1. SOW Laser Bore.pdf

Statement of Work

Laser-Based Bore & Chamber Inspection System (LBIS-BC) for 105/120/155mm Cannons

1.0 SCOPE

This Statement of Work describes a set of portable Laser-Based Inspection System (LBIS-BC) for use on 105 millimeter (mm), 120mm and 155mm cannon tubes. This system will be capable of mapping the full length of the barrels, including the bore and chamber. The contractor shall ensure the system includes the following capabilities:

Precision bore cannon tube erosion profiling and laser-based measurement of rifled and smooth-bore gun tubes and chambers

High resolution imaging of the bore and chamber surface, measured simultaneously with the profile measurements

Material loss and erosion feature detection 3D digital modeling of the profile data

The LBIS System shall include the equipment as stated in Table 1.

Laser‐Based Bore & Chamber Inspection System (LBIS ‐ BC) Includes the following Equipment

Data Acquisition & Control Instrument (DAC) 1

Data Analysis Workstation with Analysis Modules 1

Items needed for each tube size 105m m

120m m

155m m

Laser profiling Scanner 1 1 1

Self‐propelled Sensor Delivery units 1 1 1

Muzzle guide Tube Adapter 1 1 1

TABLE 1

1.2 DOCUMENTATION

The contractor shall ensure the following documents are supplied with the LBIS-BC:

Two complete hard-copy sets of Operator’s Manuals Certification of Calibration for Calibration Rings Certification of Calibration for Laser Scanners

1.3 ENVIRONMENT

The contractor shall ensure the LBIS-BC systems shall be capable of operating in a shop or field environment with:

Ambient temperatures ranging from 10 to 45 degrees Celsius Relative humidity between 10 and 95% (non-condensing) Available power 100-240 VAC at 50-60 Hz

1.4 SYSTEM

The contractor shall ensure the LBIS-BC shall be a complete, turn-key system and shall include the following major components:

Data Acquisition and Control (DAC) unit Laser Profile Scanners (LPS) for 105mm, 120mm and 155mm gun tubes Self-propelled Scanner Delivery Units (SDU) Guide Tube Adapters (GTA) Certified Calibration Rings System Accessories / Spare Parts Data Analysis Station with analysis and reporting modules

1.5 Hardware and Accessories

The contractor shall ensure the LBIS-BC system includes the following components in detail from Table 1:

1.5.1 Data Acquisition and Control (DAC) Instrument

1 ea. Data Acquisition and Control (DAC) Instrument with hard-sided shipping case

1.5.2 Data Analysis Workstation with Analysis Modules

1 ea. Data Analysis Workstation with analysis modules and hard sided shipping case

1.5.3 105mm Kit

1 ea. 105mm Laser Profile Scanner 1 ea. 105mm Sensor Delivery unit 1 ea. 35-ft. long shielded umbilical cable 1 ea. 105mm GTA (M119) 1 ea. 5-step Calibration Ring 1 ea. Configuration Setup File 2 ea. Hard-sided shipping cases 1 ea. Operating Manual Addendum, Self-Propelled 105mm

1.5.4 120mm Kit

1 ea. 120mm Laser Profile Scanner 1 ea. 120mm Sensor Delivery unit 1 ea. 35-ft. long shielded umbilical cable 1 ea. 120mm GTA (M256) 1 ea. 5-step Calibration Ring 1 ea. Configuration Setup File

1 ea. Operating Manual Addendum, Self-Propelled 120mm

1.5.5 155mm Kit

1 ea. 155mm Laser Profile Scanner 1 ea. 155mm Sensor Delivery unit 1 ea. 35-ft. long shielded umbilical cable 1 ea. 155mm GTA (M284 / M776), for use with muzzle break removed 1 ea. 5-step Calibration Ring 1 ea. Configuration Setup File

1 ea. Operating Manual Addendum, Self-Propelled 155mm

1.6 COMPONENT DIGITAL SYSTEM COMPONENT IDENTIFICATION HARDCODE

Digital System Component Identification shall be installed in the following components:

The data acquisition and control instrument (DAC) All sensor modules All rotary scanning assemblies All Scanner Delivery Units (SDU)

Sensor and Calibration Ring calibration parameters to be stored in the Digital System Component Identification Code and to be read by the software.

The Digital System Identification code for all system components shall be stored with each data set.

2.0 DATA ACQUISTION AND CONTROL INSTRUMENT (DAC)

The contractor shall provide one DAC. The contractor shall ensure that this device is a dual channel data acquisition and control instrument with integrated internal motor control unit and laser system control functionality installed. The DAC shall meet the following specifications.

2.1 DATA ACQUISITION AND CONTROL UNIT (DAC) HARDWARE SPECIFICATIONS

Maximum Dimensions: 19” W x 11.5” H x 9.5” L Maximum Weight: 30 lbs.

Operating System: Windows 10 Minimum Processor: Intel Core i5 Hex Core; 2.8 GHz base clock speed, 4.0 GHz max boost speed Minimum RAM: 16GB DDR4 RAM; 2666 MHz Minimum Display: 15.6” Dia. 1920x1080 pixels 16:9 aspect ratio Military Grade Linear Motor and Scanner Cable connections External HDMI port Cat5e Ethernet port USB 3.0 ports (4) Wireless keyboard and mouse Automatic monitor brightness adjustment up to 1000 nits for outdoor daylight conditions Software Registration: Soft Key type Hard Sided Shipping Case

2.2 DAC FUNCTIONAL CONTROL

2.2.1 Automatic Sensor Calibration

LBIS-BC control unit shall be capable of conducting an automatic calibration routine.

Calibration function provides a Pass/Fail display of calibration test results.

If the calibration fails, the control unit shall automatically calculate corrected calibration parameters.

Calibration function shall allow the operator to manually adjust offset and slope of the calibration algorithm if required.

2.2.2 Data Acquisition

Data acquisition scan parameters shall be operator configurable.

Data acquisition workspaces shall be storable as unique files.

Scan parameter dialog window shall estimate the file size, data rate, and approximate scan time.

2.2.3 Data Display and Analysis

The contractor shall provide data analysis function which provides:

Multiple, operator-adjustable color palette application to any Color Plot display, with rainbow, thermal greyscale, and solid color palettes

Cross-sectional and axial display of surface profile data Analysis filter for post processing of data, including but not limited to: scanner tilt removal, rotate data, remove undefined data, remove bad data, variable 2D median and averaging filters, remove centering offset, and calculation of area statistics

Zoom and pan display functions

2.2.4 Motion Control

The contractor shall provide motion control function which includes:

DC servo motor control for up to two (2) axis of motion Operator-configurable scan routines for helical, step/increment Variable scan control with axial scan resolution to as low as 0.25 mm (0.010 inch) per increment Variable scan control with rotary scan resolution to as low as 0.05 mm (0.002 inch) per sample Operator-activated Forward, Reverse, Go-To, Return-to-Home Encoder position display for each axis Encoder “Set-to” and Zero functions Sensor tilt removal function

The contractor shall provide LBIS-BC scanners which are capable of monitoring and storing any tilt of the SDU and scanner module to better than one (1) degree. Analysis function shall be capable of removing tilt from data and presenting results in undistorted format over the length of the gun tube.

3.0 DATA ANALYSIS WORKSTATION WITH ANALYSIS MODULES

The contractor shall provide the Data Analysis Workstation which has Advanced Analysis modules pre-installed. Analysis and Reporting modules shall be commercial, standard product employing a Microsoft Windows-10.0 based platform with Microsoft Office professional provided. Analysis and reporting modules shall be compatible with other inspection systems deployed at Benet Laboratories, Aberdeen Test Center and Yuma Army Proving Grounds; and shall include, as a minimum, the following functions:

Basic Data Analysis Package 3D Analysis Package Bore Reporting and Automatic Feature Detection for Smooth Bores Bore Reporting and Automatic Feature Detection for Rifled Bores

3.1 DATA ANALYSIS WORKSTATION

The contractor shall provide The LBIS-BC which has a commercial-grade high-performance data station, which will employ a Microsoft Windows10-based platform. The following minimum specifications shall be met:

Processor: Intel Core i7, 9th generation or higher, 4 GHz clock Minimum LCD screen resolution: 1920 x 1080 Operating System: Windows 10 Professional Memory: 32 GB, DDR4-2666MHZ Hard Drive: 512GB SSD

LAN WG1219V GBE

USB Ports: 3.2 x 3 Microsoft Office Professional

3.2 BASIC DATA ANALYSIS PACKAGE

The contractor shall provide the Analysis Package which includes, at a minimum:

Multiple, operator-adjustable color palette application to any Color Plot display, with rainbow, thermal greyscale, and solid color palettes Cross-sectional and axial display of surface profile data

Analysis filters for post processing of data, including but not limited to scanner twist removal, rotate data, remove undefined data, remove bad data, variable 2D median and averaging filters, remove centering offset, reference subtraction, and calculation of area statistics

Zoom, pan display functions Local land/groove diameter measurement for rifled barrels Processed data file, text file, and STL image export Laser-generated images of data displaying fine scratches, heat-checking, erosion, and discoloration

3.3 3D ANALYSIS PACKAGE

The contractor shall provide the 3D analysis package which includes, at a minimum:

2D and 3D renderings of data from both smooth-bore and rifled bore gun tubes Zoom, tilt, pan functions Adjustable lighting, shading and reflections Local feature measurement Display in flat or cylindrical perspective Real-time data rotation about axis Video clip capture of rotating part Multiple color palette display options

3.4 BORE REPORTING AND AUTOMATIC FEATURE DETECTION FOR SMOOTH BORES

The contractor shall provide this report module which includes, at a minimum:

Tabular and graphical reporting of radii, diameters, and ovality User-programmable setup files specifying the axial and circumferential measurement frequency Ability to set pass/fail criteria for key report parameters Locate and size features in smooth bore data files with user-setable feature size parameters Organize features by depth, area, or volume Outline and label identified features on profile data view Calculation of local and total amount of material loss in bore Provide maximum size of erosion in the regions (zones) and total material loss in each zone of tube bore and cannon interior bore surface.

Graphical summary of the maximum material loss on cannon interior tube surface and format in

EXCEL report Printable hard-copy summary report Data shall be exportable as excel file for further analysis

3.5 BORE REPORTING AND AUTOMATIC FEATURE DETECTION FOR RIFLED BORES

The contractor shall provide this report module which includes, at a minimum:

Tabular and graphical reporting of land/groove radii/diameters, land/groove width, and bore runout Tabular and graphical reporting of rifling twist, including cumulative twist, surface angle, twist rate, and exit angle User-programmable setup files specifying axial measurement frequency and nominal barrel parameters Ability to set pass/fail criteria for key report parameters Locate and size features in smooth bore data files with user-setable feature size parameters Organize features by depth, area, or volume Outline and label identified features on profile data view Calculation of local and total amount of material loss in bore Provide maximum size of erosion in the regions (zones) and total material loss in each zone of tube bore and cannon interior bore surface.

Graphical summary of the maximum material loss on cannon interior tube surface and format in

EXCEL report Printable hard-copy summary report

Data shall be exportable as excel file for further analysis

4.0 Delivery and Training

4.1 Delivery schedule shall be no more than 120 days from acceptance contract.

4.2 Manufacturer shall coordinate the timing of on-site training with Client, which is expected to be less than 30 days after delivery. Manufacturer shall provide no less than 4 days of on-site training, covering the following topics:

System overview Laser safety System set-up Calibration verification Basic operation Data acquisition Data storage Data analysis and reporting Periodic and preventive maintenance and trouble-shooting

5.0 Quality Assurance and Warranty Provisions

The contractor shall provide the preservation and packaging. Packaging shall be in accordance with the manufacturer’s commercial practice Manufacturer shall warrant all components for one year from data of acceptance.

6.0 LBIS-BC Laser Profiling Scanners (LPS)

The contractor shall provide the LBIS-BC Laser Profiling Scanners which are supported by the Data Acquisition and Control Unit (DAC) described above.

6.1 LBIS-BC 120MM LPS

The contractor shall provide the LBIS-BC 120mm LPS which is self-centering and provided with rollers-wheels or equivalent, which will not damage the cannon gun tube bore or chamber surface. The LPS shall be capable of operating in both the bore and chamber areas of the gun tube. The LPS shall be detachable and designed for ease of storage and maintenance. The LPS shall include a replaceable laser profile sensor that meets or exceeds the specifications listed below.

The LPS shall meet or exceed the following specifications:

Sensor Measurement Resolution: 0.01 mm (0.0004 inch) Sensor Linearity: 0.013 mm (0.0005 inch) bore; 0.025 mm (0.001 inch) chamber Senor Accuracy (typical): ±0.025mm (0.001 inch) bore; ±0.050mm (0.001 inch) chamber Measuring Range (diameter): 119.5mm to 162mm (4.705 inch to 6.280 inch) Laser Spot Size (max): 0.05 mm (0.002 inch) Laser Power: 5 mW max @ 650 nm Laser Power Classification: Class 3R (scanner inside and outside of component) Angular Sampling Resolution: Variable – up to 0.05 degrees per sample (7,200 samples per revolution) Linear Sampling Resolution: Variable – up to 0.063 mm (0.0025 inch) per sample Scanner/SDU rotational tilt measurement ±80 degrees, with a resolution < 0.5 degrees

6.2 LBIS-BC 155MM LPS

The contractor shall provide the LBIS-BC 155mm LPS which is self-centering and provided with rollers-wheels or equivalent, which will not damage the cannon gun tube bore or chamber surface. The LPS shall be capable of operating in both the bore and chamber areas of the gun tube. The LPS shall be detachable and designed for ease of storage and maintenance. The LPS shall include a replaceable laser profile sensor that meets or exceeds the specifications listed below.

The LPS shall meet or exceed the following specifications:

Sensor Measurement Resolution: 0.01 mm (0.0004 inch) Sensor Linearity: 0.013 mm (0.0005 inch) bore; 0.025 mm (0.001 inch) chamber Senor Accuracy (typical): ±0.025mm (0.001 inch) bore; ±0.050mm (0.001 inch) chamber Measuring Range (diameter): 154.5mm to 170.5mm (6.083 inch to 6.713 inch) Laser Spot Size (max): 0.05 mm (0.002 inch) Laser Power: 5 mW max @ 650 nm Laser Power Classification: Class 3R (scanner inside and outside of component) Angular Sampling Resolution: Variable – up to 0.05 degrees per sample (7,200 samples per revolution)

6.3 LBIS‐BC 105mm LPS

The contractor shall provide the LBIS-BC 105mm LPS which is self-centering and provided with rollers-wheels or equivalent, which will not damage the cannon gun tube bore or chamber surface. The LPS shall be capable of operating in both the bore and chamber areas of the gun tube. The LPS shall be detachable and designed for ease of storage and maintenance. The LPS shall include a replaceable laser profile sensor that meets or exceeds the specifications listed below.

The LPS shall meet or exceed the following specifications:

Sensor Radial Measurement Resolution: 0.01 mm (0.0004 inch) Sensor Linearity: 0.013 mm (0.0005 inch) bore; 0.025 mm (0.001 inch) chamber Senor Accuracy (typical): ±0.025mm (0.001 inch) bore; ±0.050mm (0.001 inch) chamber Measuring Range (diameter): 104.5mm to 136.5mm (4.114 inch to 5.374 inch) Laser Spot Size (max): 0.05 mm (0.002 inch) Laser Power: 5 mW max @ 650 nm Laser Power Classification: Class 3R (scanner inside and outside of component) Angular Sampling Resolution: Variable – up to 0.05 degrees per sample (7,200 samples per revolution)

7.0 SELF-PROPELLED SENSOR DELIVERY UNITS (SDU)

The contractor shall provide the Self-Propelled Sensor Delivery Units (SDU) which shall be a tractor mechanism, capable of pushing or pulling the LPS over an axial distance of no less than 9.144 meters (30 feet).

7.1 LBIS-BC 105MM/120MM SENSOR DELIVERY UNIT (SDU)

The contractor shall provide the 105mm/120mm SDU which is capable of driving the LPS over the full length of the 120mm mm bore and chamber. It shall be capable of interfacing with the either the 105mm or the 120 LPS. It shall include a high-resolution axial encoder. The SDU shall be provided with a flexible cable that includes a non-scratch protective cover.

The SDU shall meet or exceed the following specifications:

Axial encoder resolution: 0.25mm (0.010 inch) or better Unidirectional motion repeatability (typical): 5mm (0.20 inch) over a distance of 3,990mm (20 ft.)

The SDU shall be provided with a flexible cable that includes a non-scratch protective cover.

7.2 LBIS-BC 155MM SENSOR DELIVERY UNIT (SDU)

The contractor shall provide the 155mm SDU which is capable of driving the LPS over the full length of the 155mm bore and chamber. It shall include a high-resolution axial encoder. The SDU shall be provided with a flexible cable that includes a non-scratch protective cover.

The SDU shall meet or exceed the following specifications:

Axial encoder resolution: 0.25mm (0.010 inch) or better Unidirectional motion repeatability (typical): 5mm (0.20 inch) over a distance of 3,990mm (20 ft.)

The SDU shall be provided with a flexible cable that includes a non-scratch protective cover.

8.0 Muzzle Guide Tube Adapter (GTA) and Calibration Hardware

The contractor shall provide the LBIS-BC which will be provided with muzzle Guide Tube Adapters (GTA) and calibration ring gages for each barrel size. Each GTA shall attached to the muzzle of the specified barrel model and allow scanning to the end of the bore at the muzzle. The GTA shall include a precision five (5) step calibration ring gage to cover the full measurement range of the bore and chamber of each gun tube size. The Calibration Ring gage shall not include circumferential machining marks or honing “cross-hatch” marks, and shall be provided with NIST-traceable certifications with resolution of 0.0025mm (0.0001 inch). The Calibration Ring gage shall be removeable from the GTA to allow for re-certification, as well as scanning of the barrel without scanner contact of the ring surfaces.

9.0 SCOPE CHANGES

The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.