SITT_Preliminary_Design_Concept_-_Dec-2014.docx

SITT Preliminary Design Concdept - Dec 2014

· PRELIMINARY –

DESIGN CONCEPT AND REQUIREMENTS FOR A

SHOCK ISOLATOR TEST TOWER SYSTEM

UNITED STATES AIR FORCE

HILL AIR FORCE BASE

DECEMBER 2014

TABLE OF CONTENTS

1- GENERAL

2- ACRONYMS

3- SCOPE of WORK and DELIVERABLES 4- DESCRIPTION of LIQUID SPRING SIS 5- DESCRIPTION of LCC PNEUMATIC SIS

6- SI TEST PROCEDURES

7- TEST TOWER CONCEPTUAL DESIGN

8- ELECTRICAL SYSTEM

9- FIGURES

10- APPENDIX

1) GENERAL

a) The work described herein is to design, fabricate, assemble, test, install, start up and qualify a Test Tower System (TTS) per the requirements that are contained in this document. The TTS will be used to test the operating parameters of liquid spring and pneumatic Shock Isolators (SI). The SIs are critical components of the United States Air Force (USAF), Minuteman III Intercontinental Ballistic Missile (ICBM) ground support system. The TTS shall be installed at Hill Air Force Base (HAFB) in Clearfield, Utah.

b) This document is being released to invite contractors to provide the USAF with rough order magnitude (ROM) cost estimates, conceptual designs and descriptions of contractor capabilities to provide a TTS per the requirements contained herein. Preparation of these items shall be at the expense of each provider with no reimbursement from the USAF.

c) This preliminary document contains descriptions of SIs, descriptions of tests that shall be performed, and a listing of TTS requirements. It also contains a conceptual TTS design that has been developed by the USAF. The USAF sees this design as only one possible way to construct the TTS and invites contractors to propose other conceptual designs (and/or improvements to the USAF design) for consideration. ROM estimates for both the USAF design and contractor proposed designs are requested.

NOTICE: Conceptual design information that is submitted in response to this document will be subject to incorporation into a final TTS specification and release for competitive bid by the USAF.

d) ROM estimates and conceptual designs, which are received as a result of this solicitation, will be evaluated. If it is in the best interest of the USAF, a final specification will be prepared and competitive bids for the final design, fabrication and installation of the TTS will be solicited. Contractors, who have provided ROM estimates and/or conceptual design information for the TTS, shall receive notice of that solicitation.

e) Any business or corporation, which shall provide an estimate or accept a contract to provide the TTS to the USAF, shall be referred to herein as a “contractor”.

2) ACRONYMS

(Still to be determined)

3) SCOPE of WORK and DELIVERABLES The Scope of Work and Deliverables for the TTS shall include the following:

a. Developmental Design – The TTS shall be designed using 3 dimensional “SolidWorks” or other approved Computer Aided Design (CAD) software. The developmental TTS design shall be directed toward meeting the requirements of this document. The developmental TTS design package shall include a minimum of the following items:

i. A general visual description of the proposed TTS, including all of its subsystems and foundation

ii. Developmental drawings of each subsystem and a description of how these subsystems will function together to perform each required test

iii. Developmental drawings of the proposed control and data collection systems and a description of how these systems will function

iv. Developmental drawings that show the proposed physical configuration of all major components (including foundation) of the TTS. Dimensions, weights, operating parameters, etc. shall be included

v. A list of major components that will be purchased by the contractor for the TTS, including manufacturer’s names and component specification sheets

vi. A developmental TTS test plan (See Paragraph 2) f.)

b. Developmental Design Review – A review of the developmental TTS design shall be provided to members of the USAF review team. The review shall be conducted at HAFB. Hard copy prints and PDF electronic files of the design package documentation shall be provided to the review team as part of the formal presentation. All issues with respect to this design, which come to light during this review, must be resolved and the developmental design must be approved before the contractor shall proceed with the final design.

c. Final Design – The final TTS design shall be completed using the same CAD software as was used in the developmental design. The final design shall completely define the configuration of the TTS, which shall conform to all the requirements of this document. The final design package shall include a minimum of the following items:

i. A drawing package, which is defined in Section 2) d.

ii. Electronic copies of all drawing CAD files

iii. Documentation of all calculations and analysis

iv. A list of all major components and systems to be procured for the TTS – This shall include manufacturer names and part numbers

v. Specification sheets and product information for major components and systems that will be procured from other manufactures

vi. Control and data collection software documentation

vii. A preliminary version of the TTS operating instructions

viii. A final TTS test plan per paragraph 2) f.

ix. A list of all proposed subcontractors that will contribute in any way to the TTS

d. Drawing Package – The drawing package shall define the entire TTS and its foundation in sufficient detail so as to allow experienced machine tool fabricators and construction contractors to: 1) Fabricate or purchase all TTS components, 2) Construct the TTS foundation, 3) Completely assemble and install the TTS.

i. Drawings shall be 2 dimensional, but shall be derived from the 3D model CAD design files

ii. Drawings shall be available as hard copy prints and as PDF electronic files

iii. Drawings shall be produced on either UASF or contractor drawing templates with either USAF or contractor drawing numbers and cage codes. These shall depend on the final data rights that are agreed upon.

iv. Drawings shall be prepared per in accordance with ____?____standard.

e. Final Design Review – A review of the final TTS design shall be provided to members of the USAF review team. The review shall be conducted at the contractor’s facility. Hard copy prints and PDF electronic files of the design package documentation shall be provided to the review team as part of the formal presentation. All issues with respect to this design, which come to light during this review, must be resolved and the final design must be approved before the contractor shall proceed with the purchase or fabrication of TTS components.

f. Test Plan – The contractor shall develop a test plan to adequately test the functions and load carrying capacities of the TTS and to demonstrate its ability to perform the SI tests within the parameters given in the document. This plan shall be reviewed by and must be approved by the USAF prior to use.

g. System Components and Materials – The contractor may fabricate TTS components or obtain them from subcontractors or component manufacturers. However they are obtained, the contractor shall be responsible for the cost, configuration, integrity and functionality of each component and all materials used in the TTS.

h. Assembly – With exception of the foundation, the TTS shall be fully assembled at the contractor’s facility so that it can be functionally tested before being shipped to HAFB for installation.

i. System Programming – Prior to system testing, TTS control and data recording systems shall be programmed to perform their specified functions.

j. System Testing – The TTS shall be load and functionally tested at the contractor’s facility prior to shipment to Hill AFB. Testing shall be conducted and results documented per the approved test plan (See Paragraph 2) f.). Testing shall be witnessed by USAF and/or DCMA representatives. Any failures or discrepancies shall be corrected prior to shipment.

k. Dismantling – Following completion of System Testing, the TTS shall be dismantled to a level that will allow it to be safely shipped from the contractor’s facility to HAFB.

l. Packaging –The TTS components shall be adequately packaged to protect it from damage during shipment and to allow safe loading, unloading and handling at both the contractor’s facility and at HAFB.

m. Shipping and Handling – The TTS components shall be loaded for shipping at the contractor’s facility, shipped to HAFB and offloaded at the HAFB installation site. The contractor shall be responsible for the above tasks, including all arrangements and associated costs.

n. Foundation – A reinforced concrete foundation for the TTS shall be installed within an existing building at HAFB. The foundation shall be recessed below floor level as shown in the figures in this document. The foundation shall include concrete walls that close in the space between the foundation and the floor. The horizontal dimensions of the foundation opening through the floor shall be large enough to accommodate installation and future maintenance of the tower. Concrete flooring outside of the foundation perimeter that is removed to accommodate foundation installation shall be replaced. The foundation and its walls shall be designed to withstand all testing and potential earthquake conditions. Hardware that is necessary to level the TTS and to anchor it to the foundation shall be provided and installed. The contractor shall be responsible for all concrete cutting, excavation, fill material and soil compaction that are required to prepare the site for the foundation installation.

o. Installation and Assembly at Hill AFB – The TTS shall be fully assembled and anchored to the new foundation at HAFB. The contractor shall be responsible for all handling equipment, labor and materials that will be required for the installation and assembly of the TTS.

p. Electrical Power – The TTS shall be connected to a 3-phase electrical power source that shall be provided at the installation site by the USAF. All conduit, wiring, disconnects, transformers, panels, etc. that are required to bring power from the source to the TTS shall be the responsibility of the contractor.

q. Deck Plating – Floor level deck plating and a support structure system shall be installed to close in the open area between the tower and the top of the foundation walls and floor. This shall be designed to support the weight of personnel, who will be working at the tower, and the weight of SIs and loading carts that will be rolled into position at the front of the tower.

r. System Startup and Checkout – Following installation at HAFB, the TSS shall be started up and checked out to ensure that all systems are functioning per the design.

s. SI Qualification Tests – Following startup and checkout, a qualification test shall be conducted on each of the MSS, LER and LCC SIs. Test SIs shall be provided for the tests by the USAF. Tests shall be observed by USAF personnel. These tests shall demonstrate the capability of the TSS to perform its required test functions. Any issues with the TTS that prevent it from being able to adequately perform the SI tests shall be corrected by the contractor.

t. System Operating Instructions – A TTS operator’s instruction manual shall be provided. The manual shall give a general description of how the TTS is designed to function and also a description of its capabilities and limitations. Detailed instructions for how to operate the TTS and how to conduct specific SI tests shall also be given.

u. Maintenance Manual – A maintenance manual, which prescribes all required maintenance tasks for the TTS and a schedule for their performance, shall be provided. Specific instructions for how to accomplish each task shall be included. The manual shall also include a list of TSS instruments that require calibration and a calibration schedule for each. Calibration requirements shall be determined between the contractor and the USAF.

v. Training – USAF personnel shall be trained in the operation and maintenance of the test tower. Two operators and two maintenance technicians shall be trained to the point of being able to independently complete their assigned functions.

w. As-Built Design Documentation – Two each, full size, hard copy prints and PDF, CAD, or computer software electronic files, which document the as-built and installed configuration of the TTS, shall be provided. This documentation shall include the following:

i. A complete drawing package, which is defined in Section 2) d.

ii. Electronic copies of all CAD files

iii. Calculations and analysis

iv. System Control and Data Collection software & documentation

x. Data Rights – The contractor shall give to the USAF unlimited rights to use the TTS design data (including the CAD files and drawings) for whatever purpose they desire. It is assumed that the USAF will have paid for the engineering effort to create this design data as part of the contract to provide the TTS. In accepting these data rights, it is understood that the USAF shall accept responsibility for any changes that they make to the TTS design or physical configuration, which is provided by the contractor.

y. Warranty – The contractor shall provide options for one, two and five year warranties on the TTS. These shall cover all components, labor and proper functionality of the entire TTS. Any other OEM warranties that come with purchased system components shall be passed on to the USAF.

z. Counterfeit Protection Plan – The contractor shall provide a plan which will verify that counterfeit parts are not used in the test tower. The plan shall be in accordance with the requirements of the Counterfeit Protection Plan listed in Appendix a).

4) DESCRIPTION of LIQUID SPRING SIs

Liquid Spring (LS) SIs, which will be tested by the TTS, are used to dampen vibration forces in rocket launch facilities. An LS SI consists of a hydraulic cylinder and a piston, which runs axially through the cylinder and extends out each end. The outside diameter of the piston is stepped near the middle of the piston, creating a small and a large diameter on either side of the step. An eyelet is attached to the end of the small diameter side of the piston. The cylinder is filled and pressurized with a compressible silicone liquid. The liquid pressure on the area of the diameter step creates a Retract Force (RF) that pushes the piston toward its retracted position, where more of the piston’s small diameter end is inside the cylinder. In this position, the internal liquid volume is the greatest and the liquid pressure is the least.

If an Extension Force (EF), which is in the opposite direction of and greater than the RF, is applied to the piston eyelet, then the piston will be pulled away from its retracted position with respect to the cylinder. This movement brings more of the piston’s large diameter side inside the cylinder and reduces the liquid volume, which increases the liquid pressure. This increase of pressure on the area of the diameter step raises the RF until the RF and the EF come into equilibrium. At this point, the piston stops moving.

If the EF is reduced the piston retracts bringing more of the piston’s small diameter side inside the cylinder. This increases the liquid volume, decreases liquid pressure, and reduces the RF. When the RF and EF come into equilibrium the piston stops moving.

The distance that the piston is moved away from its retracted position is called the Deflection (D). The SI Spring Rate (SR) is a function of EF divided by D. The SR is determined by using EF and D data (taken at two positions of the piston) in the following formula:

SR = (EF1 – EF2) / (D1 – D2)

The following two models of LS SIs will be tested by the TTS:

· Missile Suspension System (MSS) SI

· Stroke Length = 28 inches

· Cylinder Body Length = 42 3/8 inches

· Top End of Cylinder to Eyelet ID of Extended Piston = 35 1/2 inches

· Base End of Cylinder to Bottom End of Retracted Piston = 28 inches

· Weight =

· See Appendix b) for MSS SI drawings

· Launch Equipment Room (LER) SI

· Stroke Length = 36 inches

· Top of Cylinder to Base of Spherical Ball Mounting Flange = 52 1/8 inches

· Top End of Cylinder to Eyelet ID of Extended Piston = 44 1/4 inches

· Base of Spherical Ball Mounting Flange to Bottom End of Retracted Piston = 28 1/2 inches

· Weight =

· See Appendix c) for LER SI drawings

5) DESCRIPTION of PNEUMATIC-SPRING SIs Pneumatic-Spring (PS) SIs, which will be tested by the TTS, are used to dampen vibration forces in launch control facilities. A PS SI consists of an outer pneumatic tank and an inner pneumatic cylinder, which combined together form the SI body, and a piston that extends out of one end of the cylinder. Air pressure inside the cylinder and an internal compression spring around the piston provide a net Retract Force (RF) that pushes the piston into the cylinder toward its retracted position. The outer tank is also pressurized and is interconnected with the inner cylinder by a series of check valves that allow air to flow from the tank to the cylinder and by two pressure relief valves that allow air to flow from the cylinder back to the tank. An eyelet is attached to the exposed end of the piston.

If an Extension Force (EF), which is in the opposite direction of and greater than the RF, is applied to the piston eyelet, then the piston will be pulled away from its retracted position with respect to the cylinder. This motion reduces the net volume in the cylinder, compresses the air inside the cylinder, and raises the net RF until the RF and the EF come into equilibrium. At this point, the piston stops moving. If air pressure in the cylinder is raised to the relief setting of the relief valves, then air flows from the cylinder into the tank, thus limiting cylinder pressure.

If the EF is reduced, then the piston retracts increasing the net cylinder volume. This causes cylinder pressure to drop. If cylinder pressure drops below tank pressure then air flows through the check valves to equalize the pressures. Piston motion stops when the net RF and the EF come into equilibrium.

The distance that the piston is moved away from its retracted position is called its Deflection (D). The SI Spring Rate (SR) is a function of EF divided by D. The SR is determined by using EF and D data (taken at two positions of the piston) in the following formula:

SR = (EF1 – EF2) / (D1 – D2)

The following two models of the PS SIs will be tested by the TTS:

· Launch Control Center (LCC) SI – Wing I

· Stroke Length = 28 inches

· Cylinder Body Length = 42 3/8 inches

· Top End of Cylinder to Eyelet ID of Extended Piston = 35 1/2 inches

· Base End of Cylinder to Bottom End of Retracted Piston = 28 inches

· Weight =

· See Appendix b) for LCC SI drawings

· Launch Control Center (LCC) SI – Wings III & IV

· Stroke Length = 36 inches

· Cylinder Body Length = 42 3/8 inches

· Top End of Cylinder to Eyelet ID of Extended Piston = 35 1/2 inches

· Base End of Cylinder to Bottom End of Retracted Piston = 28 inches

· Weight =

· See Appendix b) for LCC SI drawings

6) SI TEST PROCEDURES

The TTS shall be designed and constructed to conduct the following test procedures on the MSS, LER and LCC SIs. Figures ? through ? provide a visual description of how the tests shall be conducted.

Note: The TTS components referred to in the following test instructions assume that the TTS configuration is per the USAF conceptual design described in Section 6. These could change if a different TTS design is used.

Note: Pressurization of SIs shall be performed using equipment that is separate from the TTS and that will be provided by the USAF. The carts that shall be used to roll SIs into the TTS shall also be provided by the USAF. Unless specifically defined otherwise, all other equipment referred to in the procedures shall be part of the TTS.

a) MSS - Spring Rate and Friction Test Notes: For this test, the Load Cell shall be connected to the Upper Lift Plate (ULP). The 19,000 pound Upper Weight Slug (UWS) and the 22,000 pound Lower Weight Slug (LWS) shall be connected together for a combined functional weight of 41,000 pounds. The MSS-UWS Adapter shall be connected to the top of the UWS. An EF of 41,000 pounds-force will be required to complete this test.

Test Setup – With the SI piston fully retracted, use one of the USAF carts to roll the SI into the TTS. The SI shall be oriented vertically with the piston eyelet on top. Connect the eyelet to the load cell linkage. Slightly raise the ULP to, transfer the weight of the SI to the ULP. Disconnected the cart from the SI and move it away from the tower. Lower the ULP to move the SI into position and connect the SI cylinder to the MSS-UWS Adapter.

Raise and lower the ULP to extend and retract the SI piston several times while air is bled from the SI cylinder and its liquid pressure is adjusted. Lower the ULP to fully retract the piston.

Test Procedure – By raising the ULP, pull the SI piston to its fully extended position (D = 28 inches). Hold the position momentarily and then lower the ULP to allow the piston to return to its fully retracted position. Piston movement shall be at a rate of 0.6 +/- 0.4 inches per second.

Test Data Recorded – EF, D and Time (T) shall be continuously recorded with respect to each other while the piston is being extended and retracted. (Example: See T.O. XXXXX Figure 8-10) Test Disassembly – N/A – Move on to MSS Damping Test Setup

b) MSS - Damping Test Notes: For this test, the load cell shall be installed on the ULP. The UWS and the LWS shall be connected together for a combined functional weight of 41,000 pounds. The MSS-UWS Adapter shall be connected to the top of the UWS. The ULP will be subjected to a maximum of 60,000 pounds-force during this test.

Test Setup – Start this setup from the final configuration of the MSS Spring Rate and Friction Test. Activate the electromagnet to connect the 41,000 pound weight slug to the Lower Lift Platform (LLP). Simultaneously raise both the ULP and the LLP by 32 inches with the ULP moving at least 5% faster than the LLP. Adjust the position of the LLP until there is 1/16 to 1/8 inch of slack in the linkage between the load cell and the SI piston eyelet.

Test Procedure – Deactivate the electromagnet to release the weight slug and allow it to free fall, pulling the SI cylinder down with it. The load cell will hold the SI piston in place causing it to fully extend with respect to the falling cylinder. The weight of the slug and the extending SI will suddenly transfer to the load cell and the ULP. The extended SI will bear the entire weight of the slug.

Test Data Recorded – EF, D and Time (T) shall be continuously recorded with respect to each while the weight slug and cylinder are in motion. (Example: See T.O. Figure 8-11) Test Disassembly – Lower the ULP until the weight slug comes to rest on its pad and then the SI piston fully retracts. Lower the LLP until the magnet comes into contact with the top surface of the UWS. Disconnect the SI cylinder from the MSS-UWS Adapter. Raise the ULP to lift the SI into position so it can be connected to the cart. Roll the cart into position and connect it to the SI. Lower the ULP until the weight of the SI is transferred to the cart. Disconnect the piston eyelet from the load cell linkage and roll the SI away from the tower.

c) LER - Spring Rate and Friction Test Notes: For this test, the load cell shall be installed on the ULP. The UWS and LWS shall be connected together for a combined functional weight of 41,000 pounds. The LER-UWS Adapter shall be connected to the top of the upper weight slug. An EF of 19,000 pounds will be required to complete this test.

Test Setup – With the SI piston fully retracted, use one of the USAF carts to roll the SI into the TTS. The SI shall be oriented vertically with the piston eyelet on top. Connect the eyelet to the load cell linkage. Slightly raise the ULP to, transfer the weight of the SI to the ULP. Disconnected the cart from the SI and move it away from the tower. Lower the ULP to move the SI into position and connect the SI cylinder to the LER-UWS Adapter.

Raise and lower the ULP to extend and retract the SI piston several times while air is bled from the SI cylinder and its liquid pressure is adjusted. Set the position of the piston to D = 21 inches. This is designated as the Static Position.

Test Procedure – Start at the Static Position. Raise and lower the ULP to cycle the piston 6 times through the following cycle with the piston moving at a rate of 0.6 +/- 0.4 inches per second:

1) Extend the piston to 14 inches beyond the Static Position (D = 35 inches).

2) Retract the piston to 14 inches below the Static Position (D = 7 inches).

3) Extend the piston back to the Static Position.

Test Data Recorded – During the last full cycle of the test, EF, D and T shall be continuously recorded with respect to each other. The Static Position shall be shown as the zero point on the D scale of the data graph. (Example: See T.O. Figure 8-6) Test Disassembly – Lower the ULP until the SI piston is fully retracted. Disconnect the SI cylinder from the weight slug. Raise the ULP to lift the SI into position so it can be connected to the cart. Roll the cart into position and connect it to the SI. Lower the ULP until the weight of the SI is transferred to the cart. Disconnect the piston eyelet from the load cell linkage and roll the SI away from the tower.

d) LCC - Equilibrium & Differential Tests Notes: For these tests, the LCC 2-inch drop link shall be installed on the ULP in place of the load cell. The UWs and LWS shall be separated so that only the 19,000 pound UWS will be functional. The appropriate LCC-UWS Adapter shall be connected to the top of the UWS. This test shall also require the use of the LCC Pneumatic Panel-A / Hose Assembly which shall be provided by the USAF.

Test Setup – Set the position of the ULP to accommodate the SI installation. With the SI piston fully retracted, use one of the USAF carts to roll the SI into the TTS. The SI shall be oriented vertically with the piston on top. Connect the SI piston eyelet to the 2-inch drop link. Raise the ULP to transfer the weight of the SI to the ULP. Disconnect the cart from the SI and move it away from the tower. Lower the ULP to move the SI into position and connect the SI cylinder to the LCC-UWS Adapter. Connect the Panel-A hoses to the SI. Ensure that the magnet is demagnetized and raise the LLP 12 inches to provide clearance for the weight slug to be raised. With the SI depressurized, raise the ULP to extend the SI piston to D = 40 inches. Using the Panel-A controls, pressurize the SI until the SI body and the upper weight slug raise to a position of D = 34 inches. This is the Normal Position. The SI cylinder pressure should be approximately 450 psi. Open and close the interconnect valve between the SI tank and cylinder pneumatic lines to equalize the pressures in the tank and cylinder.

Equilibrium Test Procedure – Gradually increase the SI cylinder pressure to the SI tank port until D begins to decrease. Gradually decrease the SI cylinder pressure from the SI cylinder port until D begins to increase.

Recorded Equilibrium Test Data – Record the pressure at which D begins to decrease and the pressure at which D begins to increase.

Differential Test Procedure – Gradually pressurize the SI tank until the pressure in the SI cylinder begins to increase. Open and close the interconnect valve between the SI tank and cylinder pneumatic lines to equalize the pressures in the tank and cylinder. Gradually decrease pressure in the cylinder until pressure in the tank begins to decrease.

Recorded Differential Test Data – Record both the cylinder and tank pressures at each pressure reaction point described above.

Test Disassembly – Lower the ULP until the UWS comes to rest on the LWS and until the SI piston is fully retracted. Lower the LLP to its lowest position where the magnet will contact with the UWS.

e) LCC - Drop Test Notes: For this test, the LCC 2-inch drop link shall be installed on the ULP in place of the load cell. The UWS and LWS shall be separated so that only the 19,000 pound UWS will be functional. The LCC-UWS Adapter shall be connected to the top of the UWS.

Test Setup – Start this setup from the final configuration of the LCC Equilibrium and Differential Test Disassembly. Activate the electromagnet to connect the UWS to the Lower Lift Platform (LLP). Simultaneously raise both the ULP and the LLP by 32 inches with the ULP moving at least 5% faster than the LLP. Adjust the position of the LLP until there is 2 inches of slack in the drop link.

Test Procedure – Deactivate the electromagnet to release the UWS and allow it to free fall, pulling the SI body down with it. The drop link will hold the SI piston in place causing it to fully extend with respect to the falling body. The weight of the UWS and the extending SI will suddenly transfer to the drop link and the ULP. The extended SI will bear the entire weight of the UWS.

Recorded Test Data – Cylinder Pressure, D and Time (T) shall be continuously recorded with respect to each while the UWS and SI body are in motion. (Example: See T.O. 35M3-3-15-2, Figure 7-8) Test Disassembly – Lower the ULP until the UWS comes to rest the LWS and then the SI piston fully retracts. Lower the LLP until the magnet comes into contact with the top surface of the UWS. Disconnect the SI body from the LCC-UWS Adapter. Raise the ULP to lift the SI into position so it can be connected to the cart. Roll the cart into position and connect it to the SI. Lower the ULP until the weight of the SI is transferred to the cart. Disconnect the piston eyelet from the drop link and roll the SI away from the tower.

7) TEST TOWER DESIGN CONCEPT

The following Figures 1, 2 and 3 illustrate the USAF proposed conceptual design of the proposed TTS. Figure 4 shows the configuration as the SI is being loaded into the tower. Following is a more detailed description of system components and their functions:

a) Tower Structure – The tower structure shall be anchored to the foundation. It shall provide the structural mounting surfaces for the ULP and LLP linear actuators, the support structure for the LLP in its lowered position, and possibly the support structure for weight slug positioning guides. The tower and its foundation shall together be designed for the worst case static and dynamic loads imposed during the SI tests and for Seismic Zone 3 conditions. The working space inside the structure shall be adequate for operators to perform their needed functions when conducting SI tests.

b) Upper Lift Plate (ULP) – The top side of this plate shall be connected to the lower end(s) of the ULP linear actuator(s). The bottom side shall be designed to connect to both the load cell and the drop link. The plate shall transfer the static and dynamic loads from the load cell (used in the MSS and LER tests) and the 2-inch drop link (used in the LCC tests) to the actuator(s).

c) Lower Lift Platform (LLP) – The top side of this platform shall be connected to the lower ends of the LLP linear actuators. The bottom side shall be connected to the top side of the electro magnet. The platform has two purposes. First, it shall transfer the static and dynamic loads from the electro-magnet to the LLP Linear Actuators. Second, it shall provide a working floor surface for the carts that roll Sis into the TTS and for operators to walk on. In its down position, the top of the platform shall be level with the floor. The platform shall have a 26 inch diameter hole through its center to allow Sis to pass through it during drop tests.

d) ULP Linear Actuator(s) – The actuator base is supported by the upper tower structure. The actuator is connected to the top of the ULP and has multiple functions. First, it provides the Extension Force to extend SI pistons during tests. Second, it holds SI pistons in fixed positions during drop tests. In this function it also carries the weight and dynamic deceleration loads of the SI cylinder/body and the attached weight slug. Third, it is used to lift and lower Sis into needed positions. – Note: It may be possible to perform the required functions with one actuator. However, four actuators (one at each corner of a square ULP) may be required to stabilize the dynamic loading on the ULP during drop tests.

e) LLP Linear Actuators – The actuator bases are supported by horizontal cross beams on the lower part of the tower structure. The actuators are connected to the LLP. Their purpose is to raise the LLP, magnet and weight slug into position for each drop test. Following the test, they lower the LLP and magnet to their normal position.

ULP & LLP Linear Actuator Notes: All linear actuators shall be electric driven and shall have positioning control. Stroke lengths and lift capacities shall be determined as part of the design. The USAF design concept is to use jack screws for this purpose.

f) Electro Magnet – This magnet, when energized, shall generate sufficient magnetic force to lift the combined 41,000 pound weight slug. It shall be flat on top and bottom and shall have a 26 inch diameter hole through its center to allow Sis to pass through it during drop tests. It shall be designed to attach to the bottom of the LLP. The magnet shall have an electrical power source and controls that will allow it to attach to and instantly detach from the UWS.

g) Load Cell and Connecting Links – The purpose of the load cell is to provide continuous feedback to the DAS of the EF being applied to MSS and LER pistons during spring rate and damping testing. The load cell shall be connected to the bottom side of the ULP and to the SI piston eyelets with removable connecting links. The links shall provide flexibility above and below the load cell to prevent side loading. The load cell shall have a minimum 100,000 pound load rating and a +/- .05% accuracy. Two identical load cells shall be provided with the TTS to provide backup during calibration downtime. The load cells shall have load rating safety factors of 1.5 and 3.0, based on yield and ultimate respectively.

h) LCC 2-Inch Drop Link – The drop link has two functions. First, it connects the SI piston to the ULP. Second, it provides for 2 inches of unrestricted free fall of the LCC SI and UWS at the beginning of the LCC drop test. The link shall be designed to withstand all of the static and dynamic loads imposed during the LCC tests.

i) 41,000 Weight Slug – This weight slug is formed by connecting the UWS and LWS are together into one slug. It has two functions. First, is holds the MSS and LER cylinders in fixed positions while the SI pistons are being extended during spring rate tests. Second, it provides the needed drop weight for the MSS damping test. The height of this slug shall be at least as great as its maximum horizontal dimension to provide for stability during drop tests.

j) Upper Weight Slug (UWS) – The total weight of this slug shall be 19,000 pounds. The top portion of this slug shall be cylindrical and extend up through the center hole in the electro-magnet and the LLP. SI-UWS adapters shall connect to the top of this cylindrical extension. This slug shall have a 6 inch diameter vertical hole through its center. This will accommodate the retracted MSS and LER pistons when these Sis are mounted to their SI-UWS adapters. The top side of the non-cylindrical portion shall mate up to the bottom side of the electro-magnet and shall be of adequate size and finish so as to provide for needed magnetic connection forces. The bottom side shall be configured to mate to the top side of the LWS. A method shall be provided to easily attach and detach the UWS to and from the LWS.

k) Lower Weight Slug (LWS) – The total weight of this slug shall be 22,000 pounds. The top side shall be configured to mate to the bottom side of the UWS.

l) SI-UWS Adapters – The function of these adapters is to connect the MSS and LER cylinders and the LCC bodies to the top of the cylindrical portion of the UWS. The design of each adapter and its connection points shall be tailored to the configuration of its SI and shall be rated for the greatest loads imposed during applicable tests. The adapters shall be easily disconnected.

m) Weight Slug Guide System – A guide system, which will keep the weight slugs aligned with the tower centerline while they are being raised and dropped, shall be provided. The system shall not interfere with the free fall of the slugs.

n) LWS Bottom Support – A physical support structure shall be provided for the LWS to rest upon when in it in its lowered position.

o) Piston Displacement (D) Potentiometer – The purpose of this device is to provide continuous D feedback to the DAS. Special adapters that mount the potentiometer to each SI cylinder or body and piston eyelet shall be provided.

p) Tower Foundation – The tower foundation shall be constructed of reinforced concrete. It shall be designed to support the tower under worst case static and dynamic testing and Zone 3 seismic conditions. Provisions shall be provided for anchoring the tower to the foundation and also leveling the tower. The foundation shall be installed in an existing building at HAFB. Installation shall include site excavation, which will require saw cutting and removal of the existing concrete floor. Because the top of the foundation shall be below floor level, reinforced concrete walls shall close in the space between the top of the foundation and the floor. Over excavated floor that is removed to accommodate the foundation installation shall be replaced. Workspace inside the walls shall be adequate to provide needed work space around the base of the tower.

q) Deck Plate – Floor level deck plate and a support structure shall be installed to cover the open pit area between the pit walls and the LLP. The deck plate shall be designed to support personnel traffic and also the SI carts that will be used to load and unload SIs in the tower. The plate shall be removable to allow access to hardware located below floor level.

r) System Controls – The TTS functions and each specific test shall be controlled by a Programmable Logic Controller (PLC). The operator interface for the PLC shall be a desktop computer with visual human-machine interface software. This interface shall provide the operator with a pictorial representation of the tower, each of its functioning components and the SI that is installed at any given time. Positioning of tower and SI components shall be visually shown along with digital indications of all TTS parameters. The PLC shall be programmed to run each MSS, LER and LCC test per the requirements described in Section 6 and also to independently operate and control each function of the TTS. PLC programming software shall be provided to the USAF following completion of TTS project so that future programming changes may be made as needed. Safety interlocks and emergency stop functions, which will prevent personnel injury and damage to Sis and TTS components, shall be provided.

s) Data Acquisition System (DAS) – The DAS shall collect data from the load cell, piston displacement potentiometer and pressure transducers. This shall be done with respect to each other and to time. Data points shall be collected and recorded at a minimum rate of 50 data points per second. HAFB has standardized on the use of LABVIEW software for the collection and manipulation of data. This software shall be provided as part of the system and shall be programmed to accomplish its intended purposes.

t) Shock Isolator (SI) – (See Section 3) – All SIs that are required to support the TTS design, testing and qualification shall be provided by the USAF.

8) ELECTRICAL SYSTEM

A single point source of 3 Phase / VAC electrical power shall be provided by the Air Force at the site of the tower installation. The voltage is yet to be determined. The contractor shall be responsible for all electrical equipment and installation that will be required to deliver this power from this single point to the tower devices. This shall include but not be limited to: electrical cabinets, disconnects, transformers, switches, lights, relays, wiring, conduit, etc. The electrical system and its installation shall conform to all applicable electrical codes.

9) FIGURES

The following figures provide visual representations of the subject Sis, the USAF conceptual design for the TTS and the SI tests that shall be conducted.

FIGURE 1 – USAF CONCEPTUAL DESIGN

(LINEAR ACTUATORS IN LOWERED POSITIONS)

FIGURE 2 – USAF CONCEPTUAL DESIGN

(LINEAR ACTUATORS RAISED – ELECTRO-MAGNET

ENERGIZED – WEIGHT SLUGS DETACHED)

FIGURE 3 – USAF CONCEPTUAL DESIGN

(LINEAR ACTUATORS RAISED – ELECTRO-MAGNET

ENERGIZED – WEIGHT SLUGS ATTACHED)

FIGURE 4 – USAF CONCEPTUAL DESIGN

(MSS SHOCK ISOLATOR INSTALLED IN TOWER)

FIGURE 5 – MSS SHOCK ISOLATOR TEST SEQUENCE

FIGURE 6 – USAF CONCEPTUAL DESIGN

(LER SHOCK ISOLATOR INSTALLED IN TOWER)

FIGURE 7 – LER SHOCK ISOLATOR TEST SEQUENCE

FIGURE 8 – USAF CONCEPTUAL DESIGN

(LCC SHOCK ISOLATOR INSTALLED IN TOWER)

FIGURE 9 – LCC SHOCK ISOLATOR TEST SEQUENCE

APPENDIX

a) Counterfeit Prevention Plan: DI-MISC-81832

b) MSS SI Drawings:

i) 25-66608: SI – Liquid Spring (Frames 1 & 2)

ii) 990600: SI – Liquid Spring (Frames 1 & 2)

iii) 990817: Piston Assembly, SI-Upper (Frames 1 & 2)

iv) 990818: Cylinder, SI-Upper (Frames 1, 2 & 3)

c) LER SI Drawings:

i) 25-66751: Isolator, Shock, Liquid Spring (Sheets 1 & 2 – Multiple Frames)

ii) 25-66752: Piston Rod-Liquid Spring (Frames 1 & 2)

iii) 25-66753: Cylinder-Liquid Spring (Sheets 1 & 2 – Multiple Frames)

iv) 25-66754: Lower Gland Nut (Frames 1 & 2)

v) 27-10381: Spherical Bearing (Sheets 1, 18, 19 & 20)

vi) 29-46937: Spacer, Liquid Ring image1.png image2.png image3.png image4.png image5.png image6.png image7.png image8.png image9.png