk about your project!”
Contact us without obligation and tell us about your requirements. Together, we will develop the right solution—technically sound and precisely tailored to your needs.
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Why Sonplas
is your ideal partner for rotors
Customized system solutions for your rotor assembly
You receive systems from us that can be used both for development and for series production. Benefit from proven technologies as well as new solutions that we develop together with you – from rotor prototype systems to fully integrated assembly lines.
Our special-purpose machines are flexible in application
We offer flexible systems and production lines. Our concepts enable modular rotor assembly and cost-efficient adaptation to different production volumes and levels of automation. Depending on your requirements, systems can be quickly reconfigured or upgraded.
Better processes for reliable production
With our extensive expertise, we validate your manufacturing processes – giving you the confidence that they will perform reliably in practice.
Simulated processes for robust concepts
Through virtual commissioning of the rotor assembly system, we can reduce implementation time and visualize system operation at an early stage. After project kick-off, we simulate special and boundary conditions to optimize cycle times and identify productivity potential. This significantly reduces the need for physical customer parts and time required for testing. At the same time, it allows us to clearly demonstrate the capabilities and limits of a concept. Costly modifications later in the project can thus be largely avoided.
Support for prototype development in rotor assembly
We support you in rotor prototype development with our systems and process expertise – or take over this task for you as a service provider. Our R&D department provides comprehensive support, with more than 120 square meters of dedicated space. Equipped with our own machinery and supported by strong partnerships, we are able to cover all relevant rotor assembly processes for you.
Wir support you in optimizing your costs
If your production process is not performing as expected, we analyze your workflows together and develop targeted optimization measures for your production chain. The goal is to stabilize your processes and reduce production costs – enabling you to bring your solutions to market more cost-effectively.
How can our technological expertise drive your success?
Our solutions are always the result of combining our manufacturing expertise and experience, our automation and industrialization capabilities, and your know-how and application experience.
From designing prototypes for subsequent series production, we bring in-depth manufacturing and industrialization knowledge and understand how rotors can be produced reliably and cost-effectively. At the same time, we develop scalable and automated system solutions precisely tailored to your products. In close partnership with you, your application expertise and product knowledge are directly integrated into the system concepts – ensuring that all perspectives and the combined know-how from development, industrialization, machine building and application remain aligned.
This synergy leads to more stable processes, more realistic solutions and high-performance rotor assembly systems for electromobility – giving you a sustainable competitive advantage in production technology.
How can you benefit from our system flexibility?
Our strength lies in the flexible design of our system solutions. Depending on project requirements, we develop systems with varying throughput and cycle times – from prototype and small-batch solutions to highly efficient series production systems, from manual workstations to fully automated lines.
This flexibility is also reflected in the system concept. Our solutions are designed to handle different rotor types and dimensions on a single system, depending on the respective product design.
Thanks to modular concepts, our systems can be quickly retooled, adapted to new rotor variants and expanded in terms of automation level.
Whether you require assembly and test systems for high-voltage e-mobility applications at 400 or 800 volts or for 48-volt systems, as a full-service provider we support you with a solution tailored precisely to your needs.
Left: Rotor assembly line for synchronous motors
Center: Heating, pressing and shrink fitting
Right: Rotor assembly line
We are leading in
magnet fixation and shaft joining
Magnet fixation – experience from numerous rotor projects:
Over many years, we have built up extensive experience in rotor assembly and have implemented more than 100 different rotor concepts within our portfolio. In particular, we have developed exceptional process expertise in magnet fixation. Over time, we have realized all common magnet fixation methods and gained broad experience combined with a high level of variant expertise – making us one of the leading providers in this field.
Shaft-hub joining – process reliability through experience:
We also have comprehensive experience in shaft-hub joining using a variety of heating and cooling methods.
For hot shrink fitting, we apply convection heating, contact heating, induction heating or infrared heating, depending on the application.
For cold shrink fitting, we use methods such as convection cooling as well as cooling with liquefied gases or nitrogen.
These processes can be used individually or in combination – the key factor is process understanding. This is exactly where our strength lies: based on our experience, we know which combination of methods works reliably in practice and how to achieve stable, reproducible joints.
We use this expertise to provide you with concrete recommendations for robust and cost-efficient manufacturing processes. Many of these approaches have been directly transferred into our customers’ series production.
At the same time, we continuously expand our know-how through conferences, symposia and development projects, enabling us to understand new technologies at an early stage and integrate them into our system solutions.
Left: End-of-line test (dynamic)
Center: Magnetizing and magnetic flux measurement
Right: Manual loading station
Do you have any questions? Contact us.
Our references
Solutions that speak for themselves
We understand what drives our customers
Frequently asked questions about rotors
Thanks to our many years of experience and numerous successful projects we understand what drives you!
Our rotor variants differ significantly. How flexible can Sonplas systems be adapted to this?
We develop system solutions that allow different rotor variants to be produced on a single line. How many variants can be efficiently realized on one system depends on several factors, such as production demand, available personnel resources, floor space, investment costs and the design similarity of the rotors.
Our task is to evaluate these parameters together with you and develop a suitable production concept. In many cases, line sections can be shared across different variants or processes can be intelligently combined – enabling the right balance between flexibility and productivity.
We are still at the beginning of industrialization. Can Sonplas support us in the early development phase?
We support you from the early stages of development with our many years of experience and expertise. This helps you prepare your product optimally for subsequent series production. With a holistic view of assembly and testing processes, we consider industrialization requirements right from the start.
For an ideal project start, we also offer the possibility to assemble initial sample parts, prototypes and small batches directly at our facility. Measurement and analysis methods ensure the quality of your components and verify that all relevant parameters meet your specifications. This early support lays the foundation for a smooth and efficient industrialization process.
Can you support us with demanding or new rotor applications and implement suitable assembly and test technology?
Yes. Decades of accumulated process and manufacturing expertise in the field of rotors enable us to reliably implement even complex and technologically demanding applications.Where others reach their limits due to tight tolerances, leak-tightness requirements or specific operating conditions, we begin with a structured analysis to make the challenge solvable.
Complexity does not deter us – it is often the starting point for our solutions.
