References & Projects

Situation

A supplier for a premium German vehicle manufacturer needed to automate the final inspection of electrical cables before packaging. Testing was done manually — slow, unreliable and unsustainable with growing volumes and quality requirements from the end customer.

Solution

Netajo designed and built a custom machine as a rotary table. The machine handles cables from 15 cm to 250 cm in length and tests 23 different types, each with 30–60 inspections. Changeover between types takes less than 1 minute without any mechanical adjustment — the operator simply selects a recipe. The machine includes two Epson robotic arms, servo drives, Cognex vision inspection and a Keyence laser marker. The entire machine is controlled by Beckhoff.

Situation

A manufacturer of door systems for trains needed to automate functional testing of the complete electronics in door panels before dispatch. Every unit had to be tested across dozens of measurement points — manual, time-consuming, error-prone and not connected to ERP.

Solution

Netajo designed and built the testing station turnkey — hardware, software and integration. The station operates at up to 300 V DC, which places high demands on both safety and measurement accuracy. At the core is a Siemens S7-1500 controlling two DMMs and a programmable high-voltage source. Netajo's key in-house development is a switching matrix — a custom electronic board that automatically contacts individual pins of the tested connector with the measurement assembly without mechanical rewiring. Operators follow instructions on a Raspberry Pi monitor controlled directly from the PLC. Test scripts are configured from a PC without touching PLC code, and results are automatically sent to a PDF report, label printer and the customer's ERP.

Situation

A production plant with dozens of machines had no visual machine status signaling — and the end customer began requiring it as part of delivery conditions. The entire facility needed to be equipped quickly with an Andon system without production downtime and without interfering with existing machines.

Solution

Netajo supplied and connected 60 Banner LT70 signal towers (red / yellow / green) to the existing production system. To control each beacon, Netajo developed a custom USB hardware adapter — without touching existing PLCs or machine wiring. The entire deployment took 4 weeks.

Situation

The client operated standard hydraulic hose saws. The machines worked, but were struggling to keep up with growing demands for speed, safety, production cleanliness and integration with enterprise systems. After first working with Netajo, the client chose a path of gradual improvement — and Netajo became their permanent technology partner for developing their machine fleet.

Solution

Netajo carried out the modernisation in several phases. First, laser measurement was added for more precise and faster cutting. This was followed by a custom HMI panel developed by Netajo — with capacitive buttons behind a hermetically sealed cover, readable in direct sunlight and functional even in work gloves. The next phase brought safety locks and relays monitoring zero blade speed to protect operators when accessing the machine. A new frequency inverter enabled blade speed to be adapted to the type of hose being cut. For clients with cleanliness requirements, automatic purging of the hose after each cut was added. Finally, the machines were connected directly to the customer's ERP.

Situation

The legacy packaging system supplier ceased operations. No licence exists, source code unavailable. Every replacement reader had to be specially modified — at 3 to 4× the price of standard hardware on the market.

Solution

Netajo deployed a software adapter running in the Windows background. It captures data from any modern USB reader and reformats it in real time into the format the legacy system expects. Zero interference with existing technology. On-site deployment in 3 days.

Situation

Tool wear caused gradual dimensional deviations. Correction was done manually — the setup technician had to come in every shift.

Solution

Netajo's LVDT measurement station measures every workpiece, monitors the deviation trend and writes corrections directly to the Fanuc CNC. If corrections reach the limit, the system stops production.