In 2013, a leading Virginia robotics integration firm, IAS Corp. has reportedly developed the first fully automated railroad turnout processing system in the world. This process revolutionizes an industry that dates back over 230 years. As this correspondent has discovered, these spurs that allow trains to move off the mainline are traditionally hand produced by laying them out on pads using manual labor and has been since the inception of the age of railroading.

This new and revolutionary system, now capable of producing a short, low speed turnout in a day, uses four large Yaskawa Motoman Robots on precision rails that allow travels up to 30 feet along with high speed conveyors that move the blank, unprocessed ties. A crane system at the end of the production line stacks each tie into a coordinated bundle depending on length and type of plating on each tie. Ties are automatically gaged to determine if they are correctly plated and rejected if not to be passed down the line. Drilling and plating numerous tie plates, including custom, gage and standard during spiking without human intervention while holding gage (the width between each rail) which is very difficult, but achieved.

The firm, IAS Corp. with corporate offices in Hampton, Virginia and a large fabrication facility in Houston, Texas is reportedly 22 years old and involved in transportation, energy (oil/gas and nuclear) as well as chemical automation projects.

We offer many robot effectors and we can engineer to your spec!

For more information, please contact their outside operations manager, Preston Burton at 800-916-IASC (800-916-4272) extension 14.

When STIHL Power Tools needed an improvement to the company’s production line they turned to Industrial Automation Specialists (IAS Corp) in Hampton. STIHL’s Virginia Beach manufacturing plant had used IAS Corp in the past for automation solutions and selected the firm again to develop a new solution for the blower production line. Laser etching compared to dot matrixThe IAS Corp team brought their specialized expertise to the project, installing electrical components, the laser marker, sensors, pneumatics and wiring. IAS also performed initial testing, before delivering the completed machine to STIHL for integration into the manufacturing line.

The result is an improved process that handles engine marking for two different blower types. “As the engine moves Control panel for laser etching on engine componentsinto position on the production line a sensor reads a bar code and then moves the engine into position. The laser then burns a unique serial number onto the engine case based on the bar code,” explains IAS Corp Project Manager Dave Wallace. “At the same time the laser is firing the next engine is moved into position and the sensor reads the bar code.”

Wallace said the machine knows which blower model is in place by reading the bar code. “It’s part of a continuous moving conveyor, with stop gates, so there’s no interruption in the manufacturing process,” he added.

“Our sweet backpack blower with laser etching on enginespot is providing the whole project from mechanical, structural, electrical and programming for all automation projects, big and small,” said Wallace. “However, we can take on a project at any stage. This is an ideal project for our firm – we can handle the sensors, the programming and debugging, and the control systems all in-house.” He said the firm takes great pride in providing turnkey solutions and working closely with manufacturers and their design teams. This keeps costs and schedules manageable and allows the company to maintain their high quality control standards.

IAS Corp is headquartered in Hampton, Virginia’s Langley Research Park and has locations in Chester, Virginia, and Houston and Humble, Texas. The firm combines design, engineering, technical and manufacturing expertise to develop custom equipment, machinery, production lines and automation controls for diverse industries.

Industrial Automation Specialists (IAS Corp) has been named to the AutomationDirect SIDirect Integrators Program representing Virginia in the mid-Atlantic region. AutomationDirect is an industry leader in developing industrial automation controls and IAS Corp. is an authorized integrator of AutomationDirect’s systems. The SIDirect program promotes the training of system integrators like IAS Corp. on AutomationDirect products and assists them in acquiring the necessary tools to effectively and efficiently design, program, and install AutomationDirect core products such as PLCs, HMIs, AC Drives and Servos. IAS Corp. is the only Virginia company that is an SIDirect program participant.

“This recognition reinforces our expertise in the automation and controls industry,” said IAS Project Manager Dave Wallace. “We take great pride in staying on top of the industry with ongoing education and quality products and we look forward to growing our relationship with AutomationDirect,” he added. 

IAS Corp is headquartered in Hampton, Virginia’s Langley Research Park and has locations in Chester, Virginia and Humble, Texas. The firm combines design, engineering, technical and manufacturing expertise to develop custom equipment, machinery, production lines and automation controls for diverse industries.

A recent article on company behind the popular Maglite flashlight, Mag Instruments, and it’s founder outlined some of the challenges companies face when trying to be competitive (read the article, here: http://www.msnbc.msn.com/id/38025260/ns/business-us_business/) The story is a classic “pull-yourself-up-by-your-bootstraps” tale of American entrepreneurship. And while it is a warm tale, it also highlights the challenges of being in manufacturing when it seems everything can be made cheaper and faster in China.

However, as designers and manufacturers of custom machinery both large and small, we enjoyed reading about owner Anthony Maglica’s approach to business. The article states,

“Maglica is obsessed with upgrading automation and fine tuning work flow in the plant to wring out speed and efficiency — the only way, he says, that he can compete with imports from China where labor is so much cheaper. The company has invested tens of millions in automation against pressures to go overseas — a strategy that has worked remarkably well…”

We love that. Here’s a quote from Maglica, “You have to invent it, design it, and prove it works, and then you have to automate it,” he says. And then, “there are glitches to work out.”

That makes us smile, because it’s exactly what we do, and it’s nice to see the same sentiment in a company that has been so successful over the years. We take great pride in helping companies automate their manufacturing, assembly or quality assurance testing processes. Whether it’s to save money, increase speed and efficiency, or just stay competitive with a changing world market, we see first-hand the results of well-planned and designed automation.

We take our responsibilities seriously, just like Maglica, and consider ourselves to be integral parts of our customers’ success. We know businesses turn to us to make things better and come up with a new, custom solution. We strive to exceed expectations in every case and our work speaks for itself. 

If you haven’t read the article on Mag Industries, we encourage you to do so (http://www.msnbc.msn.com/id/38025260/ns/business-us_business/) and perhaps consider how automation could improve your business. Of course we’re happy to provide our expertise and guidance – you don’t have to do it alone.