DRAFT SOW.docx

PR # (remove when RFP # identified)

RFP N00173-XX-R-XXXX

Attachment # Date: XX/XX/XXXX

Naval Research Laboratory 4555 Overlook Avenue SW Washington DC, 20375-5329 Code 0000

Commissioning of NRL 66.7 Multi-axis Loading Robotic System Statement of Work (SOW)

20 May 2026

RFP N00173-18-R-MJO1

Attachment #6 Date: 11/07/2020

B2a SOW Sample_1117

STATEMENT OF WORK

(Insert Program title)

Table of Contents

Section 1 Background‑. Material tensile loading is primarily done by clamping two ends of a specimen and stretching it using a linear actuator. NRL has instead developed a multi-axis loading robotic system that can apply loads to the specimen in any direction, at any torque, and at high frequencies. This technology is used for the application of cyclic fatigue loading of sample specimens in a high speed, arbitrarily complex, and multiaxial frequency manner on order to simulate real world loading scenarios of said specimens. This is expected to lead to more optimized design of mechanical and airframe parts while also helping future customers to prevent catastrophic system or platform failures.

NRL seeks to 1) Commission the most recent iteration of the multi-axial tensile loader, codename “66.7”. This robotic system is mostly constructed; however the final hardware pieces and system design require dedicated engineering expertise. NRL also seeks to 2) prepare 66.7 for transfer to commercial entities. This includes formalizing blueprints, system hardware manuals, assembly instructions, etc. NRL wants to turn the 66.7 into something that can be ordered at a commercial/industrial level.

Section 2 Objective/ Scope‑. For the commissioning of the 66.7, the scope centers around design and provision of several pieces of hardware. Specifically, these cover hydraulic grips, weldments, spacers, hydraulic controls, mounting plates, safety shield, wheeled cart, and other safety and quality-of-life design considerations. The contractor should be proficient in machining large parts (weldments), hydraulic systems, and precision machining (encoder mounts). The contractor will be designing many of these systems in addition to providing the hardware. Electronics control expertise is not required but desired for integration of hydraulic electronic controls.

At the end of the contract performance, the robot is expected to be able to grip vertical specimens of various given lengths utilizing hydraulic grips. Once gripped, the existing hydraulic hexapod structure will be able to perform 3D displacement tests and 3D torsion (bending) tests on the specimen. In short, the robot is to be used for bending metal specimens to extract material properties. Said robot requires upgraded safety measures including a safety shielding enclosure and hydraulic lashing. Software and electronic controls are provided by NRL, this contract is strictly for hardware acquisition, robotic assembly at NRL, and system documentation.

For the commercialization of the 66.7, NRL seeks contractor expertise in compartmentalizing the 66.7 subsystems, and recommendations for system design simplification. It is understood that the 66.7 system is a custom construction for a laboratory setting. As such, many of the subcomponents could potentially be simplified or compartmentalized for production by different commercial entities, streamlining future system construction. The goal is to have instructions for constructing a system that a non-NRL entity can construct at the request of a potential client.

Section 3 Applicable Documents.

3.

3.1. Electrical Control Box Diagrams and Circuitry (Burks Engineering) NRL-00001-DWG

3.2. Solidworks files of 66.7 and 66.5 systems

3.3. Position Encoder Mount diagrams

Section 4 ‑ Requirements‑.

4.

4.1. Hydraulic grips and Support Systems

4.1.1. 2 count Collet Blocks, equivalent to “FlexC® 42 Hydraulic Collet Block (65502H) 2000psi”

4.1.2. 4 count FlexC Collets compatible with NRL flat specimens and “FlexC® 42 Hydraulic Collet Block (65502H) 2000psi”

4.1.3. 4 count FlexC Collets compatible with NRL round specimens and “FlexC® 42 Hydraulic Collet Block (65502H) 2000psi”

4.1.4. 1 count hydraulic pump: Enerpac PUJ-1200B or equivalent

4.1.4.1. Must have manual control

4.1.4.2. Must generate 5000+ PSI

4.1.4.3. Must run on 115/120VAC using standard NEMA-15 plug

4.1.5. 1 count controls for routing hydraulic power to top and bottom collet blocks to open or close them on demand.

4.1.5.1. Must have controls to

4.1.5.1.1. “enable”

4.1.5.1.2. “close top grip”

4.1.5.1.3. “open top grip”

4.1.5.1.4. “close bottom grip”

4.1.5.1.5. “open bottom grip”

4.1.5.2. Must have manual mechanical controls such as switches or knobs to execute the above commands.

4.1.5.2.1. Must have a 15ft cord for remote control

4.1.5.2.2. Must be hardwired, no wireless technologies permitted

4.1.5.3. Must have option to accept electronic control using 24V @ 0.5A maximum (overridden by manual switches). Must integrate with M12-8A Male Plug (commands) and M12-4T male plug (enable/disable command)

4.1.6. Hydraulic lines, rated to at least 3000psi with appropriate hydraulic fittings

4.1.6.1. 2 count Lines to and from pump to hydraulic controls, 30ft length

4.1.6.2. 2 count hydraulic routing system, solenoid or similar. See hydraulic controls section. System must be equivalent to Parker Fluid Control Division 71215SN2MN00N0C111C2 Solenoid Valve, 2-Way Normally Closed, 1/4" NPT, Direct, 24 VDC, 7000 Series

4.1.6.3. 4 count Lines to and from the hydraulic routing system to collet inputs, 6ft. length.

4.1.6.4. Adapters and hardware for connection between hydraulic lines and pump (1/4 NPT for PUJ-1200B), hydraulic routing systems, and collet inputs (1/4 NPT for 65502H)

4.1.6.5. Hydraulic lines must not leak under 2000PSI of hydraulic pressure along all 6 hydraulic lines described for 10 hours of continuous operation. Continuous operation defined as opening and closing the grips using manual and electronic controls.

4.1.7. 2 count ENERPAC Hydraulic Oil: HF-101, 1 gal, Jug, ISO Grade 32, Blue or equivalent

4.2. Risers and Adapter Plates

4.2.1. All components to be fabricated from A36 steel or equivalent.

4.2.2. Block tolerances of +/- 0.005” observed on all dimensions.

4.2.3. Interface surfaces between components to remain unpainted.

4.2.4. Adapter plates and risers must be manufactured so that the installed grips are parallel to each other, open/close in the same direction, and have hydraulic connection lines on the same side.

4.2.5. Non-interface surfaces to be painted with RAL7015 “Slate Grey” or equivalent

4.2.6. 1 count adapter plate “A” 1” in height between the 66.7 top platen and Interface 6A175C-Q11 loadcell

4.2.6.1. 66.7 top platen has 6 holes of 16mm diameter equally placed 60degrees apart along a circle with a radius of 70mm.

4.2.6.2. Interface loadcell specs are available from manufacturer

4.2.6.3. Adapter plate “A” needs bolt holes to be counter bored in order to provide a flush interface.

4.2.6.4. Adapter plate “A” must be bolted flush to the top of the top platen and flush with the Interface loadcell.

4.2.6.5. 6 count 5/8” diameter bolts and nuts for attaching plate “A” to top platen

4.2.6.6. 6 count bolts for attaching plate “A” to Interface loadcell

4.2.7. 2 count adapter plate “B” 1” in height between Interface 6A175C-Q11 loadcell and Hydraulic Collet Block (65502H)

4.2.7.1. Interface loadcell specs are available from manufacturer

4.2.7.2. Collet block specs are available from manufacturer. These bolt holes will need to be tapped for ½” thread

4.2.7.3. Adapter plate “B” needs bolt holes to be counter bored in order to provide a flush interface.

4.2.7.4. Adapter plate “B” must be bolted flush to the top of the interface loadcell and flush with the bottom of the bottom collet block.

4.2.7.5. 6 count bolts for attaching plate “B” to Interface loadcell

4.2.7.6. 4 count ½” bolts for attaching collet block to plate “B”

4.2.8. 3 count risers for connection between top of exoskeleton and adapter plate “B”

4.2.8.1. Exoskeleton has 12 holes of 16.5mm diameter equally placed 30degrees apart along a circle with a radius of 112.5mm.

4.2.8.2. Adapter plate “B” has been previously described

4.2.8.3. Exact riser height to be determined prior to manufacture

4.2.8.4. Risers will be of different heights in increments of 4”. For example, risers may be 8”, 12” and 16” tall.

4.2.8.5. 12 5/8” bolts and mating nuts for attaching riser to exoskeleton

4.2.8.6. 6 count bolts for attaching plate “B” to riser. These are to be the same as those used for attaching plate “B” to interface loadcell

4.3. Mounting of position encoders onto the hydraulic actuators (design currently in progress)

4.3.1. 6 count encoder mounting plates – NRL to provide the design

4.3.2. 6 count encoder-piston connectors – NRL to provide the design

4.3.3. To be made out of ¼ or 1/8” aluminum plate – as NRL specifies

4.3.4. Position Encoders are “FORTIS-N 170C SHT DS 5UM 32B/10NM”, supplied by NRL

4.3.5. Hydraulic Actuators are “Parker 012-20-AD-01: D1FPE50MH9VB7040”

4.3.6. 40+ count #10 bolts – as NRL specifies

4.3.7. 100+ count washers – as NRL specifies

4.4. Other Hardware Deliverables

4.4.1. 1 count mobile dolly with mounting solution

4.4.1.1. For Electronic Control box; Hammond EN4SD30312GY (30”x30”x12” ~100lbs)

4.4.1.2. Specifications to meet or exceed Uline H-1793

4.4.1.3. 4” wheels

4.4.1.4. Flat top (no lip on edges)

4.4.1.5. Control box is to be bolted onto the cart.

4.4.1.5.1. Control box is to have 4 holes drilled in the bottom at each corner. Interior electronics cannot be damaged.

4.4.1.5.2. Matching holes to be drilled into dolly

4.4.1.5.3. Control box affixed to dolly using 4 bolts + nuts. Bolt minimum size to be ¼”. Washers are to be used on the bolts to distribute load.

4.4.1.5.4. 4 count bolts + nuts

4.4.1.5.5. 16 count washers

4.4.2. Safety shielding solution

4.4.2.1. Must provide protection from flying debris generated by tests, and provide protection equivalent to an ANSI Z87.1-compliant face shield.

4.4.2.2. Must cover at least 270degree angle of the system to protect 66.7 users and observers.

4.4.2.3. Must provide access for technicians either through a door or by being lightweight and easy to move

4.4.2.4. Must be free-standing. It is not permitted to be supported by the exoskeleton or other supports.

4.4.3. Hydraulic Lashing

4.4.3.1. 4 count lashing solutions to accommodate the 2000psi grip hydraulic lines in order to prevent wear and tear on the hydraulic hoses

4.4.3.2. 12 count lashing solutions for existing 4000psi 66.7 lines.

4.4.3.2.1. This may require rerouting existing hydraulic lines and/or manifolds.

4.4.4. Cable management

4.4.4.1. Open to proposals

4.5. Assembly of provided parts into existing 66.7 framework.

4.5.1. Attachment and demonstration of hydraulic grips using the manual controls

4.5.2. Attachment and demonstration of different riser heights

4.5.3. Attachment and demonstration of encoder mounts

4.6. Commercialization of 66.7: subsystem compartmentalization

4.6.1. Breaking down of the 66.7 into appropriate subsystems for commercial manufacture.

4.6.2. Bill(s) of materials for each subsystem identified.

4.7. Commercialization of 66.7: system design and documentation

4.7.1. Digital design files (preferably solidworks, or STEP-203 compatible interchange formats).

4.7.2. Blueprints of 66.7 and substystems

4.7.3. Total bill of materials for entire 66.7 system

4.7.4. Recommendations for simplifying the overall system (a 5 page report?)

TODO – Bolt/Nut specifications

Section 5 Problem Reports and Change Requests

TBD

Section 6 Use of Existing Corporate Plans, Policies, and Procedures

TBD

Section 7 Key Personnel

TBD

Section 8 GFM/GFP

TBD

Section 9 Data Rights Assertions:

Any manuals, schematics or technical drawings produced by this effort belong to NRL.

Section 10 Deliverables

9.1 (CDRL A001) Installation of hydraulic grips and support systems.

9.2 (CDRL A002) Demonstration of hydraulic grips

9.3 (CDRL A003) Demonstration of technique for changing risers and adapter plates

9.4 (CDRL A004) Provide 6 encoder mounting plates, 6 encoder-piston connectors, and associated hardware for mounting position encoders

9.5 (CDRL A005) Mount and connect position encoders to hydraulic actuators

9.6 (CDRL A006) Test encoder mounts by extending the hydraulic actuators while the position encoders are mounted.

9.7 (CDRL A007) Provide mobile dolly

9.8 (CDRL A008) Attach electronic control box to mobile dolly

9.9 (CDRL A009) Design safety shielding solution for NRL approval

9.10 (CDRL A010) Provide agreed-upon safety shielding solution

9.11 (CDRL A011) Propose a cable management solution

9.12 (CDRL A012) Install agreed-upon cable management solution

9.13 (CDRL A013) Provide a lashing solution for the 16 hydraulic lines

9.14 (CDRL A014) Install agreed-upon lashing solution

9.15 (CDRL A015) Propose a system of breaking the 66.7 hardware into subsystems

9.16 (CDRL A016) Provide a Bill of Materials (BOM) for each subsystem

9.17 (CDRL A017) Create digital design files (solidworks or STEP-203 compliant)

9.18 (CDRL A018) Create PDF blueprints for 66.7 hardware and subsystems

9.19 (CDRL A019) Provide a Bill of Materials for entire 66.7 system

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