Attachment 1 PD_Rev4_22M-299A-OP AFPSL - Automatic Dual Indexing Table.docx

19C-234A-OP

19 November 2018

REV1

22M-299A-OP

13 October 2022

REV 4

PURCHASE DESCRIPTION

FOR

Automatic Dual Indexing Table

1. SCOPE: This procurement is to replace the Automatic Dual Indexing Table (ADT) located at Air Force Primary Standards Laboratory (AFPSL). The ADT is an aging system and does not produce repeatable measurements during calibration of test instruments. This ADT system requires two stacked indexing tables with a common axis of rotation, motors, encoders, and a controller. This system shall automate the calibration of True Square, Optical Cube, and Polygon workload at AFPSL.

2. PERFORMANCE REQUIREMENTS:

2.1. Index Accuracy: Each indexing table in the system shall be able to achieve any angle position to within +/- 0.25 arc seconds.

2.1.1. The ADT system is expected to maintain the 0.25 arc second accuracy requirement after 1300 consecutive movements/index positions.

2.2. Bandwidth Accuracy: Each indexing table in the system shall have a bandwidth no greater than 0.5 arc seconds.

2.3. Angle Repeatability: Each indexing table in the system shall be able to repeat any angle to within +/- 0.05 arc seconds.

2.3.1. The repeatability of the ADT system will be evaluated using the Dual Circular Closure technique.

2.4. Stability: Each indexing table in the system shall remain stable at each position to within +/- 0.05 arc seconds.

2.5. Units: Each indexing table shall be in imperial units (Degrees).

2.6. Indexing Table Resolution: Each indexing table shall have a resolution not to exceed 1/2 degree.

2.7. Total System Specifications:

2.7.1. Total Index Accuracy: Total composite index accuracy will be no more than +/- 1.0 arc seconds for both stages.

2.7.2. Top Surface Parallelism: At any compound angle of the two indexing tables, the top surface of the top indexing table shall be parallel with the bottom surface of the assembled system to within 0.0001 inches Total Indicated Reading (TIR).

2.7.3. Axis Concentricity: The rotational axis of the two indexing tables shall be concentric within 0.005 inches Total Indicated Reading (TIR).

3. FUNCTIONAL REQUIREMENTS:

3.1. Automated and Manual Operation: The ADT System shall meet all required specifications in automated or manual operation.

3.1.1. The operator shall be able to index either table as needed, using a jog feature or by some manual means.

3.2. Operation: The ADT System shall be capable of operating autonomously through the longest calibration sequence.

3.3. Motor and Assembly: The ADT System shall have motors or pneumatics to control the rotational and vertical movement.

Note:

If indexing is mechanized using pneumatics, the air that enters the system shall be pure and free of any contaminant that could interfere with the accuracy of the system.

3.3.1. Indexing Table Rotation: The ADT System shall be able to rotate each indexing table independently. Each table shall be capable of 360-degree continuous rotation in both clockwise and counter-clockwise directions.

3.3.2. Indexing Table Vertical Movement: The ADT System shall be capable of providing vertical lift with a jog feature or manual means.

3.4. Cables, Accessories and Adapters: The ADT System shall come with all necessary Cables, Accessories, and Adapters needed to make the system function as required. This would include, but not limited to: special tools, cables, fixtures, programs, adapters, and standards.

3.5. Warm-Up Time: The ADT System shall have a starting warm up time not to exceed 10 minutes.

4. PHYSICAL AND DIMENSIONAL REQUIREMENTS:

4.1. Indexing Tables: The ADT System shall consist of two indexing tables that are the same make and model from a single manufacturer.

4.2. Diameter: Each indexing table shall be at least 7 inches in diameter.

4.3. Maximum System Weight: The total weight of the ADT System (excluding controller) shall not exceed 300 pounds.

4.4. Weight Capacity: The ADT System shall operate normally and maintain accuracy and repeatability specifications under a 25-pound Unit Under Test (UUT) mounted on the top surface.

4.5. Operational Environment: The ADT System shall be capable of being operated at a temperature of 68±1°F with a Relative Humidity (RH) of 20% to 45% without loss of required performance.

4.6. Total System Size: The total footprint of the ADT System, excluding the controller, shall fit and properly operate on the existing unit’s 24 inch x 24 inch workspace.

4.7. Power Requirements: The ADT System shall run off of 110/120 V, 50/60 Hz single phase. Any special power requirements or facility modifications for power that is needed to operate the ADT System shall be approved by Air Force Metrology and Calibration (AFMETCAL).

4.8. Material: The ADT System shall be made of materials that reduce any thermal expansion experienced, such as tooled steel.

4.9. Design and Construction: It is expected that the design of this system takes the safety of the user into account and proper attempts are taken to ensure user safety while operating this system. The ADT System shall be designed in such a way as to eliminate cable twist or wrapping during indexing. The ADT System components shall be designed and constructed of materials that meet the requirements of this specification and in accordance with the best commercial practices for industry approved equipment. It shall be designed and manufactured to maximize reliability, maintainability, accuracy of operation, and ease of operation, all parts such as shafts, bearings, regulators, switches, controls, etc. shall have proper clearance and adjustments. They shall work together so that the equipment shall supply the rated requirements without unnecessary strains, vibrations, or overheating. They shall be able to withstand the conditions met in shipping, storage, installation, and service. All material and parts of this system shall be capable of withstanding the environmental constraints listed in this Purchase Description.

4.10. Bolt Pattern: The index tables shall have a bolt pattern consisting of uniformly spaced circular rings concentric with the table axis. There shall be at a minimum three rings, consisting of 12 evenly spaced bolt holes. Bolt hole threading is 10-24 UNC.

4.11. The ADT shall be designed so that it can be disassembled and reassembled by an engineer or technician familiar with the system if ever needed.

5. CONTROLLER REQUIREMENTS:

5.1. Hardware Requirements:

5.1.1. Controller: A Laptop controller is required that can efficiently operate under Microsoft Windows 10 Long-Term Servicing Channel (LTSC) 64 bit operating system. All major components of the system shall be commercially available and fully supportable by commercial sources. Where specific brands are identified in this specification, no substitutes are allowed without prior approval from the AFMETCAL. The Controller shall meet or exceed Microsoft Windows 10 LTSC hardware requirements.

5.1.2. Memory: Minimum 8 GB system Memory.

5.1.3. USB: Minimum of two USB 3.0 ports not being utilized by other components shall be available.

5.1.4. External video support shall be possible.

5.1.5. Display Panel: 15-inch (diagonal) or larger viewable display.

5.1.6. Hard Drive: Minimum 120 GB Solid State Drive.

5.1.7. DVD-ROM: Internal or External DVD +/- RW dual layer or Blue-Ray.

5.1.8. Operating System and Software: All software shall run under Microsoft Windows 10 LTSC 64 bit operating system. All software shall run Windows 10 as a non-elevated user

5.1.9. Lenovo brand controller will not be acceptable.

5.1.10. Additional Hardware: Additional hardware required to make this system function as identified by this purchase description shall be required.

5.2. Software Design:

5.2.1. Automated Calibration Process: The ADT System being designed shall integrate with the existing POPTI-POLYGON-000-00 software and perform designated calibrations as described in Air Force Calibration Procedures for True Squares, Optical Cubes, and Polygons with minimal technician interaction. The contractor will be provided a copy of the POPTI-POLYGON-000-00 software for ADT development.

5.2.2. Programing Expectations: The contractor shall deliver an ADT system that operates according to specifications listed in this document, using the same programming and interface as the existing ADT system. Minimal changes to the existing POPTI-POLYGON-000-00 source code and graphical user interface are expected to complete this requirement.

5.2.2.1. The contractor shall write drivers that operate any automation component of the ADT System in the current VB.net using .Net Framework 4.5.2.

5.2.2.2. Source code modifications can include but are not limited to: motor control module, configuration file for motor control, calibration form for motor call outs, and other aspects of programing related to motor control and indexing.

5.2.2.3. The contractor shall make every attempt necessary to limit source code modifications to indexing and mechanical positioning of the system in order for the AFPSL to maintain the fundamental calculations used in calibrating Test Instruments with this system.

5.2.2.4. The contractor shall provide a log of all changes and modifications made to the source code and user interface to be used in the validation and verification of the delivered system, with rights for AFMETCAL to reuse and modify source code.

5.2.3. Data Acquisition: The contractor shall construct, assemble, and program the ADT system such that it shall have the capability to perform automatic data acquisition throughout the measurement function(s) and range(s).

5.2.4. Drivers and Driver Utilities: The software shall contain the drivers and driver utilities to completely configure the system interface in the Windows 10 environment; as well as diagnose and verify hardware and software installation/configuration.

5.3. Software Requirements:

5.3.1. Software Warranty: The contractor shall warrant that the software product meets this purchase description, is free from defects in design and operation, and shall perform to stated specifications within this purchase description for the length of the equipment warranty.

5.3.2. The contractor (at no additional cost) shall update or replace the software product as necessary to correct any deficiencies identified in the software. Replacement software shall meet or exceed the requirements in this purchase description, shall not require additional training to operate, and shall be warranted for the remainder of the equipment warranty.

5.3.3. The contractor shall bear transportation costs for all replacement products.

5.3.4. The contractor (at no additional cost) shall provide technical support for normal software usage, clarification of documentation, and resolution of software problems. The contractor shall have multiple methods for convenient contact of Technical Support. Contact methods may include but are not limited to on-line or telephone.

5.3.5. Interchangeability:

5.3.5.1. When firmware or software upgrade is anticipated by a manufacturer during the life of this contract, the contractor shall contact AFMETCAL for concurrence. If AFMETCAL concurs with the proposed upgrade all previous units delivered under this contract shall be updated to this upgrade.

5.3.5.2. All firmware or software provided under this contract shall be at the same version, revision, and revision date at the completion of the contract.

5.3.6. Software Validation and Verification (V & V) Plan: Software shall be operationally validated and verified but need not be fully commercially compliant. Software shall be written for operation by skilled technicians commensurate with experience and expertise at a primary standards laboratory without any training. All documents shall be submitted in an electronic format to AFMETCAL.

6. DOCUMENTS:

6.1. Final Documentation: All associated documents necessary for the validation, use, support, and calibration of the ADT System and associated equipment shall be provided. These include but are not limited to: Technical Diagrams, Drawings, Source Code, and Troubleshooting.

6.2. Manual: Developed software and operator’s manual describing features and functions, assembly, operation, technical data, preventative maintenance and care, and warranty shall be provided.

6.3. Calibration Certificate: Each indexing table shall come with a calibration certificate from an ISO 17025 accredited laboratory.

7. ENVIRONMENT, SAFETY, AND OPERATIONAL HEALTH: A combination of the system manual, other documentation, and/or the system itself shall identify potential environment, safety and operational health hazards and how they are mitigated when the design itself cannot mitigate them. This will be accomplished through stating the hazard and accompanying mitigation through the use of safety devices, use of warnings, or use of special operational procedures to counter such hazards.

8. INSTALATION & TRAINING REQUIREMENTS:

8.1. Location: Installation and Training shall be performed at the AFPSL.

8.2. Installation shall take no more than 2 consecutive days during normal working hours (6am-5pm) to begin on the first or second day of the work week.

8.3. The system shall be fully installed and be operational, by an engineer or technician familiar with the designed system.

8.4. Installation and Training shall be completed in a single work week (Monday to the following Friday).

8.5. Installation and Training shall be coordinated with AFPSL 30 days prior to installation.

8.6. Training shall consist of 2 consecutive days during normal working hours (6am-5pm).

8.7. Training shall begin no later than the following day after installation is completed.

8.8. Training shall be done by an engineer or technician familiar with the designed system.

8.9. Training shall consist of a class size of at least four trainees.

8.10. Content:

8.10.1. Day 1 Training shall include hands on step by step setup and use of the ADT system and its components, troubleshooting, and preventative maintenance.

8.10.2. Day 2 Training shall include source code, system verification, and features described by this Purchase Description.

9. GOVERNMENTS FURNISHED PROPERTY:

9.1. For the development of the ADT, the government will furnish upon award:

9.1.1. POPTI-POLYGON-000-00 software

9.1.2. The Original ADT Operators manual

10. TESTING: This item will be inspected and accepted at destination as stated in the contract. The item will be checked with test equipment with parameters equal to or better than those required to ensure that specified performance parameters are met. Test equipment used shall have first echelon certification directly traceable to the National Institute of Standards Technology (NIST) or other AFMETCAL-approved equivalent international laboratory. Tests will be performed to ensure that the item meets the requirements of this purchase description. Such testing at destination does not relieve the contractor of performing all inspections and quality checks at the point of manufacture as necessary to assure performance as specified herein. Acceptance Testing will be performed at the Air Force Primary Standards Laboratory (AFPSL).

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