With a fully integrated system and proprietary technologies, Comau helps Li Auto achieve 400,000-unit annual production capacity for its EV range extender line.
Comau has engineered and deployed a next-generation automation solution tailored for Li Auto’s new line of electric vehicle (EV) range extenders. This comprehensive system enables the Chinese automaker to reach an annual production capacity of 400,000 units.
The project spans the entire production process—from design and digital simulation to mechanical integration and commissioning—delivering high performance and scalability in response to the fast-moving EV market. The solution supports assembly operations for internal and external lines, cylinder heads, pistons, and connecting rods, dramatically improving operational reliability, efficiency, and process flexibility.
High-throughput automation built for scale
At the core of the system is a sophisticated assembly line integrating 45 automatic and semi-automatic machines with 15 collaborative robots. This setup not only meets current production goals but is designed for rapid reconfiguration, allowing Li Auto to adapt quickly to future model changes.
A standout feature is Comau’s proprietary SmartCell technology. Inspired by machining center principles, SmartCell enables high-precision press-fitting of valve manifolds across a wide variety of cylinder head designs. This system boasts an industry-leading first-pass yield exceeding 99%, significantly enhancing quality assurance on the production floor.
Robotic precision meets real-world flexibility
To mitigate human error and boost repeatability, Comau has deployed collaborative robots equipped with advanced vision systems for tasks such as spark plug and connecting rod cap installation. This not only improves accuracy and consistency but also reduces overall operational costs.
Further enhancing flexibility, a six-axis robotic solution replaces traditional crankshaft assembly techniques, allowing for more precise handling, faster cycle times, and easier adaptation to product variability. Such innovations are crucial for accelerating time-to-market and scaling production as EV adoption grows.
Strategic partnership for sustainable innovation
“The ambitions of Li Auto in the electric vehicle sector demand reliable partners like Comau,” stated Ju Yubo, Director of Range Extender Process Development at Li Auto. “Comau’s commitment to advanced automation and cutting-edge technology aligns with our vision of sustainable innovation. This collaboration will drive new efficiencies and elevate product quality to meet the high expectations of today’s EV consumers.”
Jeff Yuan, Head of Comau APAC, echoed the sentiment: “Our collaboration with Li Auto highlights Comau’s mission to deliver highly flexible, scalable, and efficient automation solutions that meet long-term customer needs. By combining our expertise in robotics, proprietary technologies, and digital tools, we’ve achieved a new benchmark in automated precision manufacturing—one that evolves alongside market demands.”
