PD.pdf

ROBOTIC PAINT REMOVAL SYSTEM, B180 (L7WC10)

PURCHASE DESCRIPTION

26 Jun 17

1. Scope: This document provides the description that shall be used to acquire one (1) system.

The system shall consist of one system designed to remove paint from various off airframe components, including stabilizers, elevators, flaps, and ailerons, see Appendix D. The miscellaneous component paint removal system shall be installed in the existing dwell area of building 180. The existing dwell area is approximately 35’x53’, see Appendix A.

1.1. The purchase price shall include the system, delivery, all listed accessories/options, installation, to include site prep building modifications (once 332 approval has been received), testing/verification, training/familiarization, and warranty.

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

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

1.4. The total Period of Performance shall not exceed 18 months.

2. Design: The system 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 system shall consist of the following. Contractor shall provide all Commercial Off-the-Shelf (COTS) Equipment Manuals for the following components.

(CDRL A003, Commerical Off-the-Shelf (COTS) Equipment Manual Requirements, DI-TMSS- 80527C)

3.1. Automated Chemical System for B180 (L7WC10)

A. Work Envelope:

(i). The system shall have enough reach to allow spraying of all sides of each of the assets shown in Appendix D. Appendix D shows the approximate dimensions for each asset.

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

(ii). The dimension of the existing dwell area is: thirty five (35) feet wide by fifty three (53) feet long for the dwell area (Appendix A).

(iii). The system shall provide no less than 35’ x 53’ for the work envelope.

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

(v). The contractor shall provide the support structure for the rail and robot. This structure shall be floor mounted and not rely on the building structure. The structure shall be designed to minimize the impact on the work envelope. The structure shall be designed to be installed without the use of footers.

(vi). The system shall not have any structural components that will interfere with the loading of any part. During loading the only areas permitted to contain structual components are indicated in Appendix A using a red, square hatch pattern.

(vii). The system shall have safety mechanisms that prevent personnel from entering during robot operation.

(viii). There is an overhead hoist in the area, shown in Appendix A in orange. The system shall be interlocked with the hoist to prevent the robot and hoist from colliding, yet not preventing both items from being used at the same time.

(ix). All components of the system that could come into contact with the chemicals in use, shall be protected from the chemicals listed in Appendix B.

B. Chemical Application:

(i). The system shall have a chemical distribution system consisting of multiple fluid systems. The fluid systems shall consist of lines, pumps, valves, and guns as required.

(ii). The system shall have one (1) pump for use with 55 gallon drum or 300 gallon tote for each of the chemicals listed in Appendix B.

(iii). The non-atomizing type gun shall have an 8”-10” plum at a 10” standoff.

(iv). All of the components of the system shall be able accommodate and must be rated for all the chemicals listed in Appendix B.

(v). The chemical application step shall be part of the recipe, dictating how many coats of chemical, pump control parameters, application speed, which robot program to use, and allow for an adjustable delay between coatings and before proceeding to the next step.

C. Agitation:

(i). The system shall have the ability to agitate/scrub the parts once the chemical has been applied.

(ii). The system shall utilize a brush meeting military specification MIL-B-23958 for the agitation.

(iii). The agitation head shall be automatically picked up and dropped off via a quick change head.

(iv). The agitation step shall be part of the recipe, dictating how many times to agitate along the path, agitation speed, which robot program to use, and allow for an adjustable delay between agitations and before proceeding to the next step.

D. Rinse:

(i). The system shall have the ability to rinse the parts with the hot water provided. The temperature of the water will not exceed 140 Degrees Fahrenheit. The system shall include all required valves to control the flow of hot water.

(ii). The system shall have the ability to rinse the parts with the pressurized water provided.

The pressure of the water will be between 3,000 and 15,000 psi and shall be selectable through the HMI, which will communicate with the existing high pressure pump. This pressurized water shall be applied with a rotary nozzle spinning at a minimum of 5200 rpm free speed. The system shall include all components required to control the nozzle speed.

(iii). The current rotary gun being used is the Jet Stripper style 40-150-WR. The high pressure pump in use is the Ultra Boss Model E-75. Both items are made by CESCO - 1-888- 772-3726.

(iv). The system shall interface with the existing hot water and pressurized water systems.

(v). Each rinse (hot water and high pressure) step shall be part of the recipe, dictating how many passes, pump/valve/nozzle control parameters, speed, which robot program to use, and allow for an adjustable delay between rinses and before proceeding to the next step.

E. Steam Clean:

(i). The system shall have the ability to apply the provided steam to the parts. The system shall include all required valves to control the flow of steam.

(ii). Each steam clean step shall be part of the recipe, dictating how many passes, valve control parameters, speed, which robot program to use, and allow for an adjustable delay between steam cleanings and before proceeding to the next step.

F. 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 paint removal of each of the assets listed in Appendix D.

(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 have the iRVision options loaded.

(vii). The robot controller shall not be located in the booth. The robot controller shall be installed in an enclosure such that it is protected from the chemicals and water used in the operation and kept at the proper operation temperature.

(viii). The robot teach pendant shall reach all areas in the work envelope for teaching.

(ix). The robot and any other electrical devices/systems in the work envelope shall have Class

1 Division 1 Classification issued by a Nationally Recognized Testing Laboratory.

(x). The robot shall employ Fanuc Dual Check Safety (DCS) and Collision Guard.

G. Subsystem Hardware:

(i). The auxiliary systems (chemical application, agitation, steam clean, and rinses) shall be controlled by a single Rockwell Automation/Allen-Bradley programmable logic controller (PLC) (Logix 5000 family). This shall be located at the operator controls.

(ii). The Human Machine Interface (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 Redundant Array of Independent Disks (RAID) 1 hard drives.

(iv). The PLC/HMI shall interface with the robot controller, in order to restore/backup Teach Pendant (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 Input/Output (I/O) shall be Ethernet/IP.

H. Subsystem Software:

(i). The Operating System (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 third 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 modification, if required.

I. Data Recording:

(i). The contractor shall provide a DVR for recording video (resolution of 1920x1080) 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.

J. Programming:

(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 have the option of employing software that will meet the following requirements:

1). Automatic, reach-error free, generation of a motion path program to the surface of a provided model with complete parameter control, including raster path offsets, raster direction, and off part travel.

2). Graphics showing the real-time position of the robot/structure, obstacles, and parts during automatic and manual operations.

3). Automatic error recovery motion path generation. This path shall return the robot/structure to a safe position avoiding all parts and obstacles in the work envelope.

4). Real-time collision avoidance for all parts and obstacles in the work envelope, that shall be active during automatic and manual operations.

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

(v). 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 asset programs to be run within the same production run.

(vi). The contractor shall provide a total of four (4) non-consecutive weeks of programming support.

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

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

K. Control Room:

(i). The system shall include a control room with its own AC/Heat that will house the operator interface and PCs.

(ii). The control room shall be installed in the general vicinity shown in Appendix A.

(iii). The control room shall be just large enough to house the operator interface components and two operators, yet not protrude into the travel of incoming assets.

4. Acceptance Testing:

4.1. The complete factory and site acceptance plan for the 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 Chemical System for B180 (L7WC10) - Factory Acceptance Testing (CDRL A006, Acceptance Test Plan, DI-QCIC-80553)

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

B. Once the mock setup is completely assembled, working and the Government has approved the factory test plan, the contractor shall notify the Government POC via email. The Government shall send representative(s) to verify the following and within thirty (30) days:

(i). The contractor shall demonstrate the ability to automatically and completely process the part, including chemical application and chemical agitation 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 low pressure and medium pressure water feature of the chemical 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.

C. Upon successful demonstration of the above, the Government will give approval to ship the system to Robins AFB for installation.

4.3. Site Acceptance Testing (CDRL A007, Acceptance Test Plan, DI-QCIC-80553)

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

(i). The contractor shall demonstrate the ability to automatically and completely process the part, chemical application and chemical agitation 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 low pressure and medium pressure water feature of the chemical 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. The contractor shall be responsible for all other building modifications. To have the utilities installed and ready for connections, the contractor shall provide a list of all required utilities along with the required quantity and description, within the initial project planning chart (CDRL A004, Project Planning Chart, DI-MGMT-80507C)

6. Training (CDRL A005, Training Materials, DI-ILSS-80872)

6.1. Within fifteen (15) days of installation and site acceptance testing completion, operator and maintenance training will be provided for up to ten (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 the system installed and a training manual for the 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.

7. Additional Requirements:

7.1. Contractor shall have robotic de-paint experience and depot level experience.

7.2. The contractor shall provide three (3), nonconsecutive, one (1) week production support visits, to be scheduled as required throughout the first initial 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:

A. The contractor shall establish and maintain a safety and health program in accordance with the elements listed in the Appendix C (Safety Requirements). The contractor shall submit a Safety and Health Plan ten (10) working days after award for review and acceptance by the WR-ALC/SE (Safety Office). The contractor shall ensure their Safety and Health Plan addresses, in detail, the items listed in the Appendix C. If task specific procedures are incorporated into a company local document, ensure those procedures are included/attached to the company's Safety and Health Plan. Referencing the company's local procedure/document in the safety plan is not adequate. If the company's local procedure/document is not attached, the Safety Plan will be returned "Not acceptable.”

The government has ten (10) working days after receipt of contractor’s data to provide acceptance/comments. The contractor’s final submission shall be submitted within ten

(10) working days of receiving government comments.

(CDRL A001, Contractor’s Standard Operating Procedures, DI-MGMT-81580/T)

C. Mishap/Incident Reporting. The contractor shall report all mishaps/incidents in accordance with the contract Appendix C. The contractor shall immediately secure the mishap scene and damaged property and impound pertinent maintenance and training records until released by the Government's Safety Office (WR-ALC/SE). Such release shall be accomplished through the CO. The contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an

Accident/Incident Report within 24 hours of the accident/incident. The Contractor shall require all subcontractors to comply with required safety, health and fire standards.

(CDRL A002, Accident/Incident Report, DI-SAFT-81563/T, NOT 1)

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 a single Gantt Chart showing the project schedule from contract award through final inspection for the system three (3) months after contract award.

Additionally, the Gantt Chart shall be provided monthly after the initial project schedule.

(CDRL A004, Project Planning Chart, DI-MGMT-80507C)

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:

9.1. Automated Chemical System for B180 (L7WC10)

A. Total cost without options

B. Break down cost – Shall be broken out into the following categories:

(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). Chemical distribution system

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

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

(iii). Frame, top view frame layout showing:

1). Operator control station/HMI location 2). Robot location 3). Rail location and structure, including structure material, coatings, and a Finite element analysis (FEA) of the proposed structure.

4). Work envelope 5). Chemical distribution system location 6). Robot control cabinet location 7). Subsystem control cabinet location

E. RoboGuide simulation to demonstrate work envelope and robot reach.

F. 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 Accident/Incident Report A003 3 Commercial Off the Shelf Equipment Manuals and

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

A004 5.1, 7.11 Project Planning Chart A005 6 Training Materials A006 4.2 Acceptance Test Plan (Factory) A007 4.3 Acceptance Test Plan (Government Site)

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

Primary: Alternates:

Taylor Bozard Shane Groves

402 CMXG/MXDQBE 402 CMXG/MXDQBE

Robins AFB, GA Robins AFB, GA Comm 478-222-4851 Comm 478-335-6482

APPENDIX A – BUILDING 180 DE-PAINT ROBOT LOCATION

*Dimensions are approximate

APPENDIX B – OFF AIRFRAME COMPONENT CHEMICAL TABLE

Coating MSN

B&B 9095 6850-01-612-8184

CEE-BEE A-292 8010PHM00103755

CREST INDUSTRIAL STRIPPER 18 8010-01-023-0343

APPENDIX C – LOCATION OVERVIEW

Legend:

Building 180 – One (1) Off-Airframe Component De-paint Robots

APPENDIX D – PARTS