Statement_of_Work_19C-234A-OP_Rev._7_dated_22_May_2019.pdf

19C-234A-OP

22 May 2019

REV 7

STATEMENT OF WORK

FOR

DUAL AXIS ANGLE GENERATOR SYSTEM

PROJECT NUMBER: CCG715

1. Technical Problem: The existing calibration process for Autocollimators at the Air Force Primary Standards Laboratory (AFPSL) uses equipment that is old, no longer supported and no longer manufactured. The calibration of Autocollimators requires an Aero Tech AOM106M Dual Axis Angle Generator, which is obsolete and has no available COTS replacements.

2. Objectives: The Primary objective is to develop and deliver an automated Dual Axis Angle Generator System for calibrating autocollimators workload at the AFPSL. The Dual Axis Angle Generator System shall utilize a laser interferometer and be capable of generating angles in accordance with the Performance Objectives. The end deliverable product shall be one turnkey system that will be used by the AFPSL to calibrate the autocollimator workload to the methodology in Air Force Technical Order 33K6-5-400-1. The contractor shall receive Air Force Technical Order 33K6-5-400-1. The Dual Axis Angle Generator System shall include all hardware, software, and support equipment necessary to perform automated and manual autocollimator calibrations.

2.1. Performance Objectives:

2.1.1. K=2 Combined Measurement Uncertainty: The uncertainty shall not exceed +/-0.01 arc-sec within the center +/- 25 arc-sec, +/-0.03 arc-sec for the center +/-150 arc-sec, and +/-0.05 arc-sec over the full range.

2.1.2. Range: The Dual Axis Angle Generator System shall have a range of ± 3600 arc-sec in the vertical direction from level and ± 3600 arc-sec in the horizontal direction from center.

2.1.3. Cross Axis Error: The Dual Axis Angle Generator System shall have a cross axis error less than 2 arc-sec.

2.1.4. Units: The Dual Axis Angle Generator System shall have units in arc-sec.

2.1.5. Resolution: The Dual Axis Angle Generator System shall have a resolution of 0.01 arc-sec.

2.1.6. Angle Repeatability: The Dual Axis Angle Generator System shall be able to return to any angle within its range within ± 0.5 arc-sec.

2.1.7. Stability: The Dual Axis Angle Generator System shall be able to move to a position, stop, and hold its position until readings are stable within ± 0.01 arc-sec.

2.1.8. Leveling: The Dual Axis Angle Generator System shall be capable of being leveled within 5 arc-sec without interfering with the alignment of the laser.

2.1.9. Level Indicating Device: The Dual Axis Angle Generator System shall have a level indicating device for both axes that is easily seen during adjustments.

2.1.10. Line of Sight: The Dual Axis Angle Generator System shall allow the Autocollimator line of sight on a mirror to be unobstructed to within 3 inches from the center of the mirror.

Attachment 1

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2.1.11. Automated and Manual Operation: The Dual Axis Angle Generator System shall have the capability to perform automatic angle generation and data acquisition through the measurement function(s) and range(s). Additionally, the Dual Axis Angle Generator System shall be capable of making manually operated measurements.

2.1.11.1. User Interface: The Dual Axis Angle Generator System shall maximize the use of electronically programmable interfaced components. The format of the interface shall be IEEE 488.2 standard and/or USB. The Dual Axis Angle Generator System shall make use of all programmable components to perform automated measurements via the provided programmable system controller described in this SoW.

2.1.12. Warm-Up Time: The Dual Axis Angle generator system shall have a warm up period not to exceed 4 hours, and has the ability to be left on continuously.

2.2. System Design Considerations: The Dual Axis Angle Generator System will be designed such that the following will be considered.

2.2.1. Operational Environment: The Dual Axis Angle Generator System will be used in the AFPSL 68º Laboratory. This laboratory is maintained to 68±1°F with a Relative Humidity (RH) of 20% to 45%. The Dual Axis Angle Generator System shall be capable of being stored 60°F to 100°F, with a RH less than 85%.

2.2.2. Total System Size: The Total System Size of the Dual Axis Angle Generator System should be such that it will properly operate on the AFPSL’s 3 feet x 6 feet x 4 feet (W x L x H) Surface Plate with enough room for the Unit Under Test (UUT) and any other required equipment for the calibration of Autocollimators.

2.2.3. Power Requirements: The AFPSL 68º Laboratory is wired with typical 110 and 240 VAC RMS, 60 Hz outlets, Single Phase. It would be ideal for any motor to be powered using an external power supply. Any special power requirements or facility modifications for power that is needed to operate the Dual Axis Angle Generator System shall be approved by AFMETCAL.

2.2.4. Material: The Dual Axis Angle Generator System shall be made of material that the thermal expansion shall not cause measurement drift affecting accuracy.

2.2.5. Design and Construction: The equipment shall be designed and constructed of materials that meet the requirements of this specification and in accordance with the best commercial practices for industry approved equipment. It shall be designed and manufactured to maximize reliability, maintainability, accuracy of operation, and ease of operation, all parts such as shafts, bearings, regulators, switches, controls, etc. shall have proper clearance and adjustments. They shall work together so that the equipment shall supply the rated requirements without unnecessary strains, vibrations, or overheating. They shall be able to withstand the conditions met in shipping, storage, installation, and service. All material and parts of this equipment shall be capable of withstanding the environmental constraints listed in this Statement of Work.

2.3. Software Design Objectives:

2.3.1. Source Code: The Dual Axis Angle Generator System is expected to be automated. A

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controller and software are necessary products to realize a fully integrated automated system. All software must run on or under Microsoft Windows 10 Professional operating system (or greater, 64-bit, latest version release). The software shall work with Microsoft Visual Basic .NET or C# latest release on the latest framework in the Visual 2017 development environment, or as approved by AFMETCAL. If software other than Microsoft Visual Basic (VB.net) or C# is used a development program and all licensing shall be provided. Autocollimator Drivers shall be able to read an external Text or XML file format. This file will be the control codes for any specific autocollimator. Collaboration between contractor and AFMETCAL in determining Driver format. The contractor shall deliver the original source code for all software.

Software must be operationally validated and verified. A software validation and verification plan shall be provided by the contractor and approved by AFMETCAL.

The Air Force shall be granted unlimited, unrestricted data rights to the software/source code from the publisher or developer. This shall include, but is not limited to: use, duplication, modification, distribution, and disposition of the software application source code.

2.3.2. Software Identification: Display relevant information pertaining to the software such as TO number, date, version, etc. to be displayed upon startup or located in an “About” menu in the software.

2.3.3. Automated Calibration Process: The software shall be programmed to control both the Dual Axis Angle Generator System and the UUT to perform the calibration method as described in AF Technical Order 33K6-5-400-1 with minimal technician interaction.

Software shall recognize system has stabilized, then record readings, and compare the readings from the laser interferometer and the UUT.

2.3.3.1. AFPSL Workload: The software shall be programmed to calibrate the following Autocollimators:

1. Moller-Wedel: Elcomat HR, Elcomat 3000, Elcomat 2000(S), and 219511

2. Davidson Optronics: D820

3. Automated Precision Inc. DA-2000

2.3.3.2. New Workload: The software shall be programed such that New Workload (different p/n, manufacturers, etc.) can be added to the program.

2.3.3.3. Automated Calibration Process Variations: The software shall allow the technician flexibility to change calibration requirements to include, but not limited to, calibration along the Horizontal axis only, calibration along the Vertical axis only, calibration along the Horizontal and Vertical axis simultaneously, test point angle values, number of test points (minimum of 15), and number of readings.

2.3.4. Data Acquisition: The contractor shall construct, assemble and program this system such that it will have the capability to perform automatic data acquisition throughout the measurement function(s) and range(s). The following features/requirements apply to acquisition of data for the Autocollimator UUTs.

2.3.4.1. Measurement Profile: The following minimum features shall be available as user selectable and programmable options:

a. Recall Previous UUT Information: the software shall allow the user to recall pervious UUT information to prefill testing details

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b. Time Delays for Measurements / Stability Before Measurement

c. Calibration Start Time and Date

d. Number of Test Points

e. Test Point Values

f. Number of measurements to be made on a test point

g. Number of Test Runs

h. Time Between Test Runs

i. Number of Test Items measured

j. Calibration Axis (Horizontal only, Vertical only, Horizontal and Vertical simultaneously).

k. Standard Uncertainty

l. Test Item Uncertainty

m. Pass/Fail Criteria

n. Standard Deviation Limit

o. Repeat Test Point Function

2.3.4.2. Measurement Results: Measurement results shall be displayed in real-time via the controller. As a minimum, the following parameters will be displayed as measurement results:

a. Test Item Identification (with minimum of Job Control Number(JCN), Part

Number(P/N), Serial Number(S/N) and Identification Number(ID))

b. Standard Identification (with minimum of Part Number(P/N), Serial

Number(S/N) and Identification Number(ID))

c. Nominal Value/Range

d. Number of measurements made per test point

e. Applied Value

f. Measured Value

g. Deviation from Applied Value

h. Mean Value of Measured Results

i. Standard Deviation of Measured Results

j. Real-time calculation of At-Time-of Measurement System Relative

Uncertainty

k. Real-time calculation of At-Time-of Measurement System Absolute

Uncertainty

l. Pass/Fail indicator

m. Graphical Representation of Accumulated Measurements in the form of an

X-Y plot

n. Operator Identification

o. TUR/TAR

2.3.4.3. Report of Measurement: Source code shall be provided such that a Report of Measurement (Utility) can be generated, when user desired, from a Measurement Results (2.3.4.2) file with the following minimum parameters:

a. Measurement Results (2.3.4.2, a., b., c., d., e., f., g., l., n., o.)

b. Text Header (3 lines minimum, user input)

c. Date of Measurements:

d. Date of Report

2.3.4.4. Printed Results: As a minimum the following parameters shall be selectively pintable to the controller display panel for viewing and paper via an attached or network printer.

Parameter:

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a. Measurement Results (2.3.4.2)

b. Report of Measurements(2.3.4.3)

c. Measurement Data Files

d. Historical Data Files

2.3.4.5. Storage of Results: The Dual Axis Angle Generator System shall have the capability to store data to a controller internal memory and to transferable media such as recordable CDs and DVDs. This data shall also be storable in an electrical format that can be imported/exported to MS Excel spreadsheets.

Results shall be retrievable by searching for UTT Part Number, Label ID, and/or Date and Time of calibration.

2.3.4.6. Storable Parameters: The following list identifies the minimum and storable parameters:

a. Measurement Results (2.3.4.2)

b. Historical Data Files

3. Ancillary Equipment: The Dual Axis Angle Generator System shall include the following Ancillary Equipment. All major components shall be identifiable by manufacturer, model or part number, and serial number for identification.

3.1. Autocollimator Targeting Mirror: The Dual Axis Angle Generator System shall be provided with an Autocollimator Targeting Mirror. The Autocollimator Targeting Mirror and its mount shall be removable from system for calibration purposes.

3.1.1. Flatness: The Autocollimator Targeting Mirror shall have a flatness not to exceed 3 µin Total Indicated Reading (TIR).

3.1.2. Diameter: The Autocollimator Targeting Mirror shall have a diameter of at least 3 inches.

3.1.3. Autocollimator Targeting Mirror Face: The Autocollimator Mirror Face when mounted shall be parallel to within 50 µinches TIR of the reference plane.

3.2. Laser Interferometer: The Dual Axis Angle Generator System shall be provided with a Laser Interferometer with the following components and specifications.

3.2.1. Helium Neon Laser Head: The Laser Interferometer shall include a Helium Neon Laser Head. The Helium Neon Laser Head shall have a single Red-Line Helium Neon Laser Tube with automatic tuning and shall meet requirements for International Electrotechnical Commission (IEC) 60825-1 Class II.

3.2.1.1. Wavelength: The Helium Neon Laser Head shall have a Vacuum Wavelength of 632.990 nm to 632.992 nm +/- 0.5 ppm.

3.2.2. Linear Optics Set: The Dual Axis Angle Generator System shall come with all necessary optical components needed to operating to the specifications listed above in paragraph 2.1 Performance Objectives.

3.3. Environmental Compensator: A detached environmental compensator with temperature, barometric pressure, and humidity sensor(s) shall be provided.

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3.4. Controller: A controller is required that can efficiently operate under Microsoft Windows 10 Professional 64 bit operating system. All software must run Windows 10 as a non-elevated user.

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 AFMETCAL.

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

3.4.2. Hard Drive: 120 GB (Minimum) Hard Disk Drive

3.4.2.1. FIPS 140-2 certified SED

3.4.3. Memory: Minimum 8GB System Memory.

3.4.4. Processor: CPU Pass Mark Score: 4,000 or higher

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

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

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

3.4.4.4. Supports Direct Memory Access (DMA) UEIF Firmware V. 2.4 (or higher)

3.4.5. Ethernet: One 100/1000 Base T Ethernet port.

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

3.4.6.1. External video support

3.4.6.2. Adapter to DVI connection

3.4.7. USB: Minimum of three integrated USB 3.1 ports/USB-C.

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

3.4.9. Productivity Software: The Controller shall be supplied with Microsoft Word, Access, .Net Framework 4.5.2, and Excel; latest release with a non-renewable license.

3.5. Cables, Accessories and Adapters: The Dual Axis Angle Generator System shall come with all necessary Cables, Accessories, and Adapters needed to make the system function as required. This would include, but not limited to: special tools, cables, fixtures, programs, adapters and standards.

4. Expected Products:

4.1. Evaluation Report: A detailed report to describe the appropriate tasks, cost and schedule for the development of the Dual Axis Angle Generator System, submitted in .pdf or Microsoft Word file format.

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4.2. Development Documentation/Quarterly Reports: All associated documentation pertaining to the development of the Dual Axis Angle Generator System as required by each phase, submitted in .pdf or Microsoft Word file format.

4.3. Dual Axis Angle Generator System: A turnkey system with associated hardware/software will be delivered as necessary for the calibration of Autocollimators.

4.4. Software: Associated Software will be delivered as necessary for the automated calibration of Autocollimators

4.4.1. Drivers and Driver Utilities: The software must contain the drivers and driver utilities to completely configure the system interface in the Windows 10 environment; diagnose and verify hardware and software installation/configuration.

4.4.2. Source code: Copies of all source code used in these applications, with rights to reuse and modify, shall be provided.

4.4.3. Software Validation and Verification (V & V) Plan: Software shall be operationally validated and verified, but need not be fully commercially compliant. Software shall be written for operation by skilled technicians commensurate with experience and expertise at a primary standards laboratory without any training. All documents will be submitted in an electronic format to AFMETCAL.

4.5. Final Documentation: All associated documents necessary for the validation, use, support, and calibration of the Dual Axis Angle Generator System, associated equipment, and developed software.

4.6. Training: As part of the delivery of this system the contractor shall provide training on the system. Training will be required on the technical operation, physical operation, source code operation, system verification, and features described by this statement of work.

4.7. Delivery-Demonstration: Upon delivery, the contractor shall fully demonstrate the Dual Axis Angle Generator System’s capabilities. This may in-part be performed in conjunction with Training.

5. Benefits: Successful completion of this project will result in a supportable automated autocollimator calibration for the AFPSL. Autocollimators directly and/or indirectly calibrate every weapon system tracking, navigation, and display system. Without an updated calibration system, the Air Force will eventually no longer be able to calibrate Autocollimators, which will result in the inability to support the alignment and mounting of aircraft tracking, navigation, and display systems.

6. Major Tasks:

6.1. Phase 1 – Evaluation / Planning: The existing Dual Axis Angle Generator System and AF Technical Order 33K6-5-400-1 will be evaluated in detail. The evaluation shall be conducted to explore all capabilities and deficiencies with the existing system. All documents will be submitted in an electronic format to AFMETCAL.

6.1.1. Major Equipment: Purchase all major equipment needed for Phase 2, 3, & 4. This should include but not limited to Laser Interferometer, Mirror, Optics, and Controller.

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6.1.2. Deliverables: The deliverables from Phase 1 shall include a written report of the evaluation, including system components. Any recommended modifications to the plan and schedule of the SOW must be identified. Submitted in .pdf or Microsoft Word file format.

6.1.3. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and vendor, AFMETCAL will review and approve on a course of implementation action before proceeding with the next phase.

6.2. Phase 2 – Build Dual Axis Angle Generator Fixture & Initial Control Software: The Dual Axis Generator System will be built in accordance with the Performance Objectives Outlined in this SOW. This phase includes any basic control software needed for rudimentary control of the Dual Axis Angle Generator Fixture.

6.2.1. Deliverables: The deliverables from Phase 2 shall include:

6.2.1.1. Documentation for the system components used (manuals, calibration certificates)

6.2.1.2. Parts list and breakout assembly drawing for mechanical components

6.2.1.3. Basic Control Software.

6.2.1.4. Test results for any testing performed during this phase

6.2.1.5. Any recommended modifications to the plan and schedule of the SOW must be identified.

6.2.2. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor, AFMETCAL will review and approve on a course of implementation action before proceeding with the next phase.

6.3. Phase 3 – Software Design Plan: A software design plan shall be developed that specifically addresses paragraph 2.3 Software Design Objectives, User Interfaces, and any other features required to realize the Dual Axis Angle Generator System. A draft Software V&V procedure, to be used by the contractor and AFMETCAL to verify the software, shall also be developed at this time.

6.3.1. Deliverables: The deliverables from Phase 3 shall include:

6.3.1.1. A written report discussing the Software Design Plan, including any flow charts, screenshots, or drawings.

6.3.1.2. The draft Software V&V shall also be delivered.

6.3.1.3. Any recommended modifications to the plan and schedule of the SOW must be identified.

6.3.2. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor to discuss user interface and profile templates (GUI’s) and a course of implementation action before proceeding with the next phase(s).

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6.4. Phase 4 – Automation Software Development and Full System Integration: The software design will be coded in accordance with the plan delivered in Phase 3, such that it can meet the Software Design Objectives or other goals in this SOW. A calibration of at least 2 different Autocollimators shall be performed using the new system to the agreed upon specifications.

6.4.1. Deliverables: The deliverables for Phase 4 shall include:

6.4.1.1. Any documentation for the software components (manuals, certificates licenses)

6.4.1.2. Final Software V&V

6.4.1.3. Autocollimator Calibration Test Reports

6.4.1.4. Test results for any other testing performed during this phase.

6.4.2. Mid of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor to discuss software development, user interface and profile templates (GUI’s).

6.4.3. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor to discuss software development, user interface and profile templates (GUI’s). During the meeting a course of implementation action will be determined before proceeding with the next phase(s).

6.5. Phase 5 – Delivery: Thirty (30) day notice is required for installation at AFMETCAL. The hardware, software and other required equipment shall be integrated at the AFPSL as a working calibration system that achieves the objectives or other specifications in this SOW. Upon completion of installation, the contractor shall demonstrate and fully test the delivered unit.

AFMETCAL shall perform acceptance testing after installation.

6.5.1. Deliverables: The deliverables for Phase 5 shall include:

6.5.1.1. A fully operational calibration system for AFPSL Autocollimator calibrations

6.5.1.2. A test report for the calibrations performed in Phase 4.

6.5.1.3. Draft Uncertainty Analysis: A documented total K=2 uncertainty analysis shall be provided based on environmental conditions at the contractor’s facility. In addition, a draft total K=2 uncertainty analysis shall be provided based on U.S.

Air Force Primary Laboratory environmental conditions. All documents will be submitted in an electronic format to AFMETCAL. The uncertainty analysis must be written in accordance with the latest version of the Guide to Uncertainty of Measurement.

6.5.2. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor to discuss a course of implementation action before proceeding with the next phase(s).

6.6. Phase 6 – System Documentation: System Documentation shall be developed and shall include a troubleshooting guide, mechanical and electrical schematic diagrams for items designed under this project, a parts list, and a final report summarizing the various phases of the project.

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6.6.1. Deliverables: The deliverables for Phase 6 shall include:

6.6.1.1. Troubleshooting guide in contractor format, modifiable electronic form to include pdf and Microsoft Word file format.

6.6.1.2. Manual for System operation, optics alignment and placement

6.6.1.3. Manual for Theory of operation to include determination of optics distance.

6.6.1.4. Maintenance and care

6.6.1.5. Software Manual

6.6.1.6. Procedures for calibrating Autocollimators

6.6.1.7. Mechanical and electrical schematic diagrams in original program and pdf format.

6.6.1.8. Parts list in Microsoft Excel format shall be identifiable by manufacturer, model or part number, and serial number for identification.

6.6.1.9. Fully documented project report

6.6.2. End of Phase Meeting: A meeting or teleconference will take place between AFMETCAL and the vendor discuss a course of implementation action before proceeding with the next phase(s).

6.7. Phase 7 – Training and User Documentation: Documentation shall be developed suitable for use as manual and reference material by the AFPSL. Contractor format is acceptable. Using the documentation as addressed in the deliverables, training shall be provided for at least 5 trainees. The training, minimum of 2 days, shall include any needed background in theory, calculations, and shall include formal objectives

6.7.1. Deliverables: The deliverables for Phase 7 shall include:

6.7.1.1. Final Uncertainty Analysis

6.7.1.2. Calibration requirements for all components that require calibration.

7. Milestones:

7.1.

Number of days to be completed by after contract award Phase/Milestone 90 180 270 360 450 540 630 720 Phase 1 X Phase 2 X Phase 3 X

Phase 4 X Phase 5 X

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Phase 6 X Phase 7 X

8. Reviews, Meetings and Reporting Requirements:

8.1. Quarterly Reports: Quarterly Reports shall be provided and shall include at a minimum:

8.1.1. Project title and number

8.1.2. Reporting period

8.1.3. Report generation date

8.1.4. Summary of technical progress (To include photos of fixture, screen shots of software user interface and profile templates (GUI’s))

8.1.5. Any milestone problems, (technical, financial and/or schedule)

8.1.6. Plans for the following quarters

8.2. Draft copies of required documentation identified in the Major Tasks section shall be provided at least one week prior to any schedule reviews/acceptance

8.3. Contractor’s format is acceptable for all documentation

9. Government Furnished Property:

9.1. Information Items to be furnished by AFMETCAL

9.1.1. Calibration procedure 33K6-5-400-1.

Attachment to Statement of Work

19C-234A-OP

CCG 715 - AFPSL - Dual Axis Angle Generator

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).