B08_ATCH_1_STATEMENT_OF_WORK_SALIENTS.pdf

Statement of Work for

Robotic System for the Analysis of Sediment Samples

1.0 SCOPE.

This Statement of Work (SOW) describes the minimum characteristics/requirements for a robotic system for the automated handling/weighing/analysis of sediment samples in ceramic crucibles. This requirement includes system design, hardware/software integration and development, system delivery, testing, and training of operator personnel.

The equipment shall be delivered to the U.S. Geological Survey (USGS), Santa Cruz Sediment Laboratory in Santa Cruz, California. It is the Government’s intent that a single (primary) contractor be awarded this contract and be responsible for the accomplishment of all work detailed by this SOW.

1.1 Background. The USGS Santa Cruz Sediment Laboratory (SedLab) is responsible for the analysis of sediment samples in support of USGS sediment data collection activities. USGS researchers, scientists and technicians rely on the analytical services provided by the SedLab for generating sound scientific data of known quality. The proposed robotic system will be used to automate repeatable, labor-intensive tasks associated with handling, weighing, and identifying sediment samples for analysis.

Environmental samples are analyzed to provide sediment data to the USGS and to the public to adequately inform water resources and sediment management decisions.

The SedLab analyzes approximately 3,000-5,000 individual samples every year. The analysis process for each sample involves determining sediment mass by measuring the weight of filtration crucibles, with and without sediment, on an analytical balance multiple times. This process usually requires a trained laboratory technician to perform repetitive tasks at a workstation for hours.

It is anticipated that the proposed system will automate the process and increase the efficiency of handling, weighing, identifying, and preparing sediment samples for further lab analysis.

2.0 APPLICABLE DOCUMENTS.

Not applicable.

3.0 GENERAL REQUIREMENTS/SPECIFICATIONS.

The objective of this project is to acquire a fully functional automated system that will allow operator free handling, weighing, and identifying of sediment samples (contained in small crucibles) in a humidity-controlled environment.

The Contractor shall perform system design, system hardware/software integration and development, and system installation activities necessary to meet the operational and functional requirements described herein. The Contractor shall also acquire all necessary hardware, software, and other components, except those identified as existing Government Owned Property, as well as perform on-site testing and training for operator personnel. User documentation and product instruction manuals shall also be provided.

3.1 Sequence of Operations. The delivered system shall be able to perform and repeat the required sequence of tasks (listed below) for handling, weighing, identifying, and preparing samples for analysis.

The initial sequence of events is provided to understand the full process and steps leading up the application of the robotic system. Samples are first handled by a lab technician following this sequence:

1. The lab technician loads crucibles onto custom designed racks, then loads racks into drying ovens. Complete drying of the crucibles is necessary for accurate and repeatable measures of mass.

2. After the crucibles are fully dry, the technician removes the racks from the oven and places them in desiccating cabinets to cool.

3. Once the crucibles are cooled to room temperature, the technician removes the racks and places them in the robotic weighing system enclosure.

The following sequence describes what will be automated by the robotic weighing system:

1. A dedicated computer system initiates the systems weighing protocol.

2. Robot grips first crucible in rack and places it in cup on barcode reader turntable.

3. Barcode reader turntable spins and barcode is read. Each crucible has unique barcode.

4. The analytical balance is zeroed-out (tarred).

5. The robot grips the crucible in the barcode reader turntable and moves it to the balance.

6. The balance draft shield is closed so the weight can stabilize, then the weight recorded.

7. The robot returns crucible to rack and advances to next crucible in rack.

8. When all the crucibles in the rack are weighed, the robot moves to the position of the next drying rack.

9. Robot repeats sequence until all racks are finished.

3.2 Operational Requirements. The system shall be capable of performing various operational processes/functions including:

Robot Control – the system shall include features that support various robot control functions such as:

- Controls via a communication pathway

- Command functions to train movement or points

- Control movements such as opening and closing gripper/pinchers

- USB/serial communications

- Ability to execute scripts to replay path or points while interacting with other components

- Ability to receive data from measurement devices (i.e. barcode value, weight, and humidity/temperature values)

- Ability to store data with a timestamp into a .csv file with filename

Barcode Scanner Control – the system shall include features and operations to control the barcode scanner including reading the barcode and integrating the value with other measured parameters.

Scale Control – the system shall include features and operations to control the scale, including reading the scale weight and integrating the data with other measured parameters. System shall also be capable of opening/closing the enclosure (draft shield) and zeroing-out (taring) the balance.

Environmental Sensor Control – the system shall be capable of reading humidity and temperature sensors values and integrating the data with other measured parameters.

System shall be capable of receiving and capturing data from the measurement devices, including crucible barcode value, sample weight, humidity/temperature values. Such data shall be time stamped and saved into a .csv file.

Contractor shall develop compatible communication protocols for each of the system components including interfacing to the sample placement area, bar code reader, and scale.

3.3 Required Equipment.

3.3.1 Hardware and Features. In general, the system hardware shall be comprised of various components including a robotic arm (or similar device) with internal controls, gripper/tongs, a barcode reader interface and turntable, an analytical balance, a crucible handling system (racks), humidity and temperature sensors, a personal computer, power supplies, multi-level table for mounting components, uninterruptable power supplies, and cabling. The entire system shall be housed in an aluminum, plexiglass, sealed enclosure that is designed, developed, assembled by the Contractor.

The salient features for the hardware components are given below:

At a minimum, the system shall include the following hardware components or alternative devices/technology with equivalent performance characteristics:

Robotic Arm – Espon model VT6L, or equivalent device

- Capable of performing the sequence of operations described herein.

- 6-axis robot arm with all-in-one design

- Up to 900 mm reach and payload up to 6 kg

- 6o of freedom range of motion

- Suitable for simple, small parts transfer applications such as pick-and-place, loading and unloading

- Repeatable accuracy of 6 +/- 0.1mm, or better

- Self-contained motor, controller, and amp units

- Suitable for tabletop mounting

- Fieldbus interface options

- No battery required for the encoder

- Hollow-end arm to facilitate cable routing and minimize cable pinching

- Capable of operating 110/220 VAC power source

Gripper Device – Zimmer model GEP50010-00A, or equivalent device

- Compatible with the robot arm described above

- 2-jaw parallel style gripper

- Capable of pneumatic operation

- 10 mm stroke

- Self-locking mechanism

- Capable of at least 30 million maintenance free cycles

- Adjustable gripping force

- Compatible control board (robot to gripper control signal HW)

- 24 Volt power supply

- The proposed gripping device shall be such that it can be changed, or the gripper can be modified, to accommodate weighing other container types.

Tongs

- Shall include 2 sets of compatible machined tongs.

- Shall be made of aluminum.

- Shall be designed for handling and securely moving the crucible during the weighing sequence of operations.

Bar Code Reader with Turntable – Datalogic brand or equivalent device

- Shall consist of a compact industrial, stationary bar code scanner that is compatible with the proposed system.

- Shall include a turntable that the crucible samples can be placed on, and rotated, allowing the reader to scan and capture the sample bar code, and integrate it with the applicable data record for each sample.

2D Barcode Labels

- The Government will supply 2D barcode labels.

- Contractor shall investigate the use of a bar code tape with multiple 2D barcode images that can be wrapped around the crucible to facilitate correct reading of the bar code.

- Bar code labels provided by Government will be capable of adhering to ceramic crucibles over multiple of cycles of heating to 103°C and sanitization in an industrial dishwasher.

Analytical Balance with Glass Enclosure (to be provided as Government Owned Property)

– will consist of a model Sartorius Secura 225D-1S Semi Micro Balance, or equivalent device and a compatible glass enclosure.

– the Government will supply the analytical balance.

Trays – shall include 10 trays consisting of source and destination trays. Each tray shall be capable of holding at least 30 crucibles. The number of crucibles may change based on the final dimensions of the trays. Trays shall include features to hold crucibles stationary and upright. System shall include features that allowing trays to be placed-guided by a frame to ensure proper location.

Crucible Handling System

The crucible handling system shall consist of 10 racks for placing, storing the crucibles.

Each rack shall have a solid sheet bottom and holes on a top layer to hold the crucibles upright and stationary. The racks will be designed to be compatible with current laboratory equipment in use. The Government will provide dimensions and any form factor requirements.

Crucibles – will be supplied by the Government. The lab currently uses CoorsTek model 60151, 40ml ceramic Gooch crucibles.

Environmental Sensors – Temperature and Humidity

Shall include 2 sets of Wi-Fi enabled temperature and humidity sensors. One set of temperature and humidity sensors shall be inside the plexiglass enclosure and 1 set installed outside the enclosure.

- Humidity sensors shall have a resolution of 1%, an accuracy of +/- 3 % or better, and a range of 5 to 95%.

- Temperature sensors shall have a resolution of 0.1 oC, an accuracy of +/- 1.0 oC or better, and a range of 0 to 60 oC or better.

Government Owned Computer

- The vendor’s system shall be compatible with the following: Dell OptiPlex 7020 Plus MFF with Windows 11 OS, Intel Core i5 14500T vPro processor, 16GB memory, 512GB SSD storage, WiFi and Ethernet compatible, and equipped with 3 USB port, 1 Serial Port, and 1 HDMI Port.

Calibration Hub

- Shall include a calibration hub/device that will allow robot arm to alert if it is out of calibration and to perform a reset as needed.

Enclosure with Table

Enclosure

- Shall consist of a humidity-controlled enclosure that houses all weighing system components.

- Shall be constructed of an aluminum framework and include plexiglass panels.

- Shall be sealed for humidity and temperature control purposes.

- Shall include doors with hinges for access.

Table

- Shall include a worktable for placing robot system and power system components.

- Shall have a lower level for the UPS system, power supply and facilities for cable routing.

- Shall have an upper level for the robot system.

- Tabletop shall be constructed resin material.

UPS System(s)

The system shall include adequate UPS capability to protect, and operate the system for orderly shutdown during unexpected power disruptions/outages.

E-Stop Feature

- Shall be a feature that will allow the robot arm movement to be stopped or suspended.

- In the event of an e-stop event, the system may require the gripper to have crucible removed and placed back in the tray.

Cabling

System shall be delivered with all necessary cabling including, Ethernet, USB, communication, power, etc.

Wi-Fi and USB/Serial Connectivity

The system shall include Wi-Fi communications for interfacing with the environmental monitoring sensors.

As needed, the system shall include USB connectivity or a USB interface hub as well serial communication capability.

Ethernet Connectivity

The system shall include Ethernet connectivity.

Optional Add-on Features

The system shall be designed/configured, or include facilities that support additional optional add-on features such as:

- Camera

- Static discharge station

- Dry air circulation

- dehumidifier

3.4 Software. The Contractor shall develop and implement custom software, as required, to meet the system operational/functional requirements as described herein.

Any software provided with hardware devices, such as the robot system, including licensing and development software, shall be integrated with software currently used by USGS, as needed, to meet the requirement herein.

The software base provided shall include:

- Time and date scheduling of operation

- Humidity monitoring with operational trigger at levels recorded

- User interface to note status and operation

- Recovery from component and/or robot system errors,

- Calibration

- Carousel and sampler setup

- Verification and validation of data

- Logging of errors including recovery from illegible bar code scanning

Contractor shall create an extendible database that allows for full output capability and allow data mining, indexed records, reporting, and data backup.

Database and Reports – system shall be capable of providing a .csv output file for the data. Data shall also be provided in simple report output such as .ascii or .txt.

3.4.1 Intellectual Property. Any software or programming created under this agreement will be the property of the Government.

3.5 System Integration. The Contractor shall perform all steps necessary to successfully integrate all components, including hardware, software, and Government Owned Equipment to meet the requirements listed herein.

3.6 Final Assembly, Start-Up, and Testing Final assembly of the system shall be performed on-site at the USGS Water Science Center in Santa Cruz, CA.

3.6.1 Installation and Setup. The robot system, software, and all associated equipment/components shall be delivered, assembled, and setup, at USGS office in Santa Cruz, by the Contractor.

3.6.2 Software Installation. The Contractor shall install and initialize all required operational software as applicable.

3.6.3 Start-Up and Checkout. The Contractor shall complete the start-up steps for the system and make all the necessary adjustments to ensure the system is functioning properly,

3.6.4 Calibration and Functional Testing. The Contractor shall perform (1) any and all necessary equipment calibrations, and/or (2) functional tests to demonstrate the system performs in accordance with the requirements specified herein.

3.7 Training. The Contractor shall provide system operator training for up to two USGS employees. At a minimum, the training shall cover system setup and operation, basic robot operation and features, software operation, calibration (as necessary), general maintenance, and preventive maintenance.

3.7.1 Training Schedule. Training shall be scheduled and tailored by mutual agreement between the Contractor and the Government.

3.8 Government Owned Equipment. System will be integrated with the following existing government owned equipment:

Existing Government Computer –The PC is aDell OptiPlex 7020 Plus MFF with Windows 11 OS, Intel Core i5 14500T vPro processor, 16GB memory, 512GB SSD storage, WiFi and Ethernet compatible, and equipped with 3 USB port, 1 Serial Port, and 1 HDMI Port.

Analytical Balance – Sartorius Secura 225D-1S Semi Micro Balance. The Government will provide an equivalent balance if there are programmatic control issues with the current one.

Bar Code Labels – 2D bar code labels

Ceramic Crucibles – CoorsTek 60151 ceramic Gooch-style crucibles (40 mL capacity)

Technical Data – product dimensions, form factors, or other technical data of existing components as needed by the Contractor.

Data Output Format –examples of required data output file formats.

Other – As required, samples or other parts, or components that may be needed by the Contractor for performance of the contract.

Laboratory Drying Ovens –drying ovens used for the analysis of sediment samples. The ovens will allow for the complete drying of the sediments contained in ceramic crucibles with glass-microfiber filter pads.

Desiccating Storage Cabinets –desiccating storage cabinets to allow the crucibles to cool in a low humidity environment after being removed from the drying ovens.

3.9 Deliverables.

Robot System for Weighing Samples – one fully functional automated system as described herein.

Software (Source Code) – The Contractor shall provide all software including source code and licensing. All source code shall be provided to USGS and the USGS shall have all rights to own and modify the code as determined by USGS personnel.

Licensing shall allow USGS to maintain and modify any and all parts of the software provided.

User Documentation - shall include all documentation to allow operational understanding of the robot system. All source code shall be provided to USGS and the USGS shall have all rights to own and modify the code as determined by USGS personnel.

Documentation and Source Code. Shall include documentation to allow operational understanding of the robot system. All source code shall be provided to USGS and the USGS shall have all rights to own and modify the code as determined by USGS personnel.

3.10 Miscellaneous Requirements.

3.10.1 Environmental Protection & Safety. The Contractor shall be knowledgeable of and comply with all applicable federal, state, and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health while working on the Government premises.

3.10.2. Warranty. Supplies and services furnished shall be covered by warranty from defects in design, materials, and workmanship. The warranty shall be the manufacturer’s standard commercial warranty (not less than one year), which shall conform to all the requirements of the contract. The warranty period shall commence from the date of acceptance.

4.0 QUALITY ASSURANCE PROVISIONS

4.1. Responsibility for Inspection. The Contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein.

The Government reserves the right to perform any of the inspections set forth in this specification, where such inspections are deemed necessary to assure supplies and services conform to the prescribed requirements.

4.1.1. Basic Performance/Operational Tests. Basic performance/operational tests shall be conducted by the Contractor on the equipment and software to demonstrate the ability of the system to perform as required in this specification.

5.0 DELIVERY AND PERFORMANCE

5.1 Delivery Period for Equipment. The system shall be delivered and installed within 365 calendar days following contract award. The specific date and time for equipment delivery shall be coordinated between the Contractor and Technical Liaison.

5.2 Packaging/Packing. Preservation, packaging, and packing shall be in accordance with standard commercial practice, adequate to ensure acceptance by carrier and safe arrival at destination.

5.3 Work Area. Once work is completed; Vendor and USGS personnel will conduct a walk through to all associated spaces to ensure all work is complete, no damages to property, and all packing materials and trash is removed.

5.4 Delivery Point. Delivery of all items shall be made F.O.B. Origin, within consignee’s premises to the address set forth below:

U.S. Geological Survey Santa Cruz Sediment Laboratory California Water Science Center 2885 Mission Street Santa Cruz, CA 95060