C04a SOW 1232SA26Q1128.pdf

US Department of Agriculture (USDA)

Statement of Work

Contents Project

General Information

1.0 Scope of Work

2.0 Background

Contractor Requirements

3.0 Technical Requirements / Tasks

4.0 Government Furnished

5.0 Deliverables / Schedule

6.0 Travel

7.0 Contractor’s Key Personnel

8.0 Security Requirements

9.0 Data Rights

10.0 Section 508 – Electronic and Information Technology Standards

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Project Flexible film materials testing system

General Information

1.0 Scope of Work

The vendor shall provide a fully integrated 5 kN universal materials testing system, including a dual-column load frame, load-weighing system, control software, and data acquisition electronics. The system must meet all specified performance, safety, and compatibility requirements, including precise crosshead control, calibrated load cells, collision mitigation features, and multi-mode mechanical testing capability. The supplier shall install the equipment, verify performance to applicable ASTM specifications, and deliver on-site training along with full documentation. The vendor shall also provide warranty coverage and access to factory-trained service personnel for support and maintenance.

2.0 Background

The USDA is working with collaborators to develop and identify food packaging materials that are resistant to insect feeding and penetration under long term storage conditions and requires an instrument that is capable of testing physical properties of various materials used in food packaging, including woven bags and thin films, for elongation, penetration resistance, tensile strength, seal strength and puncture resistance following published American Society for Testing and Materials standard methods. The instrument must have a load measurement accuracy of +/- 0.5% down to 1/250th of a load cell capacity and +/- 1.0% down to 1/500th of load cell capacity. It must meet or exceed ASTM eF, BS1610, DIN, 51221, ISO 7500-1, EN 100002-2, JIS B7721, JIS B7733, and AFNOR A03-501 standards. It also must have a displacement accuracy of +/- 0.02 mm or 0.15% of displacement (whichever is greater) and perform accurate measurements under a range of environmental conditions, including at storage temperatures ranging from -25-55 C and at 10-90% humidity.

Contractor Requirements

3.0 Technical Requirements / Tasks

II. MATERIAL TESTING SYSTEM SPECIFICATIONS

This unit shall integrate the following major sub-systems into a complete operating system. The major sub-systems and their specifications are:

A. LOAD FRAME

1. The load frame should be a dual column loading frame that includes a digital closed loop command and feedback motion control system with a high-performance AC servo motor.

2. The moving crosshead will be driven by precision screws each with a preloaded nut providing zero backlash during reverse stress loading. Systems without ball screws or preload nuts that are not preloaded are not acceptable.

3. For lateral stiffness and robustness purposes, in addition to the ball screws described above, the load frame should include at least two (2) 25 mm diameter smooth ground guidance rods that the moving crosshead also rides on.

4. The moving crosshead must be a solid single machined piece that encloses the ball screws and guidance rods for maximum overall stiffness

5. The ball screws shall be fully enclosed to eliminate pinch points and protect the precision surfaces from damage from grips and contamination.

6. The load frame shall include a bright red ISO approved emergency stop switch.

7. The vertical distance between the load frame table and crosshead shall be 1172 mm (46.1 in) and for load cells, grips and fixtures. Maximum distance of 1651 mm (65.0 in) is an option.

8. The maximum load capacity shall be 5 kN (500 kgf, 1125 lbf)

9. The speed range should be 0.05 to 1016 mm/min (0.002 in/min to 40 in/min).

10. The maximum crosshead return speed is 1500 mm/min (59 in/min) for rapid testing turn-around.

11. The steady state speed accuracy shall be within +/-0.2%, of set speed measured over full speed range.

12. The frame shall have variable speed jog with software-defined speed. When jog is initiated, the crosshead shall gradually accelerate to reach a maximum jog speed of 1500 mm (59 in) per minute.

13. The frame column shall be powder coated to resist dents and scratches for protection.

14. The frame column shall have t-slots to allow easy attachment and movement of accessories without need to drill or use fasteners.

15. The frame column shall have a fixed measurement tape rule for easy spotting and setting of the moving crosshead and test load strings.

16. The load frame will have two secondary position limits using a microswitch to prevent crosshead run-away as a system fail-safe. The user settable limits must be attached to a solid metal rod for durability and stiffness.

17. For safety purposes, the frame shall incorporate an auto-frame standby mode that automatically stops the frame when the transducer, interface, or computer is disconnected or shutdown.

18. The system shall have an operator panel with buttons to start and stop tests, return crosshead to the origin, and jog the crosshead. The operator panel shall contain four colored status LEDs to indicate the status of the system:

disabled (white), setup (blue), caution (yellow), and testing (red).

19. The machine's movement is restricted to prevent unintended motion of the crosshead with an Operator Protect function - a two-button press sequence to move between testing modes.

20. The system shall have an Operator Protection mechanism that allows limiting crosshead jog speed and reduce grip closing pressure while setting up a test.

21. The system shall include a “PIP” input jack to allow use of an external pipping device to manual mark points of interest during data acquisition

22. The system shall have a 25 pin connection for an auxiliary encoder.

23. The system shall have active LED indicators for the user to quickly determine system status.

Users are provided clear communication on when it is safe to enter, and when to stay clear of test space. The LEDs on the Operator Panel shall match the software’s border to indicate that status of the system at all times.

24. The system shall have exhaust vents with filter to help minimize particle ingress and regulate the frame internal operating temperature.

25. The system shall include four shock absorbing feet on each corner of the frame that can be (height) adjusted for leveling the test frame. The feet must be designed for absorbing shocks to minimize vibrations to the test frame and transducers.

26. The system shall include a Collison Mitigation function to reduce damage to equipment and delicate specimens by stopping the crosshead if force is detected upon return or during a jog. The crosshead will also automatically reverse marginally to prevent damage and allow safe removal of any contacted object.

27. The system shall allow continuous operation for up to ten days (14400 hours).

B. LOAD WEIGHING SYSTEM, TRANSDUCERS, & ELECTRONICS

1. The load weighing system accuracy shall be within +/-0.5% of reading down to 1/250th and within +/- 1% of reading down to 1/500th of the load cell capacity respectively.

2. Any load cell provided shall have over range protection that will stop the frame automatically.

3. Any changing of transducers on the test system must be Plug in, Calibrate, and Run - including changing load cells.

4. Transducers, including Load Cells and Extensometers must be single piece assemblies to avoid mismatch of parts.

5. Load cells must be complete assemblies with a rigid clevis connection for easy and quick attachment to fixtures.

6. The system shall be equipped with Collision Mitigation which monitors the load readings during jog and return and will stop the crosshead if unexpected load is observed. The crosshead will also automatically reverse marginally to prevent damage and allow safe removal of any contacted object.

7. The data acquisition (DA) electronics shall be designed to be located in the test frame close to the load cell and properly shielded from the known electronic noise generated in the test frame.

8. The transducers will be automatically identified by the electronics and software with automatic calibration. This eliminates the need for any calibration curves storage or correction.

9. The system shall be compatible with Instron 2519, 2530, 2580 Series load cells used with Instron dual column table-top 336X, 446X, 556X, and 596X test systems.

B. PNEUMATIC AIR CONTROL KIT (OPTIONAL)

1. The system shall have a pneumatic air control kit integrated into the base of the frame with a push-fit connection for the inlet, accepting up to 120 psi (8.3 bar).

2. The air kit shall provide connections for two pneumatic grips via push-fit connections.

3. The air kit shall be activated with a dual-pedal footswitch. The right pedal shall close one grip upon the first press and the second grip when pressed again. The left pedal shall open both grips simultaneously.

4. The air control kit shall include a dual-stage pressure manifold which initially closes the grips at a lower administrator defined pressure in the testing software.

5. Upon starting the test, the air control kit shall move to a higher, method-defined pressure.

C. TEST FRAME CONTROL

a) The control software will have a graphical user interface meeting all Microsoft Windows standards.

b) The software must have multi levels of user access based on his or her login name and password, including support for Windows Active Directory.

c) The testing software must be able to perform tensile, compression, flexural, peel, tear, friction, and cyclic testing with an appropriate calculation list for each type of test.

d) Digital displays on the computer monitor should show live load and displacement values. Units that can be selected to be Metric, S.I., U.S. customary.

e) The system shall include a context sensitive help and reference system with hot links.

D. DATA ACQUISTION

a) The system electronics shall have an internal sampling rate of 40 kHz.

b) The control software shall be capable of acquiring data at 1000 Hz across load, displacement, and up to two optional strain channels. Data rates should not be affected by the number of strain channels collected. Maximum data rates shall be maintained throughout any test duration period without a time limit.

c) The system shall have an auxiliary digital encoder channel for connecting optional digital devices.

E. SERVICE & INSTALLATION

1. Factory trained service engineers must be available for additional training or warranty service.

2. The supplier shall install the system, verify load to ASTM specifications, and provide basic on-site training.

3. The system shall include a full illustrated operators manual.

F. WARRANTY

1. The system shall have the mechanical load frame covered under warranty for a period of 10 years from date of installation. Warranty shall cover cost of replacement parts and repair labor.

4.0 Government Furnished

• One government PC will be furnished to run the machine software

5.0 Deliverables / Schedule

All written deliverables shall be phrased in layperson language.

• The operating system training, including test method development for up to 3 operators, shall be completed at the time of installation of the machine.

6.0 Travel

• Travel expenses must be included in the vendor’s proposal.

7.0 Contractor’s Key Personnel

Describe positions which are considered key to successful performance of the contract and the information required to support key personnel qualifications, e.g., experience which correlates to SOW requirements, education, and past performance on similar projects. Specify if resumes are required and provide resume format if appropriate.

Insert Contractor’s Key Personnel Here

8.0 Security Requirements

Work onsite must be performed between the hours of 8:00 am and 4:30 pm. Visitor’s must present a valid driver’s license or state issued identification in order to gain access to our facility.

9.0 Data Rights

N/A

10.0 Section 508 – Electronic and Information Technology Standards N/A