The Design in Action
Welcome to our Project Portfolio, where you get a sneak peek into the success stories we've crafted with our clients. From mechanical designs to innovative product development, and more – each project showcases our commitment to simplicity, efficiency, and quality.
Dive into our portfolio to witness the transformative journey of ideas evolving into tangible solutions. Let the projects speak for themselves, illustrating how Design Factor turns visions into reality!
Acknowledgement: Despite acting in a leadership position in conducting the following projects, there are several other professionals who contributed to the results presented below. I would like to thank all the professionals who were directly and indirectly involved.
01
Robotic arm powered by pneumatic muscles
Imagine a robotic arm inspired by the human body, designed to work safely in high-risk areas. I used special pneumatic muscles to power its joints. Despite the initial complexity, we made it practical and easy to control. The project achieved its goals, providing a simple, effective solution.
02
Abrasive Cleaning Robots for Efficient Maintenance
In a groundbreaking R&D initiative, it was explored the creation of remotely operated robots dedicated to cleaning ship hulls and tanks. The primary goal was to efficiently remove paint residues, corrosion, and barnacles during maintenance, saving both time and costs.
By eradicating the need for scaffolding and reducing operating time and material use, this equipment provided a solution while maintaining staff safety.
Carried out while working with INSTOR
The development stages encompassed 3D conceptual designs, rapid and cost-effective prototypes, technical and commercial feasibility studies, optimized engineering design, fabrication using diverse machining processes, assembly, integration with control systems, and field tests.
The outcome? An innovative robot capable of scaling metallic surfaces with magnetic tracks, operated remotely for enhanced worker safety. This development translates into significant cost savings, environmental impact reduction through waste recycling, and a patent to mark the success of this transformative project.
Carried out while working with INSTOR
03
Painting Robots for Efficient Surface Coating
As part of an R&D initiative, it was carried out the development of a remotely operated painting robot designed for the efficient coating of tanks and ship hulls during construction or maintenance.
The primary objective was to streamline the painting process, saving time and costs by eliminating the need for scaffolding assembly and ensuring a more efficient procedure compared to conventional methods.
The project progressed through various stages, including conceptual design, prototyping, feasibility studies, engineering design, fabrication, assembly, and field tests.
The result was an innovative piece of equipment capable of scaling metallic surfaces using optimized magnetic rubber tracks, operated remotely to keep workers in a secure position. This development not only contributed to significant cost savings but also reduced operating time while enhancing the efficiency of the painting operation.
04
Weld Cleaning Robot for Petrochemical Tanks
This project was focused on the creation of a specialized Weld Cleaning Robot designed for cleaning and preparing welding areas within spherical tanks in petrochemical industries.
The primary objective was to address the challenge of cleaning oxidation and reducing roughness in confined spaces, enabling efficient inspection of weld integrity through ultrasound techniques.
Carried out while working with INSTOR and Araujo Engenharia
The project spanned various stages, including 3D conceptual drawings, prototyping, feasibility studies, optimized engineering design, fabrication, assembly, integration with control systems, complete documentation, and field validation tests.
The outcome was a versatile robot capable of scaling metallic surfaces using optimized magnetic rubber tracks, allowing operations in different orientations, including upside down, through pneumatic propulsion. Operated remotely, the robot prioritizes worker safety while delivering significant cost savings in inspection costs for the customer.
05
Security Robots for Industrial and Police Safety
The development of a group of remotely operated Security Robots with the aim of observing and addressing hazardous situations in industrial or police contexts.
The objective was to create a versatile solution for inspecting areas or equipment that posed risks to the lives of workers or security forces.
Engaging in a commercial competition to supply security robots for the 2014 World Cup and the 2016 Olympics, it was conducted conceptual and feasibility studies, prototyping, and cost evaluations throughout the project. The outcome was the successful development of three prototypes, each varying in complexity, leading to an optimized final project.
Importantly, the control mechanisms and studies conducted during this project were effectively applied to other equipment, showcasing the versatility and adaptability of the solutions offered.
06
Flexible Pipeline Test Bench
It was played a pivotal role in an R&D initiative focused on creating an automated and instrumented experimental unit designed to simulate the harshest conditions faced by flexible pipelines during offshore oil and gas extraction.
Taking charge of the mechanical development and serving as the general manager, we successfully contributed to refining the experimental test protocol, designing the automated unit, and implementing inspection and monitoring techniques.
Carried out while working with SIMEROS
The project was completed within the stipulated 18-month timeframe, adhering to the proposed budget. Notably, the thorough FMEA investigation conducted paved the way for a comprehensive test protocol, incorporating HSE recommendations, investigation procedures, and insights for future developments.
Carried out while working with SIMEROS
07
Precision Ovality Measurement Tool for Pipeline Evaluation
In this innovative project, we took the lead in developing a specialized tool aimed at measuring ovality in flexible oil and gas extraction pipe samples during crushing tests.
Acting as the program coordinator, the involvement spanned from conceptual discussions to the mechanical design, final product manufacturing, assembly, and coordination of commissioning tests.
The resulting product, accomplished in just 10 months. This precision tool, equipped with laser sensors offering 0.01 mm accuracy, significantly streamlines the inspection process. With a quick setup time of 20 minutes and a total measurement duration of approximately 30 minutes, including comprehensive investigations, the solution outperforms competitors, completing procedures within a single work shift compared to a full business day.
08
High-Pressure Mixer for Oil and CO2 Mixture Testing
In this project, we led the development of a high-pressure mixer designed to provide a continuous blend of oil and CO2 at high pressures and elevated temperatures.
The project covered a comprehensive range of tasks. This included conceptual design, extensive materials research to ensure compatibility with fluid conditions, structural calculations for all components, detailed GD&T and manufacturing processes, assembly coordination, engineering documentation, and commissioning procedures.
Carried out while working with SIMEROS
Over a span of 10 months, the project progressed from initial sketches to the deployment of the first operational machine for aging tests. The primary goal, mixing oil and CO2 under high pressure and circulating this mixture through samples, was successfully achieved.
Notable challenges included crafting a corrosion-resistant pressure vessel within a constrained budget and developing a robust rotating seal component to withstand the machine's demanding conditions. This project highlights our expertise in overcoming challenges and delivering efficient, tailored engineering solutions.
Carried out while working with SIMEROS
09
Pipe Lifting Clamp
In the quest for safer and more efficient pipe handling, we took on the challenge of developing a specialized clamp.
The primary goal was to lift flexible pipes axially, applying a maximum load of 10 tons without risking damage to the pipe structure. The project involved overseeing the entire development process, from initial concept drafting to the validation of the final product, extensively utilizing Finite Element Methods for optimal results.
Over a nimble 6-month period, the team showcased remarkable negotiation skills with suppliers and customers, navigating challenges imposed by the COVID-19 pandemic. The clamp not only met safety regulations but exceeded them, boasting safety factors during validation tests.
10
Mobile Freeze-Drying Innovation
In a bid to combat food waste at its source, we spearheaded a groundbreaking project to develop a mobile unit for freeze-drying fruits and vegetables that fell short of conventional visual standards.
As the Head of Department and project coordinator, we took charge of the entire process, from mechanical design to supplier negotiations and project management.
Despite challenges like raw material shortages and shipment delays induced by the COVID-19 pandemic, the team successfully adhered to the timeline, marking the launch of the world's first mobile freeze-drying trailer.
Carried out while working with TRENDI