CSS 04-3014 Optical Comparator V3.pdf

CALIBRATION STANDARD

SALIENT SPECIFICATION

OPTICAL COMPARATOR

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

CSS 04-3014

DISTRIBUTION STATEMENT C. DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENT AGENCIES AND THEIR

CONTRACTORS TO PROTECT PUBLICATIONS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR

OPERATIONAL PURPOSES ONLY. OTHER REQUESTS FOR THIS DOCUMENT SHALL BE REFERRED TO

MEASUREMENT SCIENCE DIRECTORATE, NAVAL SURFACE WARFARE CENTER, CORONA DIVISION, P.O.

BOX 5000, CORONA

A, CA, 91718-5000.

AUGUST 2023

CALIBRATION STANDARD

SALIENT SPECIFICATION

OPTICAL COMPARATOR

Prepared by:

Measurement Science MS33

Physical/Mechanical Standards (MS 33)

Measurement Science Department

Naval Surface Warfare Center, Corona Division

P.O. Box 5000

Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

OPTICAL COMPARATOR CALIBRATION STANDARD SPECIFICATION CSS 04-3014

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Table of Contents

1.0 SCOPE

1.1 General

1.2 Usage

1.3 Classification

1.3.1 Class

1.3.2 Configuration

1.3.3 Color

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents

2.2 Order of precedence

3.0 REQUIREMENTS

3.1 Equipment components

3.1.1 Equipment configuration

3.1.1.1 Main Unit

3.1.1.2 Control system

3.1.1.3 Software. At a minimum, the

3.1.1.4 Standard Artifacts:

3.1.1.5 Accessory set

3.1.1.6 System fittings and connectors: The

3.1.2 Finish

3.1.3 Interchangeability

3.2 Design and construction

3.2.1 Operator adjustments and controls

3.2.2 Wiring, internal

3.2.3 Warranty

3.3 Electrical power sources and connections

3.3.1 Electrical power source

3.3.2 Electrical power connections

3.3.2.3 Main unit

3.3.2.4 Control System

3.4 Environmental requirements

3.4.1 Warm-up

3.4.2 Temperature and humidity

3.5 Performance requirements

3.5.1 Range

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3.5.2 Resolution

3.5.3 Repeatability

3.5.4 Flatness measurement

3.5.9 Cable assemblies

3.6 Maintainability

3.6.1 Fault isolation

3.6.2 Repair

3.7 Calibration

3.7.1 Calibration certificate

3.7.2 Calibration methodology

3.7.3 Calibration interval

3.7.4 Calibration procedure

3.8 Technical manuals

3.8.1 Style and format, technical manuals

3.8.2 Content, technical manuals

3.8.3 Symbols

3.9 Workmanship

3.10 Installation

3.11 Training

4.0 VERIFICATION

4.1 General

4.2 Technical Manual Review

4.3 Conformance inspections

4.3.1 Production inspection

4.3.1.1 Group A inspection and test

4.3.1.1.1 Preoperational inspection

4.3.1.1.2 Level A performance tests

4.3.2 Test plan

4.3.3 Failure criteria

4.3.4 Test conditions

1.0 SCOPE

The purpose of this Calibration Standard Specification (CSS) is to provide the requirements necessary to replace the Navy’s current Calibration Equipment (NCE), Optical Comparators.

1.1 General. This document specifies the minimum requirements for the optical comparator replacement system with three-dimensional multisensory measurement system such as smartscope or vision systems. This equipment may be of a commercial design or modified commercial design. The optical comparator replacement system is intended to be used by Navy personnel in shore-based depot laboratories for calibration of a wide variety of volumetric measurements (3D) and angle measurements including thread ring gages, thread plug gages, almen gages, and inspection fixtures.

1.2 Usage. Equipment covered by this Calibration Standard Specification (CSS) is intended for use in calibrating gages and fixtures in the controlled environments.

This equipment requires to measure length in x, y ,z dimensions and angles including all thread gages (W grade) and Navy inspection fixtures. The requirements of this CSS are tailored to the intended use of the equipment.

Specific requirements of MIL-PRF-28800G, as identified in this CSS, are invoked according to the class of equipment.

1.3 Classification. Test equipment specified herein is categorized by class, (requirements arising from the intended operational environment), as specified below in 1.3.1 Class through 1.3.3 Color. The class is assigned by the most severe environmental condition expected for the equipment.

1.3.1 Class. The optical comparator replacement system shall be classified as Class 3 equipment and shall conform to Class 3 requirements in accordance with MIL- PRF-28800G, and as specified in this specification. Class 3 equipment is designed for operational environments where conditions are routinely encountered in a diverse, controlled climate.

1.3.2 Configuration. The optical comparator replacement system shall at a minimum accommodate a 0-80W Set Plug as well as a 6.000-4W Set Plug. The system shall be supported on floor or bench top with elevating bridge.

1.3.3 Color. The color of the optical comparator replacement system and the transit cases shall be the color normally provided by the manufacturer but shall not be green, magenta, or red.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-28800G - Test Equipment for use with Electrical and Electronic Equipment, General Specification for

MIL-PRF-38793 Manuals, Technical: Calibration Procedures Preparation of.

(Copies of DoD specifications are available online at https://quicksearch.dla.mil/qsSearch.aspx/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

NIST Technical Note 1297 - Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results

Copies of NIST Technical Notes are available online at http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s or from the National Institute of Standards and Technology, Gaithersburg, MD 20899-0001

NAVY METROLOGY AND CALIBRATION PROGRAM

NAVAIR 17-35QAC-01B Navy and Marine Corps Calibration Laboratory Audit/Certification Manual

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence.

Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Equipment components. Parts, materials, and process shall be as specified below in 3.1.1 Equipment Configuration through 3.1.3 Interchangeability.

3.1.1 Equipment configuration. The optical comparator replacement system shall consist of a main unit a control system with a display Console, software, traceable standards and all accessories. The Main Unit shall consist of a worktable and multisensor measurement system necessary to meet the performance requirements of this CSS. The Control system shall consist of a system driver and system controller to operate the instrument, software.

3.1.1.1 Main Unit. The optical comparator replacement system shall be designed to facilitate quick and easy installation and removal of test instruments. The http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s worktable shall be hard coat anodized with fixture holes, include removable stage glass, rotary vise and can handle 50 lbs test equipment. The main unit shall be designed to include multisensor measurement system and shall make measurements via optics, interferometry, form trace, or a combination of these three. The main unit shall be designed with an elevating bridge, a combining video and autofocus to perform accurate measurement with high productivity.

The system shall have multiple illumination sources, including sub-stage profile light, coaxial surface light and green LED oblique illuminator to detect an edge of test instrument.

3.1.1.2 Control system. The Control System shall consist of a system driver and system controller. The system driver shall consist of DC servo with 4-axis control (x, y, z and zoom), an air bearing z axis with multifunction handheld controller. The system controller shall be a PC Windows 11 based with up-to-date processor.

The PC based compatible controller with the latest generation microprocessors, all required operating software, cabling, keyboard, mouse, and all interface connections necessary to operate the system and meet the requirements of this CSS. The PC shall support USB 2.0 or better and include a DVD/CD write capable drive. The system controller shall include a printer for hardcopy of data, charts, and graphs. The Control console shall also include a minimum of a 24-inch color monitor for displaying all necessary control and measurement information.

3.1.1.3 Software. At a minimum, the optical comparator replacement system shall come with 3D metrology software to process the data from high speed camera and scanning laser. The software must be capable to operate offline and might come with live visualization to capture display values of the TI. Complete copies of the executable software (latest version) shall be provided with each system.

3.1.1.4 Standard Artifacts: The optical comparator replacement system as a complete system shall consist of all standard artifacts such as precision grids and lines scales to calibrate the system in x-y-z direction. All standards shall be able to be calibrated by the Navy Primary Standards laboratory and shall be traceable to National Institute of Standards and Technology (NIST).

3.1.1.5 Accessory set. The optical comparator replacement system as a complete system shall consist of all mounting and holding accessary set to support a wide variety of gages and fixtures such as V-blocks and mounting for all thread plugs.

In addition, the compressed air shall be required; thus, the air dry kit must be provided as a system. If flank angle measurements are made optically, then the helix of the angle must be address.

3.1.1.6 System fittings and connectors: The optical comparator replacement system as a system shall include all fittings and connectors required to connect the system together for measurement.

3.1.2 Finish. Unless otherwise specified the equipment shall be the finish normally provided by the manufacturer.

3.1.3 Interchangeability. A model number shall be designated for all units provided.

All units with the same model number and the replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis.

3.2 Design and construction. The optical comparator replacement system shall be designed and constructed to permit compliance with all applicable requirements, as defined in this CSS as well as the operation, performance, accuracy, and other requirements in this CSS.

3.2.1 Operator adjustments and controls. Operator adjustments and controls shall be as specified below in 3.2.1.1 Operator adjustments and 3.2.1.2 Operator controls.

3.2.1.1 Operator adjustments. The optical comparator replacement system shall include adjustments or compensating methods for any function or parameter that would exceed the specified tolerance within the calibration interval defined in 3.7.3 Calibration interval. All adjustments or compensation methods shall be able to be completed by Navy personnel. Under all specified service conditions the variation of any adjustment or control shall produce the desired control action to bring the system within tolerance.

3.2.1.2 Operator controls. Operating controls shall be readily accessible to the operator from the front of the equipment. All operator controls shall be clearly labeled.

The readings presented on the control/ metrology software shall be available to the operator without extra conversion or calculation.

3.2.2 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance and calibration.

3.2.3 Warranty. The optical comparator replacement system shall have a minimum of a one year warranty after initial installation.

3.3 Electrical power sources and connections. The electrical power sources and connections shall be as specified below in 3.3.1 Electrical power source and

3.3.2 Electrical power connections.

3.3.1 Electrical power source. The optical comparator replacement system shall operate at nominal voltage of 120 VAC, single-phase 50 Hz and 60 Hz source.

3.3.2 Electrical power connections. The requirements specified in 3.3.2.1 Input power cable through 3.3.2.4 Control Console shall apply to equipment rated at 10A rms, or less. Power connectors and connections for equipment rated above 10A rms shall be as specified in the purchase description. When single-phase operation is specified, the equipment shall operate with a ground at the primary power source on either or neither side of the single phase input power line.

3.3.2.1 Input power cable. Unless specified, the input power cable shall be a detachable power cable normally provided by the manufacturer.

3.3.2.2 Input power switches. The operator shall be able to energize the equipment to activate and deactivate the equipment. If such a capability is provided, suitable warnings shall be placed in the operating and service manuals and on the equipment to warn the operator of possible shock hazards during servicing, due to partially activated power supplies.

3.3.2.3 Main unit. The optical comparator replacement main unit shall be provided with a fuse or circuit breaker to protect the equipment in the event of excessive current.

3.3.2.4 Control System. The optical comparator replacement control system shall be provided with a fuse or circuit breaker to protect it in the event of excessive current.

3.4 Environmental requirements. The optical comparator replacement system environmental performance requirements shall be as specified below in 3.4.1 Warm-up through 3.4.2 Temperature and humidity. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.4.1 Warm-up. The optical comparator replacement system shall comply with the specified performance requirements after a 30-minute warm-up period preceded by a maximum 12-hour non-operating temperature stabilization period.

3.4.2 Temperature and humidity. The temperature ranges and humidity limits for operating conditions shall be as specified below in 3.4.2.1 Temperature operating and 3.4.2.2 Humidity operating.

3.4.2.1 Temperature operating. The optical comparator replacement system shall conform to the specified performance and accuracy while being operated at temperatures over the range of 67 °F to 69 °F.

3.4.2.2 Humidity operating. The optical comparator replacement system shall conform to the specified performance and accuracy while being operated a humidity range of 20% RH to 45% RH.

3.5 Performance requirements.

3.5.1 Range. The optical comparator replacement system shall be capable of measuring volumetric (x, y, z) and angles. In x, y and z directions, the system shall, at a minimum, accommodate a 0-80W Set Plug as well as a 6.000-4W

Set Plug. For angle measurement, the system must be capable of measuring throughout 360°.

3.5.2 Resolution. The optical comparator replacement shall be capable of recording a measurement within 1 µin. resolution and 30 seconds of arc or better.

3.5.3 Repeatability. The optical comparator replacement shall be capable of repeating measurements within 1 µin.

3.5.4 Flatness measurement: The optical comparator replacement shall be capable of measuring flatness.

3.5.5 Measurement uncertainty. The optical comparator replacement system as a complete system, shall be capable of measuring the below features with a test uncertainty, ratio of 4:1(Coverage factor of 2 IAW NIST Technical Note 1297):

SET PLUG Feature Tolerance

0-80 W lead/pitch 0.0001 in

0-80 W flank angle 20 mins

0-80 W root clearance

0.001563 in (nominal)

6.000 - 4 W lead/pitch 0.0003 in

6.000 - 4 W flank angle 4 mins

3.5.6 Data display formats. The optical comparator replacement system as a complete system, shall be capable displaying measurement data in a spreadsheet format with user selectable fields. Data shall be selectable measured parameters such as length, angle and flatness.

3.5.7 Data printing and graphing. A color printer shall be provided with each system.

The optical comparator replacement system shall be capable of color printing and graphing all data and the Report of Calibration and Certificate of Calibration.

Printing shall be in user selectable fields as described in 3.5.6 Data display formats. All graphs shall have user selectable ranges, units, resolutions, scaling, and headings/titles.

3.5.8 Data storage and export. The optical comparator replacement system shall store calibration data in user-selected data fields. Data shall be stored in a format that can be easily retrieved and displayed. All data shall be capable of being easily exported to Microsoft Excel spreadsheets in user selectable fields.

The operating environment of the controller will support Microsoft Excel 2016 and later editions in use at the time of contract award.

3.5.9 Cable assemblies. All cable assemblies such as power cable, external signal cable, external motor cable and USB cable to support the optical comparator replacement system shall be provided.

3.6 Maintainability. Maintainability shall be as specified below in 3.6.1 Fault isolation through 3.6.2 Repair.

3.6.1 Fault isolation. The design of the equipment shall permit isolation of faults, and repair down to the component/subassembly item or lowest replaceable unit with the maintenance provisions furnished.

3.6.2 Repair. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies and subsequent testing procedures to ensure the performance of the component or the repair action taken. Spare parts information shall be provided for all major components of the system.

3.7 Calibration. The optical comparator replacement system shall meet the calibration requirements as specified below in 3.7.1 Calibration certificate through 3.7.5 Alignment. For the purpose of this CSS, calibration refers to the process of comparing a test instrument with a calibration standard to determine the indicated error at specified test points. Alignment refers to the process of characterizing and adjusting a test instrument to cause it to indicate within its specified accuracy limits.

3.7.1 Calibration certificate. All equipment provided under this CSS shall have a current calibration certificate, with an accredited 17025:2017 report of calibration, a calibration data sheet, traceable to the National Institute of Standards and Technology (NIST).

3.7.2 Calibration methodology. The preferred calibration methodologies for the optical comparator replacement system shall be through a direct comparison method using standard artifacts. A minimum 4:1 test uncertainty ratio or better is necessary and uncertainty calculation must be provided. The system software shall support the above method.

3.7.3 Calibration interval. The minimum interval between calibrations shall be 12 months. At the end of this interval, a minimum of 85 percent of the system parameters shall remain in tolerance.

3.7.4 Calibration procedure. The calibration support methodology for the system shall be provided in the system documentation. The information provided must be sufficient to allow development of a Navy calibration procedure in accordance with MIL-PRF-38793.

3.7.5 Alignment. Alignment is the process by which individual system and their measurement circuitry and displays are adjusted to ensure that the system parameters are within the requirements for the overall system measurement uncertainty. Alignment shall not require use of external devices other than commercially available calibration/measurement standards. The optical comparator replacement system shall be capable of alignment in place by Navy personnel.

3.8 Technical manuals. Two copies of an operation and maintenance manual shall be provided with each unit. Technical manuals shall conform to the requirements specified in 3.8.1 Style and format, technical manuals through

3.8.3 Symbols. The technical manuals shall be provided in both printed and electronic format. The electronic copy shall be in a Portable Document Format (PDF) and Microsoft Word on a CD or DVD.

3.8.1 Style and format, technical manuals. All text shall be legible. A cover page shall include, equipment name and model number. A table of contents shall be provided.

3.8.2 Content, technical manuals. The contents of the technical manuals shall include sections addressing safety, general information, use and installation, maintenance and service. Drawings of the optical comparator replacement system with sufficient detail to identify all controls and connections shall be supplied. The content of the sections shall conform to the description provided below in 3.8.2.1 Safety, technical manual section through 3.8.2.4.2. Part replacement information.

3.8.2.1 Safety, technical manual section. The manual shall contain warnings, cautions and notes to prevent injury to personnel and damage to equipment. The warnings shall contain safety precautions where hazards such as high voltage, high pressure, and high temperature may be present during installation, operation, or maintenance.

3.8.2.2 General, technical manual section. The manual shall contain the following:

purpose and functions, capabilities, performance characteristics, description (model number, dimensions, and weight), power information, and operational environment requirements.

3.8.2.3 Use and installation, technical manual section. This section shall contain information on the following: operating instructions (illustrations and explanations of the uses and functions of all controls and software), initial adjustments and control settings, startup procedures, required clearances, illustrations of equipment connections, and installation precautions.

3.8.2.4 Maintenance and servicing, technical manual section. The level of maintenance philosophy shall be unit operational verification, and component level.

Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies on the systems. Testing procedures to ensure the performance of the component or the repair action taken shall be provided.

3.8.2.4.1 Cleaning maintenance. Cleaning information covering intervals, types of solvents, and materials used shall be listed in the maintenance and servicing section of the technical manual.

3.8.2.4.2 Part replacement information. Common commercial parts shall be identified by part number and description to facilitate substitutions of parts from other sources.

3.8.3 Symbols. All symbols used in the technical manual shall be standard or common to the trade. Where nonstandard symbols are used, explanations shall be provided.

3.9 Workmanship. The manufacture and assembly of the items covered by this CSS shall be representative of the best commercial practices and shall conform to the requirements of this CSS. All items will remain securely held in place during normal transit. Adequate protection will be afforded for the equipment on all sides to avoid transient damage.

3.10 Installation. The manufacturer will be responsible for installation of the optical comparator replacement system. The manufacturer will be responsible for shipping of the optical comparator replacement system to the receiving site.

Any damage to the shipping container will be reported to the manufacturer when received by the Navy. The Navy shall locate a delivered optical comparator replacement system in the test area where it will be used. The Navy will uncrate the optical comparator replacement system from its shipping container and position it as required. The manufacturer is responsible for all wiring and connections between the main unit, Interface electronics, Control system and Display Console, as well as all connections to power storage and printout sources. The Navy will provide the required power and facility in the test area.

The optical comparator replacement system must meet all CSS performance, functional and design requirements at the delivery site before the system is considered installed.

3.11 Training. After completion of the optical comparator replacement system installation, on-site training shall be provided by the manufacturer. Training shall include instruction on how to operate, maintain, and calibrate the optical comparator replacement system and shall include a) A complete review of all topics in the operating manual b) Instruction on the use of all software functions and menus. c) Calibration of the optical comparator replacement system d) Instruction on required periodic maintenance. Only one training session will be required at each installation site.

4.0 VERIFICATION

4.1 General. All optical comparator replacement system procured shall be capable of satisfying all of the requirements indicated in Section 3 of this CSS and shall be subjected to testing. Verification shall be accomplished by using the test procedures in MIL-PRF-28800G for Class 3 equipment for those tests identified and as modified in the following paragraphs.

4.2 Technical Manual Review. The optical comparator replacement system Technical Manual(s) shall be reviewed and examined for compliance with the requirements specified in paragraph 3.8 Technical manuals of this CSS.

4.3 Conformance inspections. The test methods, procedures, and conditions specified in 4.3.1 Production inspection, Group A through 4.3.5 Accuracy of test instruments are required for conformance inspection.

4.3.1 Production inspection, Group A. Each unit shall be subjected to the Group A inspection and test of 4.3.1.1 to ensure qualitatively the proper functioning of the equipment, including all operating controls, and conformance with safety requirements.

4.3.1.1 Group A inspection and test. Group A inspection shall consist of the inspections of 4.3.1.1.1 Preoperational inspection through 4.3.1.1.2 Level A performance tests.

4.3.1.1.1 Preoperational inspection. The preoperational inspections shall consist of mechanical and visual examination and test to determine that all materials, workmanship, and safety characteristics comply with the specified requirements. The equipment shall be examined or tested to confirm that all electrical wiring is correct and that no mechanical problems are evident.

4.3.1.1.2 Level A performance tests. The Level A performance tests shall verify conformance of the system to the performance requirements of this CSS. At a minimum the Level A performance tests shall include the following:

calibration of all required system parameters, verification of system capability, system calibration demonstrations including thread gages and connector gage kits.

4.3.2 Test plan. An equipment test plan shall be developed by the manufacturer. The test plan must be reviewed and approved by the Navy prior to installation of the system. The test plan shall be used to verify conformance to the requirements of the contract and this specification.

4.3.3 Failure criteria. For the purposes of this CSS, equipment failure is defined as any departure from the required performance requirements or operation outside of the required accuracies (not correctable by normal use of the operating controls), or deviation from the criteria specified in 3.5 Performance requirements after the test is initiated. The item shall have failed the test when any of the conditions specified in a. through g. below occur:

a. Monitored functional parameters deviate beyond acceptable limits

b. Catastrophic or structural failure

c. Mechanical binding or loose parts, including screws, clamps, bolts, and nuts, that results in component failure or a hazard to personnel safety

d. Malfunction

e. Degradation of performance beyond limits established in the purchase description

f. Any additional deviations from acceptable criteria established before the test

g. Deterioration, corrosion, or change in tolerance limits of any internal or external parts that could in any manner prevent the test item from conforming to operational service or maintenance requirements

4.3.4 Test conditions. Unless otherwise specified the inspections specified herein shall be performed under the conditions of a. through d. Ambient conditions within the specified ranges need not be controlled. For equipment having a specified warm-up or stabilization period after turn-on, formal measurements and observations shall be made only after the specified time period as specified previously in 3.6.1 Warm-up.

h. Temperature: 67 °F to 69 °F

i. Humidity: 20% RH to 45% RH

j. Power: Nominal or alternate power source specified for the equipment

k. Attitude: Normal operating position

4.3.5 Accuracy of test instruments. The test instruments used to control or monitor the test parameters shall be verified to be within their calibration cycle prior to performing tests.