Final Purchase Spec Dated 25 May 2010 Amendment 0001.doc

25 May, 2010

PURCHASE SPECIFICATION DOCUMENT (PSD)

FOR THE

DEVELOPMENT OF TWO (2) GANTRY SYSTEMS

FOR THE OOALC SYSTEM INTEGRATION LAB (SIL)

25 May, 2010 Prepared By

Ogden Air Logistics Center (OO-ALC)

F-16 OFP Development, Test Station Support Branch (519th SMXS/MDEB)

Hill Air Force Base, Utah 84056-5826

TABLE OF CONTENTSPRIVATE

31.

GENERAL OBJECTIVES:

1.1 Purpose:

1.2 Responsibility:

2.

GANTRY SYSTEM OVERVIEW:

2.1 Scope of Work:

2.2 Gantry Systems Development, Installation and On-Site Systems Integration Milestones/Timeline:

3.

Gantry System Illustrations 3.1 Gantry System Location 3.2 Gantry System Drawings 4.

Gantry System Technical Specifications 4.1 General Items 4.2 System Specifications:

5.

Off-Site Construction/On-Site Installation:

6.

On-Site Training 7.

Gantry System Acceptance Testing

TABLE OF FIGURES

5Figure 3‑1 Gantry System Inside of Chamber (Mock-Up)

6Figure 3‑2 Gantry Viewed From the Front

6Figure 3‑3 Gantry Viewed From the Top

7Figure 3‑4 Gantry Three Dimensional Front and Side View

8Figure 3‑5 Gantry Viewed From the Bottom

8Figure 3‑6 Gantry Front View with Nominal Dimensions (inches)

8Figure 3‑7 Gantry Side View with Nominal Dimensions (inches)

9Figure 3‑8 Gantry Viewed from the Bottom with Nominal Dimensions (inches)

9Figure 3‑9 Gantry System Servo Motor and Sensor Location

9Figure 3‑10 Gantry System Servo Motor and Sensor Location Legend

1. GENERAL OBJECTIVES:

To construct and install two (2) gantry systems in the OO-ALC System Integration Lab (SIL), at Hill Air Force Base (AFB), in support of the F-16 C/D software development effort. Both gantry systems shall be constructed off-site at contractor/vendor facilities with on-site incidental assembly and installation services. Each gantry system shall be software controlled, and will be used with the Integration Test Stations (ITS) to support development and test of the F-16 C/D Operational Flight Programs (OFPs).

1.1 Purpose:

The purpose of this Purchase Specification Document (PSD) is to specify the scope of requirements for the construction and installation of the gantry systems.

1.2 Responsibility:

Use best commercial practices, documentation and standards, except as noted, in the performance of the requirements outlined in this PSD. The management procedures utilized to satisfy the requirements of the contract are the sole responsibility of the contractor.

GANTRY SYSTEM OVERVIEW:

1.3 Scope of Work:

The contractor shall supply labor, materials, engineering, equipment, tools, and supplies required to design, engineer, fabricate, ship, install and verify design of two (2) gantry systems. All mechanical/moving parts associated with the gantry systems shall be warranted for a minimum 12 month period from construction completion date.

1.4 Gantry Systems Development, Installation and On-Site Systems Integration Milestones/Timeline:

Gantry systems development, installation and on-site systems integration timeline shall not exceed 20 weeks. Upon contract award the contractor shall comply with the following development milestones:

· Design Kick-off Review – The contractor shall be expected to hold a design kick-off review (on-site at OO-ALC) within the first 2 weeks of contract award. At this meeting the contractor shall work out all initial gantry development details with the OO-ALC.

· Approved Design Specifications – The contractor shall allow for four weeks to produce the gantry system design specifications and drawings. The four week timeline shall begin upon completion of the Design Kick-off Review. During this design period the contractor shall be expected to consult frequently with OO-ALC engineers. The contractor shall begin actual gantry system development ONLY after design approval by OO-ALC engineers.

· Complete Work, Package and Ship – Once approved design specifications are in hand, the contractor shall have a period of 11 weeks to complete work, package, and ship both gantry systems to the OO-ALC.

· Installation and On-Site System Integration/Training – The contractor shall allow for a period of 3 weeks for system installation/integration and training. Training shall only occur after the final acceptance test.

2. Gantry System Illustrations

2.1 Gantry System Location

Each of the gantry systems shall be located inside of a separate chamber. A mock up of the desired gantry system location is shown in the following picture. The chamber is shown in grey, with the gantry system inside. The rooms themselves have reinforced concrete flooring and are located on the second floor. Due to the room location, there are weight considerations which will be explicitly specified at the Design Kick-off Review.

2.2 Gantry System Drawings

The following is a series of drawings, which show different viewpoints of the expected gantry system. All dimension values shown are nominal.

Figure 3‑4 Gantry Three Dimensional Front and Side View

Figure 3‑5 Gantry Viewed From the Bottom

Figure 3‑6 Gantry Front View with Nominal Dimensions (inches)

Figure 3‑7 Gantry Side View with Nominal Dimensions (inches)

Figure 3‑8 Gantry Viewed from the Bottom with Nominal Dimensions (inches)

Figure 3‑9 Gantry System Servo Motor and Sensor Location

Figure 3‑10 Gantry System Servo Motor and Sensor Location Legend

Servo Motor Locations

Sensor Locations

3. Gantry System Technical Specifications

3.1 General Items

· Vendor shall provide a complete and thorough Operations Manual for the gantry system, which shall fully describe (at a procedural level) all operational aspects of the gantry system.

· Vendor shall provide complete drawings of the gantry system in DXF or Solidworks format. The preferred format is Solidworks.

· Vendor shall program all controllers and servo drivers.

· Vendor shall provide/release all firmware/software images.

· Vendor shall provide/release source code for all firmware/software, if possible.

· Vendor shall provide a Software Requirements Document (SRD)/Programmers Manual for all firmware/software. Vendors SRD shall meet this requirement if available.

· Vendor shall provide detailed compilation and loading procedures for firmware/software.

· Vendor shall provide a Hardware Software Interface Document (HSID) for the controllers and servo drivers. Vendors HSID shall meet this requirement if available.

· All electronics shall meet or exceed Conformité Européenne (CE) testing and Federal Communications Commission (FCC) regulations to avoid interference.

3.2 System Specifications:

· Each of the two (2) gantry systems shall be identical in design and development.

· The gantry system shall have four (4) axes (two (2) horizontal and two (2) vertical). All the axes shall be linear and all shall be servo controlled. Reference Figure 3‑9.

· The gantry system shall be anchored by three (3) vertical stanchions, which will sit on three (3) solid base plates. Adjustment capabilities for the stanchions and base plates shall be provided with assembly. Reference Figure 3‑9.

· Each of the three (3) base plates shall be bolted to the existing concrete flooring. Coordination with facilities engineers shall be required for this task, with initial coordination conversations taking place at the Design Kick-off review.

· The entire gantry system shall be isolated from ground.

· The three vertical stanchions of the gantry system shall be connected to two sets of parallel horizontal rails. The rail sets themselves shall be secured to the stanchions and immovable (horizontally or vertically).

· One of the horizontal rails shall be a follower rail, with the second horizontal rail having a linear drive system. The horizontal rails used shall be Parker’s HLE’Z or equivalent.

· Connected to the standard carriages of the two parallel sets of horizontal rails shall be two individual vertical rails. The standard carriages of each horizontal rail set shall be programmable to move the attached vertical rails horizontally, independent of each other. For purposes of this document, the movements of the two vertical rails on the two parallel horizontal axes are called X1 and X2.

· The X1 and X2 movement shall be controlled by two (2) separate Parker Gemini servo drivers and shall have part number CP*GV-U12E-14516.

· The servo drivers shall control 2 separate servo motors. The servo motors used shall be J092 3 Step Servo Motors or equivalent. Reference Figure 3‑9 for suggested servo motor location.

· There shall be six (6) limit/home sensors used on the X1 and X2 movement. Reference Figure 3‑9 for suggested sensor location.

· Each vertical rail shall have a ball screw drive system. Each of the ball screw drive systems shall be able to move a payload vertically on each vertical rail, independent of each other. For purposes of this document, the movements of the vertical payloads on the vertical axis are called Z1 and Z2.

· The vertical rails used shall be Parker 406XR Ball Screw square rail driven petitioners, or equivalent.

· The Z1 and Z2 movement shall be controlled by two (2) separate Parker Gemini servo drivers and shall have part number CP*GV-U12E-14516.

· The servo drivers shall control two (2) separate servo motors. The servo motors used shall be J092 3 Step Servo Motors or equivalent. Reference Figure 3‑9 for suggested servo motor location.

· There shall be six (6) limit/home sensors used on the Z1 and Z2 movement. Reference Figure 3‑9 for suggested sensor location.

· The mechanism/capability to attach a payload to the system shall not be complex.

· The mass/weight handling capacity of the system shall be for multiple 25lbs. payloads which shall move independently.

· All gantry system elements shall be able to withstand industrial grade automation applications.

· The Center of Gravity (CG) of the mass shall be centered on the system.

· All of the motors shall be mounted at 12 (O’clock) orientations.

· The motion controller used for the system shall be the Parker 6K8 controller and shall have part number CP*6K8-14517.

· The feedback and power cables between the four (4) Parker Gemini servo drivers and stepper motors shall be an appropriate length.

· All of the motion sensors (Shown in Figure 3‑9) shall be routed from the gantry to separate terminal blocks, which shall then route their signals to four (4) separate VM25 I/O modules. One for each axis of motion.

· The feedback and power cables between the motion sensors and terminal blocks shall be an appropriate length.

· The VM25 I/O modules shall be routed to the Parker 6K8 controller.

· The Parker 6K8 controller shall be routed to the four (4) separate Parker Gemini Servo Drivers. One for each axis of motion.

· The contractor shall provide all controller cables, USB/Ethernet programming cables and command cables between the Parker Gemini servo drives and the Parker 6K8 controller.

· There shall be a cable carrier assembly for the X and Z axis to ensure that all cables are dressed appropriately and that no movement interference occurs.

· The input power to the gantry system shall be appropriate to run the automation equipment.

· All power specifications/needs for the system should be specified by the contractor at Design Kick-off Review, and will be made available to the system upon installation.

· Push buttons, 65 A contactors and auxiliary contacts shall be used where appropriate in the gantry system.

· EMC line filters shall be used when providing power to gantry system components.

· All external (to the gantry) components shall be located in a separate enclosure cabinet, which shall be located at a maximum distance of 60 feet from the gantry system. All cables routed from the gantry system to the enclosure cabinet should be able to accommodate the maximum distance.

· An emergency shut-off switch for the system shall be attached externally to the enclosure cabinet.

· The enclosure cabinet shall have a standard locking mechanism.

· The external enclosure cabinet shall contain, but is not limited to the following:

· Parker 6K8 Controller

· Parker Gemini Servo Drivers

· Terminal Blocks

· VM25 I/O modules

· Appropriate power supply system

· Push buttons, 65 A contactor and auxiliary contacts

· EMC line filter, fuse holders and accessories.

3.2.1 Horizontal Axis (X1 and X2)

· Each horizontal axis (X1 and X2) shall only be able to travel between the outside stanchion and the central stanchion (shown as “½ travel” in drawings).

· The X1 and X2 horizontal axis shall not cross each other and shall meet over the central stanchion.

· The X1 and X2 horizontal axis shall not be able to move past the outer stanchions, which shall be controlled by two (2) limit sensors for each axis. Reference Figure 3‑9.

· Each X1 and X2 horizontal axis shall have homing sensors, as shown in Figure 3‑9.

· The X1 and X2 horizontal axis shall be designed to move/position themselves at velocity of 5 meters/sec.

· The X1 and X2 horizontal axis shall have a repeatable positional granularity of +/- 25 microns.

· Each X1 and X2 axis shall be controlled by a Parker Gemini servo driver. The Parker Gemini servo driver used shall have part number CP*GV-U12E-14516.

· The servo drivers shall control 2 separate servo motors. The servo motors used shall be J092 3 Step Servo Motors or equivalent. Reference Figure 3‑9 for suggested servo motor location.

3.2.2 Vertical Axis (Z1 and Z2)

· Each vertical axis (Z1 and Z2) shall be able to travel the full length of each vertical rail and shall move independently of each other.

· The Z1 and Z2 axis shall not be able to outside of the upper and lower limits, which shall be controlled by four (4) limit sensors (two on each axis). Reference Figure 3‑9.

· Each Z1 and Z2 axis shall have homing sensors, as shown in Figure 3‑9.

· The Z1 and Z2 axis shall be designed to move/position themselves at velocity of 5 meters/sec.

· The Z1 and Z2 axis shall be have a repeatable positional granularity of +/- 0.1 mm.

· Each Z1 and Z2 axis shall be controlled by a Parker Gemini servo driver. The Parker Gemini servo driver used, shall be part number CP*GV-U12E-14516.

· The servo drivers shall control 2 separate servo motors. The servo motors used shall be J092 3 Step Servo Motors or equivalent. Reference Figure 3‑9 for suggested servo motor location.

4. Off-Site Construction/On-Site Installation:

The gantry system construction shall occur off-site and be modular in design. On-site installation systems integration and startup assistance for the gantry system shall be provided and performed by experienced and trained personnel. All personnel shall follow all applicable safety and work rules while on site and maintain constant coordination with the appropriate customer personnel throughout execution of the project. All onsite installation activities shall be conducted during normal business hours (8 AM to 5 PM). Onsite installation team supervision and/or project management shall be an integral part of the project. Design changes or scope of supply changes shall be discussed on a case-by-case-basis.

5. On-Site Training On-site training for operation, maintenance and engineering personnel shall be provided and performed by experienced and trained personnel. Contractor shall plan for a full week (40 hours) of training. Contractor shall also plan for a training audience of 10 personnel, consisting of operation, maintenance and engineering personnel.

6. Gantry System Acceptance Testing

Upon completion of the gantry system the contractor shall demonstrate the following:

· Ensure that gantry system is fully software controllable. This shall be shown by contractor test software.

· Ensure that all velocity, movement and response requirements have been met.

· Ensure that all proximity sensors are operating correctly and strict axis movement limitations have been met.

· Ensure that all axis movement is free of any obstructions.

Figure � STYLEREF 1 \s �3��� SEQ Figure \* ARABIC \s 1 �3� Gantry Viewed From the Top

Figure � STYLEREF 1 \s �3��� SEQ Figure \* ARABIC \s 1 �2� Gantry Viewed From the Front

Figure � STYLEREF 1 \s �3��� SEQ Figure \* ARABIC \s 1 �1� Gantry System Inside of Chamber (Mock-Up)

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