Attachment 0001- Hydrostatic Roller Burnishing System Statement of Work.pdf

Attachment 0001 Statement of Work

For Customized ECOROLL HG38 Hydrostatic Roller Burnishing System

1.0 Description: The statement of work defines the requirements and specifications for an

ECOROLL HG38 high-pressure hydrostatic roller burnishing tool, hardware, and operating system. This statement of work’s defined requirements and deliverables are to be used in the selection and procurement of a hydrostatic roller burnishing system.

2.0 Scope: The scope of this project includes the procurement of the ECOROLL HG38 hydrostatic roller burnishing element and the accompanying hydraulic fittings and hoses, sensors, fluid reservoir, high pressure pump, operating system, and all necessary hardware, accessories and/or software needed for the proper operation and integrated into the automation components detailed in the requirements section of this statement of work.

3.0 Requirements: The contractor shall provide a final product that conforms to the following minimum required specifications:

3.1 Characteristics:

3.1.1 Dimensions:

3.1.1.1 Hydrostatic Roller Burnishing Element

Description Value Units Roller Element Spherical Diameter 38.0 mm Roller Element Hub Stroke 12 mm Max Input Hydraulic Pressure 600 Bar

3.1.1.2 Hydraulic Hoses/Fittings

Description Value Units Max Working Pressure 720.0 Bar Distance between Rear Face of Ring and Chuck Body

25.0 mm

Supply Port Thread Size NPT 3/8” inch Alternate Supply Port Threads Allowed G1/4 or 12mm x 1.5

3.1.2 Performance Specifications:

Description Value Units Max Working Pressure 600.0 Bar Hydraulic Flow Rate 4.0 L/min Min Reservoir Capacity 150 L Operating Pressure 2-8 Bar Max Pressing Force 52 kN

3.2 Features

3.2.1 The hydrostatic rolling element must be of spherical shape and be configured in the HG38 Part Design.

3.2.2 Long stroke length with rapid traversing and clamping zones.

3.2.2.1 Stroke Position detection plate to prevent clamping during rapid traversing of the jaws during actuation.

3.2.3 Hydraulic Base Body, HPU-1-1.4:

3.2.3.1 Hydraulic Valves:

3.2.3.1.1 Pressure supply with media HFA (cooling lubricant)

and HLP (hydraulic oil) from 2-68cSt viscosity.

3.2.3.1.2 KSS (HFA) with 400 bar - Hydraulic oil (HLP) 600 Bar

3.2.3.1.3 Flow rates adapted to tools, 1,400 mL/min.

3.2.3.1.4 Manual pressure control

3.2.3.1.5 Functional expansion via modules

3.2.3.1.6 Tank volume 160 L | usable volume 115 L

3.2.3.2 Electrical:

3.2.3.2.1 Three Phase Motor for radial piston pump 2.2kW

3.2.3.2.2 480VAC at 60Hz

3.2.3.2.3 M-Function for Machine Connection

3.2.4 Module Filtration, HPU-1-F1:

3.2.4.1 Duplex filter without elements – switchable during operation

3.2.4.2 F1/ filtration grade – 10μm standard

3.2.4.3 Electrical filter monitoring with signal output

3.2.4.4 Dependency: Low pressure module 179096

3.2.5 Module Low Pressure System

3.2.5.1 Module low pressure system

3.2.5.2 HPU-1-N1-KSSmax.

3.2.5.3 4.5bar-max.40l/min

3.2.5.4 Low-pressure pump for coolant for modules cooler 179113, filter 179093, series operation

3.2.5.5 Supply of the low-pressure system

3.2.5.6 N1 = module low-pressure system mainly for low-viscosity media such as coolant

3.2.5.7 0.92 KW

3.2.5.8 220-240V 50Hz 3PH --> 3.8A --> 2840 1/min

3.2.5.9 380-415V 50Hz 3PH --> 2.2A --> 2840 1/min

3.2.6 Module Monitoring, HPU-1-S1:

3.2.6.1 Module for flow monitoring

3.2.6.2 Flow measurement with control limit monitoring

3.2.6.3 Flow rates 0-8,000 ml/min.

3.2.7 Module Cooler, HPU-1-K1:

3.2.7.1 Air/Oil/Coolant Heat Exchanger

3.2.7.2 Automatic temperature monitoring with cooler control

3.2.7.3 Dependency: Low pressure module 179096 (coolant)

3.2.8 Module for Increased Pressure, HPU-1-X:

3.2.8.1 Module increased pressure

3.2.8.2 HPU-1-X

3.2.8.3 Module increased pressure HPU-1-X

3.2.8.4 Pressure increase up to 600 Bar

3.2.8.5 Attention: HPU can only be operated with oil >46cSt

3.2.8.6 Cooling Lubricant is no longer permitted as a medium

3.2.9 Module for Increased Volumetric Flow Rate, HPU-1-1.40

3.2.9.1 Module increased flow HPU-1-4.0, 4.0 L/min

3.2.9.2 Increased flow module

3.2.9.3 Expansion of the delivery capacity of the radial piston pump

3.2.9.4 especially for tool type HG-11

3.2.10 High Pressure Hydrualic Hose, X4:

3.2.10.1 Minimum working pressure of 720 Bar.

3.2.11 All necessary hardware/software required for proper fitment, installation, alignment, and operation of the product.

4.0 Hardware Deliverables

4.1 The contractor will produce and deliver the following components that meet the requirements and specifications listed in this Statement of Work:

4.1.1 Two (2) HG38 Roller Burnishing Elements. ECOROLL Part Number:

162230.

4.1.2 Four (4) HG38 Roller Ball Inserts ECOROLL Part Number: 162229

4.1.3 Eight (8) HG38 Roller Burnishing Element Throttle ECOROLL Part

Number: 162070.

4.1.4 One (1) HPU-1-1.4 Module Base Body ECOROLL Part Number: 179081

4.1.5 One (1) HPU-1-F1, Module Filtration ECOROLL Part Number: 179093

4.1.6 One (1) HPU-1-N1-KSS, Module Low Pressure System ECOROLL Part

Number: 179096

4.1.7 One (1) HPU-1-S1 Module Monitoring System ECOROLL Part Number:

179099

4.1.8 One (1) HPU-1-K1 Module Cooling System ECOROLL Part Number:

179113

4.1.9 One (1) HPU-1-X Module Pressure Increase ECOROLL Part Number:

179677

4.1.10 One (1) HPU-1-4.0 Module Volumetric Flow Rate Increase ECOROLL

Part Number: 179676

4.1.11 One (1) X4 High Pressure Hydraulic Hose

5.0 Written Deliverables

5.1 The contractor shall prepare and provide a certificate of compliance for the components stated in section 4.0. (DI-MISC-81356A)

5.2 The contractor shall provide all user, maintenance, and operating manuals and provide technical drawings and documents for all components and systems.

6.0 TDP

6.1 Benet Laboratories will provide applicable drawings and 3-D Models of the cannon barrel, Sub-System Concepts, and other requirements immediately after contract award.

6.2 Benet Laboratories will provide technical information related to process application immediately after contract award, to include mechanical properties and process parameters.

7.0 Warranty

7.1 The Contractor shall offer a standard commercial warranty, including onsite service warranty on labor, parts, and materials for a minimum period of one (1) year from the date of installation. Additionally, the contractor shall provide application and technical support free of charge.

8.0 Final Acceptance:

8.1 Shall be done at Watervliet Arsenal upon completion of inspection, installation, pressure testing, and proper functionality of all moving parts.

9.0 General Requirements and Information

9.1 Delivery shall be executed over thirty-six (36) weeks from the date of award.

9.2 Delivery of all components shall be executed over twelve (12) weeks from the date of award.

9.3 This effort is Unclassified.