In context
In early 2024, the automotive industry was accelerating its shift toward electrification, with hybrid powertrains playing a critical transitional role. Manufacturers sought automation solutions that could deliver high-volume production while maintaining flexibility for evolving designs. This project exemplified how robotics integrators were addressing those demands in China's rapidly growing new energy vehicle sector.
What was reported
Comau designed and deployed a high-volume automated assembly line for HYCET, a Great Wall Motor subsidiary specializing in Dedicated Hybrid Transmission (DHT) technology. The system supports production of the L.E.M.O.N. hybrid DHT, which enables simultaneous use of gasoline engines and electric motors for efficient power sharing.
The end-to-end solution comprises 12 robots across six lines, achieving an annual production capacity of 150,000 units per line with a cycle time under two minutes. Comau developed all necessary components, including e-motor assembly, gear and shaft assembly, main assembly, and assembly test lines, covering full-process assembly from individual components to fully functional units.
Key features include a process-integrated station design ensuring stability and quality, with an equipment availability rate of 90 percent. A Manufacturing Execution System (MES) optimizes line management and scheduling, while critical parameters such as force and displacement are continuously monitored for quality control and data traceability. The line is designed for easy customization to accommodate future DHT product upgrades and varying market needs.
Why it mattered
This project underscored the growing importance of flexible, high-volume automation in hybrid and electric vehicle manufacturing. By combining error-proofing, real-time monitoring, and modular design, Comau demonstrated how automation can help manufacturers achieve large-scale production targets while reducing costs and preparing for future technology shifts—a model increasingly relevant across the automotive industry's electrification journey.
“By prioritizing flexibility, efficiency, and absolute quality within the manufacturing philosophy, Comau has designed a 100 percent error-proof production process that allows HYCET to enhance efficiency, reduce costs, and meet its large-scale manufacturing goals.”
Source: Robotics & Automation News (roboticsandautomationnews.com) · Published 2024-01-07 · “Comau implements high-volume, automated assembly line for HYCET”