1.03 Statement of Work.pdf

STATEMENT OF WORK: MTS Controller Update

From: Peter Joyce Date: 01/25/2023

A controller update for the TESTRESOURCES portable 3,000 lb hydraulic test machine in Ri025G is needed by the School of Engineering & Weapons. The TESTRESOURCES hydraulic test machine is managed by the Mechanics, Materials, and Structures functional lab group within the School of Engineering & Weapons. The test machine gets regular use from faculty and midshipmen primarily within the Mechanical & Nuclear Engineering Department at USNA. The controller update is needed to modernize the test machine. The updated controller will ensure stable operation of the machinery as well as providing a modern control, and data acquisition interface for the end user.

Specifically, the provided controller update should possess the following components and characteristics all integrated into a single working system (all satisfied by the quote from TEST RESOURCES see Sole Source Justification):

The required device is an update to the control hardware and software for a portable 3,000 lb hydraulic test machine in the School of Engineering & Weapons. The controller must be compatible in every aspect with the existing TESTRESOURCES test machine. The controller is comprised of new hardware (1) the controller, and (2) a new desktop PC (Win10) that runs (3) updated control and data acquisition software.

(1) NEWTON Fatigue Materials & Products Testing Package

General Fatigue and Materials Testing Software

* Test Manager and Operator user privileges included

* Simple User Interface Test Panels

* Control Modes: Closed Loop Control of Position, Load, Stress, and Strain

* Configure and save an unlimited number of customizable test profiles

* Function Generator for Ramp, Sine, Pulse, and Triangular waveforms

* Peak Amplitude Adaptive Control Algorithm

* Real time display of live feedback channels, command output, and cycle count

* Real time graphing of any combination of data sets

* 5000 Hz data acquisition rate

Signal Conditioning Channels or Hardware Configuration

* Position (encoder based)

* Load (strain based)

* Strain (strain based)

* 2 High Level Input (+/- 10V)

* 1 Digital Input/Output

- Digital input can be used to terminate test/segment or pause test

- Digital output can switch TTL level low or high or pulse during a segment

- Or remotely trigger Start/Stop of test

Data Analysis Reporting includes real time display of measurements and data plots

* Test Report Generator - automatically creates test reports that include data, calculations and graphs, reports are customizable with logos, calculations, comments, etc.

* Offline analysis allows new analysis, graphing and calculations of previous data sets

* Calculates following values and makes available for display and reports:

- Yield strength, Modulus of elasticity

- Max load, Load at break, Average load, Max stress, Max load/stress

- Elongation, Displacement at break

- Load at displacement, Displacement at load

- Custom calculations available upon request

* Data Export to text file formats TestCreator: Multi Segment Test Method Generator

* Create custom test control sequences (profiles) with a simple, user friendly interface.

* Complex cyclic test sequences are readily created with waveform building steps

* Test method is graphically displayed as you create it

* Allows you to simulate just about any product or component in-use loading sequence

Hardware Controls and Electronics

* 24 bit resolution on Load / Strain channels

* Automatic recognition of load cells and extensometers

* 16 bit Servo/Daq Output

* P-I-D servotuning controls actuator speed and loading rate

- Independent Feedback Channel parameters

* Pendant with Jog UP/DOWN and Emergency Stop Newton Signal Conditioner for Stroke Channel

* Additional LVDT Based Signal Conditioner

TestCalc: Real-time and Post Test Advanced Data Analysis Calculator

* Powerful data analysis software module for Newton

* Create any sort of simple or complex formulas, including logs and sines

* Apply formulas to data in real-time to create a new data stream for plotting or visual meter

* Apply to previously acquired data reanalyze test results

* Apply to former calculation results and specimen parameters to create new and custom calculations

* Many calculated results can be used in real time to affect subsequent test segments based on previous test segment calculations.

* These custom calculations can be included in test reports

Calibration of Position

* NIST Traceable Calibration Per ASTM E2309 up to Class B

* Calibration Standards fee included

* Cost is per Sensor

Calibration of Load Cell - 5kN - 100kN Force Capacity

* For load cells ranging from 5kN - 100kN (1,125 lbs. to 22,500 lbs.) Force Capacity

* NIST Traceable Calibration Per ASTM E4 or Better

* Calibration Standards fee included

* Cost is per load cell

Calibration of Extensometer

* NIST Traceable Calibration Per ASTM E83 Up to B1 Classification

* Calibration Standards fee included

* Cost is per Extensometer

(2) TESTRESOURCES Computer; WIIN10, 8GB RAM (minimum), 250 GB HD (minimum), Desktop

* Processor (3.0 GHz min)

* Integrated Video card

* Includes 2 Ethernet ports - PC to Newton & PC to network

* Keyboard & Mouse

* Installation, startup, setup and checkout service included

* 22” Monitor PC specifications change on a regular basis. The above represents the minimum supplied configuration.

(3) NEWTON FATIGUE MATERIALS & PRODUCTS TESTING PACKAGE

Software Features

● Displays a visual representation of the test methods as the test engineer creates and saves test methods

● Real time visual representation of sensors in a graphical and numerical form.

● User calibration of sensors - no need to use outside support

● Automatic calibration recognition of load cell transducers

● Two levels of user security with discrete supervisor and operator modes

● English and SI units for all test profiles

● User configurable screen content for simplified operator displays

Test Control and Data Acquisition

● Constant amplitude control of load, position and strain

● Define test method, control machine, and collect data for reporting

● Creates and stores unlimited number of custom test methods

● Ramp, sine, square and triangular waveforms

● Manual operation with function generator and jog controls

● High speed closed loop servo control with live PID tuning

● Peak amplitude adaptive control

● Segment by segment adjustable data acquisition rates to capture only necessary data

● Collect timed or peak and valley data

Data Display

● Real time display of multiple measurement data meters such as position, load, cycle count, set point plus any additional available sensors or measurements

● Real time display of user defined data plots such as load v position and stress v strain

● Second scope pop-up window, and meters if desired

● Simplified operation - Only displays what operator wants to see

Test Reports and Analysis

● Reports can be automatically displayed and saved, if desired

● Post test analysis allows for different or new calculations and data plots

● Export data to ASCII format for further analysis and record keeping

● Customizable test reports - Add logo, make comments, add title, specify calculations and data plots as desired

● Distinguish outliers of S-N curves

● Test reports include:

○ Specimen ID, User Comments

○ Measured and Calculated results

○ Graphical Plots

○ Total cycles

○ Load v position, load v time, position v time if desired

TestCalc Advanced feature that expands the calculation features Add New Calculations: Create new single point calculations, calculations based on other calculated results, derived data streams, custom formula calculations.

Edit Calculations: Rename existing calculations to conform to your preferred terminology and modify any calculation’s functionality.

Copy Existing Calculations: Duplicate existing calculations to obtain similar results at multiple instances during the test.

TestCreator

• TestCreator enables users to easily replicate loading profiles that mimic the product and device service conditions.

TestCreator makes it possible to automate test sequences easily. All Newton test packages include single or dual ramp test methods. The TestCreator expands a users flexibility to automate tests involving a sequence of up to independent steps. These steps or sets of steps can be included in a loop for any number of cycles. This software module can be added to any Newton software package.

• Users can then develop step by step loading patterns to mimic functional use or service simulations.

Designed to add simplicity to tests that require step-by-step loading patterns that fall outside of a standard single or two-segment test. Sophisticated cyclic test sequences can be created by using any combination of TestCreator’s waveform segment building block steps including triangle waves, ramps, and dwells. The Newton Fatigue controller applications add sinusoidal segments to the mix.

• Utilize looping of test sequence logic into simple or complex cyclic profiles. A key feature is that data acquisition settings can be set for each segment. For instance, a stress relaxation test of a biological tissue commonly is configured with a fast first cycle and then a dwell period that can last 5 decades of time. With Newton, you can capture lots of data on that first segment and then gather data slowly over the relaxation phase.

• Each segment can be set to control and respond to the same or different transducers (load, position and strain) and external devices including chamber thermal cycling profiles and other digital sensors. Additionally, all available digital input and output channels can be programmed by segment as well.

In conclusion, the requested system represents the minimum requirements of the government.