E-drivers & Inverters Production Automation
Nextomation designs and integrates automated production systems for electric powertrain components. Our solutions combine precise mechanical assembly, power electronics integration, controlled dispensing and sealing, joining, electrical verification and end-of-line testing. We support manufacturers from early process analysis and production simulation through implementation, ramp-up, traceability integration and long-term service.
E-drive production systems
Inverters
Automotive inverters convert direct current from the high-voltage battery into controlled alternating current for the traction motor. Their production requires accurate integration of power electronics, busbars, capacitors, cooling components and housings. We develop automated systems that combine controlled assembly, thermal material application, sealing and comprehensive electrical verification.
Processes
- Power electronics and busbar assembly
- Thermal interface material dispensing
- High-voltage insulation, sealing and potting
- Controlled tightening and precision joining
- Electrical, functional and power testing
- Vision inspection and full traceability
E-drive production systems
Power Converters
Direct current to direct current (DC/DC) converters manage voltage levels between high-voltage and low-voltage vehicle systems. Our automation solutions support repeatable assembly of electronic modules, connectors, busbars, cooling elements and sealed housings, followed by insulation, functional and load testing.
Processes
- Power electronics and printed circuit board integration
- Busbar, connector and cooling component assembly
- Thermal material dispensing and gap filling
- Housing sealing and controlled potting
- Insulation and dielectric verification
- Functional, load and end-of-line testing
E-drive production systems
E-Drive Final Assembly
Integrated electric drive units combine the electric motor, power electronics and transmission within a compact powertrain system. We design final assembly lines that coordinate component identification, precise module mating, controlled tightening, sealing and comprehensive end-of-line verification within one traceable production process.
Processes
- Component identification and automated handling
- Precision module positioning and mating
- Press-fit and controlled tightening operations
- Gasket application, dispensing and sealing
- Leakage, torque, speed and functional testing
- Production data collection and traceability
From concept to production
Considering a new automotive production process?
Validate the concept, cycle time and testing strategy before implementation. Our engineers can help define the right next step.
E-drive production systems
Gearboxes
Electric vehicle gearboxes require accurate integration of gears, shafts, bearings, seals and lubrication components. Our production systems support controlled component handling, selective assembly and parameter verification to achieve repeatable mechanical performance, low noise and reliable operation.
Processes
- Gear, shaft and bearing assembly
- Selective assembly and tolerance compensation
- Bearing and seal press-fitting
- Controlled lubrication and oil filling
- Backlash, end-play and rotational testing
- Leakage, torque and noise verification
E-drive production systems
Gear Cases
Gear cases provide the structural housing and sealing interface for electric drive transmission components. We integrate dimensional inspection, bearing and seal installation, controlled dispensing, tightening and leakage testing into automated processes designed to maintain cleanliness, geometry and sealing performance.
Processes
- Automated housing handling and identification
- Dimensional and surface inspection
- Bearing, seal and insert installation
- Gasket dispensing and sealing
- Controlled tightening and fastening
- Leakage testing and traceability
E-drive production systems
Electric Motor Rotors
Electric motor rotors require precise integration of shafts, lamination stacks, magnets and retaining components. Our automated production systems support controlled handling, joining, dimensional verification and balancing to ensure repeatable geometry, stable rotation and reliable motor performance.
Processes
- Shaft and lamination stack assembly
- Magnet handling, positioning and verification
- Controlled press-fitting, bonding and joining
- Runout and dimensional inspection
- Dynamic balancing
- Final mechanical and functional verification
ur projects
Selected case studies
Explore our automotive case studies and see how custom automated assembly lines improve production efficiency, quality and scalability across complex manufacturing processes.
8.5-second cycle time
Automotive · E-Mobility
Automated Assembly Line for EV Coolant Circulation Pump
Eight robots and seven stations delivering a fully automated assembly and testing process.
Project scope
6.5-second cycle time
Automotive
Multi-Reference Assembly Line for Accelerator Pedal
Stable cycle performance across multiple product variants in demanding serial production.
Project scope
Micrometer-level inspection
Automotive · Electronics
Robotic 3D Glue Bead Inspection System
Automated quality control combining robotics with precise three-dimensional vision inspection.
Project scope
Automation for Electric Powertrain Production
Planning a new production line or optimizing an existing electric powertrain process? Our engineering team can help define the right assembly, dispensing, joining and testing concept for inverters, converters, integrated e-drive units, gearboxes, housings and rotors. We support the complete project lifecycle, from feasibility analysis and simulation to implementation, ramp-up and long-term service.
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