Prototype building and production

All customer-specific components are designed, confidentially, under one roof.

Our prototype building and production department builds prototypes and small batches of all components, as well as entire systems for electrical drives and power electronics.

This also includes production and assembly of all mechanical components, such as rotors, stators, magnets, and windings, combined with stringent quality control checks after every step.

We have all the necessary measurement technologies for this purpose.

We also have extensive experience in the fields of bonding and molding technologies. For special materials, we also have, among other things, annealing furnaces, e.g. in an atmosphere with hydrogen.

Power electronics and controls are designed in-house and entirely by ourselves. The corresponding instruments for quality assurance are also available, including test benches for power modules and circuit boards.

Production of power electronics systems takes place in an assembly room, in line with ESD guidelines. For limited series production of mechanical and electronic components, we can supply our clients with up to 1,000 units per year.

Expertise and skills:

Acquiring hardware for prototypes and limited series (approx. 1,000 units)
- Laboratory samples, A and B samples
- Limited series of all components and systems
Assembly work
- Production and assembly of electric motors
  - With integrated positioning sensors
  - With integrated power electronics
  - With integrated transmission
  - Production and assembly of electronics in an ESD-protected environment
- Assembly of individual components and installation kits
  - Rotors
    - Balancing
    - Producing rotors as external rotors
    - Producing rotors as internal rotors
    - Production of GRP / CRP / Zylon rotor sleeves Assembly of rotor sleeves (laminating / shrinking / winding)
  - Stators
    - Cutting laminates
    - Packaging laminates
    - Vacuum molding
    - Molding within an atmosphere
  - Electrical testing
    - Surge voltage
    - HV testing
    - Partial discharge
    - L + R measurement
  - Magnets
    - Bonding of magnets
      - NdFeB
      - SmCo
      - Plastic-bonded
    - Packaging of magnets
      - From discs up to 0.5 mm
    - Bonding to rotor shafts
    - Production of magnet packages for buried magnets
    - Magnetization
    - Measurement of magnetic materials
    - Measurement of magnetic circuits
  - Windings
    - Winding formed coils
    - Production of insulation
    - Mechanical stripping
    - Thermal stripping
    - Electrical testing
      - Surge voltage
      - HV testing
      - Partial discharge
      - L + R measurement
  - Connection elements
    - Wiring
    - Crimping
    - Soft soldering
    - Resistor soldering
- Assembly of mechanical modules and components
  - Bearings
  - Transmission
  - Housing
  - Cooling circuits
  - Cold soldering
  - Leak tests
    - Pressure drop test
    - Helium leak tests
  - Flow tests
  - Plasma treatment
- Assembly of mechatronic modules and components
  - Actuators
  - Pneumatics
  - Electropneumatics
- Assembly of electronic modules and components
  - Power units
  - Control electronics
  - Signal converters
  - Cable harnessing
  - Hand soldering THT
  - Vacuum soldering
  - Vacuum vapor phase soldering
  - Component testing
  - Functional testing
- Bonding and molding technologies with various glues and casting compounds
  - Single-component glues
  - Dual-component glues
  - Heat-curing glues
  - Cold-curing glues
  - Epoxides
  - Acrylates
  - PU systems
Device construction
- Joining and press-in devices
- Positioning devices
- Bonding and masking devices
- Molding devices
- Soldering devices
- Workpiece carriers for mechanical processing
- Bending devices
- Measurement and testing devices
- Manipulators for handling and transport
- Leak test adapters
- Test benches and test bench adaptations

News:

Congratulations to the winners of the WRC and many thanks for the last 4 years

Congratulations to Hyundai Motor Company's Thierry Neuville / Martijn Wydaeghe for the Drivers' World Championship title and to TOYOTA GAZOO Racing Europe for the 2024 FIA World Rally Championship Manufacturers' World Championship title.

Compact Dynamics' time as the exclusive series supplier of the FIA's hybrid system for the WRC rallies from 2022 to 2024 will unfortunately come to an end with the abolition of the hybrid unit in the Rally1 cars from 2025.

Many thanks to the teams of Hyundai Motor Company, Toyota Motor Corporation and Ford Motor Company/M-Sport, to the WRC Promoter GmbH and to the FIA World Rally Championship for the good cooperation. A heartfelt thank you to Edouard Montagner Fricker, Laurent Le Bastard and Barny Whitwham, our WRC track support team, for their excellent work on site.

More Information

Compact Dynamics GmbH
Moosstraße 9
82319 Starnberg
Phone +49 8151 9043-0
Fax +49 8151 9043-20