FMS_Technical_Specifications.pdf

Technical Specification

For A

5-Axis Flight Motion Simulator System

For The

Guided Weapons Evaluation Facility

782TS/RNWG

18 June 2015 ii

Revision History

Rev. No. Description Date

Initial Release 5/21/2015

1 Revised specifications on hydraulic pump continuous operation, roll drive performance, and pitch/yaw axis accelerations and frequency response.

6/2/2014

2 a. Updated UUT specifications

b. Re-inserted omitted specification for UUT #5

c. Added UUT drawings in appendix

6/18/2014 iii

ABBREVIATIONS, ACRONYMS, AND SYMBOLS

AC Alternating Current arc-sec Arc-second

API Application Program Interface

BNC Bayonet Neill-Concelman. Miniature version of the Type C RF connector.

BRD Belt Roll Drive dB Decibel deg/sec Degrees per second

EMI Electromagnetic Interference

FLA Full Load Amperage

FMS Flight Motion Simulator

FO Fiber-optic

GUI Graphical User Interface

GWEF Guided Weapons Evaluation Facility

HPU Hydraulic Power Unit

Hz Hertz. Unit of measurement for frequency.

IDAS Integrated Data Acquisition System

I/O Input/Output

KHz Kilohertz lbm Pounds-Mass.

HSCRD High-Speed Continuous Roll Drive

LED Light Emitting Diode

MHz Megahertz ms millisecond

N/A Not Applicable

NEMA National Electrical Manufacturers Association

OS Operating System

PC Personal Computer. Intel compatible processor based computer running either a

Microsoft Windows or a Linux variant operating system.

PSI Pounds per square inch. Unit of measurement for pressure.

RFI Radio Frequency Interference

RMS Root Mean Square

RPS Revolutions Per Second

SAE Society of Automotive Engineers

SCRAMNet A shared common random access memory network system manufactured by

Curtiss-Wright. Currently available in two models, the older SCRAMNet+

SC150/150e and the newer SCRAMNet GT200 (“GT”).

SCS Servo Control System

TBD To be determined

UUT Unit Under Test. The test item installed on the FMS roll axis.

VAC Volts Alternating Current

VDC Volts Direct Current iv

Table of Contents

1 INTRODUCTION

2 GENERAL REQUIREMENTS

System Axes ..................................................................................................................... 2 2.1

Prime Power ..................................................................................................................... 2 2.2

Compatibility with Existing GWEF Roll Drives ............................................................. 2 2.3

System Physical Size ........................................................................................................ 2 2.4

System Plumbing ............................................................................................................. 2 2.5

System Cabling ................................................................................................................ 3 2.6

Axes Limit Switches ........................................................................................................ 4 2.7

Uninterruptable Power Supply ......................................................................................... 4 2.8

Safety ................................................................................................................................ 4 2.9

System Brakes .............................................................................................................. 4 2.10

Shocks and Stops .......................................................................................................... 4 2.11

Axes Actuator Drive ..................................................................................................... 4 2.12

Hydraulic Actuators .................................................................................................. 4 2.12.1

Electric Actuators...................................................................................................... 5 2.12.2

EMI / RFI Requirements .............................................................................................. 5 2.13

Design for Maintainability............................................................................................ 5 2.14

System Components Quality and Lifespan .................................................................. 5 2.15

Computer Operating System(s) .................................................................................... 5 2.16

Measurement of Dynamic Performance ....................................................................... 5 2.17

3 Unit Under Test and Target Test Loads

Unit-Under-Test (UUT) Loads......................................................................................... 7 3.1

UUT Loads – Delivered Roll Drive(s) ............................................................................. 7 3.2

UUT Load– HSCRD ........................................................................................................ 7 3.3

UUT Load– Belt Roll Drive ............................................................................................. 7 3.4

Azimuth/Elevation (Target Axes) Loads ......................................................................... 7 3.5

4 ROLL AXIS SPECIFICATIONS

General ............................................................................................................................. 9 4.1

Range of Motion............................................................................................................... 9 4.2

“D” Distance .................................................................................................................... 9 4.3

Compatibility .................................................................................................................... 9 4.4 v

Dynamic Performance ...................................................................................................... 9 4.5

Accuracy, Resolution and Repeatability ........................................................................ 10 4.6

Expected Axis Duty Cycle ............................................................................................. 10 4.7

Rotary Gas Joint ............................................................................................................. 10 4.8

Electrical Slip Ring Package .......................................................................................... 11 4.9

OPTION 1. Hybrid Electro-Optical Slip Ring with Integrated Rotary Gas Joint ..... 12 4.10

OPTION 2. Integrated Data Acquisition System ...................................................... 12 4.11

OPTION 3. Electrically Isolated Roll Table-Top ...................................................... 14 4.12

5 YAW AXIS SPECIFICATIONS

Range of Motion............................................................................................................. 15 5.1

Dynamic Performance .................................................................................................... 15 5.2

Accuracy, Resolution and Repeatability ........................................................................ 15 5.3

Attachment to Roll Axis ................................................................................................. 15 5.4

6 PITCH AXIS SPECIFICATIONS

Range of Motion............................................................................................................. 16 6.1

Dynamic Performance .................................................................................................... 16 6.2

Accuracy, Resolution and Repeatability ........................................................................ 16 6.3

7 AZIMUTH AXIS SPECIFICATIONS

Range of Motion............................................................................................................. 17 7.1

Dynamic Performance .................................................................................................... 17 7.2

Accuracy, Resolution and Repeatability ........................................................................ 17 7.3

Target Mounting Surface ............................................................................................... 17 7.4

8 ELEVATION AXIS SPECIFICATIONS

Range of Motion............................................................................................................. 18 8.1

Dynamic Performance .................................................................................................... 18 8.2

Accuracy, Resolution and Repeatability ........................................................................ 18 8.3

9 SERVO CONTROL SYSTEM (SCS) SPECIFICATIONS

Cabinetry/Housing ......................................................................................................... 19 9.1

Removable Storage Media ............................................................................................. 19 9.2

Performance ................................................................................................................... 19 9.3

Clock Synchronization ................................................................................................... 19 9.4

SCS Sensor Compatibility .............................................................................................. 19 9.5

Operator Interface .......................................................................................................... 20 9.6

Help Menu ...................................................................................................................... 20 9.7 vi

Mode, Command and Limit Checking ........................................................................... 20 9.8

High/low Gain Operation ............................................................................................... 20 9.9

Dither .......................................................................................................................... 20 9.10

Actuator Pressure Imbalance Correction .................................................................... 21 9.11

User Analog Interface Connections ............................................................................ 21 9.12

System Variable Availability, Scaling and Formatting .............................................. 21 9.13

Data Collection and Playback..................................................................................... 21 9.14

Deterministic and Harmonic Error Corrections .......................................................... 21 9.15

Script Files .................................................................................................................. 21 9.16

System Configuration Protection................................................................................ 21 9.17

Configuration, Compensation and Tuning ................................................................. 22 9.18

Configuration Files ..................................................................................................... 22 9.19

Configuration Backup................................................................................................. 22 9.20

Emergency Stop Operation ......................................................................................... 22 9.21

Limit Switches ............................................................................................................ 22 9.22

User Defined Limits ................................................................................................... 22 9.23

Prime Power Operation .............................................................................................. 22 9.24

Axis Standby Solenoid Operation .............................................................................. 23 9.25

Brake Operation .......................................................................................................... 23 9.26

Hydraulic Pressure Bleed-off ..................................................................................... 23 9.27

Real-time Computer Interface .................................................................................... 23 9.28

Non-real-time Computer Interface ............................................................................. 23 9.29

Operational Modes ..................................................................................................... 23 9.30

Axis Motion Types ..................................................................................................... 25 9.31

Frame Rate .................................................................................................................. 25 9.32

Computer Operating System(s) .................................................................................. 25 9.33

10 HYDRAULIC POWER UNIT (HPU) SPECIFICATIONS

General System Description ....................................................................................... 26 10.1

General Requirements ................................................................................................ 26 10.2

Facility Installation ..................................................................................................... 26 10.3

Reservoir ..................................................................................................................... 26 10.4

Plumbing, Tubing and Fittings ................................................................................... 26 10.5

Hydraulic Pumps ........................................................................................................ 27 10.6

Electric Motors ........................................................................................................... 27 10.7 vii

Heat Exchanger Oil Cooling System .......................................................................... 27 10.8

Kidney Loop System .................................................................................................. 28 10.9

HPU Sensors ............................................................................................................... 28 10.10

Personnel Safety ......................................................................................................... 28 10.11

Oil Filtration ............................................................................................................... 28 10.12

System Control Panel ................................................................................................. 29 10.13

System Remote Operation Electrical Interface .......................................................... 29 10.14

Noise and Surge Suppression ..................................................................................... 29 10.15

Appendix A High-Speed Continuous Roll Drive (HSCRD)

Appendix B Belt Roll Drive (BRD)

Appendix C Yaw Bolt Pattern for Carco Electronics Model S-458R-5E, G.O. 80634

Appendix D HSCRD Table Top Bolt Hole Pattern

Appendix E Target Mount Bolt Hole Pattern

Appendix F Unit-Under-Test (UUT) Dummy Loads Models and Data

1 INTRODUCTION

a. This specification is for a five-axis flight motion simulator (FMS) system for the Guided

Weapon Evaluation Facility (GWEF), 782 Test Squadron/RNWG, Eglin AFB, FL.

b. Three options are specified. Option 1 is for a hybrid fiber-optic based electro-optical slip ring with integrated rotary gas joint. Option 2 is for an integrated data acquisition system that would interface with the hybrid electro-optical slip ring and provide a full electrical and signal interface to the unit under test. Option 3 is for an electrically isolated roll drive table-top.

c. The terms “Threshold” and “Objective” may be used throughout this specification. A threshold is the minimum acceptable requirement. An objective is a desired capability.

d. Contractor Proposals should identify any specifications that are not technically feasible or have an undue impact on cost. Should this occur, proposals should provide recommended alternatives to the identified specification as well as impacts on overall system performance and cost.

2 GENERAL REQUIREMENTS

System Axes 2.1

a. The FMS system shall consist of roll, yaw, pitch, azimuth, and elevation axes.

b. The axes orthogonal error tolerances shall not exceed 30 arc-seconds. Each gimbal shall include precision ground bosses machined and aligned to the above tolerances.

c. All axes shall produce smooth, stable, repeatable performance over the full range of motion with any of the test loads installed.

Prime Power 2.2

a. The prime power system shall be sufficient for continuous operation of the pitch, yaw, azimuth, and elevation axes simultaneously at maximum velocity sine wave response with continuous roll at maximum velocity. Maximum velocity sine wave response is defined as sinusoidal motion for the maximum travel range and reaching maximum velocity at the midpoint of travel.

Compatibility with Existing GWEF Roll Drives 2.3

a. The FMS shall be compatible with and capable of using two existing facility roll drives at their full rated performance specification. The additional roll drives are the electric High Speed Continuous Roll Drive (HSCRD) and hydraulic Belt Roll Drive

(BRD). Descriptions and technical specifications for these drives are in Appendix A and Appendix B.

b. The FMS shall contain hydraulic supply, return, scavenge, and case drain lines as well as couplings sufficient to fully power the BRD.

c. The peak required hydraulic fluid flow rate for the BRD is 15 gallons per minute at

1800 psi.

System Physical Size 2.4

a. Entry into the GWEF and the installation area will be through multiple doorways measuring approximately 84 inches high and 94 inches wide, including an RF door with a bottom lip seal. The installation location contains a raised floor approximately

16” above the concrete slab and there is approximately 12 feet of vertical clearance between the raised floor and the ceiling tiles. The main hallway is approximately 9’ 2’’ wide.

b. The FMS system base flooring, that part normally walked upon by service personnel, shall be level with the raised flooring when installed on its concrete foundation. No part of the assembled FMS with test loads installed may approach the ceiling tiles closer than six (6) inches for all axes full range of motion.

System Plumbing 2.5

a. All system tubing, piping and fittings shall be stainless steel. Hose fittings and swivel joints may be standard steel if not available in stainless steel. All swivel joints shall be

Super Swivel brand or equivalent, and all hose shall be Parker or equivalent with part number and date of manufacture attached.

b. System plumbing shall be designed for minimal line loss by making use of custom formed tubing instead of fittings, and using integrated manifolds where possible.

c. System plumbing shall incorporate return line check valves for all axes.

d. System plumbing shall include oil sample ports at appropriate locations on the FMS and hydraulic power unit.

e. System plumbing shall use Nacol or equivalent pleated bladder accumulators on the supply and return lines, each containing dial and digital pressure gauges.

f. Hydraulic fluid filtration shall be rated for ≤ 3 microns absolute at the full system flow rate. Filter canisters shall be top-load type and contain a visual and electrical filter change indicator.

g. System plumbing shall include a dial type pressure gauge and an electronic pressure gauge located on the FMS base assembly. The electronic pressure gauge output shall be incorporated into the servo controller for use in system analysis.

System Cabling 2.6

a. All cabling traversing under the facility raised flooring must be plenum rated.

b. SCS cabling shall be sufficient to allow the SCS to operate the FMS up to fifty (50) feet away from the FMS base.

c. SCRAMnet cabling shall be sufficient to provide SCRAMNet communication with a

Government simulation computer up to seventy-five (75) feet away from the SCS.

d. Any electric actuator (e.g. electric roll drive) cabling shall be sufficient to enable placement of the associated drive power supply at least fifty (50) feet away from the

FMS base, and at least fifty (50) feet away from the SCS.

e. All cabling used on the FMS axes shall be continuous flex rated, shall contain insulation that does not absorb oil, and is not harmed by prolonged oil contact.

f. All cabling containing metallic conductors shall be of stranded, tinned copper construction.

g. Cables used to provide power to any axis electric motors shall be rated for variable frequency drives, shielded, and continuous flex rated.

h. FMS slip ring cabling originating at the roll axis shall contain an industrial twist-lock connector installed into a connector bracket which mates with an installed roll axis slip ring stationary end connector.

i. FMS conductors connected to slip ring power circuits shall be sixteen (16) gauge or larger.

j. FMS conductors connected to signal circuits shall be twenty (20) gauge or larger.

k. FMS conductors connected to data circuits shall be CAT 6e rated or better.

l. FMS slip ring cabling at the FMS base exit point shall be installed in an enclosed metal box and all wires shall be terminated using spade lugs on screw-type terminal boards.

m. A junction box shall be installed on the FMS to serve as a cabling disconnect between the SCS and FMS.

Axes Limit Switches 2.7

Each axis shall contain limit switches to disable axis drive at the axis travel limit.

Uninterruptable Power Supply 2.8

The FMS system shall contain an uninterruptible power supply capable of sustaining power to the SCS and all associated FMS servo valves and components and with sufficient reserve capacity to perform a safe, controlled and non-violent FMS system shutdown upon any power failure or anomaly.

Safety 2.9

a. The FMS system shall be designed such that failure or drop out of any referenced power supply turns off the system without producing damaging motion and requires operator action to re-activate the system.

b. The FMS system shall be designed such that any sudden primary AC power reduction turns the system off without incurring damaging axis motion and requires operator action to re-activate the system.

c. The FMS shall be designed with electrical push-button safety switches capable of rendering the gimbal drive sources inactive. The safety switches shall be located within reach of an operator in the vicinity of the motion table, the control console, the hydraulic supply, and the Government owned computer simulation system which may be located 100 or more feet from the FMS and SCS.

System Brakes 2.10

Brakes shall be installed on all axes except roll, shall be capable of holding each axis with the heaviest load installed at an axis angle producing the greatest load on the brakes, and shall be capable of being engaged and disengaged electronically via the SCS.

Shocks and Stops 2.11

The FMS shall have adjustable shocks and stops on all axes except roll. Shocks and stops shall be capable of arresting gimbal motion at full axis performance with maximum installed axis load, without inflicting damage to the FMS or the axis load.

Axes Actuator Drive 2.12

Hydraulic Actuators 2.12.1

a. For any axis using hydraulic actuators, the following shall apply.

1. Axes incorporating two or more hydraulic actuators shall use an electronic method of balancing pressures between the actuators. Hydraulic balance lines will not be used.

2. Hydraulic actuators shall be equipped with case drains and scavenge lines to route any seal leakage back to the hydraulic power unit reservoir.

3. Hydraulic actuator pressure relief valves shall be fast acting type, with a response time not-to-exceed 1 millisecond.

4. Hydraulic actuators shall include a hydraulic soft start solenoid.

Electric Actuators 2.12.2

Reserved.

EMI / RFI Requirements 2.13

Neither the FMS nor any of its subsystems shall induce any electromagnetic interference

(EMI) or radio frequency interference (RFI) into any unit under test (UUT), slip ring package, laboratory system, or facility power grid. Schaffner or equivalent high performance filters shall be utilized where practical to minimize EMI/RFI.

Design for Maintainability 2.14

The system shall be designed for ease of routine user performed maintenance, specifically with respect to maintenance and replacement of slip rings, rotary gas joints, soft start solenoids, and oil filters.

System Components Quality and Lifespan 2.15

All FMS system components, including but not limited to, servo valves, electric motors, hydraulic pumps, power amplifiers, computer systems, and sensors shall be of a manufacturer/model having a well-established U. S. track record for dependability, durability and trouble free operation in an industrial environment. The contractor shall perform due diligence to ensure no FMS components are used that are nearing the end of their manufacturing life cycle or are scheduled for revision.

Computer Operating System(s) 2.16

Any computer operating system (OS) used by the FMS servo control system must be the current distributed version and supportable by the OS manufacturer for a minimum of five

(5) years. If a Microsoft Windows-based OS is used, it must be Windows 7 or later.

Measurement of Dynamic Performance 2.17

a. Dynamic performance shall be measured with the servo system, consisting of the controller, motion axis, and test load, operating fully within the linear performance region with no uncontrolled or spurious motion.

b. Frequency response (bandwidth) shall be measured using a swept sine wave input that does not exceed a maximum velocity or acceleration limit.

1. Position stimulus input shall be ≥ 0.5 degrees peak-to-peak.

2. Velocity (rate) stimulus shall be ≥ 10% of the maximum required rate.

3. Acceleration stimulus shall be ≥ 10% of the maximum required acceleration.

c. Frequency response shall be measured at +/- 3dB amplitude or -90 degree phase, whichever occurs first, shall have shall have ≤ ± 1 dB peaking , and shall have ≤ 10 degrees phase lag at 10% maximum required bandwidth.

3 Unit Under Test and Target Test Loads

Unit-Under-Test (UUT) Loads 3.1

a. The set of UUT loads for this system are listed below. UUT drawings and data on which the test loads were based on located in Appendix F.

b. With the exception of UUT #6, these measurements are exclusive of any mounting fixtures and test load protuberances. UUT protuberances generally include electrical connector(s) that can extend outward from the skin of the test load up to 2 inches and a high pressure gas connector along the body, both of which require connections during testing. The mounting fixtures may significantly increase the overall inertias.

c. Moment of inertia for all loads except UUT #5 are for a 24” distance from roll table-top to the center-of-rotation. UUT #5 is for a 30” distance. Pitch and yaw moments of inertia are with respect to the FMS axes intersection.

Designation

Diameter

(inches)

Length

(inches)

Mass

(lbm) “D”

(inches)

Pitch/Yaw

(in-lb-sec

Roll

(in-lb-sec

UUT #1 2.8 17 5.5 24 0.712 0.016

UUT #2 5.0 24.4 26.5 24 10.9 0.22

UUT #3 4.7 21.8 15.5 24 4.3 0.15

UUT #4 6.8 12.6 14.2 24 1.5 0.27

UUT #5 7 28 60 30 62.23 0.9

UUT #6

Mass & inertia include mount

16 with mount plate

24.5 73 24 52 7.24

UUT Loads – Delivered Roll Drive(s) 3.2

a. For the delivered roll drive(s), the pitch, yaw, and roll axes shall be designed to be operational with UUT loads #1 through #5.

UUT Load– HSCRD 3.3

a. For the compatible High Speed Continuous Roll Drive, the pitch and yaw axes shall be designed to be operational with UUT #1 through #4.

UUT Load– Belt Roll Drive 3.4

b. For the compatible hydraulic Belt Roll Drive, the pitch and yaw axes shall be designed to be operational with UUT loads #3, #5, and #6.

Azimuth/Elevation (Target Axes) Loads 3.5

a. The azimuth and elevation axes shall be operational with the following target loads:

Designation

Length

(inches)

Width

(inches)

Height

(inches)

Mass

(lbm) Target Load 1 Equivalent size mild steel plate (s) 300

Target Load 2 44 84 24 750

4 ROLL AXIS SPECIFICATIONS

General 4.1

The objective is to have a single roll drive delivered with the system; however multiple roll drives may be supplied if it is not cost effective to supply a single drive that meets all requirements. The FMS roll drive(s) shall contain a blind mate slip ring connector, a high pressure gas fitting, a slip ring package, and a rotary gas joint.

Range of Motion 4.2

The drive shall provide continuous three-hundred-sixty (360) degree rotation for both clockwise and counter-clockwise direction.

“D” Distance 4.3

The distance from roll axis table top to the FMS axes center of rotation shall be twenty-four (24) inches with an additional extension to thirty (30) inches.

Compatibility 4.4

a. The drive shall be fully functional on the existing facility Carco Electronics Model S-

458R-5E, G.O. 80634. The yaw axis bolt-hole pattern for the S-458R-5E is in

Appendix C. This requirement may be met by use of an interface adapter.

b. The drive shall not compromise the full range of motion or dynamic performance of the pitch or yaw gimbals on the S-458R-5E FMS.

c. The drive(s) shall be capable of utilizing the existing UUT mounting fixtures currently in use for the HSCRD. This includes incorporating the blind mate connector and equivalent connection as well as utilizing the HSCRD table top bolt-hole pattern. Test load mounting fixtures can be made available for examination. The HSCRD table top bolt-hole pattern is in Appendix D.

Dynamic Performance 4.5

a. All specifications apply equally for clockwise and counter-clockwise motion with the test loads defined in Section 3.

b. For a test load accurately representing the physical size and inertia of UUT #1 plus respective mounting fixture:

Threshold Objective

Maximum

Velocity 10,800 deg/sec 14,400 deg/sec

Maximum

Acceleration

0 to 5400 deg/sec:

60,000 deg/sec

5400 deg/sec to Max Velocity:

30,000 deg/sec

0 to 7200 deg/sec:

120,000 deg/sec

7200 deg/sec to Max Velocity:

50,000 deg/sec

Frequency

Response ≥70 Hz ≥110 Hz

c. For a test load accurately representing physical size and inertia of UUT #2, #3, #4, and

#5 plus respective mounting fixtures:

Threshold Objective

Maximum

Velocity 7,200 deg/sec 10,800 deg/sec

Maximum

Acceleration 30,000 deg/sec

50,000 deg/sec

Frequency

Response ≥55 Hz ≥70 Hz

d. The delivered drive(s) are not required to be compatible with UUT #6.

Accuracy, Resolution and Repeatability 4.6

a. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec).

b. Position Accuracy: ≤ 0.00028 degrees (1.0 arc-sec).

c. Position Stability: ≤ 0.00006 degrees (0.02 arc-sec)

d. Velocity Resolution: ≤ 0.0001 deg/sec.

e. Velocity Accuracy: ≤ 0.0001% for ≤ 10,800 deg/sec

≤ 0.0005% for > 10,800 deg/sec

f. Velocity Stability: ≤ 0.0005% for ≤ 10,800 deg/sec

≤ 0.005% for > 10,800 deg/sec

Expected Axis Duty Cycle 4.7

a. The normal duty cycle will typically be twenty (20) test cycles in ten minutes of use followed by a six to ten minute rest over an 8-12 hour day.

b. A single test cycle takes approximately 30 seconds and consists of:

1. Acceleration from zero rate to 20 revolutions per second (RPS);

2. Hold at the initial rate for zero to 5 seconds;

3. A period of modulated rate between 10 and 30 RPS for 5 to 20 seconds. This portion of the cycle can be up to 60 seconds.

4. A controlled spin-down to stop;

5. Zero rate for zero to 10 seconds.

Rotary Gas Joint 4.8

a. The roll drive shall contain a rotary gas joint possessing the following characteristics:

1. Continuously supply 3,500 psi (Threshold) 6,000 psi (Objective) high purity nitrogen, argon or Freon gas to the test load.

2. Contain no elements that will contaminate the high purity gas supply.

3. Have a rated rotational lifespan greater than or equal to 30,000,000 revolutions.

4. Contain wear elements which are field replaceable with minimal disassembly of the roll axis.

5. Provide sustained operation at a 25 Hz rate, for the expected duty cycle in Section

4.7, and for intermittent use to the maximum drive rate.

Electrical Slip Ring Package 4.9

a. The roll drive shall contain an electrical slip ring package with the following characteristics:

1. Provide full rated voltage and current for all circuits simultaneously with sustained operation at 25 Hz rate, for the expected duty cycle in Section 4.7, and for intermittent use to the maximum drive rate.

2. Conductors shall be shielded single conductor, stranded tinned wire, with insulation which does not absorb oil, is not harmed by prolonged oil contact and does not separate from conductors at sustained maximum roll rates.

3. Contain, at a minimum, the following circuits:

a. Thirty-six (36) signal circuits rated two (2) amps at sixty (60) volts RMS.

b. Sixteen (16) power circuits rated five (5) amps at sixty (60) volts RMS.

c. Eight (8) signal circuits capable of 10Base-T serial data rates (Threshold), 100Base-T serial data rates (Objective).

d. Twelve (12) separate shield circuits with no more than six (6) conductors grouped to a single shield circuit.

4. Slip ring noise shall be no more than 0.4 millivolts at one (1) amp and twenty (20) revolutions per minute.

5. Minimum sixty (60) dB isolation at 1 kilohertz between any two rings to minimize crosstalk.

6. No more than sixty (60) milliohms (Threshold) ten (10) milliohms (Objective) resistance across the brush/ring connection.

7. A rotational lifespan greater than or equal to 30,000,000 revolutions.

8. Provide for simple, quick, easy maintenance and lubrication while installed on the roll axis.

9. Provide for simple, quick, easy, complete slip ring package replacement with minimal disassembly of the roll drive and without disturbing axis position sensors.

10. Wiring shall be terminated on the table top Hypertronics NEH11-11PFR-TAH or equivalent floating blind mating connector containing socket contacts.

11. Wiring shall be terminated on the stationary end into Amphenol

D38999/24WH35PN or equivalent industrial rated twist lock connector(s) containing pin contacts.

OPTION 1. Hybrid Electro-Optical Slip Ring with Integrated Rotary Gas Joint 4.10

a. The hybrid electro-optical slip ring package shall combine a fiber-optic (FO) slip ring component, an electrical power slip ring component, and an integrated rotary gas joint.

b. The hybrid slip ring package shall be interchangeable with the delivered electrical slip ring and gas joint.

c. The fiber-optic slip ring component shall:

1. Be a commercially available single mode fiber-optic slip ring capable of simultaneous bi-directional high data rate transfer > 2.5 Gbps.

2. Terminate into a roll table top mounted fiber optic connector for connection to externally mounted Government supplied fiber-optic based telemetry kits as well as an optional integrated data acquisition system described in Section 4.11.

d. The electrical power slip ring component shall:

1. Provide a minimum of sixteen (16) available individually shielded power circuits rated five (5) amps at sixty (60) volts RMS.

2. Shall meet all other electrical and dynamic performance specifications of the supplied Electric Slip Ring Package.

e. The rotary gas joint shall conform to the requirements stated in Section 4.8

f. The hybrid package shall:

1. Have a rated rotational lifespan of > 30,000,000 revolutions.

2. Provide sustained operation and full rated voltage and current for all circuits simultaneously at 25 Hz rate, for the expected duty cycle in Section 4.7, and for intermittent use to the maximum drive rate.

3. Provide for simple, quick, easy maintenance and lubrication while installed on the roll axis.

4. Provide for simple, quick, easy, complete slip ring package replacement with minimal disassembly of the roll drive and without disturbing axis position sensors.

g. The hybrid slip ring package shall include a plenum-rated fiber optic cable sufficient to provide communication with a Government simulation computer up to seventy-five

(75) feet away from the FMS base.

OPTION 2. Integrated Data Acquisition System 4.11

a. The integrated data acquisition system (IDAS) shall augment the hybrid electro-optical slip ring package described in Section 4.10. The IDAS functions as the electrical power and signal interface between the UUT and the hybrid electro-optical slip ring package.

b. The IDAS shall contain at a minimum the following attributes:

1. The IDAS, when combined with the hybrid electro-optical slip ring package, shall be interchangeable with the delivered electrical slip ring and gas joint and fit in the same volume.

2. Shall function as the complete electrical power and signal interface between the

UUT and the facility simulation computers by providing signal filtering, scaling and digitization for all UUT analog and digital signals as well as providing UUT electrical power, power configuration and conditioning.

3. Provide the following analog input circuits from the UUT:

a. ≥ 24 shielded analog inputs;

b. Input signal range of ±50 mV to ± 60 VDC;

c. ≥ 1Mohm input impedance per channel;

d. 16-bit synchronous sampling at ≥ 20kHz;

e. Programmable analog channel gains and offset;

f. Programmable anti-aliasing filters.

4. Provide the following analog output circuits to the UUT:

a. ≥ 8 analog outputs;

b. Programmable output signal range of ±50 mV to ± 60 VDC at 10 ma;

c. 16-bit synchronous digital-to-analog conversion;

d. Programmable analog channel gains and offset.

5. Provide a minimum of four (4) discrete inputs and four (4) discrete outputs.

6. Provide one input and one output channel capable of 10Base-T serial data

(Threshold), 100Base-T serial data (Objective).

7. Shall provide simultaneous, fully clock synchronized, bidirectional data transfer between the UUT and simulation computers via the fiber optic slip ring.

8. Shall have the capability to synchronize with the Government simulation computer generated clock or an externally provided master clock operating at up to100 kHz.

9. Signal filters, scaling, and power conditioning/conversion shall be rapidly reprogrammable via the fiber-optic interface without requiring removal from the roll drive.

10. Rapidly removable and configurable for multiple and varied UUT signal sets.

11. Shall have a modular design to provide future upgradability with new signal modules.

c. Electrical signals shall terminate on the roll drive table top Hypertronics NEH11-

11PFR-TAH or equivalent floating blind mate connector containing socket contacts

d. Interface hardware, application software, and a user application program interface

(API) shall be provided to be installed on a Government simulation computer.

1. The interface card shall be PCIe compliant and shall make all IDAS signals, channels, and communication available in digital form to the simulation computer.

The interface card shall also contain a connector which makes all UUT signals available in analog form sufficient for monitoring or recording by chart recorders.

2. Application software shall be provided to fully configure and operate the IDAS, capture data, and transfer synchronized data into the Government simulation computer in real time.

3. A user application programming interface and sample code shall be provided to allow for customer software development for the IDAS.

4. All software, APIs, and device drivers shall run on Concurrent iHawk systems.

OPTION 3. Electrically Isolated Roll Table-Top 4.12

a. The contractor shall quote as an option a roll drive table-top that electrically isolates the unit under test from the FMS. The intent is that all electrical connections and grounds are controlled via the blind mate connector.

b. The table-top and other fittings (gas, etc.) may be of non-conductive material or may be a standard table-top and fittings that are electrically isolated from the rest of the

FMS.

c. The table-top shall include one grounding point that provides for a ground to the FMS structure.

5 YAW AXIS SPECIFICATIONS

Range of Motion 5.1

Usable range of motion shall be +/- 45 degrees (Threshold), +/- 50 degrees (Objective).

Dynamic Performance 5.2

a. The following dynamic performance specifications shall apply equally for clockwise and counter-clockwise motion with the test loads defined in Section 3:

1. Maximum Velocity: ≥ 300 deg/sec (Threshold), 400 deg/sec (Objective)

2. Maximum Acceleration:

a. UUT 1-4, 24” D: ≥ 12,000 deg/sec (Threshold), ≥ 15,000 deg/sec (Objective)

b. UUT 5, 30” D: ≥ 9,000 deg/sec (Threshold), ≥ 12,000 deg/sec (Objective)

c. UUT 6, with BRD, 24” D: ≥ 9,000 deg/sec (Threshold), ≥ 12,000 deg/sec (Objective)

3. Frequency Response:

a. UUT 1-4, 24” D: ≥ 30 Hz (Threshold), ≥ 35 Hz (Objective)

b. UUT 5, 30” D: ≥ 25 Hz (Threshold), ≥ 35 Hz (Objective)

c. UUT 6, with BRD, 24” D: ≥ 25 Hz (Threshold), ≥ 35 Hz (Objective)

Accuracy, Resolution and Repeatability 5.3

a. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec)

b. Position Accuracy: ≤ 0.0001 degrees (0.36 arc-sec)

c. Position Stability: ≤ 0.00005 degrees (0.18 arc-sec)

d. Velocity Resolution: ≤ 0.0001 deg/sec

e. Velocity Accuracy: ≤ 0.01%

f. Velocity Stability: ≤ 0.001%

Attachment to Roll Axis 5.4

The yaw bolt hole pattern shall be compatible with the existing Carco Electronics Model

S-458R-5E, G.O. 80634, to allow for interchanging roll drives. The yaw axis bolt-hole pattern for the S-458R-5E is in Appendix C.

6 PITCH AXIS SPECIFICATIONS

Range of Motion 6.1

Usable range of motion shall be ± 50 degrees (Threshold), ± 90 degrees (Objective).

Dynamic Performance 6.2

a. The following dynamic performance specifications shall apply equally for clockwise and counter-clockwise motion with the test loads defined in Section 3:

1. Maximum Velocity: ≥ 300 deg/sec (Threshold), ≥ 400 deg/sec (Objective)

2. Maximum Acceleration:

a. UUT 1-4, 24” D: ≥ 12,000 deg/sec (Threshold), ≥ 15,000 deg/sec (Objective)

b. UUT 5, 30” D: ≥ 9,000 deg/sec (Threshold), ≥ 12,000 deg/sec (Objective)

c. UUT 6, with BRD, 24” D: ≥ 9,000 deg/sec (Threshold), ≥ 12,000 deg/sec (Objective)

3. Frequency Response:

a. UUT 1-4, 24” D: ≥ 30 Hz (Threshold), ≥ 35 Hz (Objective)

b. UUT 5, 30” D: ≥ 25 Hz (Threshold), ≥ 35 Hz (Objective)

c. UUT 6, with BRD, 24” D: ≥ 25 Hz (Threshold), ≥ 35 Hz (Objective)

Accuracy, Resolution and Repeatability 6.3

a. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec)

b. Position Accuracy: ≤ 0.0001 degrees (0.36 arc-sec)

c. Position Stability: ≤ 0.00005 degrees (0.18 arc-sec)

d. Velocity Resolution: ≤ 0.0001 deg/sec

e. Velocity Accuracy: ≤ 0.01%

f. Velocity Stability: ≤ 0.001%

7 AZIMUTH AXIS SPECIFICATIONS

Range of Motion 7.1

Usable range of motion shall be ± 45 degrees (Threshold), ± 50 degrees (Objective).

Dynamic Performance 7.2

a. The following dynamic performance specifications shall apply equally for clockwise and counter-clockwise motion with the target load defined in Section 3:

1. Maximum Velocity:

a. Target Load 1: ≥ 100 deg/sec (Threshold), ≥ 150 deg/sec (Objective)

b. Target Load 2: ≥ 75 deg/sec (Threshold), ≥ 100 deg/sec (Objective)

2. Maximum Acceleration:

a. Target Load 1: ≥ 1,200 deg/sec (Threshold), ≥ 2,000 deg/sec

(Objective)

b. Target Load 2: ≥ 800 deg/sec (Threshold), ≥ 1,200 deg/sec

(Objective)

3. Frequency Response:

a. Target Load 1: ≥ 11 Hz (Threshold), ≥ 14 Hz (Objective)

b. Target Load 2: ≥ 9 Hz (Threshold), ≥ 11 Hz (Objective)

Accuracy, Resolution and Repeatability 7.3

a. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec)

b. Position Accuracy: ≤ 0.0004 degrees (1.44 arc-sec)

c. Position Stability: ≤ 0.00005 degrees (0.18 arc-sec)

d. Velocity Resolution: ≤ 0.0001 deg/sec.

e. Velocity Accuracy: ≤ 0.02%

f. Velocity Stability: ≤ 0.005%

Target Mounting Surface 7.4

a. The azimuth axis shall contain a precision machined surface for mounting the target load. The machined surface shall be no smaller than 51 x 25 inches and contain an opening measuring 15 inches wide by 20 inches long and centered on the axis. The required opening and bolt-hole pattern for the target plate attachment is in Appendix E.

b. The target load mounting surface shall be 50 ± 0.125 inches from the axes center of rotation.

8 ELEVATION AXIS SPECIFICATIONS

Range of Motion 8.1

Usable range of motion shall be ± 50 degrees (Threshold), ± 60 degrees (Objective).

Dynamic Performance 8.2

a. The following dynamic performance specifications shall apply equally for clockwise and counter-clockwise motion with the target load defined in Section 3:

1. Maximum Velocity:

a. Target Load 1: ≥ 100 deg/sec (Threshold), ≥ 150 deg/sec (Objective)

b. Target Load 2: ≥ 75 deg/sec (Threshold), ≥ 100 deg/sec (Objective)

2. Maximum Acceleration:

c. Target Load 1: ≥ 1,200 deg/sec (Threshold), ≥ 2,000 deg/sec

(Objective)

d. Target Load 2: ≥ 800 deg/sec (Threshold), ≥ 1,200 deg/sec

(Objective)

3. Frequency Response:

a. Target Load 1: ≥ 11 Hz (Threshold), ≥ 14 Hz (Objective)

b. Target Load 2: ≥ 9 Hz (Threshold), ≥ 11 Hz (Objective)

Accuracy, Resolution and Repeatability 8.3

a. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec)

b. Position Accuracy: ≤ 0.0004 degrees (1.44 arc-sec)

c. Position Stability: ≤ 0.00005 degrees (0.18 arc-sec)

d. Velocity Resolution: ≤ 0.0001 deg/sec

e. Velocity Accuracy: ≤ ± 0.02%

f. Velocity Stability: ≤ 0.005%

9 SERVO CONTROL SYSTEM (SCS) SPECIFICATIONS

Cabinetry/Housing 9.1

The SCS and its associated electrical and electronic controls necessary for the operation, calibration, and checkout of the FMS system will be housed in standard slope-front half-height 19” equipment rack(s) on casters.

Removable Storage Media 9.2

The contractor shall provide a means of readily and efficiently replacing/exchanging SCS storage media without SCS disassembly to allow transition between unclassified and classified operations.

Performance 9.3

a. The SCS shall produce smooth, stable and repeatable servo performance for all axes over their full range of motion up to the limits of the FMS as stated in this document and the included appendices of this document.

b. The SCS shall not be the limiting factor in overall system accuracy, resolution, and repeatability. Assuming adequate sensor devices and FMS performance, the SCS shall be capable of providing the following minimum digital mode accuracy, resolution, and repeatability:

1. Position Resolution: ≤ 0.000005 degrees (0.018 arc-sec)

2. Position Accuracy: ≤ 0.000014 degrees (0.05 arc-sec)

3. Position Stability: ≤ 0.00006 degrees (0.02 arc-sec)

4. Velocity Resolution: ≤ 0.0001 deg/sec

5. Velocity Accuracy: ≤ 0.0001% for rates ≤ 10,800 deg/sec

≤ 0.0005% for > 10,800 deg/sec

6. Velocity Stability: ≤ 0.0001% for ≤ 10,800 deg/sec

≤ 0.005% for > 10,800 deg/sec

Clock Synchronization 9.4

The SCS real time interface shall be capable of automatically synchronizing with a

Government host simulation computer as well as accepting and synchronizing to an externally provided 10 MHz timing signal.

SCS Sensor Compatibility 9.5

The SCS shall support all sensors used on the FMS, HPU, power amplifiers, and compatible roll drives without modification or purchase of additional hardware or software.

Operator Interface 9.6

a. The SCS shall contain an operator interface consisting of a graphical user interface

(GUI) touch screen display. The GUI shall allow the operator to completely configure, tune and operate all aspects of the SCS. The SCS shall also contain provision for operation with an external computer mouse and keyboard. The SCS touch-screen GUI shall provide at a minimum servo mode, axis mode and axis information for all axes simultaneously accessible from one menu page. Other setup parameters such as gain, limits, offsets, etc. may be in other menus. Menu nesting shall be minimized to ensure often used parameters and information are easily and quickly accessible.

b. The GUI shall provide at a minimum the following functions:

1. Select and monitor operational modes.

2. Command and read axis motion.

3. Query axis status.

4. Modify and monitor system configuration parameters.

5. Perform servo configuration of all axes.

6. Perform servo compensation of all axes.

7. Log data for post processing axis performance.

8. Develop and implement script files for axis motion

9. Configure real time host computer interface and operation.

Help Menu 9.7

The SCS shall contain a detailed built-in readily accessible help menu describing all system commands and functions.

Mode, Command and Limit Checking 9.8

The SCS shall contain a means of checking and preventing invalid modes of operation, invalid commands and invalid values from being entered and acted upon.

High/low Gain Operation 9.9

The SCS shall contain a high gain and a low gain mode that can be locally or remotely operated. All FMS axes shall be in low gain mode when first energized.

Dither 9.10

The SCS shall contain a means of independently adjusting dither frequencies for each FMS axis to eliminate dither resonances and interference, and a means of dither synchronization between axes to eliminate any beat note frequencies that may develop with dither frequencies that are slightly different from each other.

Actuator Pressure Imbalance Correction 9.11

The SCS shall contain a means of digitally controlling and correcting the hydraulic pressure imbalance for each FMS axis containing dual actuators. Hydraulic cross-port tubes shall not be utilized for pressure imbalance correction. Actuator hydraulic pressures shall be available for GUI display as well as host simulation computer logging.

User Analog Interface Connections 9.12

The SCS shall contain at a minimum one BNC analog input and two BNC analog output jacks for each axis to provide for analog voltage command to and analog voltage feedback from each FMS axis. The analog voltage jacks shall be assignable to allow at a minimum the commanding and reading of position, velocity, or acceleration functions.

System Variable Availability, Scaling and Formatting 9.13

The SCS shall provide the capability to independently and simultaneously send any system variable to the GUI display, to analog output jacks and to the Government simulation computer via remote interfaces. The SCS shall allow the user to scale and format all system variables displayed on the GUI.

Data Collection and Playback 9.14

The SCS shall be capable of real-time simultaneous data logging of at least 64 system variables and storing the results in a data file for analysis. The SCS shall have the capability to post process the data, create graphs, plots and charts, and analyze and store the results. The SCS shall be capable of exporting the logged data and plots in a Microsoft

Office Excel format to internal and external storage media. The SCS shall have the capability to collect real-time system data during Government simulation computer runs and play back the data to exactly replicate…