Purchase_Description_19M-260A-DI_Rev._1_dated_12_December_2018.pdf

19M-260A-DI

12 December 2018

Rev 1

PURCHASE DESCRIPTION

FOR

Long Gage Block Comparator Upgrade

1. SCOPE: This is a procurement to upgrade P/N 130B-16 Long Gage Block Comparators. The long gage block comparators are used by the Air Force Primary Standards Laboratory (AFPSL) and the Precision Measurement Equipment Laboratories (PMEL) to calibrate gage blocks that range in length between 5 to 20 inches (125 to 500 mm). The upgrade shall replace the current analog measurement system with an electronic measurement system that is interfaced to a laptop controller.

2. PERFORMANCE REQUIREMENTS: The Upgraded Long Gage Block Comparator (ULGBC) shall include the following characteristics:

2.1. Dual Contact Comparator with Floating Head design.

2.2. Gage Block Capacity: 0 to 24 inches (0 to 600 mm).

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

2.4. Adjustable Upper Contact and Lower Contact Gaging Force.

2.4.1. Nominal Upper Contact Gaging Force: Approximately 4 oz (113 g).

2.4.2. Nominal Lower Contact Gaging Force: Approximately 2 oz (56 g).

2.5. Measurement Units: Inch (µin) and Metric (µm).

2.6. Amplifier Range: +/- 500.0 µin, (+/- 10.0 µm).

2.7. Amplifier Resolution: 0.1µin, (0.001µm).

2.8. Amplifier Uncertainty:

2.8.1. Linearity: +/- 1.0 µin, (0.025µm) in the central +/- 50.0 µin (1.25µm) range of amplifier.

2.8.2. Linearity: +/- 1.0 µin, (0.025µm) in any 50.0 µin (1.25µm) range of amplifier.

3. FUNCTIONAL REQUIREMENTS:

3.1. The ULGBC shall mechanically operate the same as the original design: floating head, adjustable upper gaging force, and adjustable lower gaging force. The gage head shall be able to be lowered and/or lifted using the lifting lever. Dual Stylus Design; one fixed stylus and one electronic gage head.

3.2. Replace the sliding comparator staging table, crank, and mechanism.

3.3. Replace the staging table.

3.4. The vertical sliding assembly shall be move up and/or down smoothly and be able to be locked in place. If necessary, replace locking mechanism and other components.

3.5. Replace all reed springs.

3.6. Replace the upper and lower stylus contacts.

3.7. Replace the electronic gage head.

3.8. Replace analog and/or digital display with Laptop Controller.

3.9. If missing, replace circular bubble level.

3.10. If missing, replace the adjustable feet.

3.11. Calibration Requirements: The ULGBC shall be calibrated/aligned using U.S. Air Force owned gage blocks. When the ULGBC does not meet calibration requirements, alignment shall be accomplished using the Alignment Software. Gaging force shall be adjusted manually.

3.12. Assign a new Air Force System Part Number.

4. ANCILLARY EQUIPMENT: The ULGBC shall include:

4.1. Dynamometer with pointer, for measuring Lower Gaging Force.

4.1.1. Dynamometer Specifications:

Range: 0 to 100 grams.

Resolution: 2 to 5 grams.

Attachment 1

Rev 1

Accuracy: +/- 1 div.

4.2. Electronic Weigh Scale, for measuring Upper Gaging Force.

4.2.1. Electronic Weigh Scale Specifications:

Range: 0 to 200 grams.

Resolution: 1 gram.

Accuracy: +/- 4 grams.

4.3. Electronic Depth Gage, for measuring Lower Contact Protrusion.

4.3.1 Electronic Depth Gage Specifications:

Range: +/- 0.040 inches.

Resolution: Not to exceed 0.0005 inches.

Accuracy: Not to exceed +/- 0.0005 inches.

4.4. Double Sided Optical Flat, for inspecting gage block surfaces.

4.4.1 Optical Flat Specifications:

Range: 2.0 inch Diameter.

Accuracy: Flatness not to exceed 1.5 µin TIR.

4.5. Tongs for picking up and moving long gage blocks.

4.6. Air Bulb/Brush for cleaning gage blocks.

4.7. Serrated Aluminum Oxide Deburring Stone with case (approximately 1”x2”x3”).

4.8. All cables, connectors, electronic interfaces, operating software, calibration software and other equipment necessary to operate and/or calibrate the ULGBC.

5. MECHANICAL & PHYSICAL REQUIREMENTS:

5.1. Model and Serial Number Identification: A metal plate shall be attached to the ULGBC. The metal plate shall identify the Air Force System Part Number, the ULGBC Part Number, Serial Number, and Manufacturer.

5.2. 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.

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

5.3.1. Laboratory Temperature: 68 +/- 1° F.

5.3.2. Relative Humidity: 20 to 50%.

5.4. Electrical and Facility Requirements:

5.4.1. Electrical Power and Connections: The ULGBC must operate using 110 volts AC at 50/60 Hz, 15 amps.

5.4.2. Electrical Safety: The ULGBC must be grounded.

5.4.3. Fuse: The ULGBC must have a fuse.

6. CONTROLLER REQUIREMENTS:

6.1. The ULGBC shall be interfaced with a Laptop Controller that includes Gage Block Calibration

Software and Gage Block Comparator Alignment Software.

6.2. 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.

6.3. The Laptop Controller and all Software shall be usable with the ULGBC and the U.S. Air Force owned P/N 130B-38AF Short Gage Block Comparators.

6.4. The Controller and Amplifier Box shall be designed so both the ULGBC and the U.S. Air Force owned P/N 130B-38AF Short Gage Block Comparator can be plugged into the system at

Rev 1 the same time. The System Configuration Software shall allow either the ULGBC or the U.S.

Air Force owned P/N 130B-38AF Short Gage Block Comparator to be activated when performing gage block calibrations.

6.5. The U.S. Air Force owned P/N 130B-38AF Short Gage Block Comparator is currently using the Gage Block Calibration and Comparator Alignment Software developed by Mahr and is identified as V 4.0A, Build 3 (08.16.2011).

6.6. The ULGBC shall include Gage Block Calibration and Comparator Alignment Software that uses the same measurement processes, techniques, corrections, calculations, etc. as the Software described in Par 6.5.

6.7. Laptop Controller Salient Characteristics:

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

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

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

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

Management units).

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

6.7.1.5. Supports Direct Memory Access (DMA).

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

6.7.2. Memory: Minimum 8 GB system Memory.

6.7.3. 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:

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

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

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

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

6.7.3.4.1. External video support.

6.7.3.4.2. Adapter to DVI connection.

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

6.7.5. Hard Drive:

6.7.5.1. 120 GB (Minimum) Hard Disk Drive.

6.7.5.2. FIPS 140-2 certified SED

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

6.7.7. 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.

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

6.9. 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.

6.10. Warranty:

6.10.1. 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 within this purchase description

6.10.2. 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.

6.10.3. 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.

Rev 1

6.10.4. 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.

7. SOFTWARE, GAGE BLOCK CALIBRATION:

7.1. Software shall use the same measurement processes, techniques, corrections, calculations, etc.

as the Software described in Par 6.5.

7.2. Software shall allow master gage block set files with set p/n, set id#, set s/n, material and deviations to be developed and saved so the master gage block files can be recalled to calibrate test gage blocks.

7.3. Software shall allow test gage block set files with set p/n, set id#, set s/n, material, individual gage block s/n’s to be developed and saved.

7.4. Software shall follow a sequence that compares each test gage block in the set to a master gage block. The measurement sequence can be stopped and resumed at any time. Software shall save measurement data automatically.

7.5. After all test gage blocks in the set have been compared to a master gage block once, the sequence described in Par 7.4 is repeated for a second set of measurements.

7.6. After the two measurement sequences described in Par 7.4 and Par 7.5 are completed, the software calculated deviations for each test gage block in the set are compared and must agree within the specification input into the Spread Value contained within the Configuration Menu.

7.7. If the two calculated deviations for any test gage block in the set, exceed the Spread Value, the those particular test gage blocks are flagged and must be compared to a master gage block for third time.

7.8. Once all test gage blocks in the set meet the Spread Value, the software shall direct technician to print a certificate of calibration and case card.

7.9. Certificate of Calibration shall identify the set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

7.10. Case Card: The software shall allow case cards to be printed. Case cards are small card sized charts that fit into the gage block set. The case card shall identify set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

7.11. Software Configuration shall allow the technician select units for length, deviations and temperature.

7.12. Software Configuration shall allow the technician to select laboratory temperature, gage block temperature or manual entry.

7.13. Software Configuration shall allow the technician to select the expansion coefficients for various gage block materials such as, but not limited to ceramic, steel, tungsten and chromium carbide. The numerical expansion coefficient value for each material must be identified.

7.14. Software Configuration shall allow the technician select the penetration coefficient for various gage block materials such as, but not limited to ceramic, steel, tungsten and chromium carbide or a manually entered value. The numerical penetration coefficient value for each material must be identified.

7.15. Software Configuration shall allow the technician to select the master gage block set being used, enter the test gage block variation in µin, enter the spread value in µin, and the allowed column edits for test gage block data for dev 1 and dev 2.

7.16. Software shall save all final test gage block calibration data.

7.17. Software shall allow a replacement test gage block to be added to a previously calibrated test gage block set. The replacement test gage block s/n and deviation shall be able to be input into the test gage block file and a new certificate of calibration and case card to be printed.

Rev 1

8. SOFTWARE, GAGE BLOCK COMPARATOR ALIGNMENT:

8.1. Software alignment process and techniques should be the same as the Software described in

Para 6.5.

8.2. The comparator alignment software shall guide or prompt the technician through the entire measurement process.

8.3. The comparator alignment software shall allow the technician to enter the number of gage blocks being used, the deviation of each gage block and if necessary the spread between the gage blocks.

8.4. The comparator alignment software shall guide or prompt the technician through the entire alignment process.

8.5. The comparator alignment software shall provide quantifiable measurement data to determine if the alignment process is acceptable or if it should be repeated.

8.6. The comparator alignment software shall allow the technician to accept and save the new alignment data or reject it and repeat the alignment process.

9. OPERATOR’S MANUAL:

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

9.2. Cover Page: Shall identify the Air Force System P/N, Contract Number, Noun, Mfg, Rev

Number, and Date.

9.3. Shall include an index, a description that identifies the system and its various parts, components and display. Graphics and technical description of the comparator and how it works. Graphics and technical description of the display, menu bar, function buttons, sensor positon readout, measurement readout, etc.

9.4. Shall include the technical specifications such as capacity, upper and lower gaging forces, contact radius and material, range of signal, range of sensor positon, resolution (inch and metric), linearity accuracy, repeatability, thermometer p/n, thermometer mfg, thermometer range, thermometer resolution and thermometer accuracy for the provided thermometer.

9.5. Shall include instructions for un-packing, set-up, installation instructions, interfacing all electrical connections and thermometer and installing software.

9.6. Shall include instructions for measuring and adjusting the upper and lower gaging forces using the dynamometer and weigh scale.

9.7. Shall include instructions for checking and adjusting the cam clearance, for measuring and adjusting the lower contact stylus protrusion height.

9.8. Shall include maintenance instructions for cleaning, replacing upper and lower stylus contacts, electronic gage head replacement and alignment, over-travel stop screw check and adjustment, adjusting the staging table perpendicular to the spindle, measuring contact protrusion height and adjustment using depth gage, checking and aligning contacts.

9.9. Shall include instructions for adjusting comparator to obtain the full amplifier range.

9.10. Shall include instructions for using the comparator and software to calibrate gage blocks. The instructions shall discuss the menu’s, setting up test and master files, entering individual gage block serial numbers, setting up the configuration, units, environment, expansion coefficients, penetration coefficients, measuring mode, the two run comparison measurement process, re-running a gage block a third time if the two first runs exceed the Spread Value requirement, how to print certificates and case cards.

9.11. Shall include instructions for calibrating and aligning the comparator using gage blocks. The instructions shall provide guidance for determining if the alignment process measurement results are acceptable or un-acceptable.

9.12. Shall include description and calculations used to determine the Penetration Coefficients.

9.13. Shall include description and calculations used to determine the Coefficient of Thermal

Expansion constants.

Rev 1

10. SOFTWARE MANUAL:

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

10.2. Cover Page: Shall identify the Air Force System P/N, Contract Number, Noun, Mfg, Rev

Number, Software Version and Date.

10.3. Shall include installation and log-in instructions.

10.4. Shall include a description of all main screen menus, buttons and other components associated with each menu.

10.5. Shall provide instructions for setting coefficient of thermal expansion, material environment, units, etc.

10.6. Shall include instructions for setting up master gage block set files: How to input information such as set part number, set serial number, material, nominal gage block sizes and certified deviations.

10.7. Shall include instructions for setting up test gage block files: How to input information such as set part number, set serial number, material, nominal gage block sizes and individual gage block serial numbers.

10.8. Shall include instructions for calibrating a test gage block set: How to select a test and master gage block set. A description of the measurement process and sequence. Description of measurement runs and how to compare measurement results (allowable variation) to determine if the two measured test gage block deviations are acceptable.

10.9. Shall provide instructions for measuring variation in length.

10.10. Shall include instructions for re-measuring test gage blocks when the measurement results are not acceptable.

10.11. Shall include instructions for measuring single test gage blocks.

10.12. Shall include instructions for printing measurement results, certificates and case cards.

10.13. Shall provide instructions for developing new certificates and case cards.

11. SHIPPING CONTAINER: The contractor shall provide the PMEL with one or two shipping containers, bolts for attaching the comparator to the shipping container, and packing instructions.

PMELs having one comparator upgraded shall require one shipping container. PMELs having two comparators upgraded shall require two shipping containers.

12. INSTALLATION and TRAINING: The contractor shall coordinate with PMEL, set-up the comparator, and provide at least one day of training (excluding travel time) for each destination site.

Training shall include operation, calibration, and maintenance of the gage block comparator.

13. TESTING: Installation and system operation overview by the contractor shall take place at the customer’s premises. The contractor shall spend a minimum of one day on site. The ULGBC 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 ULGBC 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-260A-DI

Long gage Block Comparator 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).