Large & Custom Machinery

 

CoatBot XL

View infomation on the CoatBot XL

 

 


 

 

Award Winning “Tool” Reduces Injury, Saves Time & Money for US Navy Carriers

Challenge:   The US Navy contracted Northrop-Grumman (NGC) to find a more efficient and productive way to rebuild catapult troughs while an aircraft carrier was being overhauled.  NGC relied on IAS Corp. for assistance designing the custom machine that needed to mill, drill and tap with absolute precision. Award Winning “Tool” Reduces Injury, Saves Time & Money for US Navy Carriers

IAS Corp. Solution:   Design & Build / Multi-Function Tool

IAS Corp., together with Newport Cutter Grinding, created a prototype machine that automated work once done by sailors using heavy hand-held drills.  Weighing as much as 40 pounds, these drills made onboard wrist injuries and fatigue commonplace.  Almost immediately the “Multi-Function Tool” helped reduce on-the-job injuries by 25%, and its ease of use and quick cycle times added up to a savings of $649,500 per ship.  The “Multi-Function Tool” won Northrop-Grumman an Institute of Industrial Engineers "Ergo Excellence" award, which recognizes companies that find innovative and cost-saving ways to improve the work environment.  (Click here for more [VA Pilot story from April 14 2007]) The “Multi-Function Tool”has since gone through multiple modifications, yet the original prototype is still in use today. Click here for more information.

 

IAS Corp. Services Delivered:

 

“We're very proud of this," said Ed Elliott Jr., a member of the shipbuilder's team that helped develop the project.  “It's a step in the right direction to reduce costs and injuries.”  (as reported in an article by Virginian Pilot reporter Jon W. Glass,  April 14, 2007)

 


 

Machinery Retrofitted for Major Corporations New Location

Challenge:   IAS Corp. was asked to bring an older Lucas Horizontal Boring Mill up to today’s standards with a machine that is accurate, easy to use, reliable, and affordable.Boring Mill Moves to CK&B Machine Retrofitted for New Location

IAS Corp. Solution:   Retrofit machine

Following a complete inspection of the machine, our technicians removed the control, motors, drives, and associated electronics.  The older control was replaced with a Fagor 8055CNC control, motors were refurbished, the drives were replaced with Baldor units, and electronics were updated.  In addition our technicians went through the mechanics and hydraulics. This process was very fast and within a matter of a few months the retrofitted mill was set up and operational at its new location in Pearland, TX.  IAS Corp. has since become the primary service provider for this machine shop and has built several additional machines/systems for them.

 

IAS Corp. Services Delivered:

  • Mechanical retrofit/update
  • Electrical retrofit/update
  • Hydraulic retrofit/update
  • Setup and training
  • Large Machine Retrofit
  • Custom Controls

 


 

Planer Retrofitted into CNC Drill for Steam Boiler Manufacturer

Challenge:   English Boiler and Tube contacted IAS Corp to convert an old Gray planer into a CNC drill that was accurate, easy to use, reliable, and affordable for steam boiler manufacturing.Planer Retrofitted into CNC Drill for Steam Boiler Manufacturer

IAS Corp. Solution:   Retrofit Machine           

Following a complete inspection, our technicians stripped the machine down to the basics.  We then went through the mechanics.  The cutting section was replaced with a Mititoyo Cylco-reducer, and a new spindle motor with custom mount.  Fuji VFD’s, Trak encoders, and custom PC based control (AcroLoop) were installed. This machine was up and running at its home in Richmond, VA in less than 2 months.  ROI on this machine was quick and IAS Corp was awarded the contract to do another machine in much the same way. We delivered the second machine in late 1998, and have since been called for service only twice.  Machines retrofitted by IAS Corp. technicians are reliable to say the least, and do not interrupt daily production work.

 

IAS Corp. Services Delivered:

  • Mechanical retrofit/update
  • Electrical retrofit/update
  • Hydraulic retrofit/update
  • Installation
  • Setup and training
  • Retrofit of Large Machines
  • Custom Controls

 


 

Big Repairs for Large In-Service Cranes at Shipping Terminal

Challenge:   Virginia International Terminals (VIT) in Newport News VA contacted IAS Corp. when their large crane for unloading shipping containers went down and they were not able to repair it in-house.  On-site service technicians, typically performed all repairs but this crane had outdated 1960’s technology control boards from a company that no longer existed.  Many of the failing parts were obsolete, and VIT needed a solution that would get them up and running again fast and on a budget.Big Repairs for Large In-Service Cranes at Shipping Terminal

IAS Corp. Solution:   Design new boards to replace failing/obsolete units.

Our technicians took an in-depth look at the existing control boards, and were able to make repairs so that the crane could be put back into service immediately.  We then designed and built new boards that fit into the existing control and replaced the outdated/obsolete ones.  We provided complete board sets for the cranes along with spare units and parts lists for the service techs.  In less than 2 weeks VIT’s cranes were no longer controlled by 1960’s technology, but instead were operating under custom-built state of art control units from IAS Corp. 

 

IAS Corp. Services Delivered:

  • Emergency service and repair
  • Electrical retrofit/update
  • Installation
  • Retrofit of Large Machines
  • Custom Controls

 


 

Team inspects & re-assembles large milling machine at new location

Challenge:   A major corporation purchased a TOS Horizontal Milling machine from an auction and had it shipped to their facility in Texas.  The machine was in good mechanical condition but the control was no good.  IAS Corp. was contracted to retrofit this machine into an accurate, easy to use, reliable, and affordable piece of production machinery.Team inspects & re-assembles large milling machine at new location

IAS Corp. Solution:   Retrofit machine

Following a complete inspection, our technicians first went through the TOS Horizontal Milling machine from top to bottom.  We then refurbished the motors and drives, updated the electronics, and replaced the control with a Fagor 8055CNC.  In less than two months our technicians had the retrofitted machine up and running production work.  IAS Corp. has since become the primary service provider for this machine shop and has built several additional machines/systems for them.

 

IAS Corp. Services Delivered:

  • Mechanical retrofit/update
  • Electrical retrofit/update
  • Hydraulic retrofit/update
  • Installation
  • Setup and training
  • Custom Controls

 


 

IAS Corp has completed projects for defense contractors, machine shops, manufacturing companies, and many others in need of Large and Custom Machines, including:

 

 

Whether you have a small part that needs testing for viability or an entire facility that needs to run more efficiently, contact IAS Corp. today to see how our Custom Machine capabilities can work for you.


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