• Comau has developed and deployed a high-volume automated production line for lemon blend DHT production
End-to-end solutions ensure annual production capacity of up to 150,000 units per production line while controlling the production time in less than 2 minutes
This highly scalable system is designed to reduce production costs for future DHT product upgrades, demonstrating superior adaptability and efficiency
• Flexible and expandable production lines are customized to meet changing market demands

Comau recently successfully designed and deployed a high-volume automated production line for Honeycomb Drive, a leading manufacturer of DHT technology under Great Wall Motor. The assembly line is designed for the Lemon Hybrid DHT, a next-generation drivetrain that enables efficient power sharing between gasoline engines and electric motors. To achieve large-scale manufacturing goals, Comau’s end-to-end solution features 12 robots on each of six production lines, ensuring an annual production capacity of 150,000 units per line while controlling the production time to less than two minutes.

Comau fully developed the components required for the project scope, including the motor assembly line, the shafting assembly line, the main assembly line and the assembly test line, covering the entire process assembly from the component to the assembly line. This high-speed production solution not only meets the stringent manufacturing accuracy and product quality requirements of Honeycomb drives, but also ensures better adaptability and efficiency, helping to reduce production costs for future DHT product upgrades. Production lines designed by Comau are remarkably flexible and can be easily customized to meet different market requirements.

Comau also uses an integrated process station design to ensure stability and product quality throughout the entire production line, while equipment mobility is up to 90%. Through MES (Manufacturing Execution System), Hive Drive optimizes line management and scheduling, enables continuous monitoring of key process parameters such as force and displacement, ensures quality control throughout the production process, and supports traceability of subsequent data.

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“Honeycomb Drive DHT technology demonstrates cutting-edge innovation in the field of hybrid vehicles, injecting outstanding performance into Great Wall Lemon DHT products. As a partner for our new technologies, Comau’s reliable design and engineering capabilities confirm its outstanding position in this field, “said Wu Hongchao, Vice President of Beehive. “During the project execution phase, despite repeated outbreaks, Comau was delivered strictly on schedule and with consistent manufacturing quality. This stability is essential to our production processes, allowing us to meet market demand and maintain efficient production.”

“This project is a great opportunity for Comau to work with a leading company in hybrid transmission technology,” explains Yingjun Yuan, Head of Comau Asia Pacific. “By prioritizing flexibility, efficiency and absolute quality in our manufacturing philosophy, Comau has designed a 100% error-proof production process to help the Honeycomb drive reduce costs and increase efficiency to achieve large-scale manufacturing goals. Our competitiveness in the field of electric mobility stems from our long experience in conventional engines and powertrains, making Comau a global leader in new energy vehicle solutions.”

Comau is committed to the development of electric drive technology by constantly expanding its technology portfolio to meet the growing needs of electric vehicle applications. The company specializes in the design, manufacture and integration of flexible, modular, reconfigurable and scalable automation solutions, including stator assembly systems, rotor assembly systems, electric drive assembly systems, electronic control assembly systems and electric drive system shell machining solutions. At the same time, Comau focuses on the development of automated manufacturing systems covering cells, modules and various battery packs to provide solutions for different stages of battery production, including battery formation technology. Thanks to its comprehensive product portfolio, process capabilities and cutting-edge technologies, Comau offers one-stop solutions for everything from prototyping and pre-manufacturing to mass production and waste battery recycling.

At the forefront of innovation in automation and electrification, Comau is empowering customers around the world to upgrade through advanced technology, process development and digital tools. The company is focused on large-scale electrification of the automotive market, fully supporting customers in developing market-leading new energy vehicles and providing advanced solutions for the future.