Purchase_Description_for_Fatigue_Tester.pdf

PURCHASE DESCRIPTION

and

PRODUCT SPECIFICATION

for

FATIGUE TESTER CONTROLLERS AND

SOFTWARE SYSTEMS

(CONTROLLERS)

for the

809th SCIENCE & ENGINEERING LABORATORY

(809 MXSS/MXDEA)

Hill AFB, UT

12 January 2015

1. SCOPE:

This purchase specification covers the detailed specifications and performance requirements for fatigue tester controllers and software for two Satec fatigue testers. Bidders shall propose a fully integrated test system including installation and calibration at Hill AFB, Utah. From this point on, the fatigue tester controllers and software systems will be referred to as CONTROLLERS throughout this Product Specification (PS). The CONTROLLERS will be able to properly regulate and perform test procedures for the Satec fatigue testers. This includes constant and variable amplitude cyclic loading profiles as well as industry standard practices for both tension and compression testing.

2. OVERVIEW:

The acquisition of the CONTROLLERS will ensure fatigue testing capabilities for mechanical testing at Hill AFB. The Science and Engineering Laboratory has two Satec fatigue testers, one

55 kip and one 22 kip, that are currently inoperable since no controller is attached to either tester.

Without a controller to deliver commands and to apply safety limits, neither of the testers is operational. The Science and Engineering Laboratory is proposing to have each of these testers connected to a separate controller.

The Science and Engineering Laboratory has two additional MTS fatigue testers, aside from the

Satec testers, that already have new MTS controllers. Many of the laboratory personnel have been trained by MTS to correctly use their controllers and software applications. The two new

CONTROLLERS must use the same software applications and functionality as the current MTS controllers in order to minimize the training needed to properly run the Satec testers. In addition, the hydraulic system that will run all four of the fatigue testers is also an MTS hydraulic power unit (HPU). Proper communication between the CONTROLLERS, the MTS controllers and the

HPU must be maintained at all times to ensure safety and proper operation of all four fatigue testers. All four of the fatigue machines must run on the same controller interfaces to allow for

“First On, Last Off” operation which would ensure safety of operators by allowing the safety parameters to coordinate with each of the individual testers. The two Satec fatigue testers must run on the same operating system to protect against the loss of mission critical information as well as to maintain safety. The HPU must operate in a fashion that will allow the testing procedures to run properly regardless of which machine is on/off.

3. SYSTEM DESIGN:

ENGLISH: All documents and software submitted by contractor to USAF contracting office must be in English. All documents and software provided with the CONTROLLERS must be in

English.

The CONTROLLERS shall be new and one of the manufacturer's current production models, which, on the date of this solicitation, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. The

CONTROLLERS shall be an off the shelf design meant for laboratory testing. Products such as a prototype unit, pre-production model or an experimental unit do not qualify. The machines shall include all components, parts and features necessary to meet the requirements specified herein and be ready for use.

SAFETY: The following safety features shall be included with the CONTROLLERS

3.3.1.1 Ability to set load and position limits

3.3.1.2 Integrated test area enclosure(s) for operator safety

3.3.1.3 Limiting function that restricts actuator motion during setup

ELECTRONIC CONTROL SYSTEM SPECIFICATIONS: The proposed CONTROLLERS system shall meet or exceed each of the following requirements.

CONTROLLER: Easy to use and program electronic closed loop control system

3.4.1.1 User friendly graphical user interface

3.4.1.2 Ability to pause and resume a test at the same point, either immediately or at some future time regardless of waveform command

3.4.1.3 On screen display of real time command and feedback for load, displacement, strain, cycle count, etc. with capability to output recorded data for entire test

(command vs. feedback for every point in test)

3.4.1.4 Minimum of four control channels allowing load, strain and position control modes

3.4.1.5 Capable of integration of additional instrumentation (Strain Gages, Extensometers, Clip Gages), that self-identify

3.4.1.6 Maximum system update rate of 4096 Hz for 3-4 control channels

3.4.1.7 Analog output resolution of 16 bit or better

3.4.1.8 Signal processing input resolution 16 bit minimum

INSTRUMENTATION: The CONTROLLERS shall allow the future integration of extensometer(s) and clip-on gage(s)

3.4.1.9 Allows fracture mechanics testing, ASTM E399

USER INTERFACE: The user interface shall consist of a desktop computer with all necessary software programs for full operation

3.4.3.1 RAM (DDR3 1600MHz): 8 GB or better

3.4.3.2 Quad-core I5 2

nd

Gen Processor: 3.0 GHz or faster

3.4.3.3 Hard Drive (7200RPM): 500 GB or better

3.4.3.4 Operating System: Windows 7 or newer

3.4.3.5 Monitor Size: 21.5 inches or larger (LED or LCD)

3.4.3.6 USB keyboard and optical mouse with pad or better

3.4.3.7 DVD +/- RW optical drive or better

SOFTWARE: The most current software package(s) shall be included and updateable

3.4.4.1 Software provided shall not require programming or compiling to set up and run tests

3.4.4.2 Templates shall be included for testing to commonly used ASTM and ISO test standards such as fracture toughness and fatigue crack propagation, ASTM

E399 & E647

3.4.4.3 Allows operators to easily create new templates for custom tests

3.4.4.4 All software patches and updates are included during warranty period

3.4.4.5 Software shall be able to correct for peaks and mean levels in cyclic waveforms

3.4.4.6 Software shall contain graphical drag - and - drop test layout design

3.4.4.7 Software shall allow for test template creation

3.4.4.8 Software shall allow data acquisition (timed, P/V, level crossing, cyclic / logarithmic)

3.4.4.9 Software shall be able to handle function generation up to 100 Hz on all channels

3.4.4.10 Software shall run all sine, square, triangle, ramp, hold, profile and custom waveform activities

3.4.4.11 Software shall have parallel branches for test execution and logical operators

(if/then, while)

3.4.4.12 Software must be able to do limit sensing, sequencing triggers, and interface to digital I/O

3.4.4.13 Software shall data export to ASCII

3.4.4.14 Software shall allow for cyclic fatigue analysis using history and cyclic charts

3.4.4.15 Software shall allow for fracture analysis using crack growth charts/data

3.4.4.16 Software shall allow for report generation while the test is running

3.4.4.17 Software shall allow for user input variable amplitude file, with reasonable limit on number of data points within file

4. OTHER DELIVERABLES

WARRANTY: The contractor shall provide a warranty for CONTROLLERS which warrants all products provided under this contract, under normal use, to be free from defects in materials and workmanship and that system will perform its design function for a period of no less than one (1) year. Warranty period to start from date of final acceptance of installed unit/system. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be repaired by the contactor at no additional cost to the government. The warranty shall cover the cost(s) of, parts, shipping, and labor expenses.

Warranty repairs are to be completed within 15 calendar days of notice of failure. A monitored service phone number shall be provided to government for all service needs and questions

MANUALS: The Contractor shall supply and deliver operations and maintenance manuals containing all necessary instructions for operation, calibration, maintenance and repair of the

CONTROLLERS system and its peripheral equipment. The Contractor shall generate the manuals and provide at least two bound hard copies and one .pdf format electronic copy upon delivery of the CONTROLLERS system, see CDRL A001.

INSTALLATION & TRAINING:

The CONTROLLERS system shall be installed on-site at Hill AFB by qualified factory trained service technician(s) directly employed by the Contractor. Upon completion of installation, after testing is completed and after final acceptance of the machine, basic training in machine operation and service maintenance must be provided, for a minimum of 3 operators.

Within 6 months following installation, the Contractor shall provide more advanced Controllers applications training by a qualified applications specialist for a minimum of 3 operators, to be performed on-site at Hill AFB, Utah, for at least two 8 hour days. Training must cover all included software and all component functions of the CONTROLLERS. The training should include hands-on maintenance and operation of controller-based systems and their related electronic, hydraulic, and mechanical components. The training should discuss major system components and present the principles of closed-loop servo control. More specifically, the training should familiarize the operators with correct operational techniques for efficient setup and operation of material, simulation, and component testing.

All labor, per diem, travel and accommodation expenses for the service engineer(s) and applications specialist(s) shall be included.

CALIBRATION: Following installation, the Controller system shall be calibrated on-site at Hill

AFB, Utah, by qualified factory trained service engineer.

The system shall be calibrated for stroke/position over full range, at least 5 points

The system shall be calibrated for speed, at least 3 speeds in each direction

The system alignment between crosshead mount and base mount shall be verified, with crosshead in at least 3 different positions

The load cell(s) shall be calibrated over full range in both tension and compression

The extensometer and clip-on gage shall be calibrated over their full range

5. DELIVERY, STORAGE & HANDLING:

Contractor to make all arrangements necessary, provide all equipment necessary, and cover all costs to deliver and off load all job related equipment, supplies, materials, fabrications, etc. to the job site at Hill Air Force Base, Utah. Contractor to coordinate delivery and off-loading with 809

MXSS/MXDEA.

6. INSTALLATION REQUIREMENTS: Contractor shall provide a turnkey installation to include all setup requirements of the new CONTROLLERS at its final location. The contractor shall be responsible for the crating and shipment of machine to its final destination IAW standard commercial practice.

WORK ON-SITE:

COORDINATION: Contractor must coordinate all on-site delivery, work and installation schedules with the USAF project manager.

INSTALLATION TIME REQUIREMENTS: Contractor shall make every effort to complete the installation of system within 14 days of its arrival.

NORMAL WORK HOURS: When working in the laboratory the contractor, unless noted otherwise, is to work during normal work hours whenever possible. Normal work hours are defined as 0700 to 1630 Monday through Thursday and 0700 to 1530 on Fridays, however, No training can occur on holidays. Recognized Holidays: The contractor is not required to provide service on the following days: New Year’s Day, Martin Luther King Day, Presidents’ Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans’ Day, Thanksgiving

Day, and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

TOOL CONTROL:

LOST TOOLS: If tools and/or equipment are lost, the contractor will report the loss to the customer within 30 minutes of discovering the item is lost. Every effort shall be made to recover the item before reporting it as lost.

PERFORMANCE/ACCEPTANCE TEST: Performance tests shall be conducted in accordance with the manufacturer’s recommendations and procedures. The contractor shall operate the machine including the hydraulic actuator for a minimum of 2 hours with no load to ensure proper operation. The contractor shall demonstrate machine operation and perform testing on the machine to ensure conformance with this specification. An acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of a thorough examination and a demonstration of the equipment. Acceptance shall be made after the machine has met all requirements. Any abnormal noises, excessive vibration, inaccuracy or other findings shall be cause for re-assessment and contractor must take action to fix any of the problems or findings in the design of the machine that do not meet the performance and/or design requirements or that are a safety concern.

7. AFTER CONTRACT AWARD: After contract award the successful bidder shall deliver the Controller system within 90 days, fulfill all of the above requirements and demonstrate to the project manager that the system is fully functional and that all included pieces/parts are present and accounted for to receive final acceptance. Failure to meet all requirements outlined in this PS shall be grounds for rejection.