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Fascinating World of TSA Production

How we create our motors

Our mission starts with the concept of the vehicle manufacturer. Before a rail vehicle can be equipped with a complete drive or a bus with an e-motor, several requirements need to be examined in advance. Accompany us along the development process of our electric drives!

Feasibility check

Creating a good concept is one of the most important steps. At this point, we define rough dimensions such as length and diameter, along with a cooling concept. Based on these parameters, we can calculate whether the electric motor is suitable for the intended use.

TSA Engineers in meeting

Electromagnetic calculation

In this step, we check the functional configuration of the motor. At TSA, we have a wide portfolio of simulation options such as: electromagnetic simulation using analytical and numerical methods, drive cycle analysis for thermal behavior and energy consumption, prediction of harmonic losses at the inverter and analysis of short-circuit behavior. 

Most of the programs used for calculation were developed by TSA.

TV screen showing CFD airflow simulation

Rapid Prototyping

Rapid prototyping through 3D printing can also be used to quickly investigate and test various design options. This way it is possible to determine at a very early stage how the new machine will behave. For us, this is the optimal process to develop the right motor for you as fast as possible.

Part of a sample of a TSA electric motor is printed in 3D printer


We set great value on a sustainable value chain. Therefore, we obtain materials predominantly from Europe. If this is not possible, we import materials by rail from different countries around the world.

Inspection of a TSA material part

‘For us, three factors are important:
human, machine, material.’


Production and various product tests

At our plant in Wiener Neudorf, we have an enormous depth of added value. Lean Management, optimization of value stream and layout, digitalization and automation are the core contents of our Production Roadmap.

Customized stator and rotor metal sheets are stamped from electrical steel sheets weighing several tons. After this step, stators and rotors take separate production paths.

TSA employee during production inspection at eccentric press

Stator production

The manufacturing of stators begins with the stacking of steel sheets. These are then welded by quality controlled robots and by our technical experts. After this step, the stator undergoes processes that prepare it for the installation of the coils.

TSA employee working on stator

Rotor production

In the meantime, the rotor unit has been assembled. The rotor metal sheets have been drawn onto the shaft as a package, so the next step is to manufacture the squirrel-cage from high-quality copper, and finally machining, spinning and balancing it. In permanent magnet motors, magnets are inserted into the prefabricated rotor metal sheets instead.

TSA employee during rotor production

Surface coating

Another in-house core competence is surface coating and impregnation. In 2020, Traktionssysteme Austria purchased a new industrial painting system for the company headquarters in Wiener Neudorf. Ongoing investments in our production facilities ensure that we can also meet future quality requirements.

Employee with TSA products in painting booth during surface coating

Final assembly

One of the most comprehensive steps is the final assembly. Here our highly trained and skilled workers assemble all components into one motor, alternator or drive.

TSA employee at final assembly electric motor

Serial testing

In order to ensure readiness for series production, we carry out measurements of sound and vibration in addition to electrical and thermal tests.

TSA employees during series testing of electric motor

From the initial inquiry to the finished motor.
Everything from one source.

Quality control

Each drive unit needs to undergo quality testing. A successful test report proves that the final product can be delivered to the customer.

TSA employee at quality control stator

Measurements of sound and vibration

Since each project is individual and tailored exactly to customer requirements, other quality tests can be performed as necessary. 

TSA employee at measurement of sound and vibration of an electric motor

Delivery & Aftersales

TSA employee with forklift in the warehouse

TSA powers vehicles around the world