EV drive motor systems are one of the core systems of new energy vehicles, and their performance directly determines key vehicle driving characteristics, including climbing capability, acceleration performance, and maximum speed. The drive motor system mainly consists of the motor and its controller. The motor is composed of key components including the stator, rotor, housing, connector, resolver, and other assemblies.
HONEST Automation entered the field of R&D and customized manufacturing of EV drive motor automation production lines in 2019, providing tailored automation solutions for drive motor manufacturing.
1. Hairpin Stator Assembly Line
Line efficiency: Up to 80 stators per hour, with a cycle time (CT) of 45 seconds, supporting 6-layer, 48-slot stator production.
Designed for the fully automated production of hairpin stators for EV flat wire motors, the production line is equipped with a flexible wire forming machine. It supports up to 6-wire, 12-layer stator configurations. In the event of a failure of one machine, the remaining equipment can continue operating to maintain production.
Modular design: The production line can be configured with the appropriate number of machines according to different capacity requirements. Production capacity can be easily expanded by adding additional equipment, enabling rapid capacity expansion with lower initial investment.
Key spare parts of the production line are manufactured in-house using precision machining equipment and managed through a lifecycle management system. Production data is tracked in real time, with seamless data uploading and distribution throughout the manufacturing process.
Equipment Specifications
Production Capacity: Up to 80 pcs/hour
Yield Rate: ≥ 98%
Equipment Utilization Rate:≥ 95%
Power Consumption: 40 kW
Control System: PLC-based bus control
Air Pressure: 0.4–0.6 MPa
Voltage: AC 3-phase 380 V
Application: EV drive motors
2. X-Pin Stator Assembly Line
Line efficiency: Up to 60 stators per hour, supporting 6-layer, 48-slot stator production.
Advantages of X-Pin stators:
The reduced end-turn height helps further decrease motor size and optimize axial space utilization in vehicle integration. It improves power density while offering a simpler manufacturing process compared with wave winding. The production line investment is lower than that of current hairpin stator assembly lines. With superior product performance and cost advantages compared with wave winding technology, X-Pin is expected to become a new trend in flat wire motor manufacturing.
Equipment Specifications
Production Capacity: Up to 60 pcs/hour
Yield Rate: ≥ 98%
Equipment Utilization Rate: ≥ 95%
Power Consumption: 40 kW
Control System: PLC-based bus control
Air Pressure: 0.4–0.6 MPa
Voltage: AC 3-phase 380 V
Application: EV drive motors
3. 48V BSG Motor Stator Assembly Line
This production line is designed for the assembly of automotive BSG motors and vehicle generators, with a production capacity of up to 600 units per 8-hour shift. Servo motors are controlled through a bus system. Key components are manufactured in-house using precision machining equipment, while standard components are sourced from leading international brands.
Intelligent Features:
Key component lifecycle management, facial recognition, real-time production data tracking, data uploading and distribution, and seamless integration with MES systems.
4. EV Drive Motor Rotor Assembly Line
The production line consists of 19 workstations and 24 machines. The front section adopts a conveyor line with pallet carriers, while the rear section uses robotic handling. The material flow direction is from left to right.
Through a series of processes, including magnet insertion, injection molding, rotor stacking, shaft insertion, nut locking, dynamic balancing, dimensional inspection, magnetizing, demagnetizing, surface magnetic field testing, and laser marking, the line completes the assembly and testing of the motor rotor assembly.
With the application of intelligent, standardized, and modular design, the production line features high efficiency, excellent quality performance, high flexibility, and wide model compatibility.
Equipment Specifications
Cycle Time: ≤ 128 s/pc
Yield Rate: ≥ 99%
Equipment Utilization Rate: ≥ 90%
Power Consumption: 430 kW
Air Pressure: 0.4–0.6 MPa
Voltage: AC 220 V / 380 V, 50 Hz
5. EV Drive Motor Assembly Line
The EV drive motor assembly line is designed for the automatic assembly of 170 kW three-in-one e-powertrain systems. The controller assembly section adopts a single-machine configuration combined with a U-shaped speed chain conveyor system, and is equipped with RFID-based data traceability functionality.
The production line requires no more than 15 operators, along with additional line inspectors and maintenance technicians. Material loading adopts a semi-automatic feeding mode, combined with robotic automatic sorting and handling.
Equipment Specifications
Cycle Time (CT): ≤ 98 s/pc (OEE calculated at 85%)
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
HONEST Automation provides both semi-automatic and fully automatic assembly lines for the above production solutions. We also offer standalone equipment and prototyping services for hairpin stators and BSG stators based on customers’ specific manufacturing processes.
With multiple successful drive motor stator, rotor, and BSG stator assembly line projects delivered worldwide, our technologies are mature and market-proven. We welcome you to contact us for product catalogs, quotations, or customized solutions.
