Case Study: Humanoid Robot Motor Assembly Line Delivered to Customer Factory
Customer Profile
The company is a technology-driven, platform-oriented automotive components supplier. Leveraging its advanced R&D capabilities, manufacturing technologies, quality management systems, and global supply capacity, it has established strong partnerships with numerous domestic and international automakers. The company has become a global strategic partner to leading OEMs, including Audi, BMW, Stellantis, General Motors, Geely, Ford, Mercedes-Benz, Volkswagen, Li Auto, NIO, XPeng, Rivian, and Lucid.
Project Background & Challenges
Honest Automation had previously collaborated with the customer’s parent group on electric tool charger terminal spot welding equipment. Based on the successful cooperation and proven delivery performance, the parent group recommended Honest Automation to its subsidiary.
The subsidiary is actively engaged in R&D for automotive and humanoid robot motors and related components. As a new humanoid robot motor project, the customer needed to move from development to stable mass production while improving overall manufacturing efficiency.
Compared with automotive motors, humanoid robot motor stators are relatively small and do not require the same level of ultra-high precision or complex testing. However, they place stringent requirements on winding neatness and slot fill factor, which directly impact motor torque output, efficiency, and overall performance. Achieving consistent winding quality while ensuring production scalability was the key challenge.
Solution Provided by Honest Automation
Honest Automation first supported the customer with motor sample production to verify winding quality, slot fill rate, and assembly feasibility. After the samples were fully validated and approved by the customer, Honest Automation delivered a customized humanoid robot actuator frameless torque motor assembly line.
The solution adopts a modular architecture and supports flexible configuration to meet current production needs while allowing future expansion. It is designed for humanoid robot actuator motors, frameless torque motors, and related stator assembly applications, with optional non-standard customization based on specific product requirements.
Key Equipment Features
Modular design compatible with multiple product models; fast changeover via program switching and fixture replacement
Precisely engineered mechanical structure with rigorous and stable process logic
Integrated high-precision sensors and vision inspection systems to ensure appearance consistency and assembly quality
Vision-assisted inspection to enhance winding neatness and slot fill consistency
MES connectivity for work order reception, material status feedback, and production data management
Comprehensive data functions, including backup, migration, and cleaning
Dedicated safety gratings and safety door interlocks on manually operated stations to ensure operator safety
Main Equipment Parameters (Reference):
Cycle time: 180 s/pcs (customizable)
Quality rate: ≥99%
Utilization rate: ≥90%
Control system: PLC + HMI
Application: Humanoid robot actuator / frameless torque motor assembly
Performance & Results
Stable mass production achieved after sample validation
Consistent winding quality with improved slot fill rate and orderly coil arrangement
High yield rate (≥99%) supporting reliable downstream motor performance
Production efficiency and utilization rate met customer expectations for new product ramp-up
Equipment operation proved stable, supporting continuous production with minimal downtime
Why Honest Automation
Proven and mature motor winding and assembly technologies with low project risk, validated by the market
Deep understanding of advanced motor manufacturing processes aligned with industry-leading customers
Highly experienced and stable core engineering team with strong hands-on motor and equipment expertise
Ability to provide process support, not just equipment delivery
Strong after-sales service capability, including remote online support and rapid on-site response
Application & Scalability
Honest Automation’s equipment is designed for long service life and stable long-term operation. Some customers have operated Honest Automation production lines for over 10 years while maintaining reliable performance.
The system supports:
Compatibility with additional motor models
Future process upgrades and line modifications
Targeted retrofit solutions instead of full line replacement
This approach significantly reduces customers’ long-term investment, operating, and maintenance costs while ensuring production flexibility and sustainability as product requirements evolve. Following the success of the initial line, the customer placed orders for three more identical lines, further demonstrating confidence in Honest Automation’s solutions.
