Comau, a Stellantis company, has implemented a high-performance turnkey solution to automate manufacturing of NIO’s next-generation electric drive systems. The multi-faceted project also ensures fast and reliable co-line production for the electric vehicle manufacturer’s third-gen induction and permanent magnet motors, both of which are integral parts of its proprietary electric drive systems (EDS).
The solution includes primary lines such as e-motor assembly lines, gearbox manufacturing and inverter assembly lines, as well as EOL (End of Line) testing processes.
It is designed to support a large-scale annual production capacity of 1 million units, to be used within NIO’s electric sedans, coupes and SUVs, as well as select models of its sub-brand ALPS.
Comau’s advanced automation solution delivers flexibility and scalability, allowing Nio to adjust its production environment to accommodate different process parameters as needed for new products. To increase production line flexibility further and to enable co-line production of the two electric drive systems, Comau has collaboratively developed a new adapter with zero-point positioner together with NIO’s e-drive team.
This accessory effectively unifies design, process, and control standards, allowing different assembly requirements to be met while maintaining maximum flexibility.
Comau’s highly automated manufacturing environment also features 3D vision-guided robots, AGVs for autonomous material supply, and automatic tool-end loading, which have helped significantly enhance the customer’s production efficiency.
The widespread use of quadnocular stereovision 3D cameras has allowed Comau to successfully overcome the limitations of vision guidance technology in terms of field of view and gripping range, granting automatic part positioning and assembly in addition to excellent repeatability.
