Lead
Comau developed and deployed an automated electric drive assembly line for Geely at its Ningbo Verui plant.
Complete assembly of motors, gearboxes and inverters.
Comau has developed and deployed an automated electric drive assembly line for Geely's Ningbo Verui plant for the complete assembly of motors, gearboxes and inverters. In close cooperation with the Geely team, the entire line uses a flexible automatic production system to complete the assembly of permanent magnet motor rotors, reducers and electric drive systems (three-in-one assembly), in addition to automatic quality control and testing. The innovative solution increases the automation rate of the factory from 40% to 80%, with an annual capacity of 120,000.
Comau helps Geely achieve its high-volume production goals. Multiple robots are used in the production line to co-install the motor rotor, integrating 3D visual positioning guidance, automatic high-speed installation of magnets, automatic injection molding of rotor cores and rotor double-position automatic dynamic balance correction, automatic magnetization and detection. On the other hand, some assembly lines use advanced three-in-one assembly processes such as motor stator casing hot sleeves, motor static testing, motor dynamic testing, fully automatic bearing loading and pressing, automatic bolt feeding and tightening, and automatic measurement selection of gaskets.
Comau completed the design phase of the project in just 4 months. The executive team also overcame the impact of COVID-19 and the additional challenges of product optimization changes, delivering the production line in just over 12 months. Thanks to Comau's rapid and targeted response to post-delivery modification requirements, mass production was officially launched at the end of 2021.
"The solutions we have developed make the entire manufacturing process more flexible and efficient, a tangible result achieved in cooperation with Comau," said Yongjing Sun, deputy general manager of Geely Verizon. "This automated production line helps ensure that our new models will continue to have the same level of quality and excellence, which in turn will enable the Krypton brand to succeed worldwide."
According to data released by IHS Markit, electric vehicles are expected to account for 60-80% of all new car sales by 2050. This prediction has prompted automakers to look for assembly automation methods that integrate motors, transmissions and power electronics into electric drive systems. This creates opportunities for industrial automation companies such as Comau, which is at the forefront of this trend.
"We are very pleased to further expand our long-standing relationship with Geely and support our customers on their journey to electric mobility through Comau's technical expertise in electric drive systems," said Wang Junwu, Technical Director of Comau China. "This delivered innovative assembly line is a direct result of Comau's long experience in automation, smart manufacturing and digitalization, in addition to our pioneering electrification expertise."
The successful delivery of the project provides a strong production guarantee for the production of Geely's pure electric vehicles, while enriching Comau's design and manufacturing experience in automated electric drive production lines, which will play a role in the implementation of subsequent similar projects.