How Comau Automated 80% of NIO’s Electric Drive Plant

How Comau Automated 80% of NIO’s Electric Drive Plant

• Comau has designed a high-volume automated production line for NIO’s electric drive systems plant in Mexico for its sedans, coupes, SUVs, and select ALPS models.

• The plant has an average automation rate of 80% and cycle time between 53-60 seconds, thanks to AGVs, computer vision, digital twins, and a zero-point positioner adapter co-developed by the companies.

Could you introduce us to the lines that you are helping NIO automate?

Comau has automated the production of NIO’s next-generation electric drive systems by implementing a comprehensive, high-performance turnkey solution characterized by its technical complexity as well as its flexibility. It’s designed to support an annual large-scale production of 1 million units, which will be used in the automaker’s electric vehicle lineup including NIO sedans, coupes and SUVs, as well as selected models of its ALPS sub-brand.

The complete solution includes main lines, such as electric motor assembly, gearbox production and inverter assembly, as well as EOL (end-of-line) test processes to ensure fast and reliable co-line production for NIO’s third-generation induction and permanent magnet motors, both of which are integral parts of its proprietary electric drive systems (EDS).

Can you highlight some of the innovative features of Comau’s assembly line (use of 3D vision, AGV, etc., and the benefits to automakers)?

The highly automated plant includes multiple robots guided by 3D vision systems and AGVs for autonomous material delivery and automatic loading of tool ends which improve production efficiency.

The widespread use of advanced 3D cameras has enabled Comau to overcome the limitations of guidance technology in terms of field of view and gripping distance, ensuring automatic positioning and assembly of parts, as well as excellent repeatability.

We also collaborated with NIO’s e-drive team to increase the flexibility of the line with a zero-point positioner adapter which integrates design and process and allows different assembly requirements to be met while retaining optimal flexibility in the motor production.

It’s interesting to note that we have been able to leverage much of our longstanding experience and expertise in ICE powertrain manufacturing when developing NIO’s electric motor assembly operations. This is because several processes, such as feeding and bolt tightening, have very similar requirements. Vision systems also play an important role in process automation and although we used to use 2D camera systems in ICE assembly, the 3D systems used for e-motors are key for guidance, precision, and overall efficiency.

Can you discuss the speeds of manufacturing each product, data and traceability, etc.?

The three production lines have been designed to collectively achieve an annual electric drive systems capacity of 1 million units, with an 80% average automation rate and a cycle time between 53-60 seconds.

To accomplish this, Comau developed an advanced operational platform called IMES (Intelligent Manufacturing Execution System). It’s essentially a digital transformation tool that integrates lean management principles and cutting-edge technological concepts to enhance the flexibility, transparency and automatization of crucial functions such as inventory management, production processes, quality assurance, process engineering, equipment oversight, scheduling, workforce management, and data monitoring.

In addition to contributing to improving quality and reducing costs, it increases operational efficiency and strengthens the company’s competitive edge. Digital tools also play a pivotal role in simulating new manufacturing procedures, in addition to monitoring the flow of production in real time. To this end, Comau built a digital twin of the line that runs in parallel with physical operations. In this way, we can fully monitor any changes in production and identify the source of suspected problems. Moreover, it allows for the simulation of planned changes to optimize their integration. The insights gathered from these advanced systems expedite the commissioning of duplicate production lines, ensuring faster deployment and operational readiness.

What sort of specific requirements did NIO have, that Comau offers for it to be a good fit for their production? 

From the beginning, NIO asked Comau to assess a solution that would allow the vehicles to be delivered in the shortest possible time. For this reason, there was a very close collaboration between Comau and NIO starting with a simultaneous engineering approach, which proved key to developing the assembly lines in a very tight timeframe.

Together with the NIO team, Comau immediately started working on processes that would reduce the product development time as well as cycle times for the production line. The simultaneous engineering approach allowed us to pursue the design and development of the production lines in parallel with the design and development of the new products that would be produced. Many customers start the development of their new production lines only once the product design is finalized and approved. The trust that NIO placed in Comau from the start allowed us to begin designing the line with only the prototype drawings of the next-generation electric drive system (EDS). By working closely with NIO’s R&D department, our engineers were able to quickly synchronize new information into the product design as needed. This approach allowed us to react quickly to any necessary changes, as well as provide product design suggestions to proactively optimize the automation and minimize potential challenges in the manufacturing process.

A high level of mutual trust has been created between Comau and NIO, forming a collaboration that goes far beyond a traditional customer-supplier relationship. In fact, a new project typically involves a lot of negotiation to finalize agreements and sign contracts before any work begins. We wanted to work in a holistic way to get the engineering project moving in parallel with business details, and the trusting relationship we had established in earlier projects allowed us to accomplish this.

Can you talk about the history of Comau? 

Comau’s story begins with the first robotic system in the 1970s, and continues across more than 50 years of pioneering innovation, including technologies that in the 1980s and 1990s allowed Comau to open a new, more advanced and flexible era of automation.

Faced with a growing demand for automation of more than 10 percent per year globally, according to internal estimates, Comau has been diversifying its activities by leveraging its longstanding experience in automotive, known for having the highest automation density of any industrial sector, which has allowed us to anticipate trends and enter emerging sectors that are open to automation technologies. These include but are not limited to shipbuilding, fulfillment and warehousing, pharmaceuticals, renewable energy, and e-Mobility, which accounts for 40 percent of the company’s business. Today, Comau is a world leader in providing sustainable advanced automation solutions and helping companies of all sizes, in almost every industry, reap the benefits of automation.

Supported by an ongoing commitment to the design and development of innovative and easy-to-use technologies, our portfolio also includes advanced robotic and digital solutions, project management and consulting and technical training activities organized by Comau Academy. The company is headquartered in Turin, Italy, and has an international network of 6 innovation centers and 12 manufacturing plants across 12 different countries. In addition to its 3,700 employees, Comau also has a global network of distributors and partners, which enable us to respond quickly to customers’ needs, no matter where they are in the world.

Special thanks to Volker Buchbauer from Comau for the interview!

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