DRAFT Statement of Work - Onsite MTS System Integration Support and Training.pdf

Statement of Work

For

Onsite MTS System Integration Support and Training

Federal Aviation Administration

William J. Hughes Technical Center

Structure and Materials Section (ANG-E281)

Atlantic City, New Jersey 08405

SUMMARY:

The Structures and Materials Laboratory (SML), located at the Federal Aviation Administration (FAA) William J. Hughes Technical Center (TC), was officially opened in December 2016 as a new home for advanced material and structural test capabilities. The intent for the lab, once fully operational, is to house multiple uniaxial test fixtures and space to conduct 1-3 full-scale aircraft structural component tests simultaneously on an integrated system. The identified onsite system integration support and training, as detailed in this statement of work (SOW), will provide for a fully functioning aerospace structural test fixture used for high-cycle applications. This capability will allow the FAA TC to execute research programs in support of FAA Aviation Safety (AVS) with their core mission functions of aircraft certification, continued airworthiness, rulemaking, policy and guidance development and training.

1. BACKGROUND:

The SML was specifically designed to handle the unique demands of full-scale aerospace research and development. A key design feature of the new lab space is the “strong floor” which is a reinforced concrete floor built with a grid of threaded anchors. Each anchor is capable of handling 40,000 lbs of force. This feature allows test engineers to design full-scale structural tests capable of subjecting both real and simulated aircraft parts to loading conditions typically seen in service. SML currently houses the Aircraft Beam Structural Test (ABST) and a Large Airframe Wing Structures (LAWS) test fixtures. ABST is a self-reacting structure to investigate the safety and structural integrity issues of bonded repairs to 24”x40” unreinforced composite panels representative of transport airplane wing structure. The LAWS test fixture is an upgrade of the ABST to accommodate larger reinforced composite wing panels up to 44” x 120” in size. A third full-scale Main Rotor Blade (MRB) test fixture, which also utilizes the strong floor, provides SML with another test capability of investigating aging behaviors of adhesively bonded joints in high-cycle applications such as rotorcraft blades. The MRB test fixture will be capable of simulating actual loading conditions on a 5-ft long rotor blade section.

2. OBJECTIVE:

The objective of this work is to provide the SML with the installation and integration services needed to commission the MRB test fixture. The output would be a fully integrated hydraulic test system with uniform control hardware/software and enough capacity to seamlessly and reliably support testing from designated workstations. The SML currently houses a wide variety of MTS research equipment such as hydraulic power unit (HPU), hydraulic load frames, controller, hydraulic distribution manifold, hydraulic service manifolds, computer workstations with purchased and installed MTS control software (AeroPro). The recently acquired MTS system, including MTS linear hydraulic actuator system, data acquisition system and distribution manifold assembly, must be installed and integrated into the existing MTS equipment and software in the SML to successfully and timely create an integrated system of test capabilities.

3. SCOPE

The scope of this project is to acquire onsite MTS system support services to provide a fully integrated system for all new and existing MTS equipment in SML. This includes the installation and integration of the recently purchased MTS system to commission a new test fixture and providing comprehensive training for operators. The training will be designed to equip operators with the necessary knowledge and skills to safely and efficiently operate, trouble shoot, and maintain the system.

The contractor must provide all services and materials necessary for installation and commissioning.

4.0 SERVICE REQUIREMENTS:

4.1 On-site Installation, Integration and Commissioning

The contractor must install and integrate the MTS system to successfully commission the MRB test fixture.

The SML currently houses the following MTS research equipment that is directly related to the products and services required for this effort:

• MTS 515.180 SilentFlo HPU

• MTS FlexTest 100 controller,

• MTS 293 hydraulic distribution manifold,

• MTS 293 hydraulic service manifolds,

• MTS FlexDAC 20

• One server computer workstation with MTS AeroPro control software installed

• Two client computer workstations with MTS control software installed

The newly purchased MTS system used for the MRB fixture included the following:

• MTS Series Linear Hydraulic Actuator (LHA) family with accompanying load cells, servovalves and mounts o One actuator assembly for Model 201.17A (1) o Two actuator assembly for Model 201.25A (2) o One actuator assembly for Model 201.17A (1)

• MTS FlexDAC Data Acquisition System, P/N 57928702 and a PC Workstation

• HPU Control Cable for Model 515 HPU; 200ft. length, P/N 575581-12

• Distribution Manifold Assembly, Four (4) Station, -16 Inlet, -12 Outlets. Includes

Manual Ball Valves & Check Valves, P/N 469787-01

• Pressure system (W01-358-7203 Firestone Double Convoluted Air Spring, Interface 50kip load cell and Delta P pressure controller)

The contractor must complete the following:

• Install hardware to expand the capability of FlexTest 100 Controller to accommodate 3 fixtures with the capability of 12 control channels with 36 conditioned inputs

• Install to expand the DAC capability from 1 MTS FlexDAC to 3 MTS FlexDAC

• Setup 1 server and 3 client computers for three fixtures (MRB, ABST and LAWS)

• Upgrade and update OS and AeroPro software

• Setup 3 Test Stations and required hardware in AeroPro for the three fixtures

(setup of AeroPro for MRB fixture, reassign the channels for ABST fixture as the current setup is complete and assign channels for LAWS fixture as needed)

• Provide necessary materials (e.g., specialized MTS cables) and complete valve and load cells connection with controller, and test station, hardware, control and DAC channels setup for the MRB fixture.

• Integrate pressure system (airbag, load cell and pressure controller) into the MTS control system for the MRB fixture

4.2 On-site Training

The contractor must provide the following training:

4.2.1- MTS AeroPro Operator- 4 Day Training Course

4.2.2- Customized AeroPro Training Course The training must provide operators with hands-on experience setting up and running structural tests using AeroPro Software. The training must incorporate extensive hands-on time to allow operators to practice the skills learned.

The training must include but not limited to, the following topics:

• AeroPro software includes software layout, sensor object, hardware object.

• Setting up for a simple test includes configure sensors, configure a test, calibrate, create load tables, create profile, create sequences, define event actions, set limits, tune the test, retrieve data and review data.

• Custom setup for rotor blade testing.

• System trouble shoot and maintenance

• MRB fixture integration to ensure operators can safely and effectively operate the fixture.

5. PERIOD OF PERFORMANCE:

The total period of performance will be 250 days from the Date of Award.

6. SITE LOCATION:

All work will be conducted at the FAA WJHTC, Building 245 Structures and Materials Laboratory (SML), Atlantic City International Airport located in Atlantic City, New Jersey.

7. SITE ACCESS:

Visiting Contractor employee(s) must comply will all Government escort rules and requirements. The Contractor must be escorted by FAA Point of Contact (POC) (or a representative) and display all identification and visitor badges in plain view above the waist at all times, while performing services at the FAA, WJHTC. All scheduling of services must be coordinated with the FAA POC. Access to the WJHTC campus and SML is secure and additional times must be allowed for personnel and equipment to pass through the FAA Security Operations Center (SOC).

8. TRAVEL:

Contractor will not be reimbursed separately for travel.