Capabilities
Automation International Inc. delivers full-cycle industrial solutions through engineering, machining, fabrication, assembly, and resistance welding systems. With decades of experience supporting production around the world, we serve a range of industries—from automotive to construction—with a strong reputation among wheel manufacturers and metalworking operations.
Production Capabilites
ENGINEERING DESIGN
- Mechanical
- Electrical
- Software
- 3D Modeling
- FEA Analysis
MACHINING
- Complete In-House Machining Facilities
- Large Boring Mill Capacities – Up to 20 ft.
- Vertical and Horizontal Mills
- Large Surface Grinding
- CNC Machining Centers
- Turning Center
LARGE FABRICATION
- Cutting
- Welding
- Forming
- Brazing
- Heavy Crane & Lift Truck Capacity
ASSEMBLY
- Mechanical
- Electrical
- Electronic
- Hydraulic
- Pneumatic
RESISTANCE WELDING TRANSFORMERS
- Design
- Manufacture
- Repair/Remanufacture
- On and Off-Site Testing
ENGINEERING DESIGN
Automation International, Inc. offers comprehensive in-house capabilities that enable us to meet project requirements effectively and efficiently. Our multi-disciplined team can lead a project through planning and design and through start-up and commissioning. Regardless of project size, scope, and complexity, we follow an integrated approach to delivering innovative solutions that synergize our equipment designs with our customers’ manufacturing needs. Contact us and speak to a sales engineer with questions or further information regarding your needs.
Aii engineers bring a depth of resources and experience to the project goals of its customers, as well as the ability to balance design considerations with cost and timing constraints. With a cohesive and versatile team, Aii offers cost-efficient and robust quality solutions for the manufacturing and welding industries. By applying tools and techniques, along with current 3D CAD software, Aii can ensure quality machine designs.
Aii has an extensive range of in-house design and engineering skills which are complementary to one another, such as:
- Experienced Machine Designers
- Certified Hydraulic Designers
- Motion Control and PLC Programmers
- Transformer Designer and Power Data Calculations
- Weld Control Software Designers
- Automation and System Control Integrators
- Finite Element Analysis (FEA)
- 100+ years of design through Intellectual Property
Software
Synergis Adept PDM Solution (Product Document Management)
Infor Visual ERP (Enterprise Resource Planning)
2016 SolidWorks Premium (including FEA / Simulations)
2016 Autodesk Inventor Ultimate (includes Stress Analyst & Animations)
2016 AutoCAD Inventor w/AutoCAD Mechanical
2016 AutoCAD Electrical
PTC Mathcad
RSLogix500, 5000 & Studio 5000 PLC & Safety Software for Rockwell/Allen-Bradley
Factory Talk View for Rockwell HMI design and programming
SIMatic, SIMotion, SINamics PLC & Safety software for Siemen controls
Go To Meeting subscriber – a web conferencing meeting tool
TeamViewer v.11 for remote support services
Visual Studio 2015 – IDE for code editing, debugging & designer aids
MACHINING
Our machine shop includes a wide range of equipment for both heavy and precision machining. Highlights include:
- CNC horizontal boring mills with travel up to 300” x 120” x 60”
- 4-axis machining centers with pallet changers
- Vertical turret lathes with up to 196” swing
- Surface grinders, internal/external grinders, and CMM inspection
Our journeymen machinists routinely handle large-scale parts for metal forming machines, weld fixtures, and frames used in production lines operated by wheel manufacturers. Machined components are verified with tools including digital height gauges, calipers to 120”, and CMM systems.
LARGE FABRICATION
We provide fabrication of weldments up to 90,000 pounds. Our AWS-certified welders work with aluminum, copper alloys, cast steel, carbon and alloy steels, and tool steels. Processes include MIG, TIG, brazing, and soldering.
The facility features:
- 500-ton press brake, 100- and 70-ton presses
- Linde burning machine (8′ x 20′ table, 8″ thick)
- Plasma cutting up to 1″ thick
- 4 large-capacity and 3 medium weld bays
- Subharmonic vibratory and thermal stress relief
These capabilities allow for the production of heavy structural elements, including frames for resistance welding systems and large metal forming machines.
ASSEMBLY
We operate over 34,000 square feet of assembly space equipped with dual-hoist 50-ton cranes, multiple bridge and jib cranes, and full mechanical, hydraulic, and electrical resources.
Assembly capabilities include:
- Hydraulic unit construction, tube bending, and custom hose crimping (up to 2.5”)
- Electrical panel builds, operator stations, junction boxes, and machine wiring
- Rebuild and inspection services for hydraulic and air cylinders
- Complete paint booth system, steam cleaning, and grit blasting
Journeymen electricians and mechanics assemble production-ready systems ranging from compact tooling setups to full-scale resistance welding machines for high-volume manufacturers.
Complete Paint Booth System
- Complete Hydraulic Assembly
- Tubing bending and custom hose crimping capabilities up to 2.5” hydraulic hoses.
- New hydraulic units built completely to engineered specifications with retrofitting capabilities.
- Hydraulic and Air Cylinder inspection and rebuild services.
- Tear down and inspection capabilities to rebuild equipment.
Electrical Department
- New and retro-fitted Electrical Panel builds, Electrical Cabinets, Operator Stations, Junction Boxes, Weld Controls, Hydraulic Cabinets, and Machine Wiring.
- PCB board assembly and testing.
- Micro Ohm meter.
RESISTANCE WELDING TRANSFORMERS
We manufacture and repair AC and DC welding transformers, including designs for Federal, Swift Ohio, and AI Welders (Scotland). Services include coil winding, shellac dipping, copper castings, shearing, and final machining.
Testing capabilities include:
- GE Hi-Pot Tester (up to 10,000 volts)
- Biddle Megger evaluation
- Diode secondary repair and replacement
These transformers are integral to our resistance welding machines, many of which are used by wheel manufacturers and component producers requiring high-strength welds.
WHY AUTOMATION INTERNATIONAL
From concept to commissioning, all services are completed at our facility in Danville, Illinois. Our focus on in-house capability—engineering, machining, fabrication, assembly, and testing—gives our customers faster delivery and tighter quality control.
Whether you’re building a new production line or upgrading a resistance welding machine, Automation International delivers practical, reliable solutions designed to meet your exact specifications. Contact us today to build your next metal forming or resistance welding solution with confidence.