L6WC11__L6WC24_Purchase_Description_7_Jun_16.pdf

ROBOTIC PAINT SYSTEM, B180 (L6WC11) AND AUTOMATED

PAINT BOOTH SYSTEM FOR B670 (L6WC24)

PURCHASE DESCRIPTION

June 7, 2016

1. Scope: This document provides the description that shall be used to acquire three (3) systems.

These systems shall consist of one system designed to paint radomes (L6WC24) and two designed to paint various off airframe components, including stabilizers, elevators, flaps, and ailerons (L6WC11), see Appendix G. The radome coating system shall be installed in building 670 and shall include a booth and control room. The two miscellaneous component coating systems shall be installed in existing booths in building 180. One of the existing booths is 20’x50’ and the other is 30’x50’, see Appendix H.

1.1. The purchase price shall include the systems themselves, delivery, all listed accessories/options, installation, testing/verification, training/familiarization, and warranty.

1.2. The contractor shall provide all materials, equipment, and labor necessary to deliver and install the systems.

1.3. All work shall be completed in accordance with this purchase description and subject to the terms of the contract.

1.4. The Automated Paint Booth System for B670 shall be installed first, followed by the 30’x50’ Robotic Paint System B180, then the 20’x50’ Robotic Paint System B180 System.

A. Installation of the Automated Paint Booth System for B670 System shall begin no later than 12 months after contract award.

B. The total Period of Performance shall not exceed 30 months.

2. Design: The systems shall be new and complete, custom built to meet our applications, and ready for immediate operation after installation, acceptance testing and training are completed.

3. Equipment Description: The systems shall consist of the following.

3.1. Automated Paint Booth System for B670 (L6WC24)

A. Booth:

(i). The existing room, see attached sketch (Appendix A), shall be divided up into three (3) separate areas. A radome staging area, booth, and operator control room.

(ii). The booth shall fit in the existing room. The booth shall not block access to the exit door shown in the sketch.

(iii). The booth shall have a roll up door large enough to accommodate the loading and unloading of all the radomes, see attached list of radomes and drawings (Appendix B).

A ceiling mounted rail/hoist shall be installed in the booth and will be required to lift some radomes.

(iv). The booth’s inside height shall be maximized to aid in radome loading/unloading.

(v). The booth shall have a climate controlled, operator control room with window(s) into the booth and a camera/monitor system for viewing the process. This control room shall house the HMI and be large enough for two operators. The climate control for this room shall be independent of the booth’s climate control. This room shall have direct access into the booth, access to the radome staging area, and direct access to the exit door shown in the sketch located in Appendix A.

(vi). The booth shall have fire suppression that connects to the existing building fire suppression system (see sketch in Appendix A), via an existing connection point. If there is a fire in the booth the system shall shutdown the ventilation system. The indication of fire will come from a flow switch installed at the connection point for this booth.

(vii). The air flow shall be tested as an average as measured perpendicular to the floor between 3.5’ and 6.5’ AFF. Multiple measurements shall be taken from the center of each 24” x 24” cell in a grid pattern extending wall to wall in both directions. These measurements shall be documented and averaged with equal weighting to each cell value.

(viii). The air flow in the booth shall be directed downward onto or across the part or assembly being coated.

(ix). The air shall be exhausted through a 3-stage dry particulate filter system certified by the filter manufacturer using the methods described in 40 CFR 63.750(o) to meet or exceed the efficiency data points of Tables 3 and 4 of 40 CFR 63.745(g)(2)(ii) [the Aerospace NESHAP] for new coating sources.

(x). The pressure drop across each of the three (3) stages of dry filtration and the drop across the total of all three shall be displayed on the HMI for a total of four (4) pressure drop readings.

(xi). The booth shall be temperature and humidity controlled.

(xii). The booth shall have three (3) different modes with the following parameters:

1). Robot Spray a). Temp: Programmable within the Range of 60 - 80 deg b). Humidity: Programmable within the range of 50 – 80% RH c). Time: NA (Dependent on process time) d). Air Flow: 75 acf/m/ft2 [actual flow rate in cubic feet per minute per square foot of cross-sectional area] 2). Manual Spray a). Temp: Programmable within the Range of 60 - 80 deg b). Humidity: Programmable within the range of 50 – 80% RH c). Time: NA (Dependent on process time) d). Air Flow: 75 - 100 acf/m/ft2 [actual flow rate in cubic feet per minute per square foot of cross-sectional area] 3). Cure a). Temp: Programmable within the Range of 80 - 150 deg b). Humidity: Programmable within the range of 50 – 80% RH c). Time: Programmable d). Air Flow: As required to meet Temperature and Humidity Requirements

B. Paint Distribution System:

(i). The paint distribution system shall consist of multiple fluid systems. The fluid systems shall consist of lines, pot, scale, valves, and gun as required.

(ii). One (1) premixed (the operator will mix) system for water based coatings. The pot for this system shall be 2.8 gallons.

1). One (1) on demand two component mixing system designated for non-water based coatings. The pot for this system shall be 2.8 gallons.

a). The on demand system shall mix parts “A” and “B” just prior to the gun to minimize waste and prolong paint working time.

b). The on demand system shall have the ability to adjust the ratio of parts “A” and “B” per the part program.

2). One (1) premixed (the operator will mix) system designed specifically for anti-static fiber reinforced topcoats. The required capacity for this system shall not be less than one (1) gallon, see Appendix D.

(iii). The guns shall have an 8”-10” plum at a 10” standoff.

(iv). The system shall be able accommodate all the coatings listed in Appendix D.

(v). There shall be a pot dedicated to cleaning solvent MEK NSN 6810-00-281-2762 or

Acetone ASTM 0329-07.

(vi). The distribution system shall facilitate automatic cleaning and purging of the lines and gun(s).

(vii). There shall be a waste drum supplied in the booth. This drum shall have a spray catching adapter and automatic valve. During a cleaning cycle the robot shall place the gun in the adapter, the valve shall open, and the waste paint and solvent shall be purged from the lines/gun and captured in the drum.

(viii). The contractor shall provide 500 of each size pot liner required and provide a recommended source and part number for each liner.

(ix). Each pot shall have a scale and prevent starting of a job/recipe/program if there is not enough coating to finish.

C. Robot Hardware/Software:

(i). The system shall consist of a Fanuc robot with a payload of greater than or equal to 40kg.

(ii). The robot shall have enough reach to allow painting of each of the assets listed in Appendix B. Listed are the dimensions from the top of the turn table (when installed in the mounting adapter) to the tip of the radome and the largest dimension from the vertical center line of the turn table to the outside edge of the radome.

(iii). The system shall employ Handling Tool.

(iv). Roboguide shall be loaded on the PC.

(v). The robot controller shall be of type R-30iB or later with an i pendant.

(vi). The robot controller shall not be located in the paint booth.

(vii). The robot teach pendant shall reach into the operator control room and reach all areas in the booth for teaching/jogging the robot.

(viii). The robot and any other electrical devices/systems in the booth (including the turntable) shall have Class 1 Division 1 Classification issued by a Nationally Recognized Testing Laboratory.

(ix). The robot shall employ Fanuc DCS and Collision Guard.

(x). As an option, the robot shall have an automatic quick disconnecting sanding head tooling and be capable of sanding the radomes listed in Appendix B.

(xi). There shall be a turntable installed in the booth. This turntable shall have a Fanuc motor and shall be included as an extended axis in Group 1, thus allowing coordinated motion with the robot.

(xii). The turntable shall be capable of infinite rotary motion, thus eliminating the need to “rewind” the table.

(xiii). The radomes shall be mounted on the turntable via the existing mounting adapters. The turntable’s top shall be designed per the drawing in Appendix E, allowing the existing adapters to be utilized.

(xiv). The remainder of the turn table (including total height) shall be of the contractors design.

(xv). As an option, a second turn table shall be installed in the booth. This turn table shall be used in conjunctuion with the first to process two radomes within the same production run. The diameter of the radomes may limit which radomes can be processed in this manner. For example, the system may not be able to handle two C-5 radomes at the same time.

D. Subsystem Hardware:

(i). The paint distribution system and the booth sub-systems shall be controlled by a single

Rockwell Automation/Allen-Bradley PLC (Logix 5000 family). This shall be located in the operator control room.

(ii). The HMI hardware shall consist of a PC with a 21” monitor. This shall be located in the operator control room and shall be on UPS backup.

(iii). The PC shall be configured with RAID 1 hard drives.

(iv). The PLC/HMI shall interface with the robot controller, in order to restore/backup TP programs and initiate robot motion/process (program start, recipe selection, etc.).

(v). The communication protocol used for communication between the robot, PLC, HMI, and any remote I/O shall be Ethernet/IP.

E. Subsystem Software:

(i). The OS for the PC shall be the latest version on Windows supported by the HMI, PLC, and Robot software.

(ii). The HMI software shall be latest version of Rockwell Automation RSView SE (local) and shall be loaded on the HMI PC. Factory Talk View Studio shall also be loaded on the PC.

(iii). The PLC software shall be latest version of Rockwell Automation Logix 5000 Pro Edition and shall be loaded on the PC.

(iv). The Government shall be provided and shall own the PLC and HMI source code (.ACD and .APA files) and no parts of the code shall be password protected, unless the Government will be given the password. This code will not be sold/given to 3rd parties unless the original developer goes out of business, no longer supports the system, or gives written permission to do so. The Government does reserve the right to use the code for troubleshooting, re-installing/downloading in case of program loss, or program modify if required.

F. Data Recording:

(i). The contractor shall provide a DVR for recording video of the process. This video shall be time stamped for comparison to key strokes and in-process testing.

(ii). The key strokes from the pendant and keyboard shall also be recorded and time stamped.

(iii). There shall be a database of sensors with an automated report generation.

G. Programing:

(i). The system shall allow offline programming (via models), teach pendant programming, and a combination of both.

(ii). The system shall allow for the addition of future motion programs and recipes.

(iii). The contractor shall provide and verify to the Government’s satisfaction, complete programs for all the required coatings on all radomes.

(iv). The contractor shall model each of the assets listed in Appendix B using a structured light scanning system, these models shall be used for the offline programming of the motion path.

(v). The modeling of the C-5 radome, C-130 radome, C-130 Talon II radome, C-17 radome, and C-130 spinner shall be performed at Robins AFB. The modeling will be performed with the mounting adapter installed on the asset. The contractor shall notify the Government POC via email when ready to perform the modeling and within thirty (30) days the Government shall have one of each of the above assets available.

(vi). The modeling of the F-15 radome and mounting adapter shall be performed at the contractor’s facility, for use during the acceptance testing.

(vii). All the models created shall become property of the Government.

(viii). The motion path overlaps shall be based on paint laydown and plume shape, to ensure a uniform thickness.

H. In-Process Testing:

(i). The contractor shall provide a method of automatically and programmatically testing the wet thickness of the paint after each coat. This testing shall be non-contact and non-destructive.

(ii). The device used for the thickness testing shall be picked up by the robot automatically when needed. The device shall be dropped off by the robot automatically when not needed and shall be protected from overspray when not in use.

3.2. Robotic Paint System, B180 (L6WC11)

A. Booth:

(i). The interior dimensions of the existing booth are: thirty (30) feet wide by sixteen (16) feet tall by fifty (50) feet long for the 30’x50’ system and twenty (20) feet wide by sixteen (16) feet tall by fifty (50) feet long for the 20’x50’ system (see Appendix H).

B. Paint Distribution System:

(i). The paint distribution system shall consist of multiple fluid systems. The fluid systems shall consist of lines, pot, scale, valves, and gun as required.

1). One (1) premixed (the operator will mix) system for water based coatings. The pot for this system shall be no less than five (5) gallons.

2). One (1) on demand two component mixing system designated for non-water based coatings. The pot for this system shall be no less than five (5) gallons.

a). The on demand system shall mix parts “A” and “B” just prior to the gun to minimize waste and prolong paint working time.

b). The on demand system shall have the ability to adjust the ratio of parts “A” and “B” per the part program.

3). One (1) premixed (the operator will mix) system for non-water based coatings. The pot for this system shall be no less than five (5) gallons.

(ii). The guns shall have an 8”-10” plum at a 10” standoff.

(iii). The system shall be able accommodate all the coatings listed in Appendix C.

(iv). There shall be a pot dedicated to cleaning solvent MEK NSN 6810-00-281-2762 or

Acetone ASTM 0329-07.

(v). The distribution system shall facilitate automatic cleaning and purging of the lines and gun(s).

(vi). There shall be a waste drum supplied in the booth. This drum shall have a spray catching adapter and automatic valve. During a cleaning cycle the robot shall place the gun in the adapter, the valve shall open, and the waste paint and solvent shall be purged from the lines/gun and captured in the drum.

(vii). The contractor shall provide 500 of each size pot liner required and provide a recommended source and part number for each liner.

(viii). Each pot shall have a scale and prevent starting of a job/recipe/program if there is not enough coating to finish.

C. Robot Hardware/Software:

(i). The system shall consist of a Fanuc robot with a payload of greater than or equal to 40kg.

(ii). The system shall employ Handling Tool.

(iii). Roboguide shall be loaded on the PC.

(iv). The robot controller shall be of type R-30iB or later with an i pendant.

(v). The robot controller shall not be located in the booth.

(vi). The robot teach pendant shall reach all areas in the booth for teaching.

(vii). The robot and any other electrical devices/systems in the booth shall have Class 1

Division 1 Classification issued by a Nationally Recognized Testing Laboratory.

(viii). The robot shall employ Fanuc DCS and Collision Guard.

(ix). As an option, the robot shall have an automatic quick disconnect sanding head and be capable of sanding.

(x). The robot shall be mounted from a suspended rail that will allow the robot to travel the length of the booth. This axis shall be in addition to the six (6) robot axes. This axis shall be powered by a Fanuc motor and shall be included as an extended axis in Group 1, thus allowing coordinated motion with the robot.

(xi). The contractor shall provide the support structure for the rail and robot. This structure shall be floor mounted with a leg/beam in each corner of the booth to minimize the impact on the work envelope.

(xii). Work envelope:

1). The robots shall have enough reach to allow painting of all sides of each of the assets shown in Appendix I. Appendix I shows the approximate dimensions for each asset.

Appendix I also shows the distance from the bottom of the asset to the ground when the asset is on its transportation dolly (if applicipable). The robots’ reach shall be such that the booths’ usable space can maximized by placing multiple assets in the booths for each spray session.

D. Subsystem Hardware:

(i). The paint distribution system and the booth sub-systems shall be controlled by a single

Rockwell Automation/Allen-Bradley PLC (Logix 5000 family).

(ii). The HMI hardware shall consist of a PC with a 21” monitor. This shall be located at the operator control station and shall be on UPS backup.

1). The operator control station shall be mobile and shall be able to be positioned from the back of the booth to the front of the booth on either side.

2). The operator control station shall have a camera/monitor system for viewing the process from outside the booth.

(iii). The PC shall be configured with RAID 1 hard drives.

(iv). The PLC/HMI shall interface with the robot controller, in order to restore/backup TP programs and initiate robot motion/process (program start).

(v). The communication protocol used for communication between the robot, PLC, HMI, and any remote I/O shall be Ethernet/IP.

E. Subsystem Software:

(i). The OS for the PC shall be the latest version on Windows supported by the HMI, PLC, and Robot software.

(ii). The HMI software shall be latest version of Rockwell Automation RSView SE (local) and shall be loaded on the HMI PC. Factory Talk View Studio shall also be loaded on the PC.

(iii). The PLC software shall be latest version of Rockwell Automation Logix 5000 Pro Edition and shall be loaded on the PC.

(iv). The Government shall be provided and shall own the PLC and HMI source code (.ACD and .APA files) and no parts of the code shall be password protected, unless the Government will be given the password. This code will not be sold to 3rd parties, rather it will be used to troubleshoot the system and provide a backup in case of program loss.

F. Data Recording:

(i). The contractor shall provide a DVR for recording video of the process. The system shall store two (2) or more weeks of video. This video shall be time stamped for comparison to key strokes and in-process testing.

(ii). The key strokes from the pendant and keyboard shall also be recorded and time stamped.

(iii). There shall be a database of sensors with an automated report generation.

G. Programing:

(i). The system shall allow offline programming (via models), teach pendant programming, and a combination of both.

(ii). The system shall have the option of employing an algorithm to automatically create motion paths based on the four (4) corners of flat parts (points identified by the operator) and based on the four (4) corners and additional mid-points (points identified by the operator) for curved parts.

(iii). The system shall allow for the addition of future part programs and recipes.

(iv). One goal of the system is to have the ability to run multiple copies of a part program in the work envelope. For example, if two elevators and one ramp will fit into the work envelope of the booth, the system shall be able to coat all three assets using the same base program and calling the correct asset programs.

1). The part(s) shall be located in the booth by the operator “touching off” three corners of the part(s). As an option the part(s) shall be located in the booth automatically by a laser scanner.

2). The system shall allow multiple assets programs to be ran within the same production run.

(v). For both systems, the contractor shall provide a total of four (4) non-consecutive weeks of programming support. This shall be in addition to the programming training.

(vi). Any models created shall become property of the Government.

(vii). The motion path overlaps shall be based on paint laydown and plume shape, to ensure a uniform thickness.

4. Acceptance Testing:

4.1. The complete factory and site acceptance plan for each system shall be developed by the contractor; reviewed and modified/approved (as appropriate) by the Government contract technical representative; and mutually agreed upon prior to conducting any test. Documentation verifying the acceptance testing and verification shall be provided to the Government.

4.2. Automated Paint Booth System for B670 (L6WC24) - Factory Acceptance Testing

A. The contractor shall build a mock booth and completely setup the paint distribution system, robot hardware/software, turntable, rail/hoist, subsystem hardware/software, data recording, and in-process testing at their facility.

B. The Government will provide a condemned F-15 Radome and mounting adapter for the factory acceptance tests. The contractor shall notify the Government POC via email and within days (30) days the Government shall have the radome boxed and ready for pickup by the contractor’s shipping representative.

C. Once the mock setup is completely assembled, working and the Government has approved the test plan, the contractor shall notify the Government POC via email and within thirty

(30) days the Government shall send representative(s) to verify the following:

(i). The contractor shall demonstrate the ability to load and unload the radome using the rail/hoist and the provided sling.

(ii). The contractor shall demonstrate the ability to automatically and completely process a condemned F-15 Radome, including primer, base coat, tie coat, and top coat. With data recording and in-process thickness testing active.

(iii). The programmatic, in-process, non-destructive, non-contact thickness measurements shall be compared to coupons cut from the radome per the plan in Appendix F.

(iv). The contractor shall also demonstrate the automatic cleaning/purging feature of the paint distribution system.

(v). The contractor shall demonstrate the data collection.

(vi). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

D. Upon successful demonstration of the above, the Government will approve the system to be shipped to Robins AFB for installation.

4.3. Robotic Paint System, B180 (L6WC11) - Factory Acceptance Testing: 30’ x 50’ System Only

A. The contractor shall build a mock booth and completely setup the paint distribution system, rail, robot hardware/software, subsystem hardware/software, data recording, and in-process testing for the 30’x50’ system at their facility.

B. The Government will provide a condemned asset or representative part for the factory acceptance tests. The contractor shall notify the Government POC via email and within days (30) days the Government shall have the part boxed and ready for pickup by the contractor’s shipping representative.

C. Once the mock setup is completely assembled, working and the Government has approved the test plan, the contractor shall notify the Government POC via email and within thirty

(30) days the Government shall send representative(s) to verify the following:

(i). The contractor shall demonstrate the ability to automatically and completely process the provided part, including primer and top coat. With data recording active.

(ii). The contractor shall demonstrate the ability to process three (3) assets placed within the work envelope during one production run.

(iii). The contractor shall demonstrate the ability to create a program using the four corner and four corner with mid points algorithm.

(iv). The contractor shall also demonstrate the automatic cleaning/purging feature of the paint distribution system.

(v). The contractor shall demonstrate the data collection.

(vi). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

D. Upon successful demonstration of the above, the Government will give approval to ship both systems to Robins AFB for installation.

4.4. Automated Paint Booth System for B670 (L6WC24) - Factory Acceptance Testing - Site Acceptance Testing

A. Once installation at Robins AFB is completed and the Government has approved the test plan, the contractor shall notify the Government POC via email and within one (1) week the Government representative(s) shall verify the following:

(i). The contractor shall demonstrate the ability to load and unload each radome listed in Appendix B. The radomes must be able to be loaded safely from its dolly to the turntable and back again.

(ii). The contractor shall demonstrate the ability to automatically and completely process all the radomes listed in Appendix B, including primer, base coat, tie coat, and top coat.

With data recording and in-process thickness testing active.

(iii). The programmatic, in-process, non-destructive, non-contact thickness measurements shall be compared to destructive coupons cut from the radome per plan in Appendix F on the F-15 radome only.

(iv). The contractor shall also demonstrate the automatic cleaning/purging feature of the paint distribution system.

(v). The contractor shall demonstrate the data collection.

(vi). The contractor shall demonstrate the creation of program.

(vii). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

4.5. Robotic Paint System, B180 (L6WC11) - Site Acceptance Testing: Both Systems

A. Once installation at Robins AFB is completed and the Government has approved the test plan, the contractor shall notify the Government POC via email and within one (1) week the Government representative(s) shall verify the following:

(i). The contractor shall demonstrate the ability to automatically and completely process the provided part, including primer and top coat. With data recording active.

(ii). The contractor shall demonstrate the ability to process four (4) assets placed within the work envelope during one production run.

(iii). The contractor shall also demonstrate the automatic cleaning/purging feature of the paint distribution system.

(iv). The contractor shall demonstrate the data collection.

(v). The contractor shall demonstrate the creation of program.

(vi). The contractor shall demonstrate the ability to create a program using the four corner and four corner with mid points algorithm.

(vii). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

5. Installation:

5.1. The systems shall be installed by the contractor/vendors qualified representative(s) in the government’s designated facilities/locations on Robins AFB, GA. All items shall be assembled and installed utilizing best commercial practices and manufacturer’s installation procedures. The government shall supply all required utilities within ten (10) feet of the installation site.

A. The contractor shall provide a list, via email to the Government technical POC, of all required utilities three (3) months after contract award.

6. Training:

6.1. Within fifteen (15) days of installation and site acceptance testing completion, operator and maintenance training will be provided for up to 10 Air Force civilian equipment operators and service technicians by the contractor’s qualified representative at no additional cost to the government. The listed training shall be provided for each system installed.

6.2. Training shall include:

A. Two (2) weeks of operator training, to include production runs on assets and review of the operation manual.

B. One (1) week of maintenance training, to include a complete preventive maintenance cycle, basic troubleshooting, review of the electrical/mechanical drawings and maintenance manual, and review of the HMI/PLC code.

C. Two (2) weeks of programming/engineering training, to include a complete part creation sequence and review of the programming manual. For the building 670 Radome Coating System, the part to be completed as part of the training shall be the spinner listed in Appendix B and D. Offline/Model-based programming and teach pendant programming shall be covered.

7. Additional Requirements:

7.1. Contractor shall have robotic radome coating experience, depot level experience, in-process paint thickness measurement, and experience with carbon fiber anti-static coatings.

7.2. The contractor shall provide three (3), nonconsecutive, one (1) week production support visits, to be scheduled as required throughout the year. The contractor shall be onsite within two

(2) weeks of being notified that onsite support is required.

7.3. A final walk through inspection shall be conducted with the Government Technical Representative after the installation has been completed. Any components damaged, missing, or installed improperly will be identified and corrected by the contractor in a timely manner prior to completion of the contract. Only the Contracting Officer is authorized to make changes to the resulting award document and/or contract on behalf of the Government.

7.4. SAFETY REQUIREMENTS:

7.5. Contractor shall provide signs, barricades, and lights as required to protect base personnel.

7.6. Schedule. The contractor shall schedule and perform the work as to minimize negative impacts on production.

7.7. The contractor shall perform the required work during the following normal business hours:

6:00 AM – 6:00 PM, Monday – Friday. Work performed on weekends and holidays shall be approved by the Contracting Officer before work commences. A Government Representative shall be present in the event of weekend/holiday work schedule.

7.8. The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

7.9. Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc., during equipment installation.

7.10. The systems shall include all of the necessary consumables required for initial operation.

7.11. The contractor shall provide equipment capacity/emissions information and booth manuals as required by WR-ALC Environmental Management to modify the Robins AFB Title V Air Permit. This information is due to the Government POC three (3) months after contract award.

Permit modification shall be in place and verified by WR-ALC Environmental Management prior to any equipment installation.

7.12. Three (3) months after contract award, the contractor shall provide a single Gantt Chart showing the project schedule from contract award through final inspection for each of the three systems.

8. Warranty: All standard Warranty provisions shall be included with the bid package but as a minimum shall include one (1) year parts and labor from the time of acceptance (for each system) for defects in material and workmanship.

9. Bid Package Requirements for Each System:

9.1. Automated Paint Booth System for B670 (L6WC24)

A. Total Cost without Options

B. Break Down Cost – Shall be broken out into the following categories for each of the three

(3) systems:

(i). Hardware/Software/Integration/Testing/Verification (ii). Delivery

(iii). Installation (iv). Training

C. List of requested options with associated cost D. Basic system layout, to include:

(i). Paint distribution system

1). One line diagram 2). Gun(s)/tip types

(ii). Robot / Turntable 1). Robot model (for example only- Fanuc R-2000iB) 2). Robot controller model (for example only- Fanuc R-30iA)

(iii). Booth, top view booth layout showing:

1). Booth size 2). Booth doors: entrances/exits 3). Operator control room location/size 4). HMI location 5). Robot location 6). Turntable location 7). Paint distribution system location 8). Overhead hoist location 9). Robot control cabinet location 10). Subsystem control cabinet location

E. RoboGuide Simulation for all radomes listed in Appendix B to verify robot reach.

F. Estimated Schedule

9.2. Robotic Paint System, B180 (L6WC11) 30’ x 50’ System

A. Total Cost

B. Basic system layout, to include:

(i). Paint distribution system

1). One line diagram 2). Gun(s)/tip types

(ii). Robot / Rail 1). Robot model (i.e.- Fanuc R-2000iB) 2). Robot controller model (i.e.- Fanuc R-30iA)

(iii). Booth, top view booth layout showing:

1). Operator control station/HMI location 2). Robot location 3). Rail location and Structure 4). Work Envelope 5). Paint distribution system location 6). Robot control cabinet location 7). Subsystem control cabinet location

C. RoboGuide Simulation to demonstrate work envelope and robot reach.

D. Estimated Schedule

9.3. Robotic Paint System, B180 (L6WC11) 20’ x 50’ System

A. Total Cost

B. Basic system layout, to include:

(i). Paint distribution system

1). One line diagram 2). Gun(s)/tip types

(ii). Robot / Rail 1). Robot model (i.e.- Fanuc R-2000iB) 2). Robot controller model (i.e.- Fanuc R-30iA)

(iii). Booth, top view booth layout showing:

1). Operator control station/HMI location 2). Robot location 3). Rail location and Structure 4). Work Envelope 5). Paint distribution system location 6). Robot control cabinet location 7). Subsystem control cabinet location

C. RoboGuide Simulation to demonstrate work envelope and robot reach.

D. Estimated Schedule

10. Data Deliverables/Contract Data Requirements Lists (CDRL):

CDRL # Ref. Para. Description A001 7.4.A, 7.4.B Contractors Standard Operating Procedures A002 7.4.C Mishap Report A003 3 Commercial Off the Shelf Equipment Manuals and

Associated Documents (Operator/Maintenance Manuals, Sparte Parts List, Schematics)

A004 7.12 Project Gantt Chart A005 6 Training Material A006 4 Acceptance Test Plan

11. Government supplied items

a. Fixtures to interface radomes to the turntable.

b. Slings to lift the radomes onto the turntable.

c. All coatings and solvents.

d. For the building 670 Radome Coating System, a condemned F-15 radome will be supplied for contractor pickup.

e. For the building 180 Off-Airframe Component Coating System, a condemned asset or representative part will be supplied for contractor pickup.

f. C-17, C-130, C-5 and C-130 Talon II radomes will be supplied for modeling, programing, and testing.

12. Government Technical Representatives. The on-site Government points of contact are:

Primary: Alternates:

Shane Groves Derek Bethel Scott Morgan

402 CMXG/MXDQBE 402 CMXG/MXDQBE 402 CMXG/MXDQBE

Robins AFB, GA Robins AFB, GA Robins AFB, GA Comm 478-335-6482 Comm 478-222-4075 Comm 478-222-8790

APPENDIX A – BUILDING 670 PAINT BOOTH LOCATION SKETCH

* Dimensions are approximate

10’

15’

183” Head Room

36”

Space for Booth HVAC Equipment

Existing Air Conditioning Equipment

118” Head Room

Exit

27”

32” 7”

367”

229”

Space for Booth

HVAC

Equipment

292”

162”

20” Fire Alarm

Sprinkler Connection Point

APPENDIX B – RADOMES/PARTS

Not To Scale/Dimensions Approximate

Radome/Part Height

(A) Max Height Off Turn Table (B)

Max Width Off Center (C)

Fixture Dwg # Lifting Method

F-15 Radome 97” 4” 23” X200010875 Sling/Hoist C-130 Spinner 26” 3” 15” NA Sling/Hoist C-5 Radome 42” 14” 50” X200911745 Sling/Hoist C-17 Radome 53” 19” 49” X200315911 Sling/Hoist C-130 Radome 67” 19” 38” NA Sling/Hoist Talon II Radome

95” 15” 38” 03640ASSY205A412 Fork Lift/Pallet Jack

A

C-130 Spinner

C

6”

B

A

C

F-15 Radome

B

F-15 Radome Lifting Sling – Vertical for Installing on Turntable

Lifting Point

125”

66”

66”

F-15 Radome Lifting Sling – Horizontal for Removing from Dolly

Lifting Point

51”

117”

APPENDIX B – RADOMES – CONT.

C-5 Radome At 0 Deg

C-5 Radome At 90 Deg

A

C

C-17 Radome At 0 Deg

A

C-17 Radome At 90 Deg

B

C49” 45”

B

APPENDIX B – RADOMES – CONT.

C-130 Radome At 0 Deg

C-130 Radome At 90 Deg

Talon II At 0 Deg

Talon II At 90 Deg

A

B

8”

C 36”

A

B

C

4”

C

APPENDIX C – OFF AIRFRAME COMPONENT COATING TABLE

* ALL COATINGS ARE TWO PARTS AND SHOULD BE MIXED JUST PRIOR TO THE GUN

Coating MSN Ratio of

A:B

36173 8010-01-479-0449 3:1

36251 8010-01-492-4699 3:1

36118 8010-01-492-4701 3:1

36293 8010-01-505-3700 3:1

34424 8010-01-441-6075 3:1

24052 8010-01-305-5555 3:1

36231

8010-PH-M00-

510488 3:1

33461 8010-01-258-3033 1:1

33446 8010-01-582-7282 3:1

34251 8010-00-515-1568 3:1

Primer Standard 3:1

Primer Non-Chromate 3:1

APPENDIX D – RADOME COATING TABLE

* ALL COATINGS ARE TWO PARTS AND SHOULD BE MIXED AT THE GUN

Part Kit NSN

Coating

Primer / 2-Part Base Coat / 2-Part Tie Coat / 2-Part Top Coat / 2-Part

F-15 Current 8010-01-4933963-color36118 8010-01-3198746-color36176

AREOGLA

ZE 9947

(1) Quart per kit

Requires 2 kits

AMSC

83445

COLOR

36118

AND

36176

FMS

COLOR

36320

(1) Gallon per kit

Requires 2 kits

AMS313

8/3

COLOR

36118

AND

36176

FMS

COLOR

36320

(.5) Gallon per kit

Require s 2 kits

ANTI

STATIC,

AMS313

8/6

COLOR

36118

AND

36176

FMS

COLOR

36320

(2) Quarts per kit

Requires 2 kits

F-15 Future

NON-

CHROMA

TED

WATER

REDUCIB

LE,

EPOXY

POLYAMI

DE

future

POLYU

RETHA

NE,

CAAP

CO. FP-

500, COLOR

16118 future

FLUORO

ELATO

MERIC,

CAPP

CO.

TYPE IV,

COLOR

16118 future

FLURO

ANTI

STATIC,

CAAP

CO.

TYPE V,

COLOR

36118 future

C-130 / C-17 / C-5 / Misc.

8010-00-459-1756

AREOGLA

ZE 9947

(1) Quart per kit

Requires 1 kit

AMCS-

83231A

(1) Gallon per kit

Requires 1 kit

NA NA

MIL-C-

85285

TYPE IV

CLASS

H

COLORS

36118, 36173, 37038, AND

36293.

(1) Quart per kit

Requires 1 kit

C-130 Talon

II

8010-00-459-1756

AREOGLA

ZE 9947

(1) Quart per kit

Requires 1 kit

AMCS-

83231A

(1) Gallon per kit

Requires 1 kit

NA NA

MIL-C-

85285

TYPE IV

CLASS

H

COLORS

36118

(1) Quart per kit

Requires 1 kit

Spinner

NA NA NA NA NA NA

MIL-C-

85285

TYPE IV

CLASS

H

COLOR

37038

Laminar X-500

Retarder

8-12 mil thicknes s

APPENDIX E –TURN TABLE TOP DRAWING

Contractor Designed Turn

Table Base

Turn Table Top Per Below

APPENDIX F – COUPON PLAN/LAYOUT

Part Number: SN:

Radome Station Number Circumference Location

12 O’clock 3 O’clock 6 O’clock 9 O’clock

2” Coupon

12” Coupon Coupon

24” Coupon

36” Coupon

48” Coupon

60” Coupon

72” Coupon

84” Coupon

APPENDIX G – LOCATION OVERVIEW

Legend:

Building 180 – Two (2) Off-Airframe Component Paint Robots

Building 670 – One (1) Radome Paint Robot

APPENDIX H – BUILDING 180 EXISTING PAINT BOOTHS

Suspended Rail Mounted Robot to be installed

APPENDIX I – PARTS

The bottom of this asset must be painted in the vertical position shown.