Automotive Industry
Automated Line Assembles ‘Range Extender’ Engines for EVs
At capacity, the line will be able to assemble 400,000 units annually.
Global systems integrator Comau has designed and built an automated line to assemble small “range extender” engines for EV manufacturer Li Auto. Photo courtesy Li Auto Inc.
This electric SUV is equipped with a "range extender," a gas-powered auxiliary power unit that extends the range of a battery-electric vehicle by driving a generator to charge the vehicle’s battery. Photo courtesy Li Auto
CHANGZHOU, China—Global systems integrator Comau has designed and built an automated line to assemble small “range extender” engines for EV manufacturer Li Auto Inc.
A range extender is a gas-powered auxiliary power unit that extends the range of a battery-electric vehicle by driving a generator to charge the vehicle’s battery. This arrangement is known as a series hybrid drivetrain. Hybrid electric vehicles, mild hybrids, and most plug-in hybrid EVs are primarily powered by combustion engines, while range-extended EVs are the opposite.
Comau’s line features 45 fully automatic and semiautomatic machines, in addition to 15 collaborative robots. At capacity, the line will be able to assemble 400,000 units annually.
A key component of the line is Comau’s SmartCell technology. By incorporating rapid tool-change features similar to machining centers, the system can press-fit valve collets with high precision across a wide range of cylinder head variants. The production pass rate exceeds 99 percent.
To improve process stability and reduce manual errors, Comau also deployed vision-guided cobots for tasks like spark plug and connecting rod cap installation. This enhanced precision and consistency while helping to lower operational costs. In addition, a six-axis robot is now used to install crankshafts, increasing flexibility, accuracy and setup efficiency.
“The close collaboration with Li Auto underscores Comau’s commitment to delivering highly flexible, scalable, and efficient automation solutions that enable our customers to meet their evolving needs long into the future,” said Jeff Yuan, Comau’s leader for the Asia-Pacific region. “Leveraging our ability to integrate robotics, patented technologies, and advanced digital tools…has allowed us to achieve a high level of automation and flexibility that can be easily scaled as market needs change.”Looking for quick answers on assembly and manufacturing topics? Try Ask ASM, our new smart AI search tool. Ask ASM
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