Attach 01 - NPTU Machine Shop Mx - Accurpress PWS_22 May 2025.pdf

PERFORMANCE WORK STATEMENT

FOR

NPTU REPAIR MACHINE PERFORMANCE ASSURANCE – ACCURPRESS MACHINES

Joint Base Charleston, SC

30 April 2025

1 Introduction The purpose of this requirement is to provide Performance Assurance (PA) and Comprehensive Calibration Analysis for two (2) Accurpress machines used by NPTU Repair, Joint Base Charleston, South Carolina as outlined in section 1.1.

1.1 Scope

The contractor shall perform PA and Comprehensive Calibration Analysis on an annual basis as stated in this Performance Work Statement (PWS) to ensure reliability and safe operation of the two Accurpress machines below.

The table below outlines the manufacturer information of the two machines that will require PA by factory and industry trained technicians.

Manufacturer Model Number Serial Number Service Periodicity

Accurpress 65008 7093 Annual Accurpress 7 400 10 12889 Annual

1.3 General Requirements

The PA covered shall comply with NPTU requirements for Security, Hazmat and Safety. All required information shall be forwarded to NPTU Repair Shop. The actual scheduling of said maintenance shall be determined by the Contractor and the NPTU Repair Shop. The results of the PA shall be reported to the NPTU Repair Shop soon after the inspection is provided. If parts are found to be defective or require replacement, the NPTU Repair Shop will be notified. All used parts that are serviceable will be identified as such and left with the NPTU Repair Shop.

2 Preventative Maintenance (PM) Testing The following sections provide a proposal for the PM tests that will need to be performed to ensure maximum uptime and reliability for the Accurpress machines.

2.1 Performance Assurance (PA)

The PA consists of all major maintenance checks that are recommended by the machine manufacturer that will be performed by factory trained technicians on the following systems:

mechanical, electrical, air, coolant, spindle, and way lube systems. Along with standard checks, yearly ball bar calibration is recommended. Renishaw ball bar service is performed and creates a preventative and comprehensive diagnostic report that will also give an overall assessment of the machine performance. This test provides an automatic diagnosis of up to 10 specific machine positioning errors including servo mismatch, stick-slip errors, backlash, repeatability, scale mismatch and machine geometry. Each error is ranked according to its significance to overall machine performance alongside the error value.

2.2 Comprehensive Calibration Analyses

Within this subsection, a list of the different Comprehensive Calibration Analyses and their descriptions is provided.

2.2.1 Comprehensive Calibration Test

Perform vibration analysis program to diagnose a variety of problems on the machine’s spindle including bearings, drive motors, as well as electrical problems. Vibration analysis data is collected on-site and then analyzed to determine if any corrective and preventative actions need to be taken.

2.2.2 Drawbar Force Test

Allows for early detection of drawbar tension problems with the spindle's Belleville spring stack, verification of performance of the clamping system as a whole, help prevent damage to spindle taper, premature tool wear, and other machine features critical to machining accuracy, and ultimately help to keep the machine operator safe.

2.2.3 Geometry Inspection

This series of tests and checks are performed to ensure machine accuracy and including parallelism, squareness and true perpendicularity of the Cartesian coordinate system and machine.

3 Performance Assurance Checks The following sections list all possible PA checks for different machines by a factory trained technician.

3.1 PA Checks for Shears and Press Brakes

Accurshear & Accurpress includes but is not limited to:

• Lubricate main motor grease fittings

• Lubricate backgauge ball screw/nuts

• Inspect ram ways boxes and preload o Re-torque and/or Shim if necessary

• Check linkage pin for clearance

• Check the connecting rod bearing clearance

• Check all gears, fans, motors, pumps, bearings, and mechanical connections

• Inspect blade clearance and adjust accordingly to +.0002”

• Check ram encoder backlash - Rack and Pinion Ram Encoder

• Ram encoder shaft alignment - Rack and Pinion Ram Encoder

• Clean CNC Backgauge guide rails and roller bearings

• Inspect CNC Backgauge gear belt for tension and wear o Adjust and replace as necessary

• Align and level CNC Backgauge bar o Check for swing-up at 36”

• Replace Hydraulic System Filter - Filter Not Included

• Inspect Hydraulic System for leaks and loose fittings

• Inspect Hydraulic System cooling fan rotation

• Inspect Hydraulic System heat exchanger core

• Inspect Hydraulic System main cylinders

• Inspect Hydraulic System hold downs

• Calibrate Electrical Tonnage readout - Z Pulse

• Perform CNC Backgauge positioning test o Adjust if necessary

• Check machine calibration

• Inspect electrical limit switches, wiring, relays, contactors, etc

• Check and tighten electrical connections

• Inspect, clean, and adjust Pedestal Station (as necessary) o Electrical connections o Key Pad o Buttons o LED Screen o Operator Pedestal Cable o Operator Pedestal Cable strain relief connection o If Equipped - Backgauge Control Head - Inspect all wire and cable connections

Tighten if necessary o Replace burned out indicator lamps as required

• Check for missing manuals

• Review control features with operators

• Review safety precautions with operators

• Inspect for missing or damaged decals

• Inspect safety guards

• Annual oil sample analysis

3.1.1 Technical Specifications Chart

The following chart lists specifications of some of the above PA checks for Shears and Press Brakes.

Main Motor Lubrication Lubrication interval Lubrication type Lubricant brand

6-12 months Grease Shell Dolium R Texaco Premium RB Chevron SRI No. 2

Backgauge Ballscrew Lubrication interval Lubricant brand

6-12 months 10 W

Blade Clearance Adjust to +.0002” Annually Hydraulic Oil Recommended oil change interval ISO grade

6000 hrs (with hydro-treated base oils) 3000 hrs (with conventional base oils) AW 46 (on serial #3200 and up)

Hydraulic Filter Recommended filter change interval

6-12 months