FA813220Q0019 Dual Media Blade Root Peening System STATEMENT OF WORK 04-23.pdf

STATEMENT OF WORK (SOW) / SPECIFICATIONS

Dual Media Blade Root Shotpeen System

BUILDING 3001

TAFB, OK

Purchase Request Number:

Reference CCaR H0WP52 and CSN OC-

Prepared by

Casey Johnson

76 PMXG/MXDECB

405-736-4569

November 16, 2018

Revised April 23, 2020

Oklahoma City Air Logistics Center

Tinker Air Force Base

Notes:

1. Preliminary inspection of the machine shall be at origin with final inspection and acceptance at destination upon completion of installation at the customer’s facility by the contractor.

2. Packaging shall be done in accordance with ASTM D3951-10.

3. Customer requests a requirement review meeting within 15 days after contract award to clarify requirements based on this SOW be conducted.

PURCHASE DESCRIPTION FOR DUAL MEDIA SHOT PEEN

MACHINE

1.0 SCOPE.

1.1 Scope. The contractor shall provide all labor, tools, parts, facilities, travel, transportation and incidentals to deliver and install a new gantry robotic CNC shotpeening system in accordance with this Statement of Work (SOW) and manufacturer’s specifications at Tinker AFB, OK. This specification describes the minimum requirements for the gantry robotic CNC shotpeening system required. The machines shall be used on various steels, titanium, and nickel alloys. This specification includes the machine, ancillary equipment, training, all accessories, attachments and complete installation services described herein.

2.0 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are cited in sections 3, 4, and 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they shall meet all specified requirements of documents cited in sections 3, 4, and 5 of this specification, whether or not they are listed.

2.2 Government Documents

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

STANDARDS - FEDERAL

FED-STD-H28A: Screw Thread Standards for Federal Service (1994 Ed.)

U.S Department of Labor, Occupational Safety and Health Administration (OSHA)

OSHA 29 CFR 1910: General Industry, OSHA Safety and Health Standards 29 CFR

1910 (2015 Ed.)

(Application for copies should be addressed to the OSHA Publications Superintendent of

Documents P.O. Box 37535 Washington, D.C. 20013-7535)

DEPARTMENT OF DEFENSE

ITEM UNIQUE IDENTIFICATION MARKING (IUID)

MIL-STD-130N: Identification Marking of U.S. Military Property (2012 Ed.)

SHOTPEENING MEDIA

AMS 2431 Rev C: Peening Media General Requirements (2010)

AMS 2431/3D: Peening Media (AWCR) Conditioned Carbon Steel Cut Wire Shot , Regular Hardness (45 to 52 HRC) (2007)

(Application for copies should be addressed to Air Force Product Data Systems

Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg.

262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or

0853)

2.2.2 Other Government Documents, Drawings, and Publications. The following

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

LOCAL DOCUMENTS

Attachment 1: Alignment and Accuracies Revision A

(Applications for these documents should be addressed to the contracting officer)

2.3 Non-Government Publications.

2.3.1 Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

Aerospace Material Specification (AMS)

AMS 2430: Shot Peening, Automatic (2012 Rev S)

AMS 2432: Shot Peening, Computer Monitored (2013 Rev D)

SAE J2277: Shotpeening Coverage (2003 Ed.)

SAE J2597: Computer Generated Shot Peening Saturation curves (2010)

SAE J441: Cut Wire Shot (2015)

SAE J442: Test Strip, Holder, and Gauge for Shot Peening (2017)

SAE J443: Procedures for Using Standard Shot Peening Test Strip (2017)

(Application for copies should be directed to SAE-International, 400 Commonwealth

Drive, Warrendale, PA 15096-001 Phone: (724)776-4841)

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power – General Rules and Safety Requirements for Systems and Their Components (2010 Ed.)

ISO 4414: Pneumatic power – General Rules and Safety Requirements for Systems and

Their Components (2010 Ed.)

(Application for copies should be addressed to the International Organization for

Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum) (2014 Ed.)

NEMA MG 1: Motors and Generators (2014 Rev.)

(Address application for copies to National Electrical Manufacturer's Association, 1300

N. 17th St., Suite 1847, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code (NEC) (2014 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2015 Ed.)

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

American National Standards Institute (ANSI)

MIL-STD-167-1, MIL-STD-740-2 Mechanical Vibrations

FED-STD-H28A: Screw Thread Standards for Federal Service (latest edition)

ANSI B11.23 Safety Requirements for Computer Numerically Controlled (CNC)

Machines

(Application for copies should be addressed to American National Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

National Electrical Manufacturers Association (NEMA)

NEMA MG 1 - Motors and Generators (2011 edition)

(Application for copies are available online at http://www.nema.org/pages/default.aspx or from National Electrical Manufacturers Association, 6300 Interfirst Drive, Ann Arbor, MI, 48108)

American Society of Mechanical Engineers (ASME)

ASME Y14.100-2009: Engineering Drawing Practices (Revision of ASME Y14.100-

2004) http://www.nema.org/pages/default.aspx

(Applications for copies should be addressed to the ASME International Three Park

Avenue New York, NY 10016-5990 or www.asme.org )

American Gear Manufacturers Association (AGMA)

AGMA 2015-1-A01: Accuracy Classification System – tangential measurements for cylindrical gears (latest revision)

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA

22314-1581 USA)

TECHAMERICA

TIA/EIA-267-C: Axis and Motion Nomenclature for Numerically Controlled Machines

(1990 Ed.)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania

Avenue NW, North Building Suite 600 Washington, DC 20004)

Aerospace Industries Association (AIA)

NAS 995- Specification for Computerized Numerical Control (CNC), (latest edition)

(Copies can be obtained from the Aerospace Industries Association, 1000 Wilson Blvd., Suite 1700, Arlington, VA 22209. www.aia-aerospace.org)

2.4 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

3.1 General. The items offered shall be new and a current, commercially-available model.

Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein.

A. The Machine’s related components and systems shall meet or exceed the minimum requirements for design, construction, functional capability, size, and performance as specified herein.

http://www.asme.org/ http://www.aia-aerospace.org/

B. The Contractor shall standardize the equipment utilized to maintain configuration control with existing equipment utilized by the Government in recent equipment upgrades.

C. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair.

D. Each quotation will be evaluated for technical acceptability, based on the criteria below, and by using the attached Item Cross-Reference Sheet.

3.2 System Components and Design. The machine shall comply with all specifications listed in AMS 2430, AMS 2432, Air Force T.O. 2-1-111, and GE P11TF8. The machine shall not consist of less than the following components. Each component shall be designed and constructed to meet or exceed the characteristics listed within each section below.

3.2.1 Blade Peening System.

The blade peening system shall be designed to be capable of the following:

A. Peening a minimum of two blades at a time.

B. Safely loading and unloading a minimum of two blades outside of the peening cabinet while the machine is peening blades inside the cabinet.

C. Peen a minimum of two blades at the same time, at the same intensity, and using the same process parameters.

D. Operate within the range of the facility’s supplied air pressure: 90-110 PSI.

3.2.1.1 Blade Positioning System.

The machine shall include a blade positioning system. The blade positioning system shall be designed to meet or exceed the following characteristics:

A. Sealed driving components to prevent damage from peening media.

B. Index or rotate a minimum of 2 blades and fixtures simultaneously.

C. Position and rotate blades using the same degree of rotation and to predetermined system positioning locations.

D. Position each blade at the same angle in relation to the peening nozzles.

E. The blade rotation axis shall be capable of coordinating simultaneously with all other axis motion.

F. Machine processing shall stop and provide a fault with the specific cause if actual position values deviate from the program value.

3.2.1.2 Indexing Table.

The machine shall include an indexing table and be designed to meet or exceed the following characteristics:

A. Allows for loading and unloading of multiple blades outside the peening chamber while blades are being processed within the peening chamber.

B. Includes interlocks so the table cannot index when the work door(s) are not fully open or during a peening cycle.

C. Table indexing should not be affected by the use of air hoses located on the outside of the machine.

3.2.1.3 Pressure Peening System.

The peening system shall be designed to meet or exceed the following characteristics:

A. Includes a continuous media flow pressure pot system for each size of media specified for the machine.

B. Capable of peening with each size of media specified for the machine. Each media type specified shall include its own:

a. Dedicated pressure pot assembly, and

b. Dedicated media classifier.

C. Capable of continuous peening on a single program for a minimum of 8 consecutive hours.

D. Capable of using different media sizes other than those originally specified.

E. If a different media size or substitution is made, it shall not compromise the system from being able to do any of the items listed in the specification.

3.2.1.3.1 Air Drop.

The machine shall include a single, pressurized air drop. The air drop shall be designed to meet or exceed the following characteristics:

A. Supplies air to the entire system.

B. Includes a supply shutoff valve.

a. Located at operator height, 4’9” to 6’5”, from the floor and meet all applicable OSHA and JIC codes.

3.2.1.3.2 Main Air Regulator.

The machine shall include a main air regulator with a 4” pressure gauge. The main air regulator shall be a Proportion Air 2” R000 pilot operated regulator with a DSY100 pressure transducer, and a QB2TFEE100S305S1038 electronic air pressure regulator.

A. The 4” pressure gauge shall have a range of 0-100 psig, an accuracy of ±1% across the entire range, and a liquid filled case.

B. The machine shall be configured to allow pressure transition during a CNC program, and does not require nozzle movement to make the pressure transition happen.

3.2.1.3.3 Pressure Pots.

Pressure pots shall be designed to meet or exceed the following characteristics:

A. Constructed in accordance with ASME BPVC.VII.1-2017.

B. Includes external air pressure gauges in both upper and lower pressure pots to assist with troubleshooting.

C. There shall be external air pressure gauges in both the upper and lower pressure pots to assist with trouble shooting.

D. There shall be external air pressure gauges on pinch valves, air pressure boosters, and any other locations that would be necessary for trouble shooting purposes.

E. Air pressure gauges shall be properly rated for the pressure range they are governing.

F. The lower pressure pot shall have a separate media valve located on the outside of the pot which allows all media to be drained from the system when repairs are necessary.

3.2.1.3.4 Media Shifting

The peening system shall be capable of shifting media. The system shall be designed to shift media that meets or exceeds the following characteristics:

A. Ensures a minimum amount of media is supplied from the pressure pot to the peening nozzles so that the intensity is consistent.

B. Shuts down and displays an alarm when the system runs out of media.

C. Media shifting shall not interrupt a peening cycle, or change the intensity of the shot stream.

D. Reclaims acceptable media while the pressure pot refills.

E. Prevents media backing up into the media classifier, dust collector, or cyclone separator during a pressure pot refill.

3.2.1.3.5 Media Switching Valves

The media switching valves shall be constructed to meet or exceed the following characteristics:

A. The peening system shall use durable valves that can easily be changed and maintained in locations where media comes in contact with the valves to minimize maintenance frequency and valve wear.

B. All valves shall be mounted on the outside of the pressure pots for ease of maintenance.

3.2.1.3.6 Media

The peening system shall be designed to meet or exceed the following characteristics:

A. Capable of using different sizes of Cut Wire or Cast Shot media, including but not limited to CCW 12, CCW 14, CCW20, CCW 28, SAE 70, SAE 110, SAE 170, or

SAE 230. The system shall be capable of operating with all of the shot sizes listed with either Cast Steel Shot of high hardness (55 to 62 HRC), or regular (45 to 52

HRC) hardness, and Conditioned Carbon Steel Cut Wire shot of high hardness

(55 to 62 HRC) or regular hardness (45 to 52 HRC).

B. The system shall be tested with both CCW 14 and CCW 20 meeting AMS 2431/3, with one type of media being used for one pressure pot system and the other media type being used for the other pressure pot system on the dual media system.

One pressure pot system shall be calibrated exclusively for size 14 conditioned carbon steel cut wire shot with a regular hardness and the other shall be calibrated exclusively for 20 conditioned carbon steel cut wire shot with a regular hardness.

3.2.1.3.7 Media Switching

The peening system shall be capable of switching between different types of media. How the peening system is designed to switch between different type of media shall meet or exceed the following characteristics:

A. Does not require switching media screens or emptying the peening system of media to switch from one type of media to another.

B. Does not cross-contaminate between the different types of media.

C. Switches from one media size to another within 5 minutes.

D. All components are accessible for maintenance.

E. Displays the media type selected by a peening program on the operator information screen.

F. Shuts down the peening program when the wrong type of media is selected for that program.

G. Displays a fault on the operator information screen when the wrong media is selected for a particular program.

H. All programmable commands are done in G code.

3.2.1.3.8 Media Flow Valves and Monitoring

This machine shall include an installed Electronics Inc. (EI) 578-24 MagnaValve (PN

999290) with an EI FC-24 (PN 999331) Flow Controller for each media type.

A. The EI media valve shall be accurate to ±5% of full scale rating of 3-30 lb/min.

B. The media flow range shall match what is displayed on the computer operator interface.

3.2.1.3.9 Pressure Blast Hose.

The pressure blast hose is used to transport the media to the blast nozzles. The pressure blast hose shall be a Goodyear Plicord 4-PLY or equal. If quoting an equivalent, it shall meet or exceed the following characteristics:

A. The inner diameter shall be 3/4" (19.0mm), and an outer diameter of 1.5"

(38.1mm).

B. A minimum of 15 feet (4.6m) long.

C. Capable of operating with a minimum of 150 PSI (10.2 bars).

D. Hoses and piping on each peening gun shall be the same length from the point of pressure control to the end of each nozzle, so that the pressure is passively balanced between the peening guns.

E. A quick coupling on the air supply end shall be provided to accommodate attachment and detachment. A 1-1/4" (31.8mm) NPS female fitting on the opposite end of the air supply will provide for attachment to a standard blast nozzle.

3.2.1.3.10 Media Peening Nozzles

The media peening nozzles shall be designed to meet or exceed the following characteristics:

A. Straight nozzles with an internal diameter of either 5/16” or 3/8”.

B. Made of boron carbide.

C. All peening nozzles in the system shall be the same whichever internal diameter is selected.

D. The system shall use a minimum of one nozzle per blade spindle attached to the gantry robot head for peening the parts.

E. Ability to peen within ±5% of each other.

F. Pointed away from the work door used for programming.

G. Physically located between the programmer and the blade spindle.

3.2.2 Media Recovery System

The machine shall include a media recovery system. A system shall recover reusable blasting media from the dust stream and return the blasting media to the media hopper.

The media recovery system shall be designed to meet or exceed the following characteristics:

A. No media shall be allowed to escape via the media recovery system.

B. The machine shall be equipped with a cyclone type reclaim system that separates reusable media meeting AMS2431 from spent media and dust

C. The reclaimed media shall be returned to the media hopper/pressure pot.

D. A filter or guard system in the bottom of the peening cabinet shall be used to keep larger objects, such as screws, bolts, Allen wrenches, tape, etc. from entering into the reclaim system and any moving parts.

E. Reclaim system shall be capable of moving at a minimum of 100 pounds of media per minute to the cyclone.

3.2.2.1 Dust Collector

The dust collector shall be designed to meet or exceed the following characteristics:

A. The peening cabinet shall house an integral dust collector.

B. The dust collection system shall draw contaminated air out of the cabinet.

C. This air shall be filtered and returned to the plant atmosphere. It shall use multiple cartridge filters that are 99% plus efficient at 0.5 micron at 250 cubic feet per minute (CFM).

D. Filters shall be mounted in a way that are easy to change, properly align, and seal.

E. The dust collector shall have a differential pressure gauge to monitor pressure drops across the filters and indicate when filters need replacement.

F. The system shall also include a purging system that removes dust from the filters with a timed air pulse through the filters. Larger dust shall fall freely into a trash receptacle.

G. The dust collector and the ductwork leading to the dust collector after the cyclone separator shall be capable of passing a fluorescent dust inspection test.

3.2.2.2 Media Classifier

Two SWECO® vibratory media separators/classifiers shall be provided, one for each media types, to classify the peening media specified for the machine.

The separators/classifiers systems shall be designed to meet or exceed the following characteristics:

A. It shall come with the appropriate sized screens for the specified media to ensure proper classification of media per AMS2430 and AMS2431.

B. Easily and safely accessed for maintenance, including but not limited to, changing out screens and accessing the auto lubrication devices.

C. All non-conforming media shall be discarded into a government provided fifty five (55) gallon re-sealable drum.

3.2.2.3 Media Adder System

The machine shall be equipped with an automatic media adder system.

The media adder shall be designed to meet or exceed the following characteristics:

A. This system shall add media to the reclaim system when low media is detected.

B. When the media adder system is turned on, it shall have no effect on the peening cycle or desired intensity.

C. Media adder system shall be external to the cabinet and hold between 150 pounds and 200 pounds of media.

D. Media adder system shall be placed on the ground, with the top between 36 and

48 feet above the ground.

3.2.2.4 Media Cleaning System

Media cleaning system will be used to blow all the media back into the cabinet from the table and off of the part.

Media cleaning system shall be designed to meet or exceed the following characteristics:

A. The cleaning system shall be designed so that it will clean all of the shot off of the blades, fixtures, and table when table is indexed. No media shall be blown into the operator load/unload area.

B. Media cleaning system shall be a high enough pressure to clean off the media, but a low enough pressure to avoid inadvertently peening the part.

3.2.3 CNC System

The control system shall be composed of a computerized nozzle manipulation system operated by the CNC that is user friendly and is aided by a second operator interface which stores different process parameters and controls all motion.

The CNC control system shall be designed and constructed to meet or exceed the following characteristics:

A. The machine shall conform to NAS 995 sections 3.1 and 3.2.

B. The control station shall be equipped with an industrially hardened keyboard.

C. The control shall be the latest FANUC control Series 31i that can simultaneously control motion of all axes of motion on programmed paths.

D. Shall utilize G code to control the process.

E. The ladder logic for the FANUC control for this system shall be provided and shall be unlocked.

F. The CNC shall receive all the process instructions such as nozzle movement, dwell time, total cycle time, nozzle selection, media flowrate, air pressure etc.

from the operator PC.

G. The control system shall be housed in a mounted enclosure adjacent to the robot control. The enclosure shall be rated NEMA12/IP55 to provide protection against oil and dirt.

H. The entire controller shall be integrated in accordance with NEMA 250, NFPA

79, NEMA ICS 1, NEMA ICS 6, ISO 13849 and ISO 12100.

3.2.3.1 CNC Controller

The CNC controller shall be designed to meet or exceed the following characteristics:

A. The CNC controller shall receive process parameter set points, alarm limits, shutdown limits, and recipe numbers which shall be passed to the control system for immediate implementation.

B. The system shall be designed so that the shot stream stabilizes off the part before moving into position to peen the part.

C. Each parameter shall have programmable high and low limits. If a warning or shutdown alarm occurs, a message describing the condition and the time of occurrence shall be displayed. Process tolerances to shut down the system shall be able to be set so that they will comply with AMS2432D for Computer Monitored

Shot-peening process.

D. CNC shall not execute any un-commanded movements or actions, including but not limited to robot movement, air or media flow to the nozzle, parts door(s) opening or closing, table indexing, reclaim system turning on or off, etc. (see

NAS 995 3.6.4.)

E. The system shall be capable of interrupting the peening cycle within one second, when excursions outside set tolerances are detected for shot flow, air pressure, nozzle motion speed, and/or turntable speed, and shall display actual values during processing.

F. Each alarm condition shall be supported with alarm and diagnostic messages.

3.2.3.2 Control Hardware. Minimum hardware requirements shall meet or exceed NAS 995 sections 3.1 and 3.2, and include, but not limited to, the following:

A. A large scale integration (LSI) and surface mount technology design for reliability.

B. TFT-LCD color display for ONG-type keyboard with a 10.4” screen.

C. Machine operator’s panel (portable teach pendant) equipped with an LCD and manual pulse generator as described in 3.5.3.4.

D. Shall store a minimum of 300k Program steps. It shall also have a minimum of

512 KB (1280 meters) of motion program storage for the part programs .

E. 4GB Random Access Memory (RAM)

F. 500 GB HDD storage Capacity.

G. Fiber optic FSSB connection to servo drives.

H. Program test function as described in 3.5.3.5.

I. Graduated speed adjustment as described in 3.5.3.6.

J. Over travel override function as described in 3.5.3.7.

3.2.3.3 CNC Operation. Operation of the system shall include, but not be limited to the following items:

A. Shall provide extensive help messages for the operator.

B. Shall allow the operator to edit programs while executing motion programming

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

D. Shall include “paramacro” programming features that shall allow the user to include operator G-codes to be used in a part program.

E. A security clearance device shall be implemented to prevent unauthorized users from changing any of the critical process parameters on the CNC.

F. Shall not skip any lines in program execution when program is cycle stopped and restarted again, or when the door is opened and closed again during a program stop.

3.2.3.4 Operator Control Pendant

A. An operator control jog/teach pendant shall be incorporated into the system to allow the operator to perform all jogging functions on the control system.

B. The control pendant shall be constructed to meet or exceed the following characteristics:

a. The pendant shall have an illuminated display for ease of viewing.

b. A dead man switch shall be installed on the jog pendant. The switch shall be a

“positive break normally closed” contact. The switch shall change state when an actuator turns a positive mechanical linkage within the switch. This design eliminates false signals that could otherwise be caused by broken springs or welded contacts. The switch shall be tamper resistant and mounted with tamper resistant screws.

C. This hand-held teach pendant shall include but not be limited to the following items:

a. Jogging All Axes in both Positive and Negative Directions

b. Selectable High, Medium, and Low Jog Speeds

c. Incremental Jog Speeds

d. Homing of All Axes

e. Cycle Pause Button for Program Execution

f. Cycle Run Button for Program Execution

g. Store Button to Insert the Current Position into the Motion Program

h. Jog Pendant cord between 7-15 ft long and located near the programming area

i. Convenient pendant holder on side of machine that protects the pendant and minimizes the probability that it will be bumped onto the floor.

j. Emergency Stop Push-Button (mushroom type, push to activate, twist to reset)

k. Incremental positioning wheel, for precise robot positioning

3.2.3.5 Program Test Function

The CNC system shall have a program test function mode to allow the nozzle to move through an entire program or to manually-selected points.

The program test function shall be designed as follows:

A. The program test function mode shall allow a nozzle to move with the door open but only when the Jog Pendant dead-man switch is engaged.

B. The program test function mode shall operate without air pressure or media flow in the nozzle.

C. The program test function mode shall be able to operate without engaging the reclaim system.

D. The program test function mode shall run at programmed speeds and shall not continuously run at 100% possible speed like a “Dry Run” function.

E. When the dead-man switch is released, the cycle stop is pressed, or an “E-stop” button is pressed, the program shall stop and the robot will cease movement.

However, when the program is resumed, it shall be able to continue from the point at which the robot stopped without skipping any lines of code.

3.2.3.6 Graduated Speed

The system shall have a manually operated graduated speed adjustment dial on the CNC control panel and the jog pendant. The graduated speed adjustment dial shall be easily accessible on the CNC and/or the jog pendant. It shall allow the programmer to quickly slow down the speed of the gantry robot and resume normal speed without stopping the program.

The graduated speed control shall be designed to meet or exceed the following:

A. The graduated speed control shall conform to NAS 995 paragraph 3.1.8.

B. The graduated speed adjustment shall be capable of adjusting the speed of the program, when necessary, to increase or decrease the speed for programming purposes and resume it to regular speeds for checking points.

C. The graduated speed adjustment shall have a range of no less than 0% to no less than 120% of the programmed speed.

3.2.3.7 Over Travel Override

The system shall be equipped with an industry standard over travel override button. This button will allow the gantry robot to move back into the functional working envelope if it extends past the program stop.

The over travel override shall be design to meet or exceed the following:

A. It shall either be located on the control panel or the jog pendant.

B. The system shall prevent the over travel override button from allowing the gantry robot to continue to travel beyond the working envelope in the direction it over traveled.

C. The system shall not allow the axes to extend beyond the hard stops, it shall only be capable of traveling past the hard stops by forces external to the system and not by programming errors, or pendant operational errors.

3.2.3.8 Power On/Off.

The machine shall have a power on/off button that is designed to meet or exceed the

A. A plastic guard to protect from inadvertently pressing the button.

B. Separate from the breaker installed on the machine.

C. Removes all power from the machine safely and in a controlled manner to de-energize the system before the breaker needs to be shut down.

3.2.3.9 Emergency Stop (E-STOP) Buttons.

The E-STOP buttons shall be designed to meet or exceed the following characteristics:

A. The system shall have a manually-operated E-STOP button that shall terminate the peening cycle, which includes: stopping all moving parts, all robot movement, the dust collector, reclaim system, air flow, and media flow.

B. This sequence shall have no effect on the established program.

C. The E-STOP button shall be readily available to the operator at all remote control panels, pendants, main control panel, and any other point on the machine tool frequently requiring the operator’s presence per NAS 995 Paragraph 3.4.9.

D. All E-STOP shall be mushroom type, push to activate, and twist to reset buttons.

When a E-STOP is reset, the machine shall not resume any part of the peening cycle, including but not limited to: all motion, air flow to the nozzle, media flow to the nozzle, the dust collector, or the reclaim system until a start command is given.

3.2.4 Gantry Robot.

The system shall utilize a gantry robot. The gantry robot shall be designed to meet or exceed the following characteristics:

A. Variable frequency or variable speeds drives for all axes.

B. The gantry robot shall require a rigid frame during movement for stability of nozzles with no visible signs of oscillation after quickly coming to a stop or during robotic arm traversing for any of the axes including the spindle axis.

C. The gantry robot does not oscillate when stopping or traversing any axis.

D. Minimum display resolution of 0.001 for linear axes and 0.01 for angular axes.

a. All axis values display on the CNC screen during programming and during program execution.

E. The robot shall at a minimum operate at the parameters specified in Table I.

F. The system shall meet the alignment and accuracy requirements as specified in

Table II. These requirements are in place to ensure that nozzles will be capable of peening blade airfoils for a wide variety of blades with sufficient precision.

Table I

Characteristics Size/Capacity

Stroke Lengths

Horizontal (X-Axis) 12”

Vertical (Z-Axis) 30”

Depth (Y-Axis) 14”

Tilt (A-Axis) ±90°

Positioning Speed Linear Axes 0.25”-500”/Minute

Positioning Speed Rotary Axes 360-21600°/Minute

Nozzle Head Load Carrying

Capacity 50lbs. @ 7" from A-Axis pivot

Chamber area per blade; Min 2 blade capacity 7” Ø × 36” Tall

C Axis Motion Continuous and

Indexing Motion

360° Rotational speed 1-60 rpm.

Indexing speed 1-60 rpm

Media Flow Control 3-30lbs

Air Pressure 0-100psi

Table II

Characteristic Accuracy/Tolerance

Positioning Repeatability (Bi-directional)

Linear Axes ± 0.010”

Rotary Axes ± 0.5°

Positioning Repeatability (Unidirectional)

Linear Axes ± 0.005"

Rotary Axes ± 0.1°

Spindle RPM ± 3% rated RPM

Spindle Repeatability ± 1.0°

Positioning Accuracy (Bi-directional)

Linear Axes ± 0.02”

Rotary Axes ± 1.0°

Spindle blade orientation to each other ± 1.0°

Axes Perpendicularity (X, Y, and Z) 0.010”/foot

Axes Perpendicularity (X, and A) 0.005”/foot

Intensity Range CCW 14 Shot 6-21N intensity

Intensity Range CCW 20 Shot 3-15A intensity

Backlash

Linear Axes ± 0.005”“

Rotary Axes ± 0.02° degrees

Spindle Axes ± 0.03° degrees

Air Pressure

Set point +/- 0.5psi

Maximum difference between guns 1 psi

3.2.4.1 Motors

Motors for all axis movement shall be Fanuc servo motors, and shall meet or exceed the following characteristics:

A. Motors shall be sized appropriately for the system to move the components at the rates specified.

B. Any motors that are not sealed and permanently lubricated shall have means to lubricate the motor without personnel having to climb on, under, or around the equipment.

3.2.4.2 Axes

The machine shall include axes. Axes shall be designed to meet or exceed the following characteristics:

A. The “home” position for all axes shall be the furthest the nozzles can be from the work spindles and blades.

B. The “home” position for each axis will display as 0 (with the designated number of significant digits for the specified axis).

C. When the nozzles move toward the part and away from “home,” they move in the positive direction.

D. Axes may be designed so that the center of the axis is the “home” position.

E. Nozzle Rotational Axes shall have “home” positions centered in the middle of their range with zero (0.0000) positioned with the nozzle level and pointing in the direction of the part. Rotational Axes shall have the positive direction be up from the specified home position or to the right from the specified home position as required for the designated axis.

F. The machine shall be capable of peening all features on a part and fixtures at an angle of 90°, including the top and bottom of a blade mid span when a part is in the holding fixture.

G. The standoff distance shall be adjustable from no less than 2” to 12” from the center of the spindle axis across all axes orientations.

H. Axis description shall conform to EIA-267C.

3.2.4.2.1 Axes Over Travel Limits

The machine shall include axes over travel limits on gantry axes to keep the machine within the working envelope in case of programming errors or machine malfunction. The over travel limits shall be designed to meet or exceed the following characteristics:

A. All axes, excluding the spindle rotational axis, shall have both programmed stops and hard stops so that the axis will stop if it travels beyond the range specified in

3.4.17 Table I.

B. The system shall not allow the axes to extend beyond the hard stops, unless the machine is under repair.

C. Only forces external to the machine can move it past the hard stops.

D. The machine shall have a way to travel the robot back into the working envelope from the operator control panel if it has traveled past programmed stops, either by jogging the robot or having an over travel override button.

3.2.4.2.2 Axis Ball Screws and Bearing Surfaces

Axis ball screws and bearing surfaces shall be designed to meet or exceed the following characteristics:

A. Accept antifriction type way bearings of a precise fit.

B. Include adjustable gibs, guides, or bearings for alignment of the table to the ways and to prevent excessive loading of the feed drive motor.

C. All axis ball screws and bearing surfaces leveled and aligned within:

a. 0.001” flatness and parallel for the X and Y axis with reference to the base, and

b. 0.001” flatness and perpendicular for the Z axis.

3.2.5 Cabinet Design

The cabinet shall be designed and constructed to meet or exceed the following characteristics:

A. The cabinet shall prevent any media from escaping the cabinet.

B. Cabinet design shall be such that it minimizes shot from being stored in places within the cabinet where it cannot be reclaimed.

C. An E-stop shall be provided in the operator loading/unloading area and clearly labeled as such.

D. An E-stop shall also be located in the vicinity of the programing service door so that during programing and program testing the E-stop is easily accessible.

3.2.5.1 Base.

The machine shall include a base. The base shall be designed to meet or exceed the

A. Minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine.

B. Easily and accurately level the machine by the contractor when the machine is delivered and installed.

3.2.5.2 Operator Platform.

The machine shall have an operator platform that is constructed to meet or exceed the following characteristics:

A. A platform shall be provided to allow the operator access to the blade loading/unloading area, parts door(s), and operator station.

B. The steps shall meet all applicable OSHA specifications. The platform shall ensure that operators that are 4’ 9” and taller shall be capable of loading/unloading the blades without additional assistance.

3.2.5.3 Media Peening Cabinet.

The machine shall include a media peening cabinet. The media peening cabinet shall be designed to meet or exceed the following characteristics:

A. Minimum ½” steel plate with all weld seams ground to a radius.

B. Rounded or beveled edges unless sharpness is required to perform a necessary function.

C. Inside walls protected from the peening media blast by means of at least 1/8” thick replaceable SB60 rubber liners or equivalent abrasion-resistant gum rubber.

D. Minimum ¼” thick urethane blast wear plates mounted on the cabinet wall directly in front of the nozzles to absorb energy from overspray and ricochet.

a. These plate(s) shall be replaceable.

b. These plate(s) shall cover the 1/8” thick replaceable SB60 rubber liners within the peening cabinet.

E. Sealed to reduce noise, contain media, and prevent safety hazards.

3.2.5.3.1 Work Lights

Work lights inside the peening cabinet shall be designed to meet or exceed the following characteristics:

A. At a minimum, two (2) light emitting diode (LED) light fixtures complete with dust tight, abrasive resistant covers shall be mounted in the ceiling of the media peening cabinet to illuminate the entire work area.

B. The lighting shall produce a well-lit cabinet interior with a minimum 80 foot-candles (861 lux) of light intensity.

C. Lighting shall allow for easy bulb replacement.

D. Lighting shall comply with NFPA 79 requirements.

3.2.5.4 Doors, Covers, and Panels.

The machine shall include doors, covers, and panels as necessary. Doors, covers, and panels shall be easily accessible for removal and maintenance egress.

3.2.5.4.1 Door Interlock Switch

The machine shall have a keyed interlock switches on all doors leading into the peening cabinet. The keyed interlock switch shall be designed to meet or exceed the following characteristics:

A. Verifies all doors that provide access to the peening chamber are securely closed.

B. Stop all processing if the door is opened during a peening cycle. Processes to include, but not limited to: air flow, media flow, spindle rotation, and gantry arm movement.

C. Prevent a peening cycle from starting when the door is open. No processes shall resume until all door(s) are closed and the peening cycle is restarted by the operator.

D. Deactivate when the machine is in a “Test” status and while the jog pendant is engaged. This will allow the robot to move to programmed points without running a cycle.

E. Ensure that while a peening chamber door is open, the machine will not make un-commanded movements or while the jog pendant is disengaged.

3.2.5.4.2 Light Curtain.

A light curtain shall be incorporated into the system to protect operators from injuries involving the part door(s). The light curtains will be designed to meet or exceed the following characteristics:

A. Light curtains shall be placed in loading and unloading area(s)

B. If the light curtain is obstructed, the doors shall not open or close, and the work table shall not index.

C. A fault shall be displayed on the operator computer that the light curtain is obstructed.

D. Once the light curtain is cleared, the fault shall be easily and quickly cleared to resume indexing/closing the doors on the machine

3.2.5.4.3 Parts Door(s).

The machine shall include part door(s) that provide access to the cabinet interior. All part door(s) shall be designed to meet or exceed the following characteristics:

A. The door(s) shall be sealed so no media can escape. No media shall be allowed to exit the machine during a peening cycle.

B. An abrasive resistant rubber coating on the inside surface to protect from the peening process.

C. Quick exchange between parts inside the cabinet and parts in the loading zone.

D. Safe loading and unloading outside of the peening cabinet while blades are processed within the cabinet.

E. Table can only index when the part door(s) are verified open and the machine is not in a peening cycle.

3.2.5.4.4 Service Door(s).

A service door shall be provided so programming can be performed while viewing the nozzles, the work piece, and while holding the jog pendant. The service door shall be designed to meet or exceed the following characteristics:

A. Sealed to contain media entirely within the machine.

B. A minimum of 3’ tall and 4’ wide.

C. Placed at eye level for a person between 5’ and 6’ tall.

D. Allows for retrieval of small objects if dropped into the media peening chamber.

E. Includes a magnetic door stop to keep the door open when programming.

3.2.5.5 Window.

The machine shall have a large viewing window. The window shall be designed to meet or exceed the following:

A. Constructed with clear safety glass.

B. Be a minimum of 12in high and 12in wide.

C. The window shall include a urethane slide plate.

a. Is open or closed using a lever on the side of the machine

b. The slide plate shall be made of 1/8” urethane

c. The slide plate shall completely protect the widow from being peened, or peening ricochet when it is covering the window.

d. The slide plate shall be capable of partially concealing the window while peening, and staying in place without external assistance from an operator.

D. The viewing window shall be placed in a location on the machine that optimizes the viewing angle of the operator to the part while operating the nozzle and spindle axes, for automatic peening.

E. The window shall have a removable film which can be reapplied to protect the glass surface.

3.2.5.6 Manual Blow Off.

The machine shall have manual blow off air nozzles around the machine where operators or maintenance personnel will perform routine tasks.

The manual blow offs shall meet or exceed the following characteristics:

A. At a minimum, one manual, self-coiling blow-off nozzle shall be near the part loading/unloading area, one nozzle near the pressure pots and their components, and one near the media classifiers.

B. Use of the blow-off nozzles during the peening process shall have no effect on the air pressure being used to peen the part or while indexing the table.

3.2.6 Operator Computer Station.

The operator computer station shall have a computer with an operator interface system.

The operator computer station will be designed to meet or exceed the following:

A. The computer station will be located within reach of the parts loading and unloading door(s)

B. The computer station will be located within reach of the CNC controller

3.2.6.1 Operator Computer.

The operator computer shall house all the necessary features to create files, edit, and store them for future use.

Operator computer shall run the operator interface system and Almen intensity software.

The operator computer shall be designed to meet or exceed the following:

A. High End Modern Workstation: E5-2367 3.5 Ghz dual processors

B. Windows 10 operating system

C. 16GB DDR4-2133 Memory

D. 8GB Video Card

E. 500GB Hard Drive

F. DVDRW Disc Drive

G. 19” Industrial sealed LCD touchscreen monitor with cable

H. Industrial sealed keyboard

I. Wired mouse

J. Industrial sealed jog pendant

K. 4 USB ports

L. Uninterruptable Power Supply (UPS), minimum 1 hour PC runtime with power off

M. PC shall run strictly offline

3.2.6.2 Programming Screen.

The programmer shall be capable of viewing and editing programs on the operator interface while viewing the peening chamber. This can be accomplished in different ways, including having the operator computer screen and keyboard swing from the operator station around the machine to the peening chamber, or providing a secondary programming screen near the peening chamber.

The programming screen shall be designed to meet or exceed the following characteristics:

A. The screen(s) used to program the nozzle position with relation to the parts shall be positioned near the peening chamber and service door used for programing and observing part programs and is available at the load/unload station for operation.

B. If a single screen shall be used, the programing screen shall be set up on a robust positioning mount to allow it to rotate to either side of the machine or otherwise configured to easily be able to be used at the operator station and programing location.

C. As a safety precaution the system shall be designed such that when the programming screen is not in the part loading/unloading station location no air pressure or media will flow through the nozzles.

3.2.6.3 Operator Interface System.

The operator interface system shall be used to display process control data information during a shot peen cycle.

This system shall be used to look at current/triggered alarms of a cycle, viewing and editing part programs, part identification page, reports from past peening cycles and any other important process control data from current or previous cycles.

The operator interface system shall be designed to meet or exceed the following characteristics:

A. The operator interface shall display all process instructions including, but not limited to:

a. nozzle movement

b. dwell time

c. total cycle time

d. media selection

e. air pressure

f. media flow

g. program number

h. any other information as required by other sections

B. The equipment shall shut the process down when required parameter limits are exceeded.

C. The operator interface shall be responsible for axes motion programming, full process control, process monitoring, and process/systems diagnostics ability.

D. The operator interface shall have an extensive diagnostic capability including but not limited to:

a. Help messages for all parameters shown on the display screens

b. Information on the limits and operations of a parameter

c. Information about displayed/active alarms

d. Machine and system alarm conditions, such as equipment malfunctions, shall also be supported by alarm and diagnostic messages

E. Necessary support services and peripheral equipment shall also be linked to the operator interface including, but not limited to:

a. Media probes

b. Manga Flow Controller

c. Proportion Air Pressure Transducer

d. Fanuc CNC Controller

F. Operator interface system shall have no input lag, and take less than 1s to implement inputs including, but not limited to:

a. making program selections

b. editing programing

c. changing the view of active process parameters

d. Setting new set points or alarm limits

3.2.6.3.1 Part Identification Page.

A part identification page shall be provided to allow the operator to easily locate and select which part to process.

The part identification page shall be designed to meet or exceed the following characteristics:

A. The user shall be able to enter a known part number or display a sortable list of all entered/programmed parts.

B. Along with each part recorded in the system, a minimum of 4 part pictures

(entered by the customer) per part program shall be available to aid in selecting the correct program for each part.

C. Documentation such as nozzle selection, setup description, fixturing requirements, and user specific data shall also be shown on the part identification screen.

D. The Serial Number of the part(s) must be entered into this screen in order to authorize a program run, and stored with the part information and operation parameters in the part tracking database.

3.2.6.3.2 CNC Programs.

The operator interface will be used to select, view and edit the CNC programs.

The CNC programs shall be designed to meet or exceed the following characteristics:

A. Programs shall be written by the programmer on the PC interface using G-code programming language.

B. When a part is selected by the operator, the associated part program shall automatically be sent to the CNC and made active.

C. Each part program must have a minimum of twelve (12) optional motion control or process functions that can be defined. This feature shall be used when certain areas of the part need to be processed and for Almen test locations to be run on the same program.

D. The operator shall be able to select each function required. This data shall then be passed to the CNC which will only perform the selected functions/areas.

E. Process set points and process actual values shall be displayed in an easy-to-read format on a monitor screen.

F. When the programmer enters a parameter inconsistent with the process or not within the range of a…