Successful Case: Automated Armature Winding and EPS Motor Production Solutions in India
From Single-Machine Validation to Full-Line Cooperation, a Journey of Long-Term Trust
Customer Profile
The customer is a leading mechatronic solutions provider in India, serving OEMs across the automotive, consumer, and industrial sectors, and enjoying a strong reputation in both domestic and international markets. Equipped with advanced engineering and manufacturing facilities, the customer has end-to-end capabilities spanning product design, engineering, and mass production.
With seven manufacturing plants in India and a global network of sales and sourcing offices in the USA, China, South Korea, Japan, and Germany, the customer is a highly influential player in the Indian automotive components industry.
Project Background & Challenges
As market demands for EPS motors and high-precision armatures continued to rise, the customer faced several production challenges:
Armature winding quality requires precise control of tension and repeatability
High efficiency is needed while maintaining consistent product quality
The customer seeks to reduce reliance on manual labor and ensure user-friendly operations
Long-term stable operation and reliability of equipment are critical
To address these requirements, the customer aimed to introduce advanced automation solutions, first validating the technology with a single-machine solution before expanding to full-line production.
Solution Provided by Honest Automation
In 2023, Honest Automation delivered an automatic dual-fork armature winding machine for the customer, enabling high-precision production of armatures. The machine features dual-fork synchronized winding combined with servo tension control and closed-loop feedback, ensuring stable winding quality and increased efficiency.
These two systems operate independently in production, clearly demonstrating the customer’s strong recognition of Honest Automation’s technical strength and product stability, and standing as the best testament to a long-term partnership built on trust.
Key Equipment Features
Double Flyer Synchronized Winding
Simultaneous operation of left and right forks improves production efficiency while maintaining precision.
Servo Tension Closed-Loop Control
Each step of the winding process—including wire placement, pole switching, and cutting—can be independently programmed to ensure consistent product quality.
High Compatibility and Flexible Configuration
Supports various armature specifications, suitable for high-precision production requirements.
Stable and Reliable Operation
Equipped with multiple detection and safety mechanisms for long-term continuous operation.
Ergonomic Design for Ease of Operation
User-friendly interface reduces dependency on highly skilled operators.
Performance & Results
After commissioning, the equipment achieved stable and measurable production outcomes:
Cycle Time (CT): ≤ 60 seconds per unit
Yield Rate: ≥ 99%
Utilization rate: ≥ 90%
Operator Requirement: 1 person
Operational Stability: Suitable for long-term mass production
The armature winding machine provided a reliable solution for critical processes, while the EPS motor production line enabled efficient, fully automated independent production.
Why Honest Automation
The customer continues to choose Honest Automation for the following reasons:
Extensive experience in critical motor manufacturing processes and full-line automation solutions.
Equipment is stable and reliable for long-term operation.
Capability to provide both single-machine and complete production line solutions.
Fast response to on-site customer needs with efficient and transparent collaboration.
Application & Scalability
Both the armature winding machine and the EPS motor production line feature excellent scalability and adaptability, making them suitable for:
High-precision armature production and EPS motor manufacturing
Automotive component manufacturers requiring high product consistency and production efficiency
Localized production projects in India and other emerging automotive markets
Modular design allows flexible adaptation to different product specifications and production capacities.
Local Support in India
As a key overseas market, India is a priority region for Honest Automation. We have established local business and after-sales service teams that are capable of understanding customer production requirements and providing timely, professional technical support.
The establishment of a local team reduces communication and service response costs, ensuring customers have peace of mind during equipment installation, commissioning, and long-term operation, further reinforcing their long-term trust in Honest Automation.
