Audi Hungaria
Robotic painting retrofit, G80 load cells, assembly special-purpose machines and production planning. The ongoing framework agreement covers engine manufacturing, vehicle assembly and the paint shop alike.
Industrial Automation
From design to commissioning: complete, complex automation systems for every field of industry
>> Introduction
Complete systems -
built for individual needs
Today, automation is no longer the privilege of large corporations. Indeed, at NAVIGATOR Group we believe that efficiency gains, industrial automation and various robotic and AI-supported processes are the breakthrough opportunity for European industry. In competition with Asian manufacturers, and with rising labour costs, development can provide the answer, whether it concerns an automotive giant, a Tier 1 supplier, pharmaceutical or logistics corporations, or even smaller manufacturing companies and small and medium-sized enterprises.
Navipro's engineers design and implement complete systems tailored to the customer's needs. Our team carries out every step in-house, from electrical and mechanical design through PLC programming and robot integration all the way to commissioning.
>> Areas of expertise
5 key
competences
We are proud that over the past two decades and more, our team has come up with an economically feasible proposal delivering real efficiency gains for almost every development idea and customer enquiry that has arisen.
Turnkey delivery of special-purpose machines, production cells and complete production lines, including mechanical and electrical design, manufacturing, installation and commissioning. This includes designing and building control systems for automotive assembly lines (OEM, Tier 1, Tier 2) in the fields of body, engine, transmission and steering gear manufacturing.
Design, programming and installation of robot cells on ABB, Fanuc and KUKA platforms. Online and offline robot programming for various technologies, for example in painting, welding, material handling and assembly applications.
PLC, Safety PLC and HMI software development (Allen-Bradley, Beckhoff, Siemens, Schneider, Mitsubishi), design and implementation of SCADA and DCS systems, connecting process control systems to office networks and ERP systems. Commissioning of real-time manufacturing execution (MES) systems, batch-based control, fail-safe and redundant systems, and weighing systems. Our experience also extends to the energy, chemical, food, cement, paper, steel and rubber industries and to water and wastewater treatment.
Material flow simulations (Plant Simulation), virtual commissioning (SIMIT, Process Simulate), digital twin (Digital Twin, Shadow Plant) solutions, ICONICS SCADA and IIoT platform integration. With virtual commissioning, 90% of the PLC program logic can already be developed and tested in the design phase, which means shorter lead times, lower project risk and earlier start of production. Application of machine vision and artificial intelligence in an industrial environment, and research and development of extended reality (XR, HoloLens).
Energy audits, energy efficiency consulting, power quality analysis and reports, development of electrical network protection concepts, analysis of electrical network faults and preparation of expert opinions. Design, parameterisation, testing and commissioning of MV/LV systems and electrical monitoring systems, parameterisation of protection mechanisms. Development and operation of energy management systems, with long-term maintenance and 24/7 on-call support.
>> Technologies we use
Vendor-neutral engineering
We are not tied to any single manufacturer: we adapt to the customer's existing equipment and standards, and we aim to implement the configuration that best fits the project.
Drive technology
Lenze, SEW, Sumitomo, Siemens (Masterdrive, Micromaster, Movidrive, Simodrive, Simoreg, Sinamics, Sinumerik, Simotion, Robicon)
Industrial robots
ABB, Fanuc, KUKA
PLC, HMI, SCADA
Allen-Bradley, Beckhoff, Bosch Rexroth, Fanuc, Mitsubishi, Phoenix Contact, Schneider, Siemens, Zenon
Own production
Electrical control cabinet production, special-purpose machines, tools, turnkey small and mid-sized production cells
>> Our References
Count on us
for the long run
Magyar Suzuki
Introduction of the new Vitara model in the body shop: mechanical and electrical design, commissioning of 60 FANUC robots and cycle time optimisation, with 13 new welding fixtures and conveyors.
Daimler X EBZ GmbH
BR205 project, electrical design, installation and PLC programming of 18 body-shop lines (470 robots, 48 PLCs)BR238/253, electrical redesign, refit and PLC programming of 12 body-shop lines (weekend retrofit project during ongoing production)
Schneider Electric
Building an automatic storage cell for storing and dispensing copper busbars. The cell is built entirely upon Schneider's own control components: PLC, HMI and drive technology (Drives).
Teva
Control system replacement and ERP-connected SCADA development at a pharmaceutical plant. Entering the pharmaceutical industry opens a new, fast-growing segment for Navipro.
Coloplast
Replacement of a foil bending machine and its control system on production lines. In this cooperation we gained substantial experience of work in medical cleanroom environments.
More of our projects
Automated car park, Dubai
Design (with simulations) and delivery of the complete control system for a 1,200-space car park handling 450 cars per hour, with redundant SCADA and PLC architecture and test and training environment.
Concept for total automation
For the 30,000 m² plant (of which 20,000 m² is cleanroom) of a Hungarian healthcare manufacturer, we developed the full automation concept. We mapped eleven production process chains, validated the proposals by simulation and drew up a five-year roadmap that can replace some six hundred jobs.
Robotised assembly line systems
For an automotive supplier's oil cooler production in Győr, we designed and commissioned fully automated robotic assembly lines. Robots move products within 1.6 seconds, machine vision checks quality, and a 4G connection supports remote monitoring and predictive fault analysis of the lines.
Dosing and sorting machine in a cleanroom
For an existing medical device production line, we designed, built and commissioned a new dosing and sorting machine. With our own product manipulator we achieved a cycle time of 1.5 seconds - the machine can run autonomously for five hours and replaced two jobs.
Collaborative robot cell
At a carmaker's engine plant we implemented a cell operating with two KUKA iiwa robots and designed for safe collaboration between humans and robots, from simulation and the safety concept through PLC and HMI development to full commissioning.
Aluminium strip milling machine upgrade
On the strip milling machine of a domestic aluminium processor, we replaced the obsolete controls with a modern Siemens safety PLC and motion control, with drives of 24-450 kW. The work spanned electrical design and execution to machine safety analysis and CE documentation.
>> More of our solutions