PD_Rev3_19M-512A-DI_Dial_Indicator_Calibrator_Upgrade.pdf

19M-512A-DI

December 13, 2018

Rev 3

PURCHASE DESCRIPTION

FOR

Dial Indicator Calibrator Upgrade

1. SCOPE: This is a procurement to upgrade Mahr P/N Optimar 100 Dial Indicator Calibrator. The Dial

Indicator Calibrators are used by the Precision Measurement Equipment Laboratories (PMEL) to calibrate mechanical and digital indicators that have ranges up to and including 4 inches (0 to 100 mm).

2. PERFORMANCE REQUIREMENTS: The Upgraded Dial Indicator Calibrator (UDIC) shall have the following:

2.1. Range: 0 to 4 inches (0 to 100 mm).

2.2. Units: Inch and Metric.

2.3. Resolution, Inch: 1 µin.

2.4. Resolution, Metric: 0.02 µm.

2.5. Accuracy: Not to exceed ±(0.2 + L/100) µm, L is length in millimeters.

2.6. Warm-Up Time: Shall not exceed 30 minutes.

3. FUNCTIONAL REQUIREMENTS:

3.1. The UDIC shall mechanically operate the same as the original design.

3.2. The UDIC shall have a holding device (collars) capable of rigidly supporting dial indicators, test indicators, digital indicators, and dial comparators when performing calibrations. The mounting device shall be capable of mounting indicators that have shaft dimeters of 0.2185 inch, 0.25 inch, 0.375 inch, 8 mm, and 28 mm.

3.3. Calibration Requirements: The UDIC shall be calibrated/aligned using U.S. Air Force owned reference probe, Heidenhain P/N CT6002 and mounting assembly. When the UDIC does not meet calibration requirements, alignment shall be accomplished using the UDIC Calibration Software. The UDIC must be interfaced with the reference probe to allow automatic collection of data.

3.4. All cables, connectors, electronic interfaces, operating software, calibration software, and other equipment necessary to operate and/or calibrate the UDIC shall be provided.

3.5. BV Option: Shall include camera and lighting system capable of fully automatic reading and recording of indicator measurement positions.

3.6. Ancillary Equipment: The UDIC shall include:

3.6.1. Cables to interface the electronic indicators to the calibrator when performing automatic calibrations for the following shall be provided:

3.6.1.1. Adapter/Cable, Mahr P/N 7044324 (Used with Probe P/N 1514H).

3.6.2. BV Option:

3.6.2.1. Lighting Unit

3.6.2.2. USB camera with lens

3.6.2.3. Sliding mechanisms for positioning of the camera and lighting unit

3.6.2.4. Hand wheel for manual testing

3.6.2.5. Base mounting for the Optimar 100

4. MECHANICAL & PHYSICAL REQUIREMENTS:

4.1. Part Number and Serial Number Identification: A plate shall be attached to the UDIC. The plate shall identify the Air Force System Part Number, Serial Number, and Manufacturer (The Air Force System P/N shall be different than the original P/N).

4.2. UID Label: This item shall be clearly labeled with a model number, serial number, and manufacturer’s name. Unique item identification labeling shall follow Item Identification and Valuation requirements as stated in the contract.

4.3. The UDIC shall meet all requirements of this purchase description when it within the following Operating Environment/Storage conditions:

4.3.1. Operating Temperature: 73 +/- 6° F.

4.3.2. Relative Humidity: 20 to 50%.

4.4. Electrical and Facility Requirements:

4.4.1. Electrical Power and Connections: The UDIC shall operate using 110 volts AC at 50/60

Hz, 15 amps.

4.4.2. Electrical Safety: The UDIC shall be grounded.

4.4.3. Electrical Protection: The UDIC shall have a fuse or circuit breaker to protect it in the event of excessive current. The AC line power fuses shall be user serviceable without removing any covers /panels or voiding a manufacturer’s service warranty.

5. CONTROLLER REQUIREMENTS:

5.1. The UDIC shall be interfaced with a Laptop Controller that includes UDIC Calibration

Software, UDIC Indicator Calibration Software, and for BV option, the QMSOFT/QM-DIAL Image Processing Software.

5.2. A Laptop Controller is required that can efficiently operate under Microsoft Windows 10 Professional 64 bit operating system. All major components of the system must 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 must meet or exceed Microsoft Windows 10 Professional hardware requirements.

5.3. Laptop Controller Salient Characteristics:

5.3.1. Processor: Performance Attributes -speed, cache, cores, threads, etc.

5.3.1.1. CPU PassMark Score: 4,000 or higher.

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

5.3.1.3. Supports Device Guard: VT-d or AMD-Vi; IOMMU (Input/output Memory

Management units).

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

5.3.1.5. Supports Direct Memory Access (DMA).

5.3.1.6. UEIF Firmware V. 2.4 (or higher).

5.3.2. Memory: Minimum 8 GB system Memory.

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

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

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

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

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

5.3.3.4.1. External video support.

5.3.3.4.2. Adapter to DVI connection.

5.3.4. Display Panel: 14.1-inch (diagonal) or larger viewable display.

5.3.5. Hard Drive:

5.3.5.1. 120 GB (Minimum) Hard Disk Drive.

5.3.5.2. FIPS 140-2 certified SED.

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

5.3.7. Operating System and Software: All software must run under Microsoft Windows 10

(Professional operating system or greater 64bit, latest version release). All software must run Windows 10 as a non-elevated user.

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

5.5. Software Identification: All software used in conjunction with instrument shall be identified by Name, Version, and Date; to be displayed upon startup or located in an “About” menu in the software.

5.6. Software Warranty:

5.6.1. 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 contractor's Commercial 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.

5.6.2. 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.

5.6.3. When firmware or software upgrade is anticipated by a manufacturer during the life cycle 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.

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

6. SOFTWARE:

6.1. UDIC Calibration Software:

6.1.1. The UDIC Calibration Software shall use the same processes and techniques as the current

Mahr developed software identified as Optimar Calibrator Software Version 1.20-6.

6.1.2. Software measurement process and techniques shall utilize the reference probe to calibrate the UDIC internal scale. Refer to Paragraph 3 for Reference Probe description.

6.1.3. Software shall be able to automatically adjust UDIC internal scale for linearity and hysteresis or shall allow the operator to manually change internal scale calibration corrections.

6.1.4. Software shall be able to perform pre and post adjustment measurements.

6.1.5. Software shall be able to perform lower 2 inch range separate from upper 2 inch range.

6.2. UDIC Indicator Calibration Software:

6.2.1. The UDIC Calibration Software shall use the same processes and techniques as the current Mahr developed software identified as Optimar Indicator Calibration Software Version 2.12-2.

6.2.2. Software shall provide indicator calibration measurement process settings based on ASME B89.1.10M and DIN 32876.

6.2.3. Software shall have a test file for the indicator being calibrated. The test file will allow the operator to input indicator ranges, resolution, accuracy and other technical data important to the calibration.

6.2.4. Software shall measure indicator linearity and hysteresis.

6.2.5. Software shall provide graphical display of calibration results.

6.2.6. Software shall allow the indicator to be calibrated in the Semi-Automated Mode or Fully- Automated Mode.

6.2.6.1. Semi-Automated Mode: The calibrator will displace the indicator being calibrated to the approximate measurement position. The operator will then manually adjust the calibrator to displace the indicator to its calibration position and trigger the calibrator to record measurement data. All final calibration data is automatically calculated. This process is repeated for all predesignated calibration positions.

6.2.6.2. Fully-Automated Mode: The calibrator will displace the indicator being calibrated to each measurement position and record measurement data. All final calibration data is automatically calculated.

6.2.7. Software shall be upgraded to recognize Probe Mahr P/N 1514H when interfaced for automated calibration.

6.3. BV Option: QMSOFT/QM-DIAL Image Processing Software

6.3.1. The calibrator will displace the indicator to each measurement position automatically.

Measurement positions will be able to be entered into the software prior to calibrating an indicator.

6.3.2. Software shall be capable of recognizing indicator faces to determine resolution of both dial and digital test items.

6.3.3. USB camera and separate lighting system will produce a fully automatic reading of the displayed values on both dial and digital test items.

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

7.1. Shall include at least one printed manual and an electronic copy of the manual.

7.2. Cover Page: Shall identify the Air Force System P/N, (The Air Force System P/N shall be different than the original P/N), Contract Number, Noun, Mfg., Rev Number, and Date.

7.3. Shall include an index.

7.4. Shall include a general description that identifies the system and its various parts, components and display. There shall be a functional description depicting the UDIC and describing how the UDIC works.

7.5. Shall include un-packing, set-up and installation instructions.

7.6. Shall include instructions for interfacing all electrical connections.

7.7. Shall include maintenance instructions for cleaning UDIC.

7.8. Shall include instructions for installing software.

7.9. Shall include description of the display, menu bar, function buttons, measurement readout, etc.

7.10. Shall include instructions for using the UDIC and software to calibrate indicators. The instructions shall discuss the menus, setting up test files, and how to print certificates.

7.11. Shall include instructions for calibrating and aligning the UDIC using reference probe. The instructions shall provide guidance for determining if the alignment process measurement results are acceptable or un-acceptable.

8. TESTING: The UDIC will be inspected and accepted at a destination specified elsewhere in this contract. The item will be checked with test equipment and parameters equal to or better than those required assuring specified performance requirements are met. Test equipment has first echelon certification directly traceable to the National Institute of Standards and Technology (NIST) or other approved equivalent international laboratory where required. Test will be performed to assure the UDIC meets or exceeds all of the requirements of this purchase description. Such testing does not relieve the contractor of performing all inspections and quality control checks at the point of fabrication as necessary to assure performance as specified.

Attachment:

Data Requirements

Attachment to Purchase Description 19M-512A-DI Dial Indicator Calibrator Upgrade

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) TM86-01Q and Contract Data Requirements List (DD Form 1423).