Tech Spec Ultrasonic 20110419.docx

Purchase Specifications Computer Controlled Ultrasonic Scanner

5 October 2010 (Revised 15 April 2010)

1. Scope This specification contains the minimum technical and performance requirements for the design, development, fabrication and assembly of a computer controlled ULTRASONIC SCANNING SYSTEM hereto referred to as “system”. The system will be used mainly, but not limited to, performing automated thru-transmission and pulse echo inspection of aircraft components and other materials at Hill AFB, UT.

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. Description One system shall be provided and it will comply with the general requirements described later in the specification. The system shall consist of all components required to make it a turn key commodity upon delivery; to include: scanning system and all necessary hardware to fully operate the system, and spare parts. Certain services shall be included and will be detailed later in this specification; these include: designed to fit in the location of the current existing scanning system, monthly update briefings, onsite installation, operator training, and local level maintenance training.

4. General Requirements

a. Physical Dimensions

b. The installation and permanent site will be designed to match the current footprint of the system being removed. The inspection scan envelope shall be 10 feet tall x 20 feet long.

c. UNITS of MEASURE

i. The system, controls, indicators, and software shall and or provide U.S. (English) customary units of measurement. The Ultrasonic software shall incorporate metric unit of measure at the discretion of the operator.

d. Warranty

i. The system and all of its components shall come with a five(5) year full system warranty

5. 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 with the ability to create 3D models from CNC points derived from the scan plane

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.

6. Design Review

a. The contractor shall conduct the design review meeting either via teleconference or at the TPM’s facility at Hill AFB to discuss the results of the Government review. The Government may agree to meeting at the contractor’s facility provided that the contractor’s facility is within 20 miles of Hill AFB.

i. Action items shall be generated and tracked to closure by the contractor for each agreed upon design anomaly. The contractor shall record and deliver minutes of the design review meeting.

ii. Preliminary design review due at 25%

iii. Critical design review due at 75%

7. Couplant recirculation system

a. The system shall be equipped with a couplant (water) recirculation system. This includes but not limited to pump, valves, water conditioning, and filtration for the tank which exists in the current location. A water barrier curtain to minimize the overspray of adjacent areas. The barrier shall be transparent and easily moveable for the part and personnel entry into the scanning area.

8. Anti –collision Capability.

a. An anti collision system shall be provided to minimize the possibility of part damage. When the anti-collision sensor is tripped or interrupted any moving part in the scanning area shall cease motion. Any interference must then be corrected before the system can continue. The system shall not be activated except by the operator.

9. Quality

a. The contractor shall develop a Test and Evaluation Plan and shall submit this plan to the Government for its review and approval no later than 45 calendar days after receipt of the contract. The Government will review this plan and return the plan with comments to the contractor no later than 45 days after its receipt by the government. If the comments require corrective action, the Contractor shall submit a revised Test and Evaluation Plan to the Government after receiving the government comment. In turn the government will evaluate the revised plan and provide comments to the contractor within 30 days of the revised plan. The Test and Evaluation plan shall contain as minimum a final acceptance test that is to occur after the system is installed on its permanent location in bldg 238, Hill AFB,UT. (CDRL A001)

b. General test: requirements will be performed by the Contractor. The Contractor shall perform all phases of the testing, providing all personnel, equipment, standards consumable materials, etc. necessary to operate the system and conduct the test at the Contractors facility. The Contractor Shall design the test and describe it in a step by step operation procedure. Any adjustments or modifications to the system after the test have begun, may (at the Governments discretion) require that all tests performed be repeated until all can successfully be passed without any adjustment to the system other than those normally adjusted by the operator from the control panel. (CDRL A002)

c. Final Acceptance Test: The purpose of this test is for the contractor to demonstrate that the system is capable of accurately inspecting the aerospace components currently assigned to Hill AFB. The Contractor shall execute this test in strict accordance with the Government approved plan. The government will witness this test. The contractor shall submit a report to the Government for its review and approval no later than 21 calendar days after the conclusion of the Final Acceptance Test. The Government will review the report and provide comments to the contractor advising him as to the acceptability of this report within 21 days after receipt of this report by the Government. In the event that the Government’s comments indicate that the report is unacceptable as submitted, the Contractor shall then revise the report in accordance with the comments received and shall resubmitted to the Government within 21 days after receipt of the governments comments. The report shall clearly and precisely document the exact procedures used to test the system along with the exact results. Successful competition of the final Acceptance test and the government acceptance of the Final Acceptance test Report shall constitute the final acceptance of the system. The final Acceptance Test shall be performed on the system in Bldg 238 at Hill AFB, UT.

10. Documentation

a. Technical Documentation should include power requirements such as voltages and system requirements in order to maintain the equipment after the manufacturer’s warranty expires.

b. Blue Prints; Design prints used to maintain the mechanical operation or repair and perform preventative maintenance on the system.

c. User manuals: A manual that can be used by the operators to set up and operate the system without having full manufacturers training after initial training is complete It will include scan plan as well as calibration procedures and system use for the user.

d. Maintenance Manuals: These manuals will be used by the maintenance personnel to determine preventative maintenance and troubleshooting malfunctions.

e. Parts and Spares List: The parts list will identify parts which could become worn or disposable parts that need to be kept on hand to prevent down time and keep the system operational. To include transducers filters and any manufactures suggested parts.

f.

11. 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.

b. Training curriculum and materials will be a deliverable for future training requirements. Training shall be accomplished on the delivered equipment at Hill AFB.

c. Government estimated training would last approximately two weeks.

d. Vendor Qualifications

12. Data Rights

a. All materials supplied to the Government shall be the sole property of the Government and may not be used for any other purpose. This right does not abrogate any other Government rights.