The electric drive motor is a critical component of a new energy vehicle powertrain, directly influencing important vehicle performance indicators such as acceleration, hill-climbing ability, driving speed, and overall power output. A typical drive motor system integrates the electric motor with its controller, while the motor itself consists of major assemblies such as the stator, rotor, housing, connector, resolver, and related components.

Since 2019, HONEST Automation has been developing and manufacturing customized automation equipment and production lines for EV drive motors. Based on different motor structures, production capacities, and manufacturing processes, we provide flexible automation solutions covering stator manufacturing, rotor assembly, BSG stator production, and complete drive motor assembly.

 

1. Hairpin Stator Assembly Line

HONEST Automation's hairpin stator production line is developed for high-volume manufacturing of flat-wire EV motor stators. The line can achieve a production rate of up to 80 stators per hour, with a cycle time of approximately 45 seconds, and supports 6-layer, 48-slot stator configurations.

A flexible wire-forming system enables the line to accommodate stator designs with up to 6 wires and 12 layers. The equipment is designed with production continuity in mind. If one individual machine experiences a fault, other stations can continue running, helping minimize the impact on overall production.

 

Flexible & Scalable Production

The line adopts a modular architecture, allowing customers to select the number of machines according to their required production capacity. Additional machines can be introduced as demand increases, providing a practical way to expand capacity without making a large initial equipment investment.

For critical components, HONEST Automation combines in-house precision machining with lifecycle management. Production and equipment data can be collected and monitored in real time, while manufacturing information can be uploaded and distributed across the production system to support traceability and process management.

Equipment Specifications

Item	Specification
Production Capacity	Up to 80 pcs/hour
Yield Rate	≥ 98%
Equipment Utilization	≥ 95%
Power Consumption	40 kW
Control System	PLC-based bus control
Air Pressure	0.4–0.6 MPa
Power Supply	AC 3-phase 380 V
Application	EV drive motors

 

2. X-Pin Stator Assembly Line

The X-Pin stator assembly line is designed for the automated production of flat-wire EV motor stators. It supports 6-layer, 48-slot stators and can reach a production capacity of up to 60 stators per hour.

 

Why Choose X-Pin Technology?

Compared with conventional wave winding, X-Pin technology can reduce the height of the stator end turns, helping manufacturers make better use of axial space and achieve a more compact motor design.

The reduced end-turn profile also contributes to higher motor power density and provides an alternative manufacturing route for flat-wire motors. In addition, the equipment investment can be lower than that of some conventional hairpin stator production systems.

With a combination of compact motor design, manufacturing efficiency, and cost advantages, X-Pin technology has strong potential for next-generation flat-wire EV motor applications.

Equipment Specifications

Item	Specification
Production Capacity	Up to 60 pcs/hour
Yield Rate	≥ 98%
Equipment Utilization	≥ 95%
Power Consumption	40 kW
Control System	PLC-based bus control
Air Pressure	0.4–0.6 MPa
Power Supply	AC 3-phase 380 V
Application	EV drive motors

 

3. 48V BSG Motor Stator Assembly Line

HONEST Automation provides automated stator assembly solutions for 48V BSG motors and automotive generators, with a production capability of up to 600 units per 8-hour shift.

The production system uses bus-controlled servo motors to achieve coordinated and precise equipment operation. Critical machine components are manufactured internally through precision machining processes, while standard components are selected from established international suppliers to support equipment reliability and long-term operation.

Intelligent Production Functions

The BSG stator assembly line can incorporate a range of digital and intelligent manufacturing functions, including:

• Critical component lifecycle tracking
• Operator facial recognition
• Real-time production data collection
• Manufacturing data upload and distribution
• MES system integration

These functions help improve production traceability, equipment management, and manufacturing visibility.

 

4. EV Drive Motor Rotor Assembly Line

HONEST Automation's EV drive motor rotor production system integrates 19 workstations and 24 machines into a complete automated manufacturing process.

The material handling architecture combines pallet-based conveyor transportation in the upstream section with robotic transfer in the downstream area. Materials move through the line from left to right, creating a structured and efficient production flow.

 

 

The complete process can include:

• Magnet insertion
• Injection molding
• Rotor core stacking
• Shaft insertion
• Nut tightening
• Dynamic balancing
• Dimensional inspection
• Magnetization
• Demagnetization
• Surface magnetic field inspection
• Laser marking

By integrating assembly, inspection, testing, and traceability into one automated system, the line is designed to achieve stable production quality while supporting multiple motor variants.

Its standardized and modular architecture also provides flexibility for future process upgrades and production expansion.

 

Equipment Specifications

Item	Specification
Cycle Time	≤ 128 s/pc
Yield Rate	≥ 99%
Equipment Utilization	≥ 90%
Power Consumption	430 kW
Air Pressure	0.4–0.6 MPa
Power Supply	AC 220 V / 380 V, 50 Hz

 

5. EV Drive Motor Assembly Line

For complete electric powertrain manufacturing, HONEST Automation provides automated assembly solutions for 170 kW three-in-one e-powertrain systems.

The controller assembly area uses a single-machine layout connected by a U-shaped speed-chain conveyor. RFID technology is incorporated into the production system to enable product identification and process traceability throughout manufacturing.

The complete line can be operated with no more than 15 operators, together with dedicated inspection and maintenance personnel. Material supply is handled through semi-automatic loading, while robotic systems perform automatic sorting, transfer, and handling operations.

This configuration reduces manual intervention while improving material flow, production consistency, and overall line efficiency.

Equipment Specifications

Item	Specification
Cycle Time (CT)	≤ 98 s/pc at 85% OEE
Takt Time (TT)	≤ 115 s/pc
Yield Rate	≥ 98%
Air Pressure	0.4–0.6 MPa
Power Supply	AC 220 V / 380 V, 50 Hz

 

Customized EV Drive Motor Automation

HONEST Automation supports different levels of automation according to each customer's production strategy. In addition to complete fully automated production lines, we can provide semi-automatic assembly systems, standalone machines, and prototype equipment.

For customers developing new hairpin or BSG motor products, our engineering team can also provide prototyping and process validation services before full-scale equipment deployment.

With experience in EV drive motor stator assembly, rotor assembly, BSG stator production, and complete motor assembly, HONEST Automation has delivered multiple automation projects for the global automotive and new energy vehicle industries.

Our engineering team can develop the production concept around your motor design, process flow, target capacity, quality requirements, and automation level.

 

Contact HONEST Automation to request our EV drive motor equipment catalog, project quotation, prototype service, or a customized production solution.