Vector_1_PURCHASE_SPECIFICATION.DOCX

DEPARTMENT OF THE AIR FORCE

HILL AIR FORCE BASE, UTAH

PURCHASE DESCRIPTION/SPECIFICATION FOR A

Laser Tube Measurement Machine for Fabrication of Critical Aircraft Components 10 February 2015

Prepared by:

Kent Johnson, phone 801-586-5330 Hill AFB, UT 84056 Table of Contents

1. Scope This purchase specification covers the general design and performance requirements for procurement of a CNC tube-measuring machine with equipment and accessories as described herein. This includes all costs associated with purchase, handling, shipping, installation, training, runoff, testing, and follow-up services as defined in this document.

2. Equipment and Tooling This purchase specification has been written to describe the requirements for a single machine and accessories.

3. Applicable Documents The machine described in this Purchase Specification shall be manufactured in accordance with these documents. The latest dated document shall be the one applicable to this Purchase Specification.

3.1 Government Publications

The following Government documents, drawings, and publications form a part of this Purchase Specification to the extent specified herein:

STANDARDS – FEDERAL

OSHA 1910 General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2011 EDITION

3.2 Other Publications

The following documents form a part of this Purchase Specification. Since the details of the design are proprietary and have not been disclosed at the time this specification was written, it shall be the responsibility of the contractor to ascertain which sections of these standards are applicable to their product and to comply with those requirements. Subsequent references in this purchase specification to these standards shall not be construed as overriding any design feature required elsewhere in these standards. Nor shall such reference be construed to be the only applicable portion of the standard because it was specifically referenced and others were not. The most recent revision of these documents at the time of the issue of this contract shall be considered as binding during the performance of this contract.

ELECTRICAL STANDARDS

NFPA 70 Specification for Electrical system installation.

NFPA 79 Electrical Standard for Industrial Machinery. (2012)

NEMA ICS 6 Enclosures for Industrial Controls and Systems. (R2011)

NEMA 250-2008 Enclosures for Electrical Equipment

NEMA MG 1 Motors and Generators. (2011)

LOCAL INSTRUCTIONS

Hill AFB Instr. 91-302 Control of Hazardous Energy (Lockout/Tagout)

3.3 Order of Precedence

In the event of a conflict between the text of this Purchase Specification and the references cited herein, the text of this Purchase Specification shall take precedence. Nothing in this Purchase Specification shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3.4 Technical Proposal

A team including process engineering, management, operations, and the contract administrator as a minimum will evaluate technical aspects of the proposals. Additional team members may be included as required at the option of the Government.

4. Design The machine shall be new and shall be of the manufacturer's current production models. A current production model is defined as the manufacturer's current product, which on the date this solicitation is issued, has been designed, engineered, sold, or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. Products such as a prototype unit, pre-production model or an experimental unit do not qualify as meeting the requirements of this Purchase Specification. The machine shall include all components parts and features necessary to meet the functional and performance requirements specified herein. Manufacturers shall submit documentation that the offering meets this requirement and how each requirement will be met.

4.1 Use of American English

Wording on all components and sub-components such as electrical motors, diagrams, hydraulic components, safety and informational charts/plates shall be written in American English. All installation diagrams, operator/users manuals, brochures, performance evaluation reports and any other data supplied, as part of this Purchase Specification shall also be written in American English and use U.S. customary units of measure. Metric units may be available as an option but shall not be considered sufficient for the purpose of this contract.

4.2 Safety and Health Requirements

4.2.1 Guarding

“One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine guarding area from hazards such as those created by point of operation, ingoing nip points, and rotating parts. Examples of guarding methods are—barrier guards, two-hand tripping devices, electronic safety devices, etc.” OSHA 1910

4.2.2.1 Guards shall be affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guards shall be designed so that they do not create accident hazards and shall be designed so that they can only be removed using tools.

4.2.2.2 Permanent guards shall be provided to cover all belts, gears, electric motors and any other mechanical moving parts where possible. Safety interlocks, over-travel limit stops, and warning devices shall protect the machine, controls and operator from damage.

4.2.3 Electrical Hazards

Shockproof controls for protecting the operator from mechanical and electrical hazards shall be provided. Safety interlocks, over-travel limit stops and warning devices shall protect the machine and controls from damage by over travel or overload of working units. The machine shall comply with OSHA 1910 safety standards and NFPA 70 and 79 electrical standards. Electrical enclosures shall be of the NEMA Type 4 or better per NEMA 250 and NEMA ICS 6. In addition, provision shall be made to provide for control of all hazardous energy sources when appropriate for lock out-tag out procedure Hill AFB Instruction 91-302.

4.2.4 Pressure Equipment: Pneumatic systems shall have guarding and secure lines that do not drag across the floor or other components of the machines causing abrasion on the lines and shall be designed and installed consistent with ISO 4414 requirements for pneumatic systems.

4.2.5 Auditory Hazards

The machines and peripheral equipment shall not exceed 75 dbA maximum noise level under a no load condition.

4.2.6 Mercury Prohibition.

The use of mercury, mercury compounds, or mercury based instruments on or in the machine is prohibited.

4.2.2 Asbestos Prohibition.

The use of asbestos and materials containing asbestos on or in the machine is prohibited.

4.3 Lubrication

All points requiring lubrication shall be equipped with easy access and a plate giving lubrication instructions. The contractor shall provide all Material Safety Data Sheets (MSDS) for all oils or lubricants required for machine operation.

4.4 Construction

The machine shall be constructed so that when it is installed and connected to power it is ready for operation. The machine shall be constructed of parts, which are without defects and free of repair. The machine structure shall be capable of withstanding all forces encountered during operation of the machine to its maximum rating and capacity without permanent distortion. All parts subject to wear breakage or distortion shall be easily accessible for adjustment, replacement and repair.

4.4.1 Painting

All surfaces subject to rust shall be cleaned of all foreign matter prior to paint application and shall be painted in accordance with the manufacturer’s standard commercial practice. Exception to painting shall be made for surfaces that cannot be painted without interfering with the mechanical operation of the machine such as sliding or bearing surfaces that are otherwise protected by rust and corrosion preventing lubricants and coatings. Corrosion resistant stainless steel and plastic components may be unpainted.

4.4.2 Installation

This machine shall be installed on site as part of the purchase contract. Floor mounting and anchoring hardware shall be supplied by the vendor following the design specifications of the manufacturer. These specifications are to be included in the documentation for the equipment.

4.4.3 Electrical power supply and electrical equipment.

All electrical equipment for the machine shall conform to the applicable requirements of NFPA standards. The machine shall draw all of its electrical power from a single circuit having a fused safety disconnect switch supplied and installed by the Air Force. The machine's electrical system shall be wired for 110 VAC 1 phase 60 Hz. The vendor shall supply an installation diagram for the machine with the proposal showing connection points and requirements for the machine including electrical power and grounding, water, compressed air, etc..

The machine's electrical system shall withstand line voltage fluctuation of 10% with no damage to the machine or its related components. If DC or reduced voltage AC is required or specified for any part of the machine operation the necessary conversion or transformation equipment shall be furnished with the machine. The electrical system shall be of solid state design and shall be suitable for connecting the size grounding conductor specified in NFPA 79 standards for the disconnect fuse rating. Each electric motor shall meet the applicable design standards of NEMA MG 1-2011 that are applicable to that type of motor.

5. Machine Components & Features The bid shall address each of the following parameters. If the bid does not adequately address the line item, it may be considered an insufficient characteristic. The machine shall meet and may exceed any of the minimums but shall not exceed specifications listed as maximums.

5.1 Computer Software

5.1.1 The software operating the machine shall be compatible with the Lightspeed® interface screens, file format, communications protocols, and features and shall run under Microsoft Windows 7 or later version of the Windows operating system. It shall include setup and operation of features unique to this machine and shall preserve all setup, production, and historical data as part of the data file received and transmitted to the Lightspeed® industrial network as well as new data generated for acceptance measurement and program and bend data correction values.

5.1.2 Access to the system shall be restricted by password with a minimum of 3 categories of access such as Administration, Operators, and Maintenance with access to various read-write functions appropriate for those individuals.

5.1.3 Bend or part shape data screens shall, without modification, be designed to accept data from a Lightspeed® file format directly with full fidelity and without external processing or manipulation. This feature shall not be added or modified as a custom feature for this purchase. The software shall also provide a simulated view of the part in 3 rotatable dimensions to visually verify the accuracy and produce-ability of the part. It shall also be capable of producing a mirror image or reversing the bend sequence when necessary to improve producibility. Design data shall be preserved in addition to measured and corrected data.

5.1.4 The bender software has the ability to define part groups so that the bender will execute the bends for each of the parts in the set in the specified quantities to create a complete set of parts. The laser measuring station software shall then allow for part evaluations between part groups for like part statistical evaluation of process changes.

5.1.5 The laser measuring station shall provide bidirectional communications consistent with the Lightspeed® file format currently in use on our industrial network, preserving all the production parameters and data storage capability in that system, allowing the transfer of all data to the existing Eaton Leonard network and back without loss of information and providing a closed loop self-correcting tube data system. That network includes a VB-80 bending machine, a VB-25 bending machine, and a stand-alone PC for statistical analysis, program simulation, archiving, and off-line programming running proprietary software designed to interface with these three machines and is used for the archival and analytical evaluation of production data on this proprietary network. It shall also be capable of utilizing and generating data files in Microsoft Excel file format for import and export purposes.

5.1.6 The software shall also provide the ability to measure bends to determine centerline radius and shall be capable of tracking different radii in a single tube. It shall also have curve location measurement capability for determining accurate bend location when vector intersect angles are very shallow or very long (ie: 0º to 6º or 174º to 186º).

5.1.7 The software shall automatically compensate for variation in ambient conditions that would otherwise affect arm accuracy. It shall also have software that is used to evaluate and verify the accuracy and repeatability of the equipment and shall be used for equipment calibration. See 8.3 for calibration hardware.

5.1.8 The software shall allow for evaluation of tubes in excess of the simple range of motions permitted by the measurement arm by allowing tube movement and recapture through data stitching to establish the new relative position before proceeding with the next portion of the tube.

5.1.9 The software shall allow multiple bending machines concurrent access so that it can keep track of the current part data being produced on each machine.

5.2 Computer Hardware

5.2.1 The personal computer workstation for this machine shall have at least 40 Gb of hard drive space for storage of bend data files, programs, and system files and shall operate under Windows 7 or later. It shall rest under the measuring table surface along with an ink jet printer, keyboard, and other components of the system except the mast and touch-screen

5.2.2 Input devices shall include a swivel mounted touch screen, full QWERTY keyboard with full stroke mechanical key switches as well as function specific buttons and switches required to operate the machine built into the grip of the arm or scanning head. It shall also have communications ports and capability for communication and file exchange with external workstations on the industrial network. Cursor control shall be available from the keyboard, touchscreen, mouse, and the scanner head.

5.2.3 The touchscreen display shall be swivel mounted and shall have a rotatable 3D graphic display of the tube as measured available and shall be capable of indicating areas that are out of tolerance to the specifications graphically.

5.3 Measuring Arm

5.3.1 Non-contact Visual Laser Scanner

The measurement system shall include a laser scanning system that automatically takes up to 100 readings along each straight section of tube and averages them together for accuracy and to eliminate sensitivity to yoke position and attitude. A single reading at each end of the straight section is influenced by material condition and manual yoke alignment and is therefore not sufficient to determine vector direction in space accurately. The system shall come equipped with a single scanning yoke that is appropriate for tubes from 1/8” to 3” OD as a minimum and shall employ a laser frequency in the visual spectrum for targeting verification.

5.3.2 Mast & Arm Construction

The joints shall ride on tapered roller bearings and the mast shall be rigidly bolted to the structural steel table frame. Position feedback of the cantilevered arm shall come from 180,000 count direct drive encoders or better, shall have automatic compensation for ambient temperature variation, and shall be counterweighted to minimize operator force and maximize sensitivity. System response to and from the operator shall include audio signals for data points acquired and commands to the system from control buttons on the grip of the arm, touchscreen, keyboard, and mouse.

5.4 Measurement Surface

5.4.1 The hard surface table that supports the tube during measurement shall be fastened to a welded structural steel frame with sufficient strength to prevent movement under thermal or humidity induced forces. The surface shall be resistant to impact, abrasion, moisture, and chemical attack

6. Labeling Plates All markings on the plates shall be permanent and legible on a contrasting non-glare background.

6.1 Lubrication Chart or Plate

If lubrication is required, a lubrication chart or plate shall be permanently and securely attached to the machine. The following information shall be furnished on the chart or plate:

Points of application Service interval Type and viscosity of lubricant

6.2 Nameplate

A Corrosion-resistant nameplate shall be securely attached to the machine.

The nameplate shall contain the information listed below:

Noun (description) Manufacturer’s name Manufacturer’s serial number Manufacturer’s model number Power input (volts total amperage phases frequency) Contract number or order number Date of manufacture (day month and year)

6.3 Caution Plate

The manufacturer shall furnish a corrosion-resistant plate secured to the machine in a visible location with all important cautions to be observed by the operator. The plate shall be permanently marked. If more than one plate is required to alert the operator and/or maintenance personnel in one or more areas caution plates shall be furnished.

7. Sizes and Capacities The machine shall conform to the requirements of Table I. (See Figure I.)

TABLE I (Sizes and capacities for the Machine)

NOTE: Requirements are not less than those shown. Where a range is indicated, the required performance is from the stated minimum or greater, and to the stated maximum or less.

8. Ancillary Equipment and Supplies The following equipment and accessories shall be furnished for this machine:

8.1 One set of wrenches, operating tools, and repair tools that are normally furnished by the manufacturer for each machine. The machine shall include removable laser scanning heads sufficient to measure tubes from ¼” to 3” in diameter. This may be a single head if it is designed to span that full range.

8.2 One counterweighted holding fixture that firmly grips the subject tube and rests on the table surface during measurement.

8.3 One fixture for evaluating point to point accuracy and repeatability and one fixture for evaluating vector analysis accuracy and repeatability. This would include measurement balls or sockets and a matching probe as well as several cylinders mounted on a rigid base and labeled permanently with the NIST traceable measurements between features. All these features may be mounted on a single rigid fixture. See 5.1.7 for software details.

9. Requirements of the Proposal Offerors shall submit (in duplicate) as part of their proposal brochures, photographs, illustrations, drawings, and narratives which clearly show that the design, construction, capacities, and operation of the equipment being offered will meet all of the requirements set forth in this Purchase Specification. Literature displaying more than one model or size machine shall be clearly marked to indicate the model or size being offered.

Proposals shall include a response to each numbered paragraph of this Purchase Specification indicating compliance or non-compliance with the paragraph's particular requirements. Each paragraph shall be numbered using the Purchase Specification paragraph numbers. Response to each paragraph shall state if the requirement will be met and specifically how it will be met. Where the proposal exceeds requirements or exceptions are taken, bid submittals shall provide specific information so the impact of the over-compliance or exception can be evaluated.

All narratives shall be in American English and all sizes and capacities of the range being offered shall be stated in the U.S. customary system of units.

This equipment shall be installed on an existing 8 inch thick steel reinforced concrete floor. Drawings of the foundation (if a foundation is required) to support the equipment and all utility requirements shall be furnished as part of the Offerors proposal.

Offers which do not include sufficient information to permit a complete compliance review by Air Force personnel shall be rejected.

10. Requirements After the Award of the Contract

NOTE - Engineering and technical support for installation requirements shall be furnished by the 309th Commodities Maintenance Group Manager. The support office at Hill AFB may be contacted at:

309 CMXG COMMODITIES MAINTENANCE GROUP PROCESS ENGINEER

7169 6th St. Bldg 510 Hill AFB, UT 84056-5228 Name: Kent Johnson Phone: (801) 586-5330 Or Name: Mike Adams Phone: (801) 586-8931 Work hours: 7:00 AM to 3:30 PM MST (Monday thru Thursday)

10.1 The contractor shall provide the Engineer and Contract Administrator an estimated date for delivery of the machine at least 30 days prior to the scheduled delivery. The Engineer’s phone number is in paragraph 10.0 above. The Contract Administrator’s phone number will be provided after award of contract.

10.2 Preliminary operational buy-off at the factory shall be witnessed by the Hill AFB Process Engineer or his assign. If operator or maintenance training is to be conducted at the factory, it may be conducted as part of the factory buy-off process. (See pp 10.10.)

10.3 The contractor shall ship to, install, and test the machine at Hill AFB, Utah. The machine shall remain the property of the contractor until the Government at Hill AFB accepts it. All costs associated with the manufacture, shipping, installation, testing and preparation of the machine for final acceptance at Hill AFB shall be the responsibility of the contractor.

10.4 The contractor shall be responsible to furnish all tools and equipment required to install the machine and perform the tests required by this specification. The Government shall furnish no tools or equipment.

10.5 Prior to award, all chemicals and hazardous materials required to make the equipment operational shall be identified by the contractor and are subject to approval by Hill AFB. All chemicals and hazardous materials required for testing at the contractors facility shall be supplied by the contractor and shall remain the property of the contractor. The contractor shall deliver the equipment free of chemicals and hazardous materials. All chemicals and hazardous materials, or equivalent, required to test and run the equipment at Hill AFB will be supplied by Hill AFB.

10.6 Special equipment, measuring equipment, and machine alignment equipment etc., required by the contractor to align the machine and perform the tests specified herein shall be furnished by the contractor and shall remain the property of the contractor.

All material for the factory tests shall be supplied by the contractor. All material to run the on-site tests as part of setup and final testing and for training shall be provided by the Air Force. The contractor shall determine amount of material required. The material shall be held to the minimum required to perform the tests and training.

10.7 The contractor shall supply and deliver with the machine two original copies of “as built” standard manuals containing all necessary electrical wiring diagrams (drawn according to NFPA standards) hydraulic schematic diagrams, operator's manuals, parts lists, preventive maintenance instructions, part programming manuals and drawings of machine components and all other instructions for operation and maintenance of the machine and its peripheral equipment. One copy shall be paper hard copy. The other may be, and is preferred to be, in electronic form. All electrical diagrams shall contain average electronic characteristic waveform and voltage readings at pre-selected points throughout the system.

10.7.1 The contractor shall provide a backup copy of the operating software for archiving purpose, to be used to restore operations in the event of failure of the operating computer. This is necessary since Air Force industrial computer systems not controlled by base IT operations, shall not be attached to computer systems outside the base. All diagnostic efforts and software updates must be done within the industrial network on site.

10.8 All hardware required for leveling or anchoring the machine to the floor shall be furnished by the contractor.

10.9 The Air Force shall provide and install all necessary fusible disconnects, circuit breakers, circuit breaker boxes, and outlets to install the machine. If hard wire connection of the equipment to the disconnect boxes is required, wiring attachment shall be the responsibility of the contractor or his assigns. Once the equipment is connected to power, it shall be disabled during the installation process and only unlocked by the contractor when required. Hill AFB Instruction 91-302, Control of Hazardous Energy (Lockout/Tagout) shall be required to protect contract employees, as well as Government employees from electrical harm.

10.10 Training Requirements

The contractor shall provide training as specified for each of the skills listed below (to include tuition and all training materials required).

Operator and Mechanic’s training may take place either at the vendors facility or at Hill AFB facilities at the discretion of the Air Force. The contractor shall provide a qualified technician(s) to administer the above training that is knowledgeable in all functions of the system, operations, and system maintenance using the contract equipment or equipment with the same features and functions. The vendor shall provide initial operator training to the student(s) concerning proper operation of the system components features and functions. If this training takes place at Hill AFB, it shall be provided after satisfactory completion of all tests, checks, inspections, and examinations required of the equipment in this Purchase Specification.

If additional training is required beyond that specified herein, it will be negotiated as part of a separate service contract.

11. Inspection and Run-off test requirements The machine shall be fully installed, fully connected, and fully operational at the time of the final run-off. Standard aspects of the machine and its’ performance shall be verified to the manufacturers specifications. The Government reserves the right to request specific test routines to verify machine performance, beyond the manufacturers’ standard verification. Any deficiencies shall be corrected by the manufacturer or contractor prior to government acceptance.

11.1 Factory verification test report

The manufacturer's standard verification test report shall be prepared by the contractor and submitted to the Process Engineer at the time of factory buy-off. All reports will be in American English with U.S. customary units of measurement.

11.2 Tests

The machine shall pass the following tests or it shall be rejected. The contractor shall furnish all instruments and tools required to perform and evaluate these tests. All measuring instruments and calibration standards shall have evidence of calibration traceable to the National Institute of Standards and Technology (NIST). Materials required for the tests and training conducted at the factory shall be furnished by the contractor. Materials for testing and training on site shall be furnished by the Air Force.

11.2.1 Operational test

The machine shall be operated at the factory for not less than 1 hour. During that test the proper operation of all controls, motors, adjusting mechanisms and other accessories shall be verified and recorded. This test shall also include a test of communications between the measuring machine and a CNC tube bending machine running the LightSpeed® control system for functionality and compatibility. If any function of the machine fails under testing, the test shall be restarted when the fault is documented and repaired and will not be considered passing until it completes an additional ½ hour test without fault or error to verify efficacy of the repair. A report of this test shall be provided to the Process Engineer at the time of the factory buy-off.

11.2.2 Accuracy Verification

The machine shall be tested to verify that it complies with the requirements of Table V using the software and standard fixture(s) supplied with this contract. This test shall be conducted using the manufacturer’s standard calibration procedure. The test shall be run at the factory as part of the factory buy-off witnessed by the Process Engineer. It must be retested to Table V after installation to identify any changes during transit. If the test result does not meet any of the values in Table V, adjustments and/or repairs shall be completed and the machine completely retested to prove the efficacy of the adjustments/repairs and to demonstrate that those repairs did not adversely affect the other capabilities being tested. This test shall be witnessed by the Process Engineer at installation. It shall be accompanied by sufficient instruction and documentation, either at the factory or at installation, that the Engineer is capable of conducting the test in the future.

TABLE V

12. Acceptance of the Machine If the machine fails to pass any test in the requirements of this Purchase Specification, it shall be rejected. After it has passed all of the tests required by this Purchase Specification, the machine will be accepted by the Group Manager. The Group Manager will sign the test report indicating that the tests were witnessed by a representative of the using activity and that all of the tests were performed satisfactorily. Acceptance shall be acknowledged by a signature sheet, including at a minimum, signatures of a Process Engineer, Production Supervisor, two operators, Quality assurance, and Maintenance.

13. Warranty Items proposed shall be warranted for 1 year and shall include parts, labor, functional adjustment, and travel expenses for repairs at the installation site.

Warranty repairs shall be conducted by factory trained repair technicians and must commence within 48 hours of notification by the Air Force that repairs are needed. Delays in response time can be negotiated at the discretion of the Air Force.

Contractors shall include a copy of each applicable warranty with their response to this solicitation. The warranty period is to start when the responsible government official makes the final buy off.

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