Statement of work.pdf

1.0 Statement of Work

Vendor shall provide a quote to perform the following services on the NASA Glenn PSL MCT- 90-122-50K Multi-axis Thrust Measurement System (TMS). The requested services are grouped into elements for which a separate cost quote is desired. Upon receipt of the cost quotes for each element, NASA will determine which elements it desires to purchase and issue a purchase order to cover those elements.

Element 1:

• Replace the center section of the TMS live bed and ground frame with a new section that will allow the engine mount features to match the MCT-87-129-40K TMS. Center section shall retain all the capability to measure 50K of axial force and to maintain 50K of axial in-frame calibration capability.

• Machine engine mounting holes in the AFT and Forward live frame that will match the engine mounting holes in the MCT-87-129-40K TMS after the center sections are replaced.

• Disassemble the entire TMS for inspection. Inspect all stable platen flexures, universal flexures, and load cells. Strip all painted parts, sandblast, and repaint. Determination will be made on all plated parts during inspections if acid strip and re-plating is necessary. Care shall be taken to not introduce hydrogen embrittlement into the hardened parts.

• Replace all screwjacks with numerical ratio screwjacks. Replace load applying bolts with custom shoulder screws to maintain alignment. Replace limit switches determining the home position of the calibration system with position transducers. Replace hydraulic motors for the calibration system. Install gear boxes and clutches in the axial and vertical in-frame calibrators. Install gear boxes and clutches in the lateral calibrators if room exists.

• Replacement of the chain drive of the axial calibrator with a second axial calibration hydraulic motor, clutch, and gearbox.

• Replace current 115 VAC hydraulic solenoids with 24V low wattage solenoids. Replace hydraulic valves, flow control valves, and pressure regulators mounted on the TMS.

Install new 304 SS hydraulic tubing to the calibration motors.

• Inspection of load cells: Currently 12 load cells have been identified for replacement.

Remaining load cells are to be evaluated. If a load cell is deemed to be defective during the evaluation process, then a recommendation shall be provide for either repair or replacement.

• Replace all fasteners that are removed. All new fasteners to be drilled for lock-wire.

• Reassemble the TMS, lock-wired all fasteners, and prepare the system for in-frame calibration.

Element 2:

This element consists of the In-frame calibration instrumentation, calibration software, and vendor required In-house equipment (non-deliverable) to perform calibrations of the TMS at the vendor’s facility (This may be interpreted as an in-situ characterization of the TMS for a given custom customer test build-ups). In-house equipment consists of but not limited to hydraulic systems and a suitable data acquisition system for the data measurement load cells. Vendor shall train NASA personnel in the mechanics and theory of operations so that they are able to maintain the TMS and conduct similar calibrations/characterizations with the thrust stand installed at PSL.

Vendor shall supply the following deliverables:

• Provide a PC based calibration control system. The control system will consist of a PC which will communicate with Ethernet cabling or fiber optics to an instrumentation panel which will monitor the calibration load cells and control the hydraulic system (a system with a high accuracy A/D converter and readily available spare parts such as the Opto 22 is required). The software will be optimized to provide the data throughput required to control the loading of the calibration load cells. The software will allow independent loading of the thrust stand in the axial, lateral, or vertical axes; roll, pitch or yaw moments; and the application of vectors which do not exceed the rated capacity of the load cells. The calibration load cells will provide sufficient feedback to allow accurate control the calibration/characterization process. The calibration/characterization system will automatically disengage by the software using position transducers as feedback and will not affect the accuracy of the measurement system during engine testing.

• The software shall have an operator interface that will allow the manual, semi-automatic, or fully automatic control of the calibration system. In the semi-automatic mode, the operator enters the desired load and then commands the load to be applied. The system shall return to the unloaded position when directed by the operator. The system shall have fail safes to prevent executing load conditions which could damage the TMS. In the automatic mode, the operator can recall stored loading profiles that are easily edited in excel. A typical calibration test profile consists of three runs for each axes and moments at 10% increments ascending and descending. The automated system should take into account and sufficiently address hysteresis when crossing over the zero force threshold from tension to compressive loading or vice versa for example.

• Calibration system shall have hardware (relay logic) handshaking for communication to the PSL data system. Handshaking signals to consist of:

Calibration Home (A signal indicating that the calibration system is completely disengaged from the live bed).

Ready to Record (A signal indicating that calibration forces requested by the operator have been set within tolerance, and are stable).

Proceed to the next load point.

Abort calibration run, return to calibration disengaged position.

• The calibration instrumentation system shall be mounted on a 19” rack.

• Vendor to conduct in frame thrust stand factory calibrations at their facility and provide the thrust stand calibration data to NASA.

• Vendor to provide a report summarizing the accuracy and repeatability of the thrust stand factory calibrations for retention by NASA as a benchmark record for the reconditioned

TMS.

• Provide training on the thrust stand calibration software tailored to the MCT-90-122-50K

TMS.

• Provide training on best practices for load cell removal.

Element 3:

Inspect, assess and provide a cost quote to repair and or fabricate (22) load cells that are used in the thrust measurement system. The new/repaired load cells shall have the same capability in terms of capacity and accuracy as the current load cells when they were newly installed.

Qty Model Description 4 BUL-MML-49-OD-25K-90-122 25K Dual Bridge Load Cell, Vented

5 FUL-PP49-28K-90-122-1 28K Dual Bridge Load Cell with Integrated Flexures, Vented

3 FUL-PP49-28K-90-122-2 28K Dual Bridge Load Cell with Integrated Flexures, Vented

2 BUL-MML-49-OD-20K-90-122 20K Dual Bridge Load Cell, Vented

4 FUL-PP49-OD-42K-90-122 42K Dual Bridge Load Cell with Integrated Flexures, Vented

4 BUL-MML-49-OD-10K-90-122 10K Dual Bridge Load Cell with integrated Flexures, Vented

Element 4 Provide modular axial load cell package that allows NASA to optimize the measurement accuracy of the TMS for lower thrust engine tests by having the ability to change from 50K lbf maximum axial thrust to 20K lbf maximum axial thrust by replacing the axial load cells as needed.