Attachment B - AFP Head Technical Requirements.pdf
PDF 195 KB Posted
- Attached to
- Single Tow AFP Head
- Solicitation number
- PR454915
- Issued by
-
Department of Energy
About this file
This document is Attachment B containing the technical requirements for an Automated Fiber Placement (AFP) Head system to be integrated with a pre-existing humm3 Discovery flashlamp at Oak Ridge National Laboratory (ORNL) in Knoxville, Tennessee.
The AFP Head system must be compatible with the existing humm3 Discovery flashlamp and capable of handling both thermosets and low-temperature thermoplastics. Hardware specifications include 230–240 VAC, 50–60 Hz power requirements (4–6 A), accommodation for ¼" width material spools with OD 315 mm and ID 160 mm dimensions, a control cabinet, and all required cable and hose assemblies (10 meters in length). The system must include spare consumables (compaction roller, cutting blades, IR lamp), external offline programming (OLP) software, HMI and GUI software for robot control, and one empty spool. NRTL certification is preferred. Deliverables include an English operational guide covering safety, equipment overview, standard operating procedures, programming, debugging, maintenance, and electrical drawings; TCP data; acceptance forms demonstrating pre-shipping evaluation; and virtual support for hardware and software for one year each.
Installation and integration will occur at 2350 Cherahala Boulevard, Knoxville, requiring two on-site technicians for one week (up to 40 hours). The site must provide 7 bar/105 psi pressurized air, 240 VAC power meeting local code, internet connectivity, and a functional 6-axis robotic arm with minimum 70 kg payload capacity. The Site Acceptance Tests (SAT) must demonstrate consolidation adjustment through increased compaction, speed control (20–50 mm/s for adhesive placement; 100–150 mm/s for layup), flashlamp functionality, and heat output adjustability. Placement accuracy requirements include path following within ±1 mm, start/stop position accuracy within ±2.5 mm, tape-to-tape gap control from 0–3 mm, overlap control less than 2 mm, and steering response capability. A 4-layer test program must execute layers at 0°, 90°, +45°, and −45° orientations with specified speeds and heat parameters on flat surface layups. Training encompasses control software instruction via conference call before delivery, on-site robotic use and maintenance training for three key users, and assistance defining daily operations and maintenance procedures with ORNL personnel.
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Text version
Attachment B - AFP Head Technical Requirements
1) Technical deliverables — Fiber Placement System
• Ensure compatibility with a pre-existing humm3 Discovery flashlamp
• Configuration capability for thermosets and low-temperature thermoplastics
• Form-fit for humm3 Discovery attachment
• Power requirements: 230 − 240 VAC, 50 − 60 Hz, 4 − 6 A
• Accommodates material spool ¼ " width, w/Spool Dimensions: OD 315 mm, ID 160 mm
• One empty spool of the desired width with spool dimensions: OD 315 mm, ID 160 mm
• Provide spare consumables including:
o Compaction roller o Cutting blades o IR lamp
• Control cabinet
• External Software for offline programming (OLP) electronic delivery is reasonable
• HMI and GUI Software for robot control
• All required cable and hose assemblies, 10 meters in length
• Provide Checklist of shipped components
• AFP Head training provided during installation
• Operational training / use of software available during installation and via conference call
• Prefer NRTL certification
• TCP data
• Acceptance forms demonstrating pre-shipping evaluation, including:
o Internal acceptance confirmation o Blank customer installation acceptance form (for completion upon integration at customer site)
• Provide virtual support for:
o Hardware: 1 year o Software: 1 year
2) Technical deliverables — Documentation
Deliver an English operational guide including chapters on:
o Safety o Overview of the equipment o Standard operation procedures o Programming o Debugging o Maintenance o Electrical drawings
3) Installation & integration at 2350 Cherahala Blvd. Knoxville
Provide installation and integration by two technicians on-site for 1 week (up to 40 hours of on-site support).
AFP Head Provider can expect the customer site is prepared prior to installation team arrival, including:
o A clean, clear, leveled floor o Required mounting holes drilled o Cell area cleared and obstacle-free
3.1) Additional customer-furnished prerequisites (before installation)
• 7 bar / 105psi pressurized air located in cell
• 240 VAC power supply for the control cabinet meeting local code
• Internet connectivity for troubleshooting purposes only to be available to installation team
• Functional 6-axis robotic arm with minimum payload capacity of 70 kg
4) Site Acceptance Tests (SAT)
4.1) Primary validation criteria (process capability)
• Demonstrate consolidation adjustment via increased compaction
• Demonstrate speed control and range
• Demonstrate ability to “flash” humm3 Discovery system when required
• Ensure humm3 Discovery lamp turns off when robot motion stops
• Demonstrate heat output changes based on parameter changes
4.2) Layer 1 adhesive placement test (no heating)
Parameter Setpoint
Flashlamp status OFF Table heater OFF/N/A Speed capability 20 − 50 mm/s
4.3) Placement accuracy criteria (all layers)
Test Criteria Requirement
Path following accuracy within ±1 mm of programmed path Start position accuracy within ±2.5 mm of target Stop position accuracy within ±2.5 mm of target Tape-to-tape gap controllable from 0 − 3 mm Overlap control <2 mm when programmed Steering response follows curves/angles
4.4) 4-layer test program requirements
• Execute the following layup program:
o Layer 1: 0∘, 150 mm/s, place only o Layer 2: 90∘, 100 mm/s, heat + place o Layer 3: +45∘, 100 mm/s, heat + place o Layer 4: −45∘, 100 mm/s, heat + place
• Conduct tests primarily on flat surface layups
5) Scope of work (included)
• Integrate AFP head to the pre-existing robot
• Integrate and test the customer supplied Humm3 flashlamp with AFP
• Perform controller wiring and rerouting
• Perform AFP head and Humm3 wiring and rerouting
• Perform SAT per Section 4
• Provide on-site training
6) Training
• Provide training in two parts:
1. Control Software training via conference call before tool delivery, covering:
Importing the specific robotic cell Tool setup and base plane alignment Creating a flat laminate, changing material parameters Setting orientations and number of layers Simulation/error checking Program creation During installation: working with the HMI to upload programs written off-line to the control system, then running the layup
2. Robotic use & AFP head - maintenance training on-site for up to three (3) key users, covering:
HMI navigation Activating each I/O and verifying corresponding actions Making adjustments Cleaning the system
3. Assist the ORNL Engineers / Scientists with defining the daily operations, maintenance operations, and the ‘contact the OEM’ list of activities
| Attachment B - AFP Head Technical Requirements |
| 1) Technical deliverables — Fiber Placement System |
| 2) Technical deliverables — Documentation |
| 3) Installation & integration at 2350 Cherahala Blvd. Knoxville |
| 3.1) Additional customer-furnished prerequisites (before installation) |
| 4) Site Acceptance Tests (SAT) |
| 4.1) Primary validation criteria (process capability) |
| 4.2) Layer 1 adhesive placement test (no heating) Parameter Setpoint |
| 4.3) Placement accuracy criteria (all layers) |
| Test Criteria Requirement |
| 4.4) 4-layer test program requirements |
| 5) Scope of work (included) |
| 6) Training |
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