23-35-1301 SPE4A8-23-Q-0031 AMENDMENT 0001 Fluid Cell Press.pdf

PDF 924 KB Posted Feb 12, 2024

Attached to: FLUID CELL PRESS
Solicitation number: SPE4A823Q0031
Issued by: Defense Logistics Agency Aviation

About this file

Written by GovTribe AI · Feb 12, 2024

This document is a purchase description for a sole source acquisition of a Quintus FlexForm press by the Defense Logistics Agency Aviation. It specifies requirements for the purchase, delivery, installation and acceptance of a Quintus FlexForm Press model QFM 1.1-800 including design, construction, components, controls, safety and health standards, noise levels, markings, technical data, installation, training and quality assurance. Key requirements include a press with maximum forming pressure of 11,600 psi, deep draw capability of 43.1 inch diameter and 10 inch depth, and ability to manufacture test parts for performance testing. The contractor must provide installation, foundation construction, utility connections, system charging and three days of training at the specified government facility by January 2024. Quality assurance will include origin and destination inspections and testing of alignment and accuracy, operations, performance and audible noise levels.

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VIBB 23-35-1301

12 JAN 2024

PURCHASE DESCRIPTION FOR THE SOLE SOURCE

ACQUISITION OF A QUINTUS FLEXFORM PRESS, QFM1.1-800

PRESS

1.0 SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for the purchase, delivery, installation and acceptance of a Quintus FlexForm Press model number:

QFM 1.1 – 800. The equipment shall be provided as a turn-key solution and shall be completed in accordance with the requirements defined in this document. The Quitus FlexForm Press shall fabricate all materials including, but not limited to, aluminum, steel, stainless steel and titanium. All materials and labor necessary to deliver and install the FlexForm Press shall be delivered to Tinker Air Force Base building 9001 post B24.

2.0 APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.1 Government Documents.

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

FED-STD-313F: Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

40 CFR Part 82: Protection of Stratospheric Ozone

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

2.1.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

ATTACHMENT A: Installation Layout

(Applications for these documents should be addressed to the contracting officer)

2.2 Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American Gear Manufacturers Association (AGMA)

AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA 22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

B11/STD B11: General Safety Requirements Common to ANSI B11 Machines

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components https://quicksearch.dla.mil/qsSearch.aspx

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

TECHAMERICA

TIA-232-F: Interface between Data Terminal Equipment and Data Circuit- Terminating Equipment Employing Serial Binary Data Interchange (1997 Ed.

2012R)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania Ave., NW, North Building Suite 600 Washington D.C. 20004-2650)

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

3.0 REQUIREMENTS.

3.1 Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the US Customary inch/pound system.

3.1.2 Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

3.1.3 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11. or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.4 Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.5 Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.1.5.1 PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide the same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

3.1.6 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.7 Lubrication. Means shall be provided to ensure proper lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements. Where applicable, when the machine is equipped with a recirculating lubrication system, it shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.8 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

3.2 Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.2.1 Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

3.2.2 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.3 Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.2.4 Gears. All gears of axis drive trains shall conform to or exceed all provisions of ANSI/AGMA ISO 1328-1-B14. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.2.5 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.7 Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

3.2.8 Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.3 Components. The machine shall consist of not less than the following components:

3.3.1 Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

3.3.2 Enclosure. The machine shall be housed within a self-contained encolosure. The enclosure shall provide for containment of any hazardous conditions for operator safety in the event of a mechanical failure or hydraulic leak. The enclosure shall be provided with a sliding door or doors and enable the operators and mechanics easy access to the machine.

The enclosure shall have a work light with an on/off switch. The enclosure shall be of an open top construction type.

3.3.3 Main Chamber. The main chamber shall be a stress relieved, weldment of high strength iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and loads.

3.3.4 FlexForm Unit. A cylinder shall be provided which meets the forming pressure requirements in accordance with paragraph 3.4 Table I. All the necessary inserts, press plate with oil channels, refill valves, and flanges serving as the press feet and foot plate shall be provided as needed per the manufacturer design.

3.3.4.1 Fluid Cell Diaphragm. The machine shall be equipped with diaphragm assembly.

The assembly shall include all diaphragms, spacers, seals, and equipment required for operation. The fluid cell diaphragm shall be made of nitril rubber. The diaphragm shall meet minimum requirements in paragraph 3.4 Table I.

3.3.4.2 Fluid Cell Diaphragm Kits. The press shall be provided with one spare kit supplied in a steel container for storage and a frame to aid in replacement of the wear layer. The kit shall contain all necessary diaphragms, spacers, seals, tools, and equipment for changing the fluid cell diaphragm. The contractor shall provide a video and visual aids for performing the replacement. The rubber diaphragm shall be repairable by cold or hot (vulcanize) method should it fail due to a sharp object piercing it.

3.3.5 Deep Draw Ram. The press shall be equipped with a deep draw ram. The ram shall meet all requirements stated in paragraph 3.4 Table I. The ram cylinder shall extend and retract in a vertical motion to provide the force for deep drawing end items.

3.3.6 Loading System. The press shall be equipped with two loading stations. The loading stations shall be complete with a part feeding working height and electrical driving mechanisms. The drive mechanisms shall not include hydraulic drive motors. The tracks on which the part trays move on shall be hardened. The tracks shall be of a type suitable for high grade precision numerically controlled machines covered by this purchase description.

The loading station shall have the same capacity as the forming surface area in paragraph

3.4 Table I. Rotating components of the drive mechanism shall be guarded such that they are not exposed to the operator during the cycle.

3.3.6.1 FlexForm Trays. The contractor shall provide one FlexForm feeding tray. The tray shall be wire-wound. The tray shall support and withstand the maximum capacity working loads. The feeding trays shall meet the minimum requirements in paragraph 3.4 Table I.

3.3.6.2 Deep Draw Trays. The contractor shall provide one deep draw tray. The tray shall support and withstand the maximum capacity working loads. The feeding tray shall meet minimum requirements in paragraph 3.4 Table I.

3.3.7 Forming Cycles. The equipment shall have at a minimum the following forming cycles.

3.3.7.1 FlexForm Forming Cycle. The press shall have a maximum cycle time of 69 seconds, excluding hold time, at maximum pressure. A cycle shall have at minimum the following steps:

a. Tray starts at Flexform load/unload station

b. Tray travels into main chamber

c. Low pressure pre-fill

d. High pressure forming

e. Hold programmed pressure

f. Decompression

g. Evacuation

h. Tray travels out to load/unload station

3.3.7.2 Deep Draw Forming Cycle. The press shall have a maximum cycle time of 138 seconds, excluding hold time, at maximum pressure. A cycle shall have the following steps:

a. Tray starts at load/unload station for Deep Draw

b. Tray is moved to the main chamber

c. Low pressure pre-fill

d. High pressure forming

e. Deep draw operation

f. Decompression

g. Evacuation

h. Tray travels out to the load/unload station

3.3.8 Data Access. The controllers shall be equipped with both Ethernet Interface (RJ45 port accessing on enclosure) and RS232C Serial Bus Interface or latest standard.

3.3.9 Controller Features. The machine controller shall consist of an Allen-Bradley programmable logic control (PLC) incorporating all standard features with programmable cycle parameters. The controllers/PLCs shall be based on Windows 10 operating system.

The machine shall be configured with 256 GB storage, maximum available RAM, USER memory, and the latest Windows 10 updates at the time of order. The machine shall include two (2) operator control terminals. One (1) terminal shall be located next to each of the loading stations. Each terminal shall meet the following minimum characteristics:

• 17” color display touch screen human machine interface o Emergency Stop o Illuminated Machine Start/Stop o Tray In/Out button o Tray selector switch o Full Alphanumeric QWERTY Keyboard

• Programmable automatic control of machine functions and operating modes

• Manual Data Input (MDI)

• Simultaneous control of all movements

• Part program edit

• Part program storage

• Control diagnostics

• Direct machine functions from part program data stored in memory

• Initiate a halt and an error signal in the event of a fault condition

3.3.9.1 Programming Parameters. The part program shall include at a minimum the following programmable parameters:

• Target pressure in increments of at most ten (10) psi

• Target pressure hold time

• Piston stroke length

3.3.10 Account Privileges. At a minimum, privileges shall be configured for user and administrative accounts. User accounts shall be able to perform all machine functions without use of Windows administrative privileges.

3.3.11 Anti-Virus Software. The controllers shall be compatible with McAfee ENS 10.7.X or later.

3.3.12 Universal Serial Bus (USB) Communications. All internal and external USB communications used on the equipment shall be clearly documented and described within the contractor provided technical data. All external USB ports that are accessible to the user shall be configured to use administrative access controls and capable of being physically disconnected or rendered inoperable by non-permanent means. Contractor shall provide, as an appendix to the technical data, detailed easy to read instructions for disabling USB ports.

3.3.13 Data Access Protocols. Each machine shall be furnished with an externally mounted, accessible Ethernet (RJ45 port) and Serial Bus (RS232C or latest standard) interface. Machine controllers shall be licensed enabled and capable of communicating using industry standard protocols to include, at a minimum, OPCUA with SQL database and MTConnect. The installed MTConnect adapter shall be version 1.3 or later. Specific data collection tags of interest acquired through OPCUA and MTConnect shall be discussed and determined within 30 working days following contract award. A complete list of all TCP-IP ports and protocols used by the machine for both internal and external communications shall be clearly described as an appendix to the technical data.

3.3.14 Discrete Input/Discrete Output (Di/Do) Information. The Contractor shall provide a complete Di/Do address and/or data tag table as an appendix to the machine technical data. The Di/Do table shall provide at a minimum the Di/Do signal address, tag name, signal or tag description, stored memory locations, and all applied conditioning value or functions.

3.3.15 Minimum Sensing Requirements. All sensors and sensor components shall be integrated into the machine control system. All discrete outputs for data collection purposes shall be conditioned to display meaningful values as defined below. All sensor data shall be made available as a discrete output for data collection purposes IAW Paragraph 3.3.13.

• Hydraulic pressures (psi)

• Hydraulic fluid level (%)

• Diaphragm pressure/vacuum (psi/mm Hg)

• Manifold pressure (psi)

• Motor temperatures (°F)

• Oil levels (%)

3.3.16 Safety Stops. All machine motions shall be provided with a means of over-travel protection to prevent damage to the machine’s power feed mechanisms.

3.3.17 Hydraulic System. Under the condition that a machine has a hydraulic system, the system shall conform to ISO 4413. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a hydraulic system to operate properly shall be considered acceptable.

3.3.18 Pneumatic System. Under the condition that a machine has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a pneumatic system to operate properly shall be considered acceptable.

3.3.19 Electrical System. The machine shall conform to NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

3.3.19.1 Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.19.2 Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

3.3.19.3 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.20 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Each motor shall have an identification plate in accordance with paragraph 3.7.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3.21 Reserved.

3.3.22 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.3.23 Hour Meter. The machine shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

3.4 Size and Capacity. The size and capacity of the machine shall be not less than specified in Table I.

Table I

Characteristic Capacity/Size FlexForm Tray Blank Diameter 38.1 inches

FlexForm Tray Depth 16.5 inches Filler Plate Thickness 1.97 inches

Press Forming Pressure 11,600 psi Deep Draw Tray…

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File details come from the government source that posted it. Updated Feb 12, 2024.