Appendix A.pdf

APPENDIX “A”

FOR

VERTICAL LIFT MODULES

AT

HILL AIR FORCE BASE, UTAH

F-35 Depot Repair Building 225

DATE: 4 DEC 2019

PREPARED BY:

ROBIN BARRACLOUGH

Program Management/Systems Engineering

OO-ALC/75ABW/SCPD

THIS PAGE LEFT BLANK INTENTIONALLY

Hill AFB, Appendix A - Page i

TABLE OF CONTENTS

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

3.2.2. STRUCTURE

3.2.3. DEFORMATION

3.2.4. EXTRACTOR

3.2.4.1. EXTRACTOR CHAIN SAFETY FACTOR

3.2.4.2. EXTRACTOR TRAY SENSORS

3.2.4.3. EXTRACTOR LOADING

3.2.4.4. EXTRACTOR FREE FALL

3.2.4.5. EXTRACTOR CALIBRATION

3.2.5. TRAYS

3.2.5.1. TRAY CONSTRUCTION

3.2.5.2. TRAY DIMENSIONS

3.2.5.3. TRAY CAPACITY

3.2.5.4. TRAY MARKINGS

3.2.5.5. TRAY PARTITIONS

3.2.5.6. TRAY CROSSWISE DIVIDERS

3.2.6. STORAGE LOCATIONS

3.2.7. PICK WINDOW

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

3.2.8.2. MAINTENANCE SERVICE PANEL

3.2.9. MAINTENANCE ACCESS

3.2.10. SERVICE LIFE

3.2.11. DRIVE COMPONENTS

3.2.11.1. MOTORS

3.2.11.2. GEAR REDUCERS

3.2.12. CONTROLS

3.2.13. OBSTRUCTION SENSORS

3.2.13.1. LOAD HEIGHT SENSORS

3.2.14. LIGHTING

3.2.15. FIRE SUPPRESSION

3.2.16. SECURITY DOOR

3.2.17. SOFTWARE CONTROLS

3.2.17.1. OPTIMIZED TRAY PLACEMENT

3.2.17.2. TOOL ACCOUNTABILITY SYSTEM COMPATIBLE

3.2.17.3. RS232 PORT

Hill AFB, Appendix A - Page ii

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

4.2. TESTS

4.3. CERTIFICATIONS

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for one(1) vertical lift module (VLM)for the 309th F-35 Depot Maintenance, Building 225 at Hill Air Force Base,(AFB) Utah. The work shall be completed in accordance with this appendix, the cover purchase description (PD), and applicable Air Force (AF) Drawings if any. This appendix covers equipment, materials, and labor necessary to complete installation of the VLM system.

1.2. DEFINITIONS

Extractor - A fabricated metal structure attached to a lift mechanism used to transport trays between storage locations and pick window.

Tray live load capacity - Actual amount of load supported by a tray, not including the weight of the tray

Tray - A container in which items are stored

VLM - Vertical Lift Module

Depth - Measurement from front to back when looking at the front of the VLM.

Width - Measurement from side to side when looking at the front of the VLM.

Height – Measurement from bottom to top inclusive of top cover.

Storage positions - The number of tray storage areas available within a Vertical Lift Module.

VLM System – Description of an operational VLM in fully automated configuration.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

TPQ for Appendix A, Hill AFB - Page 2

3. REQUIREMENTS

Contractors shall submit technical design drawings/diagrams of proposed VLM’s that demonstrate mandatory specifications stipulated in the Cover Purchase Description and Appendix “A” documents.

3.1. SYSTEM DESCRIPTION

The Contractor shall provide one (1) VLM which shall store and retrieve individual small to large sized items located on respective storage trays. Personnel shall retrieve parts, tools, or aircraft components by entering a part number into the Air Force Material Processing System (MPS). The VLM shall then respond to the appropriate MPS commands to retrieve the respective tray where needed components are stored and place at the pick window. This also applies to parts binning functions for storage actions.

The VLM shall consist of and not limited to the following major components:

a. Extractor

b. Trays

c. Storage locations

d. Pick window

e. Electronic Controls & Respective Hardware

f. Conduit, wiring, mechanical fasteners and all other items needed to install an operational VLM system.

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

The external dimensions of the VLM shall be a nominal 206 + 1 inch deep and 218 + 1 inch wide. The Contractor shall provide VLM’s that are a minimum of 360 + 1 inch high.

3.2.2. STRUCTURE

The VLM shall have a steel framework that supports the fully loaded system without the use of enclosure panel structural support. Vertical closed-section racking corner posts with a

TPQ for Appendix A, Hill AFB - Page 3 minimum of 4” X 4” X 12’square structural tubing shall be used.

Tray Rails shall be a minimum of 13 gage CR Steel formed and welded to vertical frame members. Horizontal spreaders shall be a minimum 3.5” X 3.5” X 12’ square structural tubing. Tray supports shall be factory welded. The VLM shall be securely anchored to the concrete floor in a manner that unit distortion is minimized. The VLM shall be designed such that the weight of a fully loaded unit shall be distributed over the warehouse floor with a maximum live load capacity of 300 pounds per square foot. Base plates shall not extend past the external dimensions of the VLM.

3.2.3. DEFORMATION

No VLM structural member shall exhibit elastic deformation greater than 0.10 percent of the distance between the ends of the member when loaded to capacity. No portion of the VLM shall exhibit permanent deformation.

3.2.4. EXTRACTOR

The extractor shall be used to extract and transport trays between storage locations and the pick window. The extractor horizontal drive shall be a single drive motor configuration 2 Horse Power or greater 60 FPM horizontal travel minimum. As a minimum, the extractor shall include the following:

End Plates ½ CR Steel Plate Cross members 7 Ga CR Steel – Formed and boxed Long Rails 6061 Aluminum Structural channel Vertical Rack and pinion drive - External Tooth Spur Gear with 2 ½” face – Steel Gear Rack – 2 ½” width - Steel Speed: 160 FPM vertical lift Dual#60 extractor chain with drive dogs

3.2.4.1. EXTRACTOR SAFETY FACTOR

Each extractor lift mechanism shall have a minimum 6 to 1 safety factor based on yield strength.

3.2.4.2. EXTRACTOR TRAY SENSORS

Sensors shall be used to ensure that trays movement operations are loaded onto or off of the extractor in such a manner that the extractor will not move vertically unless the tray being stored or retrieved is outside of the movement envelope of the extractor.

TPQ for Appendix A, Hill AFB - Page 4

3.2.4.3. EXTRACTOR LOADING

The extractor shall be capable of supporting the live load capacity of a loaded tray. Uneven loading shall have no effect on extractor speed or movement operations. Rack & Pinion vertical lifting mechanism shall be utilized. Vertical lift must be minimum dual 7.5 HP motors.

3.2.4.4. EXTRACTOR FREE FALL

The extractor shall be prevented from free falling in a manner such that tray components will not be damaged in any event, including power failure.

3.2.4.5. EXTRACTOR CALIBRATION

The extractor shall automatically calibrate its location as necessary to ensure continuously accurate storage and retrieval of trays. The extractor shall be easily recalibrated if tray locations are changed or in the event the unit loses electrical power.

3.2.5. TRAYS

The number of trays shall be 16 based on specified height clearance spacing requirements. Spacing shall be 5 trays @ 48”, 5 trays @ 36”, 6 trays @ 24”, for a total of 16.

3.2.5.1. TRAY CONSTRUCTION

All trays shall be welded box steel construction with corrugated floors, to provide continuous support for the capacity listed in

3.2.5.3. The rails and stiles shall be a minimum of 11 gage CR Steel formed and box welded. Tray bottom shall be a minimum of 16 gage corrugated steel. Additionally, each tray shall have Polyamor coating over entire surface. Trays must be fully assembled and completed at OEM factory.

3.2.5.2. TRAY DIMENSIONS

Tray dimensions are based on inside dimensions. These dimensions are considered to be usable space. The minimum depth of each carrier shall be 60 inches. The minimum width of each tray shall be 192 inches. The height of all tray side walls shall be a minimum 6 inch walls around the perimeter of the tray.

TPQ for Appendix A, Hill AFB - Page 5

3.2.5.3. TRAY CAPACITY

Each tray shall have a minimum live load capacity of 1,000 pounds with no deformation greater than .1 percent.

3.2.5.4. TRAY MARKINGS

Each tray shall be marked with its associated number beginning with number "1" and progressing through all the trays of the VLM. The number shall be contrasting to the tray color and shall be located in a position which is visible to personnel, on a fully loaded tray. The labels shall be located such that normal operations do not damage the labels. The numbers shall be permanently affixed to the trays.

3.2.5.5. TRAY PARTITIONS

N/A

3.2.5.6. TRAY CROSSWISE DIVIDERS

N/A

3.2.6. STORAGE LOCATIONS

Metal storage rails shall be used to support stored trays and be configured with rollers or glides including the pick window.

The storage rails shall allow tray placement on a minimum of 12 inch center locations. The storage location rails shall enable safe storage of trays loaded to maximum capacity without deformation of the storage location rails.

3.2.7. PICK WINDOW

The pick window width shall be the width of the tray plus a minimum of 1 inch on either side. The lower edge of the pick window shall be located between 36 + 2 inches from the floor.

The pick window shall be located on the front of the VLM.

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

Outer surfaces of each VLM shall have bolted solid metal enclosures for security and fire suppression. The enclosures shall be bolted from the outside to permit removal for

TPQ for Appendix A, Hill AFB - Page 6 maintenance, shelf adjustment or emergency access. A solid metal enclosure shall be installed to enclose the top of each

VLM.

3.2.8.2. MAINTENANCE SERVICE PANEL

A removable or hinged service panel shall provide for maintenance access to operating parts such as motors, brakes, and other respective components. The panel shall be equipped with safety interlock switches to prevent the unit from operating when the service panel is open. The bottom of the service panel shall be located a minimum of 18 + 6 inches above the floor.

3.2.9. MAINTENANCE ACCESS

All parts requiring periodic maintenance shall be easily accessible either by way of service panel or other access point.

3.2.10. SERVICE LIFE

All equipment furnished shall be new and be of high quality to ensure the completed VLM system is designed to operate a minimum of 20 years. This shall be demonstrated from historical performance data respective to VLM’s operational in the private sector or government.

3.2.11. DRIVE COMPONENTS

3.2.11.1. MOTORS

Vertical lift motors must be a minimum dual 7.5 HP motor configuration for 30 inches per second retrieve/store time under maximum load at continuous duty. Motors shall not exceed their fully-rated load when at the specified maximum capacity under the most severe conditions likely to be encountered. All motors shall be designed for continuous duty at ambient temperature, 40 to 110 degrees Fahrenheit. Motors shall be drip proof and be designed to operate on 230 VAC, 40 Amp, 3 phase electrical power. Motors shall have an electronically controlled soft start-stop & shall be equipped with an overload device.

Additionally, all motors & controls shall be located 18” above the floor required for explosive conditions.

3.2.11.2. GEAR REDUCERS

Gear reducers shall not permit oil to leak. The maximum input horsepower rating of the gear reducer shall not be less than the

TPQ for Appendix A, Hill AFB - Page 7 horsepower of the attached drive motor. Motor and reducer frames shall be compatible.

3.2.12. CONTROLS

The VLMs shall have a permanent control cluster that is either the push button or membrane type. The control cluster shall be located above the pick window or on a swivel arm attached to either side and shall be no higher than 42 inches from the floor. As a minimum, the control cluster shall contain an alpha numeric keypad to activate movement of the extractor, maintenance functions, operational status, and an emergency stop button. The control cluster above the pick window shall have a visual display which shall indicate the current tray number on the extractor. The VLM shall have an "on/off" key lock switch to control the unit's electrical power.

3.2.13. OBSTRUCTION SENSORS

Sensors shall be mounted on the VLM at the pick window to stop movement of the extractor if an object extends through the sensor plane opening or the extractor movement area. If this condition occurs, operations shall abort and an audible tone along with error message shall be visually displayed to the operator on the control panel.

3.2.13.1. LOAD HEIGHT SENSORS

Sensors shall be mounted in the pick window to measure load height of the tray. This shall be used by the VLM controller to ensure there is adequate height to store the load. If there is not adequate height to store the load, the storage procedure shall be aborted and an error message shall be transmitted audibly to the operator and visually displayed on the control panel. The Sensors shall be designed to monitor all load heights respective to predetermined storage locations.

3.2.14. LIGHTING

The VLM shall have overhead lighting, which shall measure not less than 50 foot-candles at the pick window. The lighting shall be continuous along the length of the pick window.

3.2.15. FIRE SUPPRESSION

TPQ for Appendix A, Hill AFB - Page 8

Two sprinkler heads shall be installed at the VLM top. The sprinkler heads and piping shall be designed to provide a minimum of 18 GPM with a single connection point. Piping for VLM’s located side-by-side shall utilize the same piping. Fire suppression drawings and calculations shall be provided and approved before installation of the VLM. Drawings shall show an installation diagram and connection point to existing fire suppression system. Contractor is responsible for installation of complete fire suppression system and connectivity.

3.2.16. SECURITY DOOR

A motorized Roll-Up type metal security door shall be provided to enclose the pick window opening when the VLM is not in use.

When closed, the door shall prevent access to components inside the unit. It shall be of sufficient strength and durability such that extraordinary means are required to gain access to the VLM when the door is closed. The security door shall be lockable using a key lock. A minimum of two sets of keys shall be provided for each lock. The door shall be an integral part of the VLM and shall allow unobstructed access to the pick window when.

3.2.17. SOFTWARE CONTROLS

3.2.17.1. OPTIMIZED TRAY PLACEMENT

N/A

3.2.17.2. SYSTEM COMPATIBLITY

The VLM shall accept retrieve & store commands from Air Force Material Processing System MPS/D230. Additionally, if operational error codes occur resulting from a malfunction they shall be transmitted to MPS with current status information.

3.2.17.3. RS232 PORT

The controller shall have a command driven interface with asynchronous responses communicating through an ASCII RS232C 9 pin connection. Tray positioning will be directed from Air Force automation control host system MPS/D230 using ASCII commands. Commands shall include current status, retrieve/move and store/move. In addition, if a tray is currently at the pick window, a retrieval command for a new tray will cause the existing pan to be automatically stored and the new tray

TPQ for Appendix A, Hill AFB - Page 9 retrieved. A command to store a tray currently in the pick window without retrieving a tray shall be supported. The controller shall respond when commands are completed and not require continuous polling to determine completion status.

Inclusion of the error code in the completion message is required. The actual failure or completion code must be available for lookup through the interface.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

The system shall be inspected to verify the VLM meets all requirements of sections 1, 2, and 3 of this appendix and the cover purchase description. These inspections shall be completed as part of system checkout and again as a part of the quality conformance testing. Acceptance is inclusive of all inspections and operational tests for conformance to appendix A and cover documents as the final approval for acceptability of the VLM system.

4.2. REMEDIAL & SUSTAINMENT MAINTENANCE

Remedial and ongoing sustainment of the VLM’s, Carousels, and other types of storage aids at Hill Air Force is performed by a specific servicing repair entity under contract agreement. All new storage aids delivered to Hill Air Force Base are subject to repair and maintenance under provisions of this contract. The Manufacturer shall agree to provide access support inclusive of technical maintenance data, replacement parts data, and VLM processor control software. Additionally, training shall be provided to the incumbent servicing repair entity inclusive of all operational and maintenance aspects of the VLM system.

4.3 TESTS

The following tests shall be performed on the system as part of the system checkout test and again as a part of quality conformance testing for final acceptance.

No. Paragraph Description

TPQ for Appendix A, Hill AFB - Page 10

1. 3.1.

An acceptance test of 2 hours shall be made on the VLM. This test shall demonstrate the reliability as specified in the cover PD ("RELIABILITY/AVAILABILITY"). All trays shall be called randomly during the test. Two trays will be loaded to capacity. If the test shows the installation is defective in any respect or does not comply with this appendix “A” and Cover PD, the Contractor shall immediately make changes necessary to correct all defects to the satisfaction of the COR prior to acceptance.

The system shall be operational at least 100 percent of the test period.

2. 3.2.3. Deformation shall be tested to determine if the storage trays exhibit deformation. The distance from the midpoint of the bottom of the selected tray shall be measured and recorded as M1. The tray will then be loaded to capacity and left for a minimum of four hours. After four hours, the tray will be unloaded and the distance between the two points where M1 was measured shall be measured and recorded as M2.

The following formula shall be used to determine the deformation:

(M1 - M2) / Usable width of tray * 100 = Percent Deformation

If permanent deformation is recorded, then the trays shall have failed the test. After all loads are removed, the trays shall be examined for permanent deformation. If permanent deformation has occurred, the trays shall be determined as unacceptable.

3. 3.2.4.3., 3.2.13.

All safety interlock switches, sensors, touch bars, and stop buttons shall be tested to ensure that they are completely operational.

TPQ for Appendix A, Hill AFB - Page 11

4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with Contract Data Requirements List.

No. Paragraph Certifications

1. 3.2.2. The Contractor shall certify that the weight of the fully loaded VLM is adequately distributed to not exceed the capacity of the floor as specified.

2. 3.2.4.1. The Contractor shall certify that all extractor support mechanisms have a minimum 6-to-1 safety factor based on yield strength.

3. 3.2.10. The Contractor shall certify that the Vertical Lift Modules are designed to function a minimum of 20 years.

THIS PAGE LEFT BLANK INTENTIONALLY