SPS - Welding Systems and Processes

• Context and evolution

  SPS – Sistemas e Processos para Soldagem emerged within a broad context, which has the global goal of enabling the identification of welding problems of Brazilian companies and providing them with the respective solutions, with national technology. As a philosophical, technological and scientific base of our company, the Welding Laboratory of the Federal University of Santa Catarina (LABSOLDA - UFSC) is present, in which SPS was incubated.

  Always in search of real innovations in the field of electric arc welding and its automation, LABSOLDA has adopted a particular modus operandi, different from other research laboratories. The identified need was complete flexibility in the systems (power sources and equipment for automation), enabling the manipulation of all parameters and welding variables, avoiding the limitations of commercial equipment. Only in this way would the potential for in-depth investigations, resulting in the generation of basic and innovative knowledge, be achieved. Therefore, the objective was to develop its own technology in welding sources, instrumentation and equipment for the mechanization of welding.

  The adopted strategy was based on the implementation of an adequate infrastructure and the formation of an interdisciplinary team, capable of identifying needs and executing the conception, design, construction, testing and evaluation of equipment related to electric arc welding. The areas represented on the team range from engineering (mechanical, electrical, materials) to physics, information technology and design. Within this range, technicians, undergraduates and postgraduates are inserted, who carry out their activities in an academic connotation, but also always with potential for practical applicability of the results.

  At this juncture, the company IMC –Soldagem emerged, a partner of SPS, a manufacturer of special energy sources and arc welding monitoring systems. Today, IMC has customers from small to large companies, with customary or special needs in welding. As a consequence of the characteristics of the equipment, the market also expanded to teaching and research institutions in welding.
  As a next step, action was taken to enable the placing on the market of mechanization equipment and other instruments for monitoring welding, which emerged as developments and continuity of academic work. In 2006, the new SPS – Welding Systems and Processes was consolidated, after a reformulation of its team. It has mechanical engineers, electricians and a physicist, prize holders and authors of several works in congresses and specialized magazines.

  The first products placed on the market were the Tartílope V2 and V2F (displacement device on two axes, flexible rail option, winner of two awards) whose development was linked to a master's work and the Orbital TIG Head, initially linked to a graduation work and placed in 3rd place in the then Petrobrás Pipeline Technology Award. This was followed by the new version of the Tartílope V1, the TIG Pen, the Orbital TIG Welding System (comprising interfaced welding head and source) and the Tartílope V4 / Orbital MIG Head, also connected to a master), with 4 degrees of freedom . The latter was developed within a cooperative project with TRACTEBEL ENERGIA, Jorge Lacerda thermoelectric generation plant, for the mechanized recovery of boiler tubes. In this project, the welding procedure for the special addition material was also developed. One of the newest developments is the Advanced Control System (SAC, linked to a master's degree), a computational tool for monitoring and controlling arc welding processes, with total flexibility in waveform design and process control methods.

  Today, in addition to providing customizable mechanization and monitoring systems, SPS also provides services for the development of welding procedures for special applications.

• Scientific-technological domain as a success enhancer

  In view of the fact that all the R&D in welding processes that were to be conducted in commercial equipment would already be outdated from the beginning, since one cannot experiment beyond the limits of the equipment nor change its characteristics, the SPS, in partnership with LABSOLDA and IMC, focuses on training in systems development (processes and equipment for automation) and instrumentation.

  This creates the possibility of daring beyond the limits of commercial machines, increasing the flexibility and potential for success of developments with a high innovative load. Through the effective alliance between theory and practice, the effective customization of technologies to the most diverse needs of each client company / institution is possible.

  In addition, mastering the scientific-technological base provides the possibility of continuity and constant evolution of research lines.

  The operation is interdisciplinary and highly specialized (doctors, masters, graduate students), with access to state-of-the-art welding technology (electronics, instrumentation, software, integrated welding systems). He is part of the personal team of electronics (power and control), software, mechanics, welding and design. This team receives or prospects customer problems, analyzes and conceptualizes possible solutions, carries out the necessary customizations / developments (design and construction), tests and improves the results.

• Technological innovation > productivity and competitiveness

  Welding is a vitally important manufacturing process for the productive sectors linked to the metal-mechanic industry, as the integrity of structures and equipment depends on it. Not only the construction, but also the assembly, repair and maintenance of these elements are carried out, on a large scale, by welding. Many of these activities require large equipment downtime and respective costs (such as thermoelectric plants or oil platforms) or represent a large percentage of manufacturing time, resulting in a large portion of total costs. Also, when it comes to emergency repairs, speed of execution becomes critical.

  The automation of welding procedures eliminates factors that make welding slower, such as welder fatigue, or stoppages due to the dimensions and/or geometry of the parts. In addition, automation ensures dynamic repeatability and weld quality. On the other hand, the welder becomes an operator, being able to move away from the electric arc, reducing his exposure to the unhealthy gases and spatter generated. The productivity of your work is increased.

  The SPS development team is inserted in an environment that represents the newest technologies related to welding. Thus, SPS's innovative and customizable equipment provides customers with flexibility in automating welding operations and the repeatability needed to increase productivity, significantly contributing to cost reduction and increased competitiveness in the market. Part of the SPS portfolio are systems for welding TIG Orbital, MIG Orbital, displacement devices for TIG and MIG (on fixed or flexible rails), device for automatic controlled wire feeding for TIG, instruments for measuring gas and wire consumption and advanced control software for welding processes (wave design). All equipment is customizable and interfaceable with compatible welding sources.

• Partnerships, a decisive differentiator

  In critical applications where high levels of quality and repeatability are required, often non-conventional welding processes are not readily enough. An effective interaction with the client is necessary, who presents his needs and the present conditions. Many of our final results, whether processes or equipment, are the result of collaborative work in which world-class scientific-technological knowledge is applied to the client's local reality. As an example, we mention the development of Tartílope V4, within a cooperative project with TRACTEBEL ENERGIA (ENGIE), within its institutional R&D program.

Awards

• Technological Innovation - FINEP 2012

  

  FINEP Innovation Award 2012

  SPS - Soluções para Soldagem Ltda was awarded 2nd place in the Micro and Small Company category of the FINEP Award of Innovation 2012 South Region, for his performance in applied research activities, his intense contact with academia and his Innovation Process. In this edition of the Award, the Micro and Small Company category from the South Region was the most competitive among all categories from all five regions, with 63 companies registered.

  The FINEP Award is the most important instrument for stimulating and recognizing innovation in the country. Since 1998, it has already awarded more than 500 companies, institutions and individuals, being responsible for projecting the recipients not only in Brazil but abroad.

  The winners of the 2012 FINEP Innovation Award from the South region were announced this Wednesday, 10/31, in Porto Alegre (RS), in a ceremony at the headquarters of the Federation of Industries of the State of Rio Grande do Sul (FIERGS). The event ended the 5th International Innovation Congress.

• Technological Innovation - FAPESC 2012

  

  FAPESC/Stemmer Innovation Award from Santa Catarina 2012

  SPS - Soluções para Soldagem Ltda was awarded 3rd place in the Innovative Micro/Small Company category Porte, for the development of the Robotic Manipulator Tartílope V2F, a low cost and high adaptability for automation of welding processes.

  The FAPESC/Stemmer Innovation Award from Santa Catarina aims to encourage researchers, companies and entities to innovate, with their important contribution to the development of the State of Santa Catarina. The award ceremony for the 3rd edition took place on December 12 in Florianópolis.

• Technological Innovation - FAPESC 2011

  

  Prof. Caspar Erich Stemmer 2011

  SPS - Soluções para Soldagem Ltda was awarded 3rd place in the Micro and Small Innovative Company category, for its development of a Robotic Manipulator for Welding Processes.

  The Stemmer Innovation Award aims to recognize the efforts of institutions, companies and people who have distinguished themselves with contributions in process innovations , goods and services carried out between 2008 and 2010, with a significant impact on the economy and social and environmental development of Santa Catarina. The ceremony for the 2nd edition of the award took place on June 22 in Florianópolis and was promoted by FAPESC.

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