Revised_Statement_of_Work.pdf

Revised Statement of Work

Robotic Arm for Concrete Additive Manufacturing

1 Background

Additive construction by extrusion (ACE) has the potential to revolutionize construction by eliminating the need to construct formwork and making possible architectural or structural designs that cannot be achieved by standard practices. The National Institute of

Standards and Technology’s (NIST) Additive Manufacturing with Cement-based

Materials project is focused on metrology of materials used in ACE applications. A robotic system capable of dispensing a cementitious material is required to study the measurement science challenges associated with ACE at the size scale approaching conventional concrete construction. The robotic system includes all hardware and software components required to dispense a cementitious material in a pattern specified by a user to create free-standing structures in a build volume of 8 m x 3 m x 3 m.

2 Objective

The contractor shall provide all hardware, software, installation and maintenance required for one robotic arm system (RAS) capable of covering a 8 m x 3 m x 3 m volume while dispensing a cementitious material. NIST will provide the hardware for mixing and pumping the cementitious material, the building where the RAS will be housed, as well as utility connections. After installation the RAS system shall be able to interface with

NIST supplied concrete batching, mixing, and pumping equipment to dispense a cementitious material along paths specified by a user at a user specified flow rate.

3 Specific Requirements

NIST is building a ACE robotic system capable of covering a 8 m x 3 m x 3 m volume.

This procurement covers all hardware, software, installation and maintenance required for a RAS that is able to dispense a cementitious material is a pattern specified by a user.

This procurement does not cover the hardware required to mix and pump the cementitious material.

3.1 Overview of ACE System

A ACE system must be able to place cementitious materials along paths specified by a user. A user shall be able to interface with the RAS through a software interface which allows the user to specify operation parameters such as, but not limited to, the path of travel and rates of travel. The RAS shall be compatible with commercially available and custom built end effectors designed to dispense cementitious materials as well as have the ability to control hardware for cement batching, mixing, and pumping. A schematic of the

ACE system is shown in Figure 1.

NIST Responsibility Contractor Responsibility

Figure 1: Schematic representation of ACE system in development at NIST.

Contractor is re- sponsible for the RAS and the Nozzle (Contract Option 1).

Photo Credit: W.R. Leal de Silva, Danish Technological Institute.

The contractor shall be responsible for providing the RAS which must interface with

NIST’s cementitious materials batching and pumping equipment. This procurement include an option to purchase a nozzle capable of dispensing concrete with aggregates larger than 4 mm. This option will be available for 3 years following with contract award date and is contingent on a demonstration by the contractor.

3.2 Robotic Arm System: Hardware Requirements

The RAS, upon delivery to NIST, shall meet the following requirements:

1. Maintain a speed between 30 mm/s to 500 mm/s.

2. Build volume of 8 m in length by 3 m in width by 3 m in height (vertical).

a. Build volume dimensions are the desired dimension in each direction. Preference will be given to proposals with a working volume whose dimensions are closest to the desired dimensions.

3. Payload capacity: ≥ 150 kg.

4. Minimum six axes of rotation

5. Voltage requirements: Compatible with US electrical supply 480 V, 60 Hz.

6. RAS environmental conditions:

a. Temperature: 5 oC to 35 oC

b. Relative humidity: Max 95 %

c. Air particulates: cement and sand

d. Water: Splashing from washing and cleaning

Contract Option 1:

Nozzle

Robotic Arm System

Supplied by Contractor

7. Path repeatability: ≤ 0.22 mm

8. Vendor supplied CAD models and industrial drawings for all components specified in proposal.

9. Interface with 3rd party cement and concrete batching, mixing and pumping equipment.

10. Data acquisition system. The RAS shall have a data acquisition system capable of recording the temperature of the environment, temperature of the materials, flow rates, and pumping pressures.

11. Build volume requirements

a. At ground level, the build area, or the area within which the RAS can reach, shall be rectangular with dimensions of 8 m x 3 m.

b. The maximum acceptable height above the ground level the robot shall reach is

2.8 m to 3.2 m. This height does not have to be maintained over the entire ground level build area.

12. The RAS system shall fit in a 9 m x 3.5 m x 4 m volume.

3.2.1 Optional Item: Nozzle to Dispense Concrete

Option 1 is to include hardware required to control the deposition of concrete with aggregate sizes ranging from 4 mm to 1.5 cm. The decision to exercise this option is at the sole discretion of NIST and will be contingent upon available funds. NIST may exercise this option no later six (6) months after the award date. The equipment required to dispense concrete shall meet the following requirements:

1. Dispense concrete formulated for ACE applications with aggregate sizes ranging from 4 mm to 1.5 cm.

2. Compatible with existing NIST hardware such as concrete batching and mixing equipment and concrete pumps.

3. Controlled deposition rate between 5 L/min and 60 L/min.

4. Width of extruded material should be a minimum of 2.5 cm up to 10 cm.

5. Capable of mixing two materials.

3.3 Robotic Arm System: Software Requirements

The RAS shall be controlled through software with a graphical user interface (GUI) running on a desktop computer (see specifications for computer requirements). The RAS shall be able to operate in two modes. One mode shall be continuous operation to create a geometry in a user-supplied CAD file and the second mode shall be manual operation where a user may supply the RAS with coordinates to which the nozzle will move. The user shall have control over the speed and volumetric flow rate exiting the nozzle through the software interface. The user shall have the ability to changes these values during RAS operation without interruption. The RAS control system shall meet the following requirements:

1. Programing with aid of CAD model. Software shall be able to utilize CAD models to assist in pro- gramming RAS paths.

a. Accept CAD file formats such as, but not limited to, .prt and .stl.

b. Automatically generate tool paths from CAD files.

c. Edit generated paths or create user defined paths.

i The user shall be able to specifiy volumetric flow rate of material exiting nozzle ii The user shall be able to specify points within build volume the robot shall move iii The user shall be able to control flow rate and speed of RAS movement on-the-fly

d. Provide debugging tools: Debugging tools include hardware and software debugging.

e. Interface with multiple robots and hardware, i.e., NIST’s concrete batching, mixing, and pumping equipment.

f. Run virtual jobs to test robot movement and determine interference.

g. View and log data such as, robot speed, power consumption, I/O signals, forces, displacements, etc.

h. Remote control. Control robot from a remote location using hand-held device.

2. Software must run on commercially available desktops meeting mimim requirements

a. Operating System: Windows 7 or 10.

b. CPU: 2.0 GHz, minimum 4 cores.

c. Graphics: DirectX 11 and Direct3D.

3. All IT related hardware and software must comply with the following:

a. DOC IT Security Program Policy ITSPP media sanitization requirements (MP-

6)

b. FAR 39.101(d) regulations involving NIST common security configuration checklists including Federal Desktop Core Configuration (FDCC) or United States

Government Configuration Baseline (USGCB) initiative

c. Personal identity verification requirements from FAR 4.1302 and FIPS PUB 201

[in accordance with Homeland Security Presidential Directive (HSPD-12)]

d. FARpart11.002requirementswhichstatethatunlesstheagencyChiefInformationOffice r waives the re- quirement, when acquiring information technology using Internet

Protocol, the requirements doc- uments must include reference to the appropriate technical capabilities defined in the USGv6 Profile (NIST Special Publication (SP)

500-267) and the corresponding declarations of confor- mance defined in the USGv6

Test Program. To meet this requirement each DOC acquisition of IP protocol technology must express requirements for IPv6 capabilities in terms of the USGv6

Profile (i.e., using the USGV6 Capabilities Check List) and vendors must be required to document their product’s support of the requested capabilities through the USGv6 test program (reference http://www.antd.nist.gov/usgv6/) using the USGv6 http://www.antd.nist.gov/usgv6/

Suppliers Declaration of Conformity.

3.4 Robotic Arm System: Safety Requirements

The RAS shall include all hardware and software necessary to operate safely and must include emergency stop buttons to halt movement without risk to operators or equipment.

Safety features shall include, at a minimum, the following:

1. Restrict robot speed, movement, and position.

2. Sensors to detect human presence.

3. Define safe operating zones and virtual barriers to limit movement.

4. Self checking of safety features to detect faults.

5. Collision detection

The contractor shall be responsible for the design and installation of all hardware and software components related to the safe operation of the RAS. NIST reserves final approval over all safety-related designs and components and may request additional safety measures as dictated by internal safety reviews.

4 Training

The contractor shall provide all documentation necessary to install and operate the RAS.

NIST reserves the option to request an on NIST site or in Maryland demonstration of the instrument capabilities. Training shall cover, at a minimum, start up and shut down of robotic arm; programming paths and material deposition; demonstration and verification of safety features; and routine maintenance procedures.

5 Government Responsibilities

NIST will be responsible for proving concrete batching, mixing, and pumping equipment;

space to house RAS; and required utilities, i.e, power, compressed air, and water.

6 Deliverables

The contractor shall be responsible for providing and installing one complete RAS as specified in this docu- ment. The complete RAS includes all hardware and software necessary to satisfy the specified requirements as well as training of users at NIST after installation is complete. Delivery shall be 4 - 6 weeks after receipt of award. Warranty coverage shall be provided for a minimum of 1 year from the date of inspection and acceptance. All documentations necessary to install and operate the unit shall be provided to NIST.

7 Evaluation and Selection Criteria

Potential candidates for purchase will be evaluated based on the requirements outlined in the

Statement of Work and the Solicitation.

8 Inspection and Acceptance Criteria

Upon arrival to NIST, the unit will be inspected for damage during shipment. The unit will be accepted after a demonstration of the RAS system to cover the specified build volume and execute a path programmed by a NIST user. The RAS shall also demonstrate the ability to interface with NIST’s cementitious materials pump, i.e., start and stop pump at desired times.