Source: Comau

Comau has designed and developed cutting-edge automation technology for Li Auto’s next-generation range extender line, allowing the Chinese electric vehicle (EV) pioneer to reach an annual production capacity of up to 400,000 units. The full-value-chain solution, which includes concept design, system simulation, assembly and commissioning, highlights Comau’s ability to support the dynamic demands of the fast-growing EV market with innovative, high-performance manufacturing systems and enabling technologies.

The integrated automation solution, which covers the interior assembly line, exterior assembly line, cylinder head line and piston-connecting rod line, has significantly enhanced reliability, operational efficiency and flexibility. Featuring a combination of 45 automatic and semi-automatic machines, in addition to 15 collaborative robots, the innovative solution has been designed to ensure rapid adaptability for future range extender models.

A key advantage of Comau’s solution is its patented SmartCell technology. By incorporating machining center-style rapid tool-change features, the system achieved high-precision valve collet pressing across a wide range of cylinder head variants, with a production pass rate exceeding 99%. To improve process stability and reduce manual errors, Comau also deployed collaborative robots with vision systems for tasks like spark plug and connecting rod cap installation. This enhanced precision and consistency while helping to lower operational costs. Likewise, a six-axis robotic solution replaced the traditional crankshaft assembly method, increasing flexibility, accuracy and setup efficiency — all of which have proven essential in managing product variation and accelerating ramp-up.