With the rapid growth of new energy vehicles and industrial automation, many hairpin motor manufacturers are realizing that traditional production methods can no longer meet the capacity and efficiency demands of large-scale orders.
Frequent equipment adjustments, complex process requirements, unstable machine performance, and rising maintenance costs have become major obstacles hindering flat wire motor manufacturers from scaling up and improving production efficiency.
While most existing hairpin motor manufacturing equipment can meet current production needs, manufacturers often find that these systems are limited to processing single wires. In an increasingly competitive market and with rising capacity demands, the pressure to boost efficiency continues to grow. Yet, under current technological constraints, further improvements seem unlikely to be achieved.
Recently, HONEST Automation launched its latest innovation: the Dual-Channel Flat Wire Forming Machine for Motor Stators, offering a new solution to overcome efficiency limitations in current flat wire production. To provide industry professionals with deeper insights into this breakthrough, we invited Mr. Liu, a lead developer from our R&D team, for a technical discussion and live demonstration of the machine’s performance and advantages.
This article summarizes the key takeaways from that session and we hope it will inspire new possibilities in flat wire motor stator manufacturing.
In the manufacturing process of hairpin motor stators, the wire forming stage plays a critical role. Its efficiency and the precision of wire shaping directly impact not only the overall production tempo but also the final motor performance and output capacity.
In conventional hairpin forming processes, production typically involves two stages: 2D forming followed by 3D forming. The wire is first bent into a preliminary shape in 2D, then further shaped into a more complex 3D structure using specialized molds. This two-step approach not only increases tool changeover time but also adds complexity to the overall manufacturing process.
To address the challenges of traditional forming methods and meet rising demands for production efficiency, HONEST Automation has remained focused on innovation and equipment upgrades. The company’s first-generation flat wire stator forming machine integrated an advanced automation control system, high-precision components, accurate wire feeding mechanisms, and a combination of pre-press mold and wire straightening technologies. This allowed for a more streamlined transition from 2D to 3D forming, significantly improving efficiency and consistency, and laying the groundwork for even greater advancements.
With the explosive growth of the new energy vehicle sector and the continued expansion of industrial automation, demand for flat wire motors has become increasingly diverse and large-scale. Customers now expect significantly higher production efficiency to meet fast delivery timelines, while also imposing stricter requirements on product consistency and precision. At the same time, the rise of multi-variety, small-batch production models is driving the need for greater flexibility and adaptability in wire forming equipment.
The first-generation single-channel hairpin stator forming machine can no longer keep pace with today’s growing demands for higher capacity and flexible manufacturing. In response to these evolving market needs, HONEST has built upon its proven technology to develop and launch a brand-new solution: the dual-channel hairpin stator forming machine.
The standout feature of this machine is its dual-channel architecture, enabling the simultaneous processing of two flat wires, effectively doubling production efficiency. Compared to traditional single-channel systems, it offers significant advantages in cycle time, automation, and product adaptability:
Efficiency Boost: With dual synchronized channels and two robotic arms inserting wires simultaneously, the system achieves a cycle time of just 1.2 seconds per wire, producing up to 300 wires per hour — a major improvement over the 1.9–2.1 seconds per wire typical of single-channel machines.
Flexible Production: An optional auto-insertion cup function allows manufacturers to toggle the feature on or off based on their specific production needs, enabling more personalized and adaptable workflows.
Quality Assurance: For 2D and 3D forming, the machine features automatic switching between 12 mold sets, delivering precise, consistent results even for complex winding structures and varied product specifications.
The machine also delivers enhanced structural integration and functional flexibility to meet the demands of high-mix, low-volume production environments:
Synchronized Cutting and Feeding: The system uses a punching-based forming method that synchronizes tool change and wire feeding operations. It also includes a tool life monitoring system to ensure consistent cutting performance and extend the lifespan of critical components.
Flexible Forming Options: Compatible with both 2D+3D split molds and integrated molds, the machine adapts easily to various winding structures. Its turret-style mold platform allows for rapid tool changes, significantly reducing setup time and supporting flexible manufacturing of diverse stator types — including Hair-pin, X-pin, and MINI-pin configurations.
Compact Footprint, High Output: With a footprint of just 1.8 × 9 meters, the machine is only about 20 cm wider than the previous single-channel model, yet it delivers double the output. This maximizes productivity per square meter, helping manufacturers make the most of limited floor space.
When evaluating this equipment, customers often ask three key questions: Is the investment cost high? What is the expected ROI period? What kind of after-sales support is included?
On Investment Cost and ROI: As with most custom automation equipment, the initial investment may be relatively higher than conventional machines. However, considering the significant gains in production efficiency and quality control, the return on investment (ROI) largely depends on factors such as production scale, product types, and market dynamics. For manufacturers with high-volume demand and a focus on product consistency, the ROI period is typically much shorter, making it a cost-effective choice in the long run.
On Customization and Value Assessment: HONEST Automation provides tailored equipment solutions and ROI analysis based on each customer’s specific production requirements, helping clients make well-informed investment decisions.
On After-Sales Support and Warranty: HONEST offers comprehensive after-sales support, including equipment installation, commissioning, training, detailed documentation, and ongoing maintenance guidance. Our experienced service team ensures fast response and timely issue resolution, guaranteeing stable operation and peace of mind for every customer.
As the era of new energy vehicles and intelligent manufacturing accelerates, the Dual-Channel Flat Wire Stator Forming Machine is poised to become a game-changing solution for motor manufacturers seeking to boost productivity. With continuous advancements in technology and evolving market demands, the application potential of this equipment is vast, not only in the NEV sector but also in areas such as industrial robotics, rail transit, and other high-end manufacturing industries.
As a dedicated provider of intelligent motor production solutions, HONEST Automation remains committed to innovation-driven development. We continuously explore the technological frontier to deliver smarter, more efficient, and highly reliable solutions to motor manufacturers worldwide. Looking ahead, we will continue to increase R&D investment, stay closely aligned with customer needs, and launch more forward-thinking and competitive equipment, empowering our clients to overcome growth bottlenecks and stand out in today’s global marketplace.
If you’re looking for hairpin motor manufacturing equipment or require customized solutions for non-standard motor production, we warmly welcome you to visit HONEST Automation. Our engineering team would be delighted to meet with you in person, explore your specific needs, and work together to develop the most suitable solution tailored to your production goals.
