PD_Rev2_19M-241A-FO_Scale_Force_Press.pdf

19M-241A-FO

28 February 2019

Rev 2

PURCHASE DESCRIPTION

FOR

60,000 lbf Automated Scale Force Press

1. SCOPE: This purchase description specifies a 60,000 lbf Automated Scale Force Press to be used in the calibration of scales by the Precision Measurement Equipment Laboratory (PMEL). This press will utilize Air Force owned load cells to calibrate aircraft and truck scales.

2. PERFORMANCE REQUIREMENTS:

2.1. Resolution: The system resolution shall be stable to at least 0.001% load cell capacity.

2.2. Range: Press shall have a continuous range of 250 to 60,000 lbf minimum.

2.3. Measurement Uncertainty: The system uncertainty shall not exceed 0.025% I.V. using the load cells mentioned in paragraph 3.1. The measurement uncertainty analysis shall be provided that lists all the sources of error along with the numerical value. See Instructions to Offerors.

2.4. Units: Display shall indicate in pounds force at a minimum.

3. FUNCTIONAL REQUIREMENTS:

3.1. The press will utilize and interface with Air Force-owned Tovey CS10-2.5K-B300, CS10-10K-

B300, CS20-30K-B300, and CS20-60K-B300 load cells. A Tovey 9150-2-300 Indicator is available at each lab for use in the system, if needed.

3.2. Operating Modes: The system shall be capable of operating in manual, semi-automatic, and automatic mode from 250 to 60,000 lbf. System shall produce a stable reading within 20 seconds once test point has been reached.

3.2.1. Manual Mode: The user shall be capable of manually selecting the desired force to be applied to the Test Instrument (TI) by using the computer while reading the TI manually/visually.

3.2.2. Semi-Automatic Mode: The user shall be capable of creating and running a calibration sequence that will stop after each test point until prompted to continue. Once the system has stabilized, it shall prompt the user to record a reading. The calibration sequence shall be able to perform at least 1 to 10 test points.

3.2.3. Automatic Mode: The user shall be capable of creating and running a calibration sequence that will apply the load to the TI and read the TI automatically through the software. The calibration sequence shall be able to perform at least 1 to 10 test points.

This mode is only applicable when the TI and the Automated Scale Force Press are from the same OEM.

3.2.3.1. Automated calibration shall include user inputs for command read prompts of TI.

3.3. Exercising: The software shall be capable of automatically exercising the TI and Standards.

3.4. User Interface: User shall interact with computer via keyboard and mouse.

Attachment 1

Rev 2

3.5. Ancillary Equipment: All mounting equipment, such as load cell adapters, shall be provided to operate system. The load cell adapter on the ram shall be a quick connect type attachment to allow for easy installation of the load cells listed in section 3.1 to the ram, while maintaining rigidity to the ram to ensure uncertainty requirements are met. All adapters shall be made to withstand a force equal to at least 150 % load cell capacity.

3.5.1. Dial Indicator/holding fixture: A dial indicator with holding fixture to mount to the ram shall be provided. The dial indicator shall be capable of measuring the perpendicularity of the ram to the working surface utilizing an Air Force provided 18 inch granite square.

3.5.2. Hardened Steel Distribution Plate: A 4x4x0.5 inch (LxWxH) hardened steel distribution plate shall be provided. The plate is used to protect the load cell at the point of contact.

3.6. The press shall be capable of performing a center check and shift test/ corner check on an Intercomp AC30-60 scale. The shift test/ corner check is performed at 12 inches from center along the diagonal.

4. MECHANICAL & PHYSICAL REQUIREMENTS:

4.1. Dimensions and Weight of Press

4.1.1. Height shall not exceed 80 inches.

4.1.2. Overall footprint (depth and width) shall be no more than 67 inches each. (Does not include hydraulic unit)

4.1.3. The working surface shall be one piece.

4.1.4. At a minimum, the system shall be capable of measuring a TI that stands anywhere between 2.5 and 7.5 inches from the table surface utilizing any of the load cells listed in paragraph 3.1.

4.1.5. At a minimum, the Ram Travel shall be able to span the measuring range described in paragraph 4.1.4.

4.1.6. Weight shall not exceed 4000 lbs.

4.2. Components:

4.2.1. All components shall be capable of being brought through a 59 inch wide x 80 inch height doorway with the use of equipment provided by the PMEL or the OEM. See Instructions to Offerors.

4.2.2. All components shall be housed as a single unit. The hydraulic pump may be a separate component.

4.2.3. All essential components shall be corrosion-proof. Preventative maintenance, such as oiling, can be required in order to retard rust and promote necessary function. The item shall not exhibit excessive pitting of essential components, which would inhibit proper function of the equipment.

4.2.4. Working surface shall be capable of being leveled upon installation using threaded bottom supports.

4.2.5. Hydraulic fluid reservoir shall have shut-off valve(s) to connect the hydraulic lines to the press and for draining purposes.

4.2.6. Hydraulic Pump shall produce a noise level of no more than 65 dB from 5 feet away.

4.3. Model and Serial Number Identification: Item’s Part Number/Model Number, Manufacturer, and Serial Number shall be identified clearly on the item in a location visible to the operator.

Unique item identification labeling shall follow Item Identification and Valuation requirements as stated in the contract.

4.4. Operating Environment/Storage: Item is not intended to be stored in an environment outside the normal operating conditions.

4.4.1. Operating Temperature: Item shall operate in an ambient temperature of 67 to 79 degrees Fahrenheit without loss of required performance.

4.4.2. Operating Humidity: Item shall operate in an environment with 20 to 50% Relative

Humidity without loss of required performance.

4.5. Facility Requirements:

4.5.1. Electrical Power and Connections: Item shall operate on no more than one 220 V single phase 60 Hz 20 A and one standard 110 V AC 60 Hz 20 A outlets.

4.6. Safety:

4.6.1. Documentation shall be provided to support the means by which electrical safety considerations have been addressed. This documentation shall consist of a minimum of a citation of a UL or ANSI identified standard or equivalent United States Standard to which the equipment conforms.

4.6.2. Pressure relief (change in range) shall be automated and have a manual override.

4.6.3. The press shall have the ability to mechanically relieve pressure from the system and allow the operator to remove the scale in case of an emergency such as a power outage.

5. CONTROLLER REQUIREMENTS:

5.1. Controller: A laptop controller is required that can efficiently operate under Microsoft Windows 10 Professional 64 bit operating system. All major components of the system shall be commercially available and fully supportable by commercial sources. Where specific brands are identified in this specification, no substitutes are allowed without prior approval from the AFMETCAL. The controller shall meet or exceed Microsoft Windows 10 Professional hardware requirements.

5.2. Processor:

5.2.1. CPU PassMark Score: 4,000 or higher

5.2.2. Supports Credential Guard: Virtualization Extensions (Intel VT-x or AMD-V)

5.2.3. Supports Device Guard: VT-d or AMD-Vi; IOMMU (Input/output Memory Management units)

5.2.4. Supports Extended Page Tables (Second Level Address Translation)

5.2.5. Supports Direct Memory Access (DMA)

5.2.6. UEIF Firmware V. 2.4 (or higher)

5.3. Memory: Minimum 8 GB system Memory.

5.4. Input Output (I/O) External Ports, Slots, and Connectors: (At minimum, the following types of I/O interface connections shall be available on the controller or via port replication).

5.4.1. USB: Minimum of three integrated USB 3.1, Thunderbolt Type 3/USB-C

5.4.2. USB-C to USBA Adapter w/USB-C port

5.4.3. Ethernet: One 10/100/1000 BaseT Ethernet port.

5.4.4. Video: G3D Video PassMark Score: 500 or higher

5.4.4.1. External video support

5.4.4.2. Adapter to DVI connection

5.5. Display Panel: 17-inch (diagonal) or larger viewable display.

5.6. Hard Drive:

5.6.1. 120 GB (Minimum) Hard Disk Drive

5.6.2. FIPS 140-2 certified SED

5.7. DVD-ROM: Internal or External DVD +/- RW dual layer or Blue-Ray

5.8. Operating System and Software: All software shall run under Microsoft Windows 10 (Professional operating system or greater 64bit, latest version release). All software shall run Windows 10 as a non-elevated user. Shall be supplied with Microsoft Word and Excel, latest release with a non-renewable license.

5.9. Additional Hardware: Additional hardware required to make this system function as identified by this purchase description shall be required.

5.10. Interchangeability:

5.10.1. When firmware or software upgrade is anticipated by a manufacturer during the life of this contract, the contractor shall contact AFMETCAL for concurrence. If AFMETCAL concurs with the proposed upgrade all previous units shall be updated to this upgrade.

5.10.2. All firmware or software provided under this contract shall be at the same version, revision, and revision date at the completion of the contract.

5.11. Software Identification: Software version shall automatically display upon startup.

5.12. Software Warranty:

5.12.1. The contractor shall warrant that the software product meets this purchase description and is free from defects in design and operation and will perform to stated specifications from the date of shipment through warranty expiration date of the equipment. The Warranty or Addendum shall include verbiage to assure the following minimum requirements are satisfied. All other clauses of the contractor's warranty shall remain in effect unless they contradict the requirements stated below.

5.12.2. The contractor shall (at no additional cost) update, or replace the software product as necessary to correct any deficiencies identified in the software. Replacement software shall meet or exceed the requirements in this purchase description, shall not require additional training to operate and be warranted for the remainder of the original warranty.

5.12.3. The contractor shall bear transportation costs for all replacement products.

5.13. Software:

5.13.1. Software shall have a minimum of five major sections, which can be selected from the opening screen:

5.13.1.1. Scale Calibration Test Files/Scripts: The user creates a Scale Calibration Test File, which includes:

5.13.1.1.1. Exercise Routine

5.13.1.1.2. Center Calibration Applied Force Values

5.13.1.1.3. Center Calibration Number of Runs

5.13.1.1.4. Shift Test Applied Force Value

5.13.1.1.5. Shift Test Number of Runs

5.13.1.1.6. Text Section for Comments

5.13.1.2. Semi/Fully Automatic Calibration: The user selects a Scale Calibration Test File that has already been written. Once test file is selected, the scale calibration file information is shown and the TI information is filled in by the user. During calibration, the user shall have the option to save the scale calibration data without finishing and the program shall prompt user to save upon exiting.

5.13.1.3. Standard Calibration File(s): The user shall input range, ID #, calibration due date, and calibration data on the standard load cells and any other calibration devices used in the system, such as a Load Cell Simulator.

5.13.1.3.1. The controller shall be used to store all calibration data in the form of a polynomial curve fit. This entry shall allow up to a 5th order curve fit.

5.13.1.4. Manual Mode: This shall allow user to manually initiate movement of press ram (both up and down) and meet the requirements of paragraph 3.2.1.

5.13.1.5. TI File Directory: The user shall be able to select previous TI calibration data.

5.13.2. Calibration Reports: System shall be able to export data into Microsoft Excel formats, at a minimum, as well as print. Report shall include date, time, calibration information and results, standard identification information, and TI identification information.

5.13.3. Operations Files: All files mentioned in section 5.13.1 shall be saved, editable, and retrievable.

5.13.4. Software Display: During calibration, the display shall show, at a minimum, the following information:

5.13.4.1. Designated test file (title), to include test points and all readings entered in a chart form.

5.13.4.2. Current Applied Force, whether or not the press/ram is in operation.

5.13.4.3. Status of Machine shall include, at a minimum, increasing force, prompt for technician to take reading, and prompt for operator to change load cell.

6. OPERATOR’S MANUAL: Manual shall be IAW DD1423 and Data Item Descriptions, and shall also include, at a minimum, the following information:

6.1. Instructions on how to use/operate system, complete with drawings/diagrams.

6.2. Drawing/Diagrams and instructions required for manual alignment/adjustment of working parts.

6.3. Drawing/Diagrams and instructions required for completing any required/scheduled maintenance, including non-destructive testing, visual inspection, and lubrication.

6.3.1. This shall also include a list of support equipment required to accomplish any maintenance.

6.4. A list of peripheral support equipment required to accomplish all calibrations and adjustments.

6.5. Information on any internal adjustments made during operation.

6.6. Definitions of all changeable settings/configurations.

6.7. Instructions on how to access settings/configurations.

6.8. Complete diagram and parts breakdown with manufacturer and part number of all components, including any Signal Conditioning Cards and Analog-to-Digital Cards.

6.9. Technical Specifications, which shall include at a minimum: overall size, measuring surface size, weight, ram travel, measurement range, accuracy, and resolution

6.10. Common troubleshooting procedures

7. INSTALLATION: The system will be installed/setup by the PMEL personnel. See Instructions to

Offerors for further details.

8. INSTALLATION MANUAL: Manual shall include all information which describes and demonstrates the installation/setup of the system to assure the system is fully functional and meets the requirements of this purchase description.

9. TESTING: This item will be inspected and accepted at destination as stated in the contract. The item will be checked with test equipment with parameters equal to or better than those required to assure that specified performance parameters are met. Test equipment used shall have first echelon certification directly traceable to the National Institute of Standards Technology (NIST) or other approved equivalent international laboratory. Tests will be performed to assure that the item meets the requirements of this purchase description. Such testing at destination does not relieve the contractor of performing all inspections and quality checks at the point of manufacture as necessary to assure performance as specified herein.

Attachment:

Data Requirements

Attachment to Purchase Description 19M-241A-FO

60,000 lbf Scale Force Press, Automated

DATA REQUIREMENTS

MANUALS: A set of operational and maintenance manuals shall be provided. As a minimum, the manuals shall include an explanation of features, performance specifications, operational instructions, theory of operation, calibration procedures, and an illustrated parts breakdown. Wherever possible, use of pictures, diagrams, schematics and mathematical formulas shall be included such that any text material may be better understood. Specifically, the calibration procedure shall include a list of required calibration equipment, by part number, connection diagrams and step-by-step instructions to follow for completing this task. In addition, a system- level manual explaining the system operation and software shall also be provided. Manuals shall be on CD/DVD-ROM in Indexed Portable Document Format (iPDF).

A validation and verification of the manuals will be required. The manual shall be in accordance with the Air Force Technical Manual Contract Requirements (TMCR) TM86-01N and Contract Data Requirements List (DD Form 1423).