VLM Specification

APPENDIX A

FOR

VERTICAL LIFT MODULES

AT

HILL AIR FORCE BASE, UTAH

BUILDING 843

CSN: LHL0A4

DATE: 9 April 2012

PREPARED BY:

RONALD D. PARSONS

PROJECT ENGINEER

403 SCMS/GUEC

ROBIN BARRACLOUGH

Program Management/ Reviewer

OO-ALC/SCPD

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Hill AFB, Appendix A - Page i

TABLE OF CONTENTS

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

3.2.2. STRUCTURE

3.2.3. DEFORMATION

3.2.4. EXTRACTOR

3.2.4.1. EXTRACTOR CHAIN SAFETY FACTOR

3.2.4.2. EXTRACTOR TRAY SENSORS

3.2.4.3. EXTRACTOR LOADING

3.2.4.4. EXTRACTOR FREE FALL

3.2.4.5. EXTRACTOR CALIBRATION

3.2.5. TRAYS

3.2.5.1. TRAY CONSTRUCTION

3.2.5.2. TRAY DIMENSIONS

3.2.5.3. TRAY CAPACITY

3.2.5.4. TRAY MARKINGS

3.2.5.5. TRAY PARTITIONS

3.2.5.6. TRAY CROSSWISE DIVIDERS

3.2.6. STORAGE LOCATIONS

3.2.7. STORAGE WINDOW

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

3.2.8.2. MAINTENANCE SERVICE PANEL

3.2.9. MAINTENANCE ACCESS

3.2.10. SERVICE LIFE

3.2.11. DRIVE COMPONENTS

3.2.11.1. MOTORS

3.2.11.2. GEAR REDUCERS

3.2.12. CONTROLS

3.2.13. OBSTRUCTION SENSORS

3.2.13.1. LOAD HEIGHT SENSORS

3.2.14. LIGHTING

3.2.15. FIRE SUPPRESSION

3.2.16. SECURITY DOOR

3.2.17. SOFTWARE CONTROLS

3.2.17.1. OPTIMIZED TRAY PLACEMENT

3.2.17.2. TOOL ACCOUNTABILITY SYSTEM COMPATIBLE

3.2.17.3. RS232 PORT

Hill AFB, Appendix A - Page ii

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

4.2. TESTS

4.3. CERTIFICATIONS

Hill AFB, App A - Page 1 of 10

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for five vertical lift modules (VLMs) for the 309 th Maintenance Group, Building 843, at Hill Air Force Base, (AFB) Utah. The work shall be completed in accordance with this appendix, the cover purchase description (PD), and Air Force (AF) Drawing LHL0A4-01.

This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.2. DEFINITIONS

Extractor - A fabricated metal structure attached to lift mechanism used to insert, extract and transport trays between storage locations and the pick window.

Tray live load capacity - Actual amount of load supported by a tray, not including the weight of the tray

Tray - A container in which items are stored

Unit - Vertical Lift Module

Depth - Measurement from front to back when looking at the front of the unit

Storage positions - The number of tray storage areas available within a Vertical Lift Module.

Width - Measurement from side to side when looking at the front of the unit.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the

Cover PD.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The Contractor shall provide five VLMs which shall store and allow retrial of individual small to medium sized parts and tools. Personnel shall retrieve parts or tools by entering a

Hill AFB, App A - Page 2 of 10 part number into the MPS Material Processing System. The VLM shall then respond to the appropriate MPS command to retrieve the part or tool and place it at the storage window. This also applies to tool binning actions. The VLM shall consist of the following:

a. Extractor

b. Trays

c. Storage locations

d. Storage window

e. Controls

f. Conduit, wiring, mechanical fasteners and all other items required to install an operational VLM system.

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

The external dimensions of each vertical lift module shall be a nominal 125 + 6 inches deep and 160 + 6 inches wide. The

Contractor shall provide vertical lift modules, which are a minimum of 288 + 6 inches high. All VLMs shall be the same height.

3.2.2. STRUCTURE

The VLM shall have a steel framework which supports the fully loaded system without the use of the enclosure panels. The VLM shall be securely anchored to the floor in a manner that unit distortion will be minimized. The VLM shall be designed such that the weight of a fully loaded unit shall be distributed over the warehouse floor with a maximum live load capacity of 250 pounds per square foot.

3.2.3. DEFORMATION

No VLM structural member shall exhibit elastic deformation greater than 0.10 percent of the distance between the ends of the member when loaded to capacity. No portion of the VLM shall exhibit permanent deformation.

Hill AFB, App A - Page 3 of 10

3.2.4. EXTRACTOR

The extractor shall be used to insert, extract and transport trays between storage locations and the storage window.

3.2.4.1. EXTRACTOR SAFETY FACTOR

Each extractor lift mechanism shall have a minimum 6 to 1 safety factor based on yield strength.

3.2.4.2. EXTRACTOR TRAY SENSORS

Sensors shall be used to ensure that trays being stored or retrieved are loaded onto or off of the extractor in such a manner that the extractor will not move vertically unless the tray being stored or retrieved is outside of the movement envelope of the extractor.

3.2.4.3. EXTRACTOR LOADING

The extractor shall be capable of supporting the live load capacity of a tray loaded to capacity. Uneven loading shall have no effect on extractor speed or effectiveness.

3.2.4.4. EXTRACTOR FREE FALL

The extractor shall be prevented from falling in a manner such that it or tray contents will be damaged in any event, including power failure.

3.2.4.5. EXTRACTOR CALIBRATION

The extractor shall automatically calibrate its location as necessary to ensure continuously accurate storage and retrieval of trays. The extractor shall be easily recalibrated if the tray locations are changed or if the unit loses electrical power.

3.2.5. TRAYS

The number of trays per VLM shall be maximized, but at a minimum contain 43 trays.

3.2.5.1. TRAY CONSTRUCTION

All trays shall be solid to provide continuous support for the capacity listed in 3.2.5.3.

Hill AFB, App A - Page 4 of 10

3.2.5.2. TRAY DIMENSIONS

The minimum depth of each carrier shall be 39 +1,-0 inches. The minimum width of each carrier shall be 144 +2,-0 inches. The height of all tray side walls shall be 5 +1, -0 inch walls around the premier of the tray.

3.2.5.3. TRAY CAPACITY

Each tray shall have a minimum live load capacity of 1,000 pounds with no deformation greater than .01 percent.

3.2.5.4. TRAY MARKINGS

Each tray shall be marked with its associated number beginning with number "1" and progressing through all the trays of the

VLM. The number shall be contrasting to the tray color and shall be located in a position which is visible to personnel, on a fully loaded tray. The labels shall be located such that normal operations do not damage the labels. The numbers shall be permanently affixed to the trays.

3.2.5.5. TRAY PARTITIONS

N/A

3.2.5.6. TRAY CROSSWISE DIVIDERS

N/A

3.2.6. STORAGE LOCATIONS

Metal storage locations shall be used to store trays. The storage locations shall allow tray placement on a maximum of 2 inch centers. Storage locations shall be maximized. The storage locations shall enable safe storage of trays loaded to maximum capacity without deformation of the storage location materials.

3.2.7. STORAGE WINDOW

The storage window width shall be the width of the tray plus a minimum of 1 inch. The lower edge of the storage window shall be located between 36 + 6 inches from the floor. The storage window shall be located on the front of the VLM.

Hill AFB, App A - Page 5 of 10

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

Outer surfaces of each VLM shall have bolted solid metal enclosures for security. The enclosures shall be bolted from the outside to permit removal for maintenance, shelf adjustment or emergency access. A solid metal enclosure shall be installed to enclose the top of each VLM.

3.2.8.2. MAINTENANCE SERVICE PANEL

A removable or hinged service panel shall provide for maintenance access to operating parts such as motors, brakes, and reducers. The panel shall be equipped with safety interlock switches to prevent the unit from operating when the service panel is open. The bottom of the service panel shall be located a minimum of 18 + 3 inches above the floor.

3.2.9. MAINTENANCE ACCESS

All parts requiring periodic maintenance shall be easily accessible.

3.2.10. SERVICE LIFE

All equipment furnished shall be new and shall be of high quality to ensure that the completed system is designed to last a minimum of 30 years.

3.2.11. DRIVE COMPONENTS

3.2.11.1. MOTORS

Motors shall be of sufficient size for a 40 FPM minimum retrieve/store time for continuous duty to be performed and shall not exceed their full-rated load when the driven equipment is operating at the specified maximum capacity under the most severe conditions likely to be encountered. All motors shall be designed for continuous duty at ambient temperature, 50 to 90 degrees Fahrenheit. Motors shall be drip proof and shall be designed to operate on 230 VAC, 40 Amp, 3 phase electrical power. Motors shall have an electronically controlled soft start and stop and shall be equipped with an overload device.

Motors shall be located at the bottom of the VLM to provide safe and easy access for service and maintenance.

3.2.11.2. GEAR REDUCERS

Hill AFB, App A - Page 6 of 10

Gear reducers shall not permit oil to leak. The maximum input horsepower rating of the gear reducer shall not be less than the horsepower of the attached drive motor. Motor and reducer frames shall be compatible.

3.2.12. CONTROLS

The VLMs shall have a permanent control cluster that is either the push button or membrane type. The control cluster shall be located above the storage opening or on a swivel arm and shall be no higher than 42 inches from the floor. As a minimum, the control cluster shall contain an alpha numeric keypad for inputting a part number, a button to clear an incorrect part number, a button to activate movement of the extractor, and an emergency stop button. The control cluster above the storage opening shall have a visual display which shall indicate the current tray number. The VLM shall have an "on/off" key lock switch to control the unit's electrical power.

3.2.13. OBSTRUCTION SENSORS

Sensors shall be mounted on the VLM at the storage window to stop the movement of the extractor if an object extends through the plane of the opening or the extractor movement area. If this condition occurs, the storage procedure shall be aborted and an error message shall be transmitted audibly to the operator and visually displayed on the control panel.

3.2.13.1. LOAD HEIGHT SENSORS

Sensors shall be mounted in the storage window to measure the height of a load. This information shall be used by the unit controller to determine the storage location and ensure there is adequate height in the unit to store the load. If there is not adequate height to store the load, the storage procedure shall be aborted and an error message shall be transmitted audibly to the operator and visually displayed on the control panel.

3.2.14. LIGHTING

The VLM shall have overhead lighting, which shall measure not less than 50 foot-candles at the storage access opening. The lighting shall be continuous along the length of the access opening.

Hill AFB, App A - Page 7 of 10

3.2.15. FIRE SUPPRESSION

Two sprinkler heads shall be installed at the top of each VLM.

The sprinkler heads and piping shall be designed to provide a minimum of 18 GPM. Piping for VLMs located side-by-side shall utilize the same piping. Fire suppression drawings and calculations shall be provided and approved before installation of the VLMs is started. Drawings shall show an installation diagram and connection point to existing fire suppression system. Contractor is responsible for conducting flow tests to determine design base point and flow and pressure testing after installation is complete. Contractor is responsible for installation of complete fire suppression system.

3.2.16. SECURITY DOOR

A lockable security door shall be provided to enclose the pick window opening when the vertical storage unit is not in use.

When closed, the door shall prevent access to the material inside the unit. It shall be of sufficient strength and durability such that extraordinary means are required to gain access to the storage column when the door is closed. The security door shall be lockable using a key lock. A minimum of two sets of keys shall be provided for each lock. The door shall be an integral part of the storage column unit and shall allow unobstructed access to the storage column pick window when not in use.

3.2.17. SOFTWARE CONTROLS

3.2.17.1. OPTIMIZED TRAY PLACEMENT

Each time a tray enters the VLM from the access opening, the height of the product being stored shall be measured. The measured height shall be used to determine the optimal storage location for the tray.

3.2.17.2. TOOL ACCOUNTABILITY SYSTEM COMPATIBLE

The VLM shall accept retrieve and store commands from MPS

Material Processing System.

3.2.17.3. RS232 PORT

The controller shall be a command driven interface with asynchronous responses communicating through an ASCII RS232C 9 pin connection. Pan positioning will be directed from Air Force

Hill AFB, App A - Page 8 of 10 automation control host system MPS/D230 using ASCII commands.

The controller shall respond when commands are completed and not require continuous polling to determine completion status.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the cover purchase description. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TESTS

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Paragraph Description

1. 3.1.

An acceptance test of 2 hours shall be made on the VLM. This test shall demonstrate the reliability as specified in the cover PD

("RELIABILITY/AVAILABILITY"). Each tray shall be loaded as determined in this appendix ("TRAY

CAPACITY") with Contractor supplied test loads.

All trays shall be called randomly during the test. If this test shows that the installation is defective in any respect or does not comply with this appendix and the Cover PD, the

Contractor shall immediately make the changes necessary to correct all defects to the satisfaction of the Contracting Officer’s

Representative (COR) prior to acceptance. The system shall be operational at least 95 percent of the test period.

Hill AFB, App A - Page 9 of 10

2. 3.2.3. Deformation shall be tested to determine if the storage trays exhibit plastic deformation. The distance from the midpoint of the bottom of the selected tray shall be measured and recorded as

M1. The tray will then be loaded to capacity and left for a minimum of four hours. After four hours, the tray will be unloaded and the distance between the two points where M1 was measured shall be measured and recorded as M2.

The following formula shall be used to determine the deformation:

(M1 - M2) / Usable width of tray * 100 =

Percent Deformation

If permanent deformation is recorded, then the trays shall fail the test. After all loads are removed, the trays shall be examined for permanent deformation. If permanent deformation has occurred, the trays shall fail the test.

3. 3.2.4.3., 3.2.13.

All safety interlock switches, sensors, touch bars, and stop buttons shall be tested to ensure that they are completely operational.

4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.2.2. The Contractor shall certify that the weight of the fully loaded VLM is adequately distributed to not exceed the capacity of the floor as specified.

2. 3.2.4.1. The Contractor shall certify that all extractor support mechanisms have a minimum 6-to-1 safety factor based on yield strength.

3. 3.2.10. The Contractor shall certify that the Vertical

Lift Modules are designed to function a minimum of 15 years or longer.

Hill AFB, App A - Page 10 of 10

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TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

VERTICAL LIFT MODULES

Offeror:

Solicitation Number:

Project Title: Vertical Lift Modules

Base: Hill AFB, Utah CSN: LHL0A4

Appendix A, Vertical Lift Module, 20 March, 2012

This questionnaire shall be completed by the Offeror. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment.

Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the

Purchase Description Appendix or recommendations/design alternatives as detailed below.

VLM Manufacturer: _________________________

Model Number: ________________________________________________

Paragraph Characteristics

3.1. Number of Vertical Lift Modules to be

provided:______

3.2.1. Unit dimensions:

Depth: ______ inches

Width: _____ inches

Height: _____ inches

3.2.2. Floor loading when unit is loaded to maximum

capacity: ______ pounds per square foot.

3.2.7. Storage opening:

Width _________ inches

Height ________ inches

Height of bottom edge of pick opening from the floor _______ inches

3.2.6. Storage location adjustability: ____ inch centers.

3.2.6. Number of storage locations ______ per VLM.

TPQ for Appendix A, Hill AFB - Page 2 of 4

3.2.4.1. Extractor lift mechanism safety factor: ______ to

3.2.4.2. Will the extractor move vertically only after the

tray being stored is outside the movement envelope of the extractor? YES NO

3.2.4.3. Extractor load capacity: _______ pounds

3.2.4.4. Is extractor free fall prevented? YES NO

3.2.4.5. Will the extractor automatically calibrate its

location as necessary? YES NO

3.2.5. How many trays are provided? ______

3.2.5.2. Tray dimensions:

Width: ______ inches

Depth: ______ inches

Wall height: ______ inches

3.2.5.3. Tray capacity: ______ pounds

3.2.5.5. N/A

3.2.5.6. N/A

3.2.8.1. Are the outer metal surfaces of the VLM bolted to

the column? YES NO

3.2.8.2. Is a removable or hinged service panel provided

which allows access to operating parts as necessary? YES NO

3.2.9. Is the maintenance access panel equipped with

safety interlock switches to prevent the unit from operating when the service panel is open?

YES NO

3.2.9. Are all the parts requiring periodic maintenance

easily accessible? YES NO

3.2.11.1. Motor ambient temperature operating range: ______

to ______° F

TPQ for Appendix A, Hill AFB - Page 3 of 4

3.2.11.1. Do the motors have electronically controlled soft

start and stop? YES NO

3.2.11.1. Are the motors equipped with an overload device?

3.2.11.1 What is the platform lift speed at 1000 load not

including tray weight?

3.2.11.1. Where are the motors located? ____________________

3.2.13.1. Are height sensors provided? YES NO

3.2.13.1. Will the extractor abort operation if an object

extends into its movement envelope?

3.2.14. Illumination level of lighting along the length of

the storage opening: ______ foot candles

3.2.15. How many sprinklers head are provided inside each

VLM? ___

3.2.16. Number of keys provided for security door: _______

TPQ for Appendix A, Hill AFB - Page 4 of 4

EXCEPTIONS/RECOMMENDATIONS/DESIGN ALTERNATIVES

Attach any exceptions taken to the Purchase Description

Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken? YES NO

Number of pages attached: ____________________________________

We have read the requirements of the Purchase Description

Appendix and will comply with all paragraphs as written, with exceptions taken only to those items indicated on the attached exception sheet.

Offeror's Signature Date

TYPED NAME:

COMPANY NAME:

ADDRESS:

PHONE:

FAX: