Tech Spec Ultrasonic 20110105.docx

Purchase Specifications Computer Controlled Ultrasonic Scanner

5 October 2010

Prepared by:

John Cope, Supervisor Advanced Composites NDI Element 809 Maintenance Support Group

1. Introduction:

The primary mission of the Advanced Composites Non-Destructive Inspection (NDI) Element at Ogden Air Logistics Center is to provide critical inspections of U.S. Air Force Weapons Systems. To accomplish this mission a number of separate, but complimentary NDI Systems are required. To maintain and to increase performance it is also required to periodically replace old or obsolete systems. Replacing the old or outdated equipment with Modern updated technology will enhance flaw detection capability and increase supportability.

2. OVERVIEW

The objective is to replace an aging unsupportable Ultrasonic scanner with a more modern State of the Art Robotic scanner. This would allow for increased motion control and sensitivity for complex shaped parts. The new system will be capable of collecting data in the form of “Through Transmission” and Pulse Echo, Time of Flight and Amplitude Data from both sides, simultaneously. Computer processing would allow for use of advanced data trending and data mining for the new Aircraft just coming into service. This system will be installed in place of an antiquated Ultrasonic scanner. This equipment will be installed in an industrial environment and should be capable of operating in this environment. A control room with climate controls for housing the computers and operators shall be considered part of this system. The current control room shall be used to house the system. Image processing and accurate coordinated measuring shall be integrated into the operating system. All inspection data will be capable of being stored in a common digital format to facilitate communication with engineering and other data collection systems to include, DICONDE.

3. CAPABILITIES : AS a Minimum

a. Design, deliver, install, operationally check and provide both operational and fundamental maintenance training for the following equipment.

b. Minimum of Seven –Axis scanning capability which can be programmable by the inspector thru use of a common format Windows based Operating system.

c. The system shall have at least 130 db of useful through transmission amplification. The means for amplification above system standard gain shall be by separate or additional high power pulser, not gain amplification. The system shall be furnished with a high power square wave or tone burst pulser, minimum 600 V p-p, switchable from, or integrated with the standard pulser for highly attenuative parts.

d. Transducers: The system shall be furnished with five sets for TTU and PE application as follows. 5 MHz, 0.75 inch diameter standard power, 2.25 MHz, 0.75 inch Dia., standard power, 1 MHz, 0.75 inch Dia., standard and high power, and .5 MHz, 0.75 inch Dia. High power. All with water collimators for adjustable variables for .25”, .375”, and .50”.

e. Full Control of all possible scan parameters and machine variables.

f. Ability to create full 3D image rotation of data with use of A,B,C scan format with full Waveform captured.

g. Network communications with the data acquisition system for scan control synchronization during scan startup and scan error recovery.

h. The ability to stop a scan and return to the scan at a later time such as next shift or next day without loses of location or data.

i. Area specific rescan to be initiated by selecting an area for rescan and not having to rescan the entire part.

j. A return to defect capability to enable defect marking and re-inspection of suspect areas.

k. Full range calibration capability for machine accuracy, machine squareness, and manipulator qualification.

l. Comprehensive transducer qualification for allowing determination of all transducer variables including length and water column variables.

m. A high speed as well as low speed (fine) adjustment of movement.

n. Easy to interpret on screen gating and positioning of X/Y axis factors.

o. Ability to print full scale one to one plots on a 30 inch wide plotter (included) and save to compact disc (CD-DVD). With the ability to scale parts for overlay directly on the part.

p. Review of all data shall be on dual monitors side by side for comparison. These shall be a minimum of 21” widescreen.

q. The inspection envelope area should be 10 feet tall by 20 feet long. To include the guide rail on which the parts holding fixture will align, which exists in the current system.

r. Information shall be transferable to other inspection systems by use of TIFF, Mpeg, Jpg, and Bmp. Formats. Allowing for transfer to Engineering staff and reports. With ample digital storage <2Tb on hard drive, which can be external for storage.

s. The contractor shall supply all tools, materials, personnel, and any other entities necessary to fulfill the requirements of this commodity.

4. Training Requirement

a. Training for at least 4 individuals on the operation and 4 individuals for routine maintenance of all equipment including both hardware and software. Training curriculum and materials will be a deliverable for future training requirements. Training shall be accomplished on the delivered equipment at Hill AFB.

5. Vendor Qualifications

a. All contractor field maintenance technicians shall be factory/manufacturer trained and certified for the specific equipment (make and model) to be installed and provide evidence of such upon request by the Administrative Accounting Officer (ACO) or designated representative. All personnel involved with the installation shall be US Citizens for access to the controlled area.

6. Supplier Quality Requirements

a. Unless otherwise specified the supplier shall maintain traceability records on file available for review by OO-ALC Composites NDI Element.

b. The supplier shall provide a system to ensure control of all documents (supplier furnished drawings, technical documents, manufacturing procedures, inspection and test procedures) for the incorporation of changes.

7. Proposal Evaluation:

a. The proposal evaluation by a procurement team based on submitter’s ability to meet or exceed the following criteria:

i. Technical competency: The system shall be capable of tolerances in accuracy of transducer alignment of

ii. Cost/Value Performance: Previous performance shall be used as a qualifier in determining effectiveness and cost of total system. The Supplier must show evidence of delivering at least 5 systems and successful operation of said units. As well as all previously stated requirements.

iii. Demonstration before acceptance shall be at the suppliers’ facility before delivery to insure performance meets requirements.

iv. Delivery time: Shall be incorporated into determining best value for system selection. 8-10 Month delivery is preferred, if not sooner.

8. Technical Documentation: Should contain details on electrical requirements such as voltages and system needs in order to maintain the equipment after the manufactures warranty expires.

9. Blue Prints: Design prints used to maintain the mechanical operation or repair and perform preventive maintenance on the system. As the system ages these will be needed by the owners engineering staff to maintain the equipment.

10. Acceptance: Will be a test of the equipment to determine its motion control and axis rotation as well as sensitivity of the Ultrasonic sensors and software.

11. User Manuals: A manual that can be used by the user to setup and operate the equipment without having full training by the manufacturer after the initial training is done. It will demonstrate scan planning as well as calibration procedures and system use for the user.

12. MX Manuals: These manuals will be used by the maintenance personnel to determine repair of or trouble shooting of malfunctions. It will also be used to determine preventative maintenance on the system.

13. Parts and Spare Parts: This list will be used to maintain a spare parts inventory for high use or disposable parts that will be needed to keep the system operational. To include transducers or filters and anything the manufacturer suggests having available.