As global climate concerns intensify, the demand for new energy vehicles (NEVs) continues to surge. Hairpin motors, known for their high efficiency and lightweight design, are rapidly replacing traditional round wire motors. HONEST Automation, with 18 years of deep expertise in intelligent motor manufacturing solutions, has been at the forefront of this transformation. Since the successful development of its first-generation automated hairpin motor assembly line in 2018, HONEST Automation has continued to innovate, now offering fourth-generation high-speed, flexible production lines. These advancements lay a solid foundation for the large-scale adoption of hairpin motors and accelerate the intelligent and flexible transformation of the NEV supply chain.

 

Visit HONEST Automation at Booth 1H15

 

Join us at the 2025 CWIEME Shanghai, taking place from June 25–27. We warmly invite you to visit HONEST Automation at Booth 1H15 for face-to-face discussions on cutting-edge motor technologies and the latest trends in the coil and winding industry.

 

1. Booming New Energy Market Drives Surge in Hairpin Motor Demand & Emerging Trends

 

As global climate concerns escalate, new energy vehicles (NEVs) have become a key strategy for achieving carbon neutrality. According to data released by EVTank, global NEV sales are projected to reach 18.236 million units in 2024—a year-on-year growth of 24.4%. Notably, the Chinese market accounts for 70.5% of global sales. In this evolving landscape, hairpin motors are rapidly replacing traditional round wire motors due to their compact size, high power density, and superior heat dissipation. Industry forecasts suggest that hairpin motor penetration could reach as high as 90% this year.

 

Amid rising market demand and the continuous evolution of NEV motor technologies, HONEST Automation has leveraged its deep experience in innovation to deliver thousands of turnkey motor production lines. The company has made significant breakthroughs in core technologies for hairpin motor manufacturing, effectively breaking the long-standing monopoly of imported equipment. With these advanced, intelligent and digitalized production systems, HONEST Automation empowers its clients with highly competitive hairpin motor manufacturing capabilities, helping elevate overall industry technology and production efficiency.

 

2. Leading the Technological Advancement of Automated Hairpin Stator Production Lines

 

As a trusted provider of intelligent motor manufacturing solutions, HONEST Automation continues to lead the industry through deep expertise and robust R&D capabilities. The company has successfully overcome multiple technical barriers and independently developed the core technologies behind automated hairpin stator mass production lines. These advanced production lines have been successfully delivered to renowned domestic and international clients and are now operating with proven stability and efficiency.

 

 

The hairpin motor stator production line adopts a modular design and supports automated manufacturing of stators with 4 to 12 layers and 48 to 72 slots. With a cycle time (CT) as fast as 45 seconds per piece, the entire line integrates intelligent solutions that enable full-process data connectivity, manufacturing execution system (MES) integration, and real-time process monitoring and analysis.

 

This advanced system effectively addresses the challenges of traditional production, such as complex workflows, high labor costs, low efficiency, and inconsistent quality, achieving truly intelligent and highly efficient mass production of hairpin motor stators.

 

3. Key Processes in Hairpin Motor Stator Production

 

（1）Universal Hairpin Wire Forming Machine

The machine supports flexible, inline production of various hairpin wire types—including H-pin, X-pin, and Mini-pin—greatly improving production efficiency while reducing overall manufacturing costs.

 

Equipped with a 36-slot mold magazine, a single wire forming machine can accommodate the full range of stator wire shapes, with rapid switching between 2D and 3D molds completed in just 5 seconds.

 

Featuring a uniquely designed 2D/3D integrated forming technology, the machine achieves a forming precision of up to ±0.05 mm. Combined with a high-speed four-axis robot and a servo-controlled wire clamping system, it ensures precise multi-layer wire insertion and effectively solves common challenges in traditional processes such as positioning instability and wire-to-wire interference.

 

This innovative technology not only meets the production requirements of various product types and specifications but also significantly enhances equipment versatility and manufacturing flexibility. It delivers comprehensive improvements in production efficiency, cost control, and product quality, empowering the transformation and upgrade of hairpin motor manufacturing processes across the industry.

 

(2) Non-Cutting Hairpin Stator Twisting Machine

 

Leveraging years of technical expertise and continuous innovation, HONEST Automation has successfully overcome key technical challenges to become the first in China to develop a flat wire twisting machine for hairpin stators that eliminates the need for pre-cutting and flattening. This breakthrough equipment has already been successfully delivered and implemented in customer factories.

 

 

Compared to traditional twisting equipment, the new flat wire twisting machine with no pre-cutting required adopts a fully servo-driven system. Through independently controlled twisting heads and optimized mold structures, the machine shares Z-axis parameters for every two layers, enabling flexible inline production for products with different slot and layer configurations.

 

After twisting, the overall flatness accuracy at the wire ends can reach 0.5 mm, allowing direct transition to the welding process without the need for a separate cutting or flattening step. This not only simplifies the production process but also reduces equipment costs while improving efficiency and ensuring stable product quality.

 

The machine effectively eliminates the complexity of conventional processes such as manual wire feeding, twisting, and end cutting. It enables fully integrated operation—from raw wire input to finished product output.

 

By offering a high-efficiency, low-cost solution, this innovative twisting machine enhances the competitiveness of motor manufacturers and accelerates technological advancement and cost optimization across the entire industry.

 

(3) Vacuum Resin Dripping – Fill Factor >95%

 

By precisely controlling the stator's tilt angle, the vacuum resin dripping process enables fast and uniform penetration into the inner windings, ensuring complete coverage with no dead zones.

 

The equipment integrates a precision pump for accurate flow regulation and high-viscosity heating technology, allowing dynamic optimization of resin flow rate, pressure, and temperature throughout the process.

 

This ensures consistently high slot fill rates and stable product quality during mass production. The vacuum resin fill factor can reach over 95%, significantly enhancing the electrical performance and durability of the stator.

 

The vacuum resin dripping system employs precision pump and valve flow control, ensuring accurate regulation of resin flow and pressure during the dripping process. This guarantees uniformity and stability in resin application.

 

The machine is equipped with a rotating tilt function, allowing the dripping head to adjust freely between 0-90 degrees. This versatility fully meets the demands of multi-angle, segmented resin dripping processes.

 

The high-frequency heating feature allows for timely temperature compensation during the dripping process, enabling the system to independently perform both dripping and curing. This ensures that the resin flows and cures at optimal temperatures, achieving a vacuum resin fill factor of over 95%.

 

As market demands for product quality continue to rise, the high fill rate resin dripping process has effectively enhanced the insulation and protection performance of products, extending their service life while reducing resin usage and lowering production costs. This process is crucial for improving the overall product quality and cost competitiveness across the industry.

 

As a global leader in motor automation equipment solutions, HONEST Automation leverages its deep expertise in hairpin stator automated assembly processes to continuously break through industry technical bottlenecks and provide efficient, reliable intelligent equipment solutions. Driven by innovation and powered by technology, we will continue to advance in the field of hairpin motor automation assembly, working closely with customers to explore more advanced processes and technologies. Together, we will enhance market competitiveness and create a new future for the industry.

 

4. Shenzhen HONEST Intelligent Equipments Co., Ltd.

 

Founded in 2007, HONEST Automation began with the independent development of customized winding machines. It has been recognized as a National High-Tech Enterprise and a National Little Giant Enterprise for four consecutive years. As a global leader in motor automation equipment solutions, HONEST Automation is committed to providing intelligent and digitalized overall solutions for industries such as new energy vehicles, rail transit, automotive electric components, humanoid robots, low-altitude aircraft, home appliances, and industrial applications.

 

HONEST Automation operates a modern facility with over 40,000 square meters of floor space and a team of more than 500 employees, of which over 35% are R&D personnel. With strong research and innovation capabilities, HONEST has established branch offices in Dongguan, Chengdu, and Suzhou, and set up sales offices in Malaysia, South Korea, India, Vietnam, Brazil, Argentina, Russia, and the United States.

 

Our business spans more than 20 countries and regions worldwide. To date, we have manufactured over 10,000 machines and delivered more than 1,000 fully automated production lines. We have helped over 800 motor manufacturers, motor parts suppliers, and automotive OEMs reduce costs and improve efficiency—empowering them to achieve smart, digitalized transformation.