Case Study: Hairpin Wire Forming and Hairpin Twisting Machine Delivered to a Multinational Automotive OEM
Customer Profile
The customer is a globally leading automotive group with operations across multiple countries and regions, enjoying a strong international reputation. The company has extensive experience in new energy vehicles and drive motor production, with strict requirements for supply chain precision and manufacturing process reliability.
Project Background & Challenges
The customer faced the following challenges in flat wire motor production:
The winding head process requires high linear precision and consistent quality.
The product involves multiple specifications and layers, demanding high equipment compatibility and fast changeover.
The production process must ensure high stability with error-proofing and a fail-safe design.
Operations should require minimal operator dependence, be easy to learn, and allow convenient maintenance.
Solution Provided by Honest Automation
To meet the customer's requirements, Honest Automation provided the following solutions:
Hairpin Stator Twisting Machine
Designed for the high-precision winding head process of drive motor flat wires, the machine utilizes a conveyor feeding system, high-precision positioning molds, and a servo-driven system to ensure consistent winding quality across all layers. Equipped with an industrial control system, the machine allows full production traceability and integrates multiple monitoring functions, enabling safety protection and error-proof operations.
Hairpin Wire Prototyping Equipment
Honest Automation also delivered an automated flat wire prototyping solution, capable of straightening, cutting, de-enameling and bending the flat wires. The system is compatible with multiple wire types, allows fast changeover, and ensures highly stable production, providing comprehensive support for the customer's flat wire manufacturing needs.
Key Equipment Features
High-Precision Molds and Positioning Fixtures
Ensure consistent and stable winding for each layer of flat wire.
Servo-Driven Control System
Supports multi-layer winding with independently adjustable parameters, providing easy operation.
Modular Design and Flexible Compatibility
Suitable for 4-layer, 6-layer, and 8-layer flat wires, with support for multiple specifications.
High Efficiency and Stable Production
Cycle time per unit ≤96 seconds, yield rate ≥99%, and overall line utilization ≥90%.
Safety Protection and Error-Proof Design
Equipped with light curtains, safety interlocks, and pneumatic protection, with real-time alerts for abnormal positions.
Industrial Control Data Collection and Traceability
All production information is fully traceable, supporting process parameter monitoring and historical data review.
Performance & Results
Voltage: Three-phase AC 200V / 50Hz
Power: 20 kW
Control System: PLC + HMI
Why Honest Automation
Extensive Experience in the automated production of flat wire motors and stators.
High Precision, Compatibility, and Flexibility of equipment to meet strict quality standards.
Industrial Control and Data Collection features ensure full production traceability and error-proof management.
An efficient Local Support Team provides timely responses to customer needs, ensuring long-term reliable operation.
Application & Scalability
The flat wire winding head machine is suitable for multi-layer flat wire motor production.
The flat wire prototyping equipment supports multiple wire types and can be replicated for other production lines or product upgrade projects.
Modular design and an industrial control system enable rapid capacity expansion and multi-specification production.
Ideal for local production deployment by global automotive manufacturers and component suppliers.
In addition to the equipment featured in this case, we have also delivered complete stator assembly lines for flat-wire drive motors and rotor assembly lines for drive motors to other Tier-1 automotive suppliers. These production lines have been upgraded to the fourth generation, with highly mature technology capable of completing 2–3 key process steps on a single machine, significantly improving production efficiency.
The new-generation equipment features a more compact design, reducing both component costs and factory floor space, while being simpler to operate and easier to maintain. This provides customers with greater production flexibility and lower long-term operating costs.
