Comau has designed and deployed a high-volume, automated assembly line for HYCET, a wholly-owned subsidiary of Great Wall Motor and a leading manufacturer of DHT (Dedicated Hybrid Transmission) technology. The L.E.M.O.N. hybrid DHT is a next-generation transmission system that allows for the simultaneous use of gasoline engines and electric motors, enabling efficient power sharing between them. To meet the customer’s large-scale manufacturing targets, Comau’s end-to-end solution features a total of 12 robots across 6 lines to deliver an annual production capacity of 150,000 units per line with a cycle time of less than 2 minutes.
Within the scope of the project, Comau has wholly developed the necessary components, including e-motor assembly lines, gear and shaft assembly lines, main assembly lines, and the assembly test lines. The system also includes critical processes that grant full-process assembly from individual components to fully functional units. Furthermore, the high-speed production solution not only satisfies HYCET’s strict requirements in terms of manufacturing accuracy and product quality, it also ensures better adaptability and efficiency while lowering the production costs for future DHT product upgrades. Indeed, the Comau-designed production line can be easily customized to meet different market needs. Comau has also used a process-integrated overall station design to guarantee stability and quality across the entire production line with an equipment availability rate of 90%. A MES (Manufacturing Execution System) allows HYCET to optimize the management and scheduling of the line. Finally, key process parameters, such as force and displacement, are constantly monitored to ensure quality control throughout the entire production process and support subsequent data traceability.
