Updated_SOW.docx

Statement of Work Fanuc CNC Upgrade for OC14851

Statement of Work for OC 14851 CNC Upgrade

FY16

CCAR# OC-14851

Updated: July 18, 2016

1.0 PURPOSE: The purpose of this effort is to remanufacture the old Allen Bradley CNC, controls, servo drives, motors and cables to the latest state of the art FANUC components for OC14851. Older control electronics are deteriorating and new replacement parts are not available. The machine has been consistently down due to faulty electronics with long delays in obtaining replacement parts. Replacement components can only be purchased in refurbished condition and have been unreliable and sometimes only borderline compatible with the current electronic system.

2.0 BACKGROUND: The F100 core facility of the 76PMXG (Propulsion Maintenance Group) is looking to overhaul its CNC on the shot peening machine to include new FANUC hardware to control the Shotpeen parameters. The current Allen Bradley CNC components are no longer being manufactured and refurbished replacement parts must be located and configured to work with the equipment. However these refurbished components have also proven to be unreliable. The machine has been consistently down due to faulty electronic components and the objective is to disassemble the electronic components and replace the entire electrical configuration to ensure coherency and compatibility within the shotpeening system. The PC directly interfaces with the CNC to develop and execute programs. There are already a large number of programs stored on the current PC which would need to be transferred to the new PC to avoid duplication of cost to the government. Core parts consistently have to be run in the F100 FDT/IFD peening machines to maintain production.

3.0 SCOPE: The contractor shall provide all labor and materials to remanufacture the CNC controls, servo drives, motors and other hardware. The computer interface shall also include the latest PRIMS® version and latest computer hardware components. The contractor shall successfully demonstrate a fully working machine and transfer of programs, recipes, pictures and surface selections for the existing Progressive Surface Automated Shotpeening System located in the F100 core workload area at Tinker Air Force Base. The contractor shall assemble and test the CNC control at their facility before shipping to Tinker AFB.

4.0 REQUIREMENTS: The contractor shall design, construct and install new FANUC 31i-A5 CNC controllers, drives, motors and mounting hardware to replace the old Allen Bradley components with a compatible PC operator interface which includes PRIMS® software as follows:

4.1 ENVIRONMENTAL

4.1.1 Mercury Restriction. Equipment shall not contain mercury or mercury compounds, nor be exposed to free mercury during the manufacturing process.

4.1.2 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

4.1.3 Chromium Restriction. Chromium-based compounds shall not be used on or in the machine.

4.1.4 Ozone depleting compound (ODC) Restriction. ODCs shall not be used on or in the machine.

4.1.5 Environmental Protection. Under the operation, service, transportation, and storage conditions described herein, the machine shall not emit hazardous materials that are prohibited by Federal, State, or local statutes in effect at the installation.

4.2 CNC

4.2.1 The contractor shall replace the old 5 axis Allen Bradley CNC, its related components, and existing control panel with the new system of FANUC 31i-A5 CNC components, servo drives, motors, cables and control panel. All five (5) machine axes shall be able to move simultaneously.

4.2.2 Hardware:

4.2.2.1 Shall include an LSI (large scale integration) and surface mount technology design for reliability.

4.2.2.2 Shall include an extensive color LCD display with sealed keyboard.

4.2.2.3 Shall include a handy machine operator’s panel (portable teach pendant) equipped with an LCD and manual pulse generator.

4.2.2.4 Shall be capable of 512 Kilobytes of motion program storage as minimum.

4.2.2.5 Shall include a fiber optic FSSB connection to servo drives.

4.2.3 Operation:

4.2.3.1 Shall include a “Softkey” function key operator menu system

4.2.3.2 Shall provide extensive operator and help messages

4.2.3.3 Shall allow the operator to edit programs while executing motion programming

4.2.3.4 Shall conform to RS-274 format for compatibility with existing programs

4.2.3.5 Shall include “paramacro” programming features

4.2.3.6 Shall include graphic motion program verification

4.2.4 FANUC servo motors and drives:

4.2.4.1 Vendor shall supply FANUC Alpha Series digital servo motors and drives to replace existing servo motors and drives.

4.2.4.2 New motors, drives, and cables shall be included for the four robot axes (X, Z, A and B) and the spindle axis (C).

4.3 PC, TOUCHSCREEN MONITOR AND CONTROL PANEL

4.3.1 The operator interface shall be a state-of-the-art PC that is housed inside the main control panel.

4.3.2 The PC shall include a touch screen monitor that is mounted on an adjustable suspension arm. This shall allow the monitor to be easily moved into a convenient position for use and then moved out of the way when not in need. An adjustable support arm shall also be provided for the industrially hardened keyboard.

4.3.3 A new Windows 7 PC and new equivalent PRIMS® software (same version of PRIMS® currently existing in machine #1703) shall be installed. The PC must have CD read and write drive and multiple USB connections for data downloading part programs or recipes.

4.3.4 A programmable teach pendant must be incorporated into the system to allow the operator to perform all jogging functions on the control system. The hand held teach pendant shall provide the following options:

4.3.4.1 Jogging all axes in positive or negative directions.

4.3.4.2 Select high, medium, low or incremental jog speeds.

4.3.4.3 Homing all axes.

4.3.4.4 Cycle run button for program execution.

4.3.4.5 Store button to insert the current position into the motion program.

4.3.4.6 Emergency Stop push-button.

4.3.4.7 A digital display of current axis position.

4.3.5 The contractor shall remove the existing control panel and replace it with a new one to house the CNC & servo drives. The control panel shall be NEMA 12/IP65 rated against oil and dirt and shall be built to conform to the U.S. National Electrical Code (NEC) ANSI/NFPA 70 and ANSI/NFPA 79 standards. Computer printed wire and terminal numbers shall be used for easy identification. The CNC and its operating controls shall be located in the same location as the old Allen Bradley.

4.3.6 A thermostatically controlled air conditioner for the control panel shall be included to maintain the enclosure at a constant temperature.

4.3.7 A new industrial grade 19” touch screen monitor and industrial grade keyboard shall be included.

4.3.8 Control system shall be capable of switching between CCW14 and CCW20 process parameters for dual media system as needed.

4.3.9 The rotary lance drive shall be controlled through programming and recipes.

4.4 CNC PROGRAM CONVERSIONS

4.4.1 Conversion software that converts Allen Bradley programs to FANUC programs automatically shall be included.

4.4.2 The conversion program shall keep same position coordinates from the original program, but shall convert the way feedrates are calculated and programmed. Other commands such as delays, setting of variables, comments and conditional commands shall be converted. Minor manual editing and testing is acceptable for each transferred program to assure original program is properly executed.

4.4.3 This conversion program shall be installed in the new PC that will be provided for the remanufacture.

4.4.4 Vendor shall convert up to 20 existing programs and pre-load them onto the new CNC controllers at the government’s discretion.

4.5 ALMEN TEST INTENSITY SOFTWARE

4.5.1 A software program shall be provided which calculates the intensity of the shot stream based upon a series of Almen tests which calculates and plots a saturation curve indicating the intensity for the given process parameters.

4.5.2 This software shall also record the entire process development, to include a plot of the saturation curves, store production verification data and print applicable data.

4.5.3 Parts shall be able to be uniquely identified based on several parameters and each part stored shall have up to 50 Almen strip locations available and up to 5 Almen strips shall be able to be averaged together at each location. Data shall be able to be stored for later use and old or incorrect data shall be able to be deleted.

4.5.4 The program shall provide a graphical representation of the saturation curve, displaying T1 and T2 and showing the numerical results. The program shall have the option of generating a report that displays all of the process data along with the curve.

4.6 PRIMS® SOFTWARE

PRIMS® (Process Reporting Integrated Monitoring System) shall be included as the operator interface software. This software shall include a process control system that constantly communicates with the machine control to provide data for the PRIMS program. It shall include process monitoring and reporting software. It shall include utilities for uploading and downloading part programs to the CNC controller. A part program editor which includes user programmable buttons for insertion of typical functions and commands (i.e. nozzle position and speed, table speed or position, process on/off commands, etc). Complete CNC motion programs can be generated by answering user specified dialog boxes. The information provided shall include:

4.6.1 Cycle Monitor and Recipe Information

4.6.1.1 Process setpoints and process actuals shall be displayed in an easy to read format. Process recipes shall be easily written, modified and saved. Process parameters shall have the capability to be changed within an approved range that is pre-set by the administrator/engineer.

4.6.1.2 Each of the parameters shall be protected by a muiti-level security system and shall give the administrator the option of allowing machine operators to modify some or none of the process parameters within the recipe. Recipe selection and storing shall also be protected by a security system that safeguards the recipe from accidental or unauthorized deletions or selections.

4.6.2 Help Messages (Operators shall be able to request a “help” message for any type of parameter shown on the display screen. The message shall provide relevant information on the limits and operation of a parameter).

4.6.3 Alarm Messages with Diagnostics (Each parameter shall have two sets of programmable high and low limits. Machine and system alarm conditions shall also be supported by alarm and diagnostic messages).

4.6.4 Trend Graphs shall be available to provide a graphical display of user selected parameters during a cycle.

4.6.5 Manual Test mode shall allow operators to manually test system components by pressing “soft-key” push buttons.

4.6.6 Part and Optional Function Selection shall allow the operator to locate and select which part to process. Each part recorded in the system shall include multiple identification fields, as well as picture options. When the part is selected by the operator, the selected part program shall automatically be sent to the robot controller and made active. Each part shall have up to 16 optional motion control or process functions defined. These shall be simply toggled on or off.

4.6.7 Data Collection and Process Recording System

4.6.7.1 The system shall continuously record critical process parameters. This data shall be stored in a database.

4.6.7.2 Reporting shall be done through an integrated database reporting utility.

4.6.7.3 Reporting shall include: process summary reports of key parameters, alarm logs, recipe print-outs, part log reports for a given time period, and strip chart records showing second-by-second data.

5.0 SHIPPING & INSTALLATION

5.1 A full turnkey installation shall be completed. This includes, but is not limited to, supplying of qualified service engineers/technicians/assemblers to accomplish all removal of old CNC, motors, cables and components and organize them so that they can be conveniently stored and re-used at Tinker AFB. Unloading of equipment from trucks. Installation of all new components of the remanufactured electrical system. Successful machine start-up and checking of all machine functions. Any rigging equipment that will be needed shall be supplied as well.

5.2 The contractor shall be responsible for all shipping charges to Tinker Air Force Base, off loading, and disposal of shipping materials.

6.0 TRAINING

6.1 Training (conducted at Tinker AFB)

6.1.1 One day of operator training covering general machine operation, part programming, and service manual organization between the hours of 0700and 1600.

6.1.2 One day of maintenance training covering general machine maintenance, maintenance schedules, machine drawings, spare parts and service manual organization between the hours of 0700 and 1600.

7.0 DELIVERABLES The contractor shall deliver the following: One fully functional Servo drive, Controls motors and PLC integrated to the new PRIMS® software with all required changes to current operation manuals.

7.1 Manuals/Drawings. The contractor shall furnish complete Operation and Service Manual updates which fully document all changes made to the machine. Machine drawings shall consist of all assembly and subassembly prints necessary for maintenance and assembly of the system. Control drawings shall include a complete set of machine control drawings (including electrical, pneumatic and hydraulic schematics) and all assembly and sub-assembly drawings required for component identification. The contractor shall also furnish 2 (two) digital copies of the complete technical manuals and drawings (original plus updates) in Adobe's Postscript (*.PDF) file format on CD-ROM(S). The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc).

7.2 Program Transfer. The contractor shall provide a means to transfer ALL the current processing programs on the PLC and CNC to the new PLC and CNC. Contractor shall demonstrate that the programs transferred to the new PLC and CNC are fully functional and operational and that they have the same cycle time, geometric points, feederates, dwell times, and other critical peening parameters, as the programs before the conversion.

7.3 Hardware. The contractor shall furnish the necessary hardware for the CNC, Servo drives, Control motors, air conditioner, and PLC for the remanufacture of the system with the new Fanuc components. The contractor shall remove the old hardware and install the new hardware on the machine.

7.4 Software. The contractor shall provide the necessary PRIMS® software for interfacing between the CNC and the PLC for programing and processing. The contractor shall also ensure that the CNC and PLC interface and that programs can easily be transferred between the two.

7.5 Accomplish final machine alignment after start-up.

8.0 ACCEPTANCE

8.1 Upon completion of the installation, the contractor shall be responsible to perform all functions required to demonstrate that the machine is fully operational after the remanufacture required by this specification.

8.2 All items shall meet requirements for section 4.

8.3 Government will provide the Almen test fixture for all acceptance tests.

8.4 Runoff will be performed at Tinker AFB and a government representative shall approve the runoff by signing-off the Acceptance Criteria developed by the vendor. Runoff will include:

8.4.1 Overview of equipment

8.4.2 Demonstration of the machine functions and capabilities

8.4.3 Review of Machine Manuals

8.4.4 Machine approval sign-off