Precision Manufacturing Solutions for Modern Rotors
Rotors are key components of electric drive systems and have a significant impact on the performance, efficiency, and effectiveness of an electric motor. Their manufacture requires high-precision assembly processes, reliable automation, and maximum process stability.
GROB develops and implements system solutions for industrial rotor production—from prototype manufacturing to fully automated turnkey series production. The production systems are individually tailored to different rotor designs, magnet concepts, and manufacturing requirements.
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Many years of experience in rotor production
For decades, GROB has been developing production systems for a wide variety of rotor and electric motor designs
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Customized system designs
Production lines are precisely tailored to rotor geometry, magnetic technology, and production volume
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Turnkey solutions from a single source
Engineering, automation, plant construction, and service form a comprehensive, end-to-end solution
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In-house process
developmentTechnical application centers enable the development, validation, and optimization of new manufacturing processes even before mass production begins
From Process Development to Turnkey Production Lines
The cost-effective manufacture of modern rotors requires far more than just individual production machines. GROB supports companies throughout the entire development and industrialization process—from the initial feasibility analysis to the turnkey production line.
Through its own technical application centers, manufacturing processes can be developed, validated, and continuously optimized under conditions that closely resemble those of series production. This results in customized production solutions for various rotor designs and production volumes.
- concurrent engineering
- Feasibility Studies
- Development of New Manufacturing Concepts
- Prototype and small-batch production
- Process Development and Validation
- Turnkey Systems
- Plant construction and commissioning
- Production optimization
Production Solutions for Various Rotor Technologies
Depending on the motor design, different rotor configurations and manufacturing processes are used. GROB develops production systems for various rotor architectures and tailors all manufacturing processes to the product, production volume, and degree of automation.
Our systems cover both the production of permanent magnet rotors and rotors using needle-winding technology.
Precise Assembly of Permanent-
Magnet Rotors (PSM)
Permanent magnet rotors (PSM) are among the most important rotor designs for highly efficient electric drive systems today. They are used in electric mobility, industrial drive technology, robotics, and numerous other applications.
GROB’s production solutions enable the automated assembly of permanent magnet rotors with high process reliability and reproducible manufacturing quality. Depending on production volume and product requirements, magnets are automatically separated, positioned, and inserted into the laminated rotor core. Various methods—such as press fit, adhesive bonding, or epoxy potting (EMC)—are available for permanent fixation.
Thanks to the modular system design, production processes can be flexibly adapted to different rotor geometries and magnet configurations.
Rotor Production Using Needle-Winding Technology
Needle-winding technology is a high-precision process for processing round wire on laminated rotor cores. In this process, a rotating winding needle guides the wire around the individual rotor poles exactly according to the defined winding pattern.
Thanks to optimally coordinated manufacturing processes, this technology enables cost-effective production of complex rotors while ensuring high winding quality and process stability. The production systems are individually designed to accommodate different winding patterns and product requirements.
Manufacturing processes can be developed, tested, and validated at the GROB application centers as early as the product development phase.
Machine Features:
- Orthocyclic winding of rotors for the automotive industry
- Special needle design to reduce stress on the wire
- Reduced wire tension through needle rotation
- Complete control of wire positioning
- High-speed orthocyclic winding
- Easy-to-program and user-friendly interface
Machine Features:
- Application of adhesive using a robot
- Insertion of magnets by robot
- High flexibility for various rotor shapes
- Rotor shaft assembly with force and position control
- Visualization system for shaft and rotor indexing
- Degree of automation ranging from low to high
Production Solutions for a Wide Range of Applications
Rotors are used in a wide variety of electric drive systems. Depending on the application, their size, power density, and production requirements vary considerably.
GROB’s production solutions support, among other things, the manufacture of rotors for:
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Download the brochure to learn more about our technologies, process expertise, and plant concepts across the entire value chain.
FAQ - Frequently Asked Questions About Rotor Production
A permanent magnet rotor (PSM) is a rotor in which permanent magnets are integrated directly into the laminated rotor core. This design enables high power density and high efficiency and is used in battery electric vehicles, industrial drives, and robots, among other applications.
Automated production lines ensure high process stability, reproducible manufacturing quality, and cost-effective mass production. At the same time, they enable short cycle times and flexible adaptation to different rotor designs.
GROB develops production solutions for permanent magnet rotors and rotors using needle-winding technology. The systems are customized to the specific product, degree of automation, and production volume.
Yes. GROB supports companies from the feasibility study and process development through prototyping and pilot production all the way to a turnkey mass production line.
The production facilities support the manufacture of rotors for electric vehicles, light e-mobility, industrial drives, building automation, alternating current generators, drones, and humanoid robot systems.
This results in flexible and scalable production concepts for a wide variety of applications and production volumes.
