Stator Inspection AI

Catch hairpin, weld, insulation, and winding defects on every stator at the station, before they fail electrical test.

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AI quality inspection of a motor stator with copper windings, displaying bounding boxes for 'weld_ok' and defects like 'pore' and 'pin_height_low', plus a magnified view of a pore.

Stator Inspection AI for the Toughest Motor, Generator, and EV Drive Lines

Deploy Anywhere, Run Everywhere
Run stator inspection on cameras at insertion, twisting, welding, and winding stations, on the edge, on-prem, in your VPC, or via API.
One Platform, Full Adoption
Tools every motor and generator team can adopt, from winders and line operators to process, quality, and test engineers, no separate ML team required.
Secure, Compliant, and Audit-Ready
Data stays safe with SOC 2 Type II compliance, encrypted data, and an uptime SLA, with an image record for every stator tied to its serial number.

“The vision AI solutions we developed with Roboflow have been a core component of connecting our teams and unlocking their ability to collaborate.”

Lou Stocco

Director of Manufacturing Advanced Analytics, USG

Read the full story See customer stories

Talk to a Vision AI engineer who's shipped in motor and electrical equipment manufacturing.

Bring us your toughest stator inspection problem and we'll map a working solution.

Ask us about:

Solution architecture that fits IATF 16949, ISO 9001, and your stator test requirements
A live demo on images from your own stator line
Deployment options: edge at the station, on-prem, air-gapped, or VPC
ROI modeling against rework hours, scrap, first pass yield at electrical test, and field returns

Over 16,000 organizations build with Roboflow.

Rivian
Pella
Chobani
USG Corporation
BNSF Railway
American Woodmark

Start where you are

Vision AI is transforming businesses

Customers across the board are solving complex challenges and driving meaningful impact.

Automotive customer
$10 million
Saved by automatically detecting defects on the production line
Logistics & freight company
90%
Less time spent manually tracking shipping inventory
Building materials supplier
60%
Lower customer return rate with improved product quality

Inspect Every Stator, from the First Hairpin to Final Test

Add a real-time inspection layer to every stator on the floor with Roboflow vision AI for stator inspection. Built for EV drive motor lines building hairpin stators by the thousand and for motor and generator plants winding large stators one at a time, where a defect found at electrical test means hours of rework on a part that has already absorbed most of its labor.

Hairpin stators for EV drive motors:

Check hairpin height, position, and gaps after insertion and twisting, before the stator goes to the welder.
Detect stripping residue on hairpin ends, which melts during laser welding and leaves pores.
Inspect every weld for pores, spatter, tilted tips, and short gaps between pin pairs, with a model trained on your own welds.

Wound stators for motors and generators:

Check coil and bar placement, slot liners, and insulation paper as each slot is wound.
Verify wedges, end-turn spacing, lacing, and lead connections before the stator is impregnated.
Flag nicked conductor, damaged insulation, and incomplete varnish coverage before they become turn-to-turn faults.

Records, holds, and rework:

Store an image history for every stator tied to its serial, so a test failure or field return traces back to the station and shift.
Hold a stator at the station through the PLC when a critical defect is found, and send every result to MES.
Catch rare defects with anomaly detection trained on good stators, then retrain on your own escapes.

Bring intelligence to every stator today. Stop winding and weld defects from becoming test failures, rework hours, and field returns.

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Frequently asked questions

What is stator inspection with Vision AI?

Stator inspection with Vision AI uses cameras at the insertion, welding, winding, and impregnation stations and a trained computer vision model (opens in a new tab) to check hairpins, welds, insulation, windings, and connections on every electric motor and generator stator. It pairs with transformer winding inspection, EV battery module and pack inspection, and electrical equipment manufacturing.

Can Vision AI inspect hairpin stator welds?

Yes. Every hairpin stator carries many laser welds, and one bad joint fails the whole stator. A detection or segmentation model trained on good and defective welds from your own line checks every weld after the welder, flags pores, spatter, tilted tips, and short gaps between pin pairs, and marks each one on the image for the operator.

Does stator inspection support IATF 16949 and ISO 9001?

Stator inspection supports the inspection records and traceability expected under IATF 16949 (the automotive quality management standard) and ISO 9001 (the quality management system standard), with an image and result for every stator tied to its serial number.

Roboflow serves as the inspection engine, and your quality and test engineering teams own the acceptance criteria and the release decision.

Can it integrate with our MES, traceability system, and station PLCs?

Yes. Roboflow writes pass/fail and defect type to a PLC tag over OPC UA or MQTT, so the station can hold a stator, and sends results and images over REST (opens in a new tab) or to a database for MES, SPC, and traceability systems.

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Stator Inspection AI