New Program Offers Better Tracking of Packaging Assembly Line
Challenge: Develop an easily adjustable PLC programming and debugging system for existing contact lens packaging assembly line.
IAS Corp. Solution: IDEC Aerospace contracted IAS Corp. to provide PLC (programmable logic controllers) programming for an assembly line that they had built for Cooper Vision in Hampton, VA. Their operation packaged contact lenses by moving the packaging into place and injecting it with saline solution. A worker then inserted a lens before packaging was moved down the line, covered and heat sealed with foil, and inspected by a vision system for defects. IAS Corp. developed the programming that tracks the work completed, records any defects, and aids production monitoring and trending. This custom program also features adjustable parameters to assist with changeovers and product variations.
IAS Corp. Services Delivered:
- Automation & Efficiency
- Programming
Task Specific Stations Simplify Tool Assembly for Stihl Incorporated
Challenge: Develop and install electrical and pneumatic components that control operations for several task specific tool assembly stations.
IAS Corp. Solution: Fulfilling Stihl Incorporated’s need to simplify specific operations in their tool assembly plant in Virginia Beach, VA, IAS Corp. designed schematics, built and installed electrical and pneumatic components, and wrote software to control several task specific stations. The “hedge trimmer station” and the “chainsaw trigger group station” are both semi-automatic (operator loads parts) and operate in much the same way. An operator loads a part into the station, once their hands are clear, the machine assembles a trigger group and with precision pushes in a pin that holds everything together. The operator then removes the assembly and puts in parts for the next cycle. IAS Corp. provided installation of ALL the electronics and pneumatics, and wrote the programs (Siemens Step7) that control the operation of both of these stations.
IAS Corp. Services Delivered:
- Electrical components and installation
- Pneumatic components and installation
- Siemens Step7 Programming
- Electrical/Pneumatic schematics
IAS Gasket Limiter Glue Station Provides Swift ROI for Chrysler
Challenge: Provide automated system that will glue metal limiters into cork gaskets for Chrysler oil pans. Must be able to run any shape gasket and apply specific amount of adhesive.
IAS Corp. Solution: This Gasket limiter glue station for ITW/Southland (Chrysler) in Virginia Beach, VA is semi-automatic (user loads parts). For this project an operator places a cork gasket onto a conveyor, inserts metal limiters into gasket, and presses the start button. A conveyor moves the gasket into the work zone where a camera detects the gasket type and recalls the info for that gasket. After identification, a custom gantry-mounted glue head applies fast set adhesive to preset spots on each limiter bonding it to the cork gasket. After glue application the assembly travels out on the conveyor where it is vision inspected. The ROI on this system was less than one year primarily due to reducing adhesive waste.
IAS Corp. Services Delivered:
- System design and construction
- C++ Programming
- System setup / installation
- Training and support
Custom Pressure Plate QC Machine offers Unique Semi-Automatic Solutions
Challenge: Provide a system that can check vehicle pressure plates. System must be accurate, reliable, and record test results to aid in trending.
IAS Corp. Solution: Our Pressure Plate QC machine for Valeo Clutches & Transmissions in Hampton, VA is semi-automatic (Operator loads parts). It monitors the pressure needed to move the fingers of pressure plate a specified distance. It utilizes LVDT's, Load cells, and current feedback to ensure the highest accuracy. Passing parts are paint marked "good" and failed parts are tagged “failed” then logged to database. Custom analysis software, the ability to run a wide variety of parts, and a unique fast-test method are a few of the custom features added to this station.
IAS Corp. Services Delivered:
- System design
- Integration into existing equipment
- C++ Programming
- Operator training
Complex Control System for Motor Winding Machine Built Easy to Use
Challenge: Several attempts by another company had been made to provide programming and debugging of a motor winding machine, but had failed.
IAS Corp. Solution: IAS Corp. was called in to provide programming and debugging of a motor winding machine for Portsmouth Tool & Die’s end customer, Black & Decker. The semi-automatic machine needed a complex control system, but is still very easy to use. An operator places an armature in the machine and connects leads. The machine automatically winds armature and then tests the winding. The program allows for fine tuning and adjustment of all machine functions. System maintains a log file of all work. Cycle time is faster than comparable machines and switches between motor types quickly.
IAS Corp. Services Delivered:
- Automation & Efficiency
- Programming
- Operation Manuals
Easy to Use System Controls Chrome and Zinc Components for Robert Bosch
Challenge: Design and install a control system for chrome and zinc plating lines that does more than chrome and zinc plate Robert Bosch injector components.
IAS Corp. Solution: Zinc & Chrome plating lines were constructed by IAS Corp. for Greystone in Toano, VA to chrome and zinc plate injector components for Robert Bosch. Line 1 is used for chrome plating and Line 2 for zinc plating. Each line is very easy to use. An operator loads a rack with the parts to be plated and rolls it to the end of the line, calls up recipe for that type of part on the PC control and hits the start button. From that point on all hoist movements to tanks are automatic. The control features custom software that allows for fine tuning of the recipe, control of system, and provides a log file of work done. Custom interface boards and remote monitoring for troubleshooting via the web are incorporated to minimize downtime.
IAS Corp. Services Delivered:
- System design
- Integration into existing equipment
- C++ Programming
- Electrical components and installation
- Operation manual
- Remote monitoring
Low Cost Station Offers System for Checking a Wide Range of Clutch Discs
Challenge: Provide a low cost station for testing clutch disc balance for a wide range of clutch discs.
IAS Corp. Solution: Our clutch check station was created for Valeo Clutches & Transmissions, Hampton, VA. The operator places a clutch disc on the test platform and starts the cycle. A motor engages and spins the disc while sensors measure the balance. Passing parts are paint marked "good." Failed parts are stopped and moved by hand while the machine shows the operator where material on the disc needs to be removed for it to balance. The operator can then drill some weight out of the disc and run the test again. This system works on a wide range of clutch discs.
IAS Corp. Services Delivered:
- System design
- Idec PLC Programming
- Electrical components and installation
- Operation manual
IAS Corp has completed projects for utilities, adhesive companies, automotive parts manufacturers, tool manufacturers, and many others in need of automation & efficiency services, including:
- IDEC Aerospace (Cooper Vision)
- Valeo Clutches & Transmissions
- Greystone of Virginia
- Stihl Incorporated
- American GFM
- Canon
- Federal Mogul
- Wagner Lighting products
- Gambro Healthcare
- Illinois Tool Works
- National Starch and Chemical
- National Adhesives
- Crane Research
- Craft Bearing
- Progressive Heat Treating
- TKL cases
- Sonoco packaging
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 capabilities in automation and efficiency services can work for you.
Celebrating 26 Years!