Statement of Work-StructuresAndMaterials LabTest Equipment Purchase.pdf

Statement of Work

STRUCTURES AND MATERIALS LAB TEST EQUIPMENT PURCHASE

1. SUMMARY:

The new Structures and Materials Laboratory (SML), located at the Federal Aviation Administration (FAA) William J. Hughes Technical Center, was officially opened in December 2016 as a new home for advanced material and structural test capabilities. The intent for the lab, once fully operational, is to house multiple uniaxial test frames and space to conduct 1-3 full-scale aircraft structural component tests simultaneously on an integrated system. The identified equipment, as detailed below in this statement of work (SOW), will provide for a fully functioning aerospace structural research and development (R&D) facility. This capability will allow the FAA Technical Center to execute research programs in support of FAA AVS with their core mission functions of aircraft certification, continued airworthiness, rulemaking, policy and guidance development and training.

2. BACKGROUND:

The SML was specifically designed to handle the unique demands of full-scale aerospace R&D. A key design feature of the new lab space is the “strong floor” which is a reinforced concrete floor built with a grid of threaded anchors. Each anchor is capable of handling 40,000 lbs of force. This feature allows test engineers to design full-scale structural tests capable of subjecting both real and simulated aircraft parts to loading conditions typically seen in service. Additionally the SML also provides a footprint for multiple material load frames, themselves capable of 55,000 lbs of force each. The test frames are used to run material characterization type tests on industry standard specimens and also small scale fatigue tests on simple or built-up coupons. Due to the smaller scale of the tests run on the load frames, more tests can be done in less time and for less money compared to full-scale. As such, work from the test frames can serve as the building blocks for the full-scale test or be used for stand-alone programs as well.

3. OBJECTIVE:

The objective of this work is to outfit the new SML with the equipment needed to create an integrated system of test capabilities ranging from small coupons up to full-scale aircraft structural components. The output would be a fully integrated hydraulic test system with uniform control hardware/software and enough capacity to support simultaneous testing from multiple stations. The system must also be easily expandable and adaptable to accommodate future needs as more test programs come on-line.

4. SCOPE AND SYSTEM REQUIREMENTS:

The proposed system will consist of five major equipment types: hydraulic pressure unit (HPU); hydraulic service manifold (HSM); digital controllers; software packages to run both load frames and full scale test apparatus; and a uniaxial load frame. The contractor shall provide complete engineering services to design, install and commission an integrated system for all of the major equipment types as well as integrating existing MTS test equipment. The new system must be easily expandable and adaptable to accommodate future fixture modifications and added test capability. The control software must be user-friendly and have an architecture that allows for in-house changes to the control and data collection of all test activities. The awarded company must have a proven track-record of operation over many years and local product support with experience serving the aerospace industry. Brief descriptions and minimum requirements for each equipment type are listed below. In addition, the system shall include all cables and hoses necessary for installation and commissioning.

Hydraulic Power Unit (HPU):

The HPU provides the hydraulic pressure needed to create the high loads mentioned in the background section above. It also provides the flow rate required to operate multiple test stations in cyclic fatigue mode simultaneously. The unit should be modular in design using multiple pumps/motors to provide redundancy and allow easy expansion of flow rate capacity with the installation of an additional module. It should also come equipped with internal controls to regulate pump/motor usage evenly based on system demand.

The HPU must come equipped with a water cooling heat exchanger, 1 gallon accumulator and produce no more than 68 dB(A) of noise. The minimum HPU requirements are listed in Table 1 below.

Table 1: HPU Minimum Requirements System Pressure 3,000 psi System Flow Rate 60 gpm Expandability to 90 gpm Accumulator 1 Gallon Noise level 68 dB(A) Cooling Method Water

Hydraulic Service Manifold (HSM):

The HSM is used to control the flow of hydraulic fluid to the various full-scale structural tests. It allows test engineers to independently control which tests are active at any given time and acts as a safety shutoff based on operator set sensor limits. The HSM must be able to operate under the expanded flow requirement (90 gpm total) of the HPU listed above and be equipped with separate pressure, return and pilot accumulators. It must be supplied with a minimum of 2 stations and be expandable to accommodate more stations as needed. Each station must be able to handle a minimum of 50 gpm. The minimum HSM requirements are listed in Table 2 below.

Table 2: HSM Minimum Requirements Stations 2 Expandability to 4 Stations HSM Flow Rate 100 gpm Station Flow Rate 50 gpm

Pressure Accumulator 1 Gallon Return Accumulator 0.5 Gallon Pilot Accumulator 0.12 Gallon

Digital Controllers:

The digital controllers (referred to as controllers from here on) are the central hubs of the integrated system. A total of two are required, one for the material test area and one for the full-scale structural tests. Each controller serves as the physical connection between the test hardware (HPU, HSM, load frames, etc.) and test software (detailed below) used by the operator. The controllers house the electronics needed to process signals sent to and from the test hardware and covert it to a form that is usable by the test software. In general each controller must meet the following guidelines:

• Fully digital configuration with real-time closed-loop control

• Coordinated control of HPU to allow automated first-on last-off for system hydraulic pressure

• Real-time control mode switch while a test is active and hydraulic pressure is being supplied

• Real-time calculations from signal inputs used to control a test

• Modular design to allow addition of functionality as needed in the field

• Digitally managed station configuration allowing shared resources between test stations without needing to move hardware

• Dedicated control PC with preinstalled software

• Internal processor

• RJ50-style connections

The requirements for each controller are broken out below.

Material Test Area Controller:

This controller will serve the new (detailed below) and existing MTS uniaxial load frames. The minimum requirements are listed in Table 3 below. The controller must be furnished with a PC station that comes with the test software (detailed below) and is capable of controlling all load frames simultaneously. This includes interfacing and controlling the existing MTS 810 uniaxial load frames, MTS extensometers, strain gage conditioner, and Fracture Technology Associates (FTA) hardware.

Table 3: Material Test Area Controller Requirements Parameter Quantity

HPU Interface 1 HSM Interface 4 Independent Control Signal Output 4 Conditioned Signal Input 10 Analog Signal Input 8 Analog Signal Output 8

UART/Encoder 2 Handset Control 2

Full-Scale Structural Test Area Controller:

This controller will serve the full-scale structural test area. The minimum requirements are listed in Table 4 below. The controller must be furnished with a master PC and client PC preinstalled with control software. The controller must be able to operate existing actuators with dual bridge load and stroke control capability. An option must be provided for a system which is expandable to at least 16 control channels.

Table 4: Structural Test Area Controller Requirements Parameter Quantity

HPU Interface 1 HSM Interface 4 Control Signal Output 8 Control Signal Expandability to 16 Conditioned Signal Input 24 Analog Signal Input 8 Analog Signal Output 16

Test Software The test software provides the graphical user interface where system resources are allocated, tests are designed, controlled and monitored, and data is recorded. The software packages must come with first on/last off control of the HPU to ensure actions at one test station do not affect the hydraulic pressure at subsequent stations running at the same time. Software should be stable and robust. Each package must integrate all components of its respective system seamlessly. The minimum requirements for the control packages are as follows.

• Simultaneous operation of multiple test stations and/or multiple actuators within a station

• Seamless transition of control source (e.g. stroke to load) mid-test

• Graphical drag-and-drop test flow design

• Test template creation with interactive guidance and error notifications

• User-configurable runtime view to display desired data while tests are running

• Data acquisition (timed, peak/valley, level crossing, cyclic/logarithmic)

• Function generation up to 100 Hz on all channels

• Sine, square, triangle, ramp, hold, profile and custom waveform activities

• Parallel branches for test execution and logical operators (if/then, while)

• Limit sensing, sequencing triggers and interface to digital I/O

• Data export to ASCII

• Report generation while test is running

• Real-time, user-definable calculations using signal inputs that can be used for control

• Aerospace industry test standard compliant templates

• Test template validation using virtual specimen

Uniaxial Load Frame:

The uniaxial load frame is capable of performing static and complex cyclic fatigue tests on standardized specimens and small built-up components. It must be equipped with an accumulator, servo valve and HSM (separate from the one detailed above and dedicated to the frame) capable of handling 10 GPM of hydraulic fluid from the HPU detailed above. The actuator and frame must be built to withstand 55,000 lbs of force. The frame must come equipped with an appropriate load cell, an LVDT to control the actuator stroke and an adjustable crosshead to accommodate specimens of varying sizes. It must be adaptable to the existing MTS hydraulic wedge grips with grip controls and supply integral to the frame. The minimum load frame requirements are listed in Table 2 below.

Table 5: Uniaxial Load Frame Requirements Force Rating 55 kip Actuator Stroke 6 inches Vertical Test Space 9.1 to 63.8 inches Column Spacing 25 inches Servovalve 10 gpm Integrated Hydraulic Grip Supply

10,000 psi

Pilot Accumulator 0.12 Gallon Close-coupled Accumulator

1 Gallon

Reliability, Service and Support:

The SML was designed and built to support the FAA’s structural R&D programs for the foreseeable future. As such, the equipment detailed in this statement of work will be utilized for many years. To ensure long term operation of the system the contractor must have a proven track record of supplying similar equipment to the aerospace industry over many years. This helps ensure the equipment delivered is reliable and provides confidence that equipment support will be accessible in the future. Additionally, due to changing test requirements and required maintenance the contractor must have locally available service technicians capable of expanding and/or maintaining the system on-site at the Technical Center.

5. TECHNICAL TASKS:

Task 1, Detailed Work Plan: Develop a Detailed Work Plan (DWP) addressing the formal requirements outlined in this SOW. It should include but not be limited to a work breakdown structure (WBS). For each major task area, the scope and objectives, schedule, and cost need to be clearly defined. A Gantt chart showing all tasks and milestones should be included and updated by the throughout the period of performance of the contract.

Deliverables Task 1: One month after contract award (MACA), a written Detailed Work Plan (DWP) per Task 1. The DWP will be presented at a Kick-off meeting with FAA sponsors.

Task 2, System Design Phase: Upon approval of the DWP, the hydraulic and control system will be designed to support the simultaneous operation of the material test frames and structural test stations. The system design will include equipment placement, hardware requirements, cabling and hose requirements, and software/workstation requirements.

Deliverable:

Two Months After Contract Award (MACA), the contractor shall demonstrate a prototype control and DAQ interface. The FAA will review and provide feedback. Upon implementing FAA input, the contractor will furnish FAA with electronic versions of all software programs.

Task 3: System Delivery & Installation Contractor shall install the hydraulic and control systems at the FAA Technical Center in the SML. FAA personal will be available to assist in the system installation.

Deliverable:

Complete system installation five MACA

Task 4: Training and Documentation The contractor shall provide training to FAA personal including test set up, calibrations, developing user interfaces, running quasi-static and fatigue (constant amplitude and complex load spectrum), acquiring data, and data reduction. In addition, technical and operating manuals will be provided

Deliverable:

Complete training and delivery of manuals six MACA

Task 5: System Acceptance Test Six MACA the contractor shall ensure the complete functionality of the all applications through an Acceptance Test Program (ATP). An ATP plan will be provided by the FAA.

Deliverables:

Six MACA, final software furnished to the FAA

6. PERIOD OF PERFORMANCE:

The total period of performance for the base program defined in this SOW shall be 6 months after the date of the contract award (MACA). Table 2 below shows the project schedule.

Table 6: Schedule for DAQ and Control Conversion

1 2 3 4 5 6

Task 1. Detailed Work Plan

Task 2: System Design

Task 3: System Installation

Task 4. Training and Manauls

Task 5: System Acceptance Test

Task Month After Contract Award (MACA)

7. TECHNICAL MONITOR

Kevin Stonaker FAA William J. Hughes Technical Center

ANG-E281

Atlantic City International Airport, NJ 08405 Phone: (609) 485-5379

FAX: (609) 485-4004