Italian automation specialist Comau has introduced its N-WG spot welding gun at Automatica 2025, targeting the growing demand for flexible manufacturing systems in electric vehicle production. The gun’s single-body design addresses a common pain point in automotive assembly: the need to rapidly switch between different welding configurations without extended downtime.

The N-WG features a patented modular architecture that covers standard and high-force welding applications within one platform. This eliminates the traditional requirement for separate gun bodies for different force ranges, reducing spare parts inventory and simplifying maintenance protocols. The system supports both X and C standard configurations, enabling integration across existing production lines with minimal modification.

Perhaps most significantly for manufacturers running mixed production schedules, the gun enables arm exchanges during normal operation. This capability eliminates production stops during tool changes, addressing a key bottleneck in flexible manufacturing systems where different vehicle models require different welding specifications.

The technical specifications reveal engineering focused on repeatability and efficiency. Force repeatability sits at ±20 daN across the operational range, meeting the precision requirements for modern steel welding applications. Aluminum welding capability is planned for future releases, expanding the gun’s applicability as automakers increasingly adopt multi-material body structures.

Power configuration spans 380V to 480V systems, accommodating different regional electrical standards. The simplified mechanical design provides direct access to all components, cutting mean time to repair from 30 minutes to 10 minutes according to Comau’s testing. This reduction stems from the elimination of complex sub-assemblies that typically require partial disassembly for component access.

The cooling system design prioritizes water efficiency and pressure stability, critical factors in high-volume production environments where cooling system failures can cascade across multiple welding stations. The gun works with major robot brands, removing the integration complexities that often arise with proprietary welding systems.

Comau manufactures the N-WG at its Grugliasco facility in Turin, adding to a welding gun portfolio that has shipped over 7,000 units in recent years. The timing aligns with automotive manufacturers’ push toward more flexible production systems capable of handling conventional, hybrid, and electric vehicle architectures on the same lines.

The modular approach reflects broader industry trends toward platform-based manufacturing equipment that can adapt to changing production requirements without wholesale replacement. As vehicle electrification accelerates, manufacturers need welding systems that can handle the precision requirements of battery pack assembly while maintaining the throughput demands of traditional automotive production.

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