Appendix A - 309 MMXG VLM 20250520.pdf

APPENDIX “A”

FOR

VERTICAL LIFT MODULE

AT

HILL AIR FORCE BASE, UTAH

309 MMXG, 581st Missile Maintenance Squadron

DATE: 20 May 2025

PREPARED BY:

BLAYNE GIPSON

Capital Investment Program Manager

309 MMXG/MXDEC

Revision

Appendix A (309 MMXG), Hill AFB, - Page i

TABLE OF CONTENTS

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

3.2.2. STRUCTURE

3.2.3. DEFORMATION

3.2.4. EXTRACTOR

3.2.4.1. EXTRACTOR SAFETY FACTOR

3.2.4.2. EXTRACTOR TRAY SENSORS

3.2.4.3. EXTRACTOR LOADING

3.2.4.4. EXTRACTOR FREE FALL

3.2.4.5. EXTRACTOR CALIBRATION

3.2.5. TRAYS

3.2.5.1. TRAY CONSTRUCTION

3.2.5.2. TRAY DIMENSIONS

3.2.5.3. TRAY CAPACITY

3.2.5.4. TRAY MARKINGS

3.2.5.5. TRAY PARTITIONS

3.2.5.6. TRAY CROSSWISE DIVIDERS

3.2.6. STORAGE LOCATIONS

3.2.7. STORAGE WINDOW

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

3.2.8.2. MAINTENANCE SERVICE PANEL

3.2.9. MAINTENANCE ACCESS

3.2.10. SERVICE LIFE

3.2.11. DRIVE COMPONENTS

3.2.11.1. MOTORS

3.2.11.2. GEAR REDUCERS

3.2.12. CONTROLS

3.2.13. OBSTRUCTION SENSORS

3.2.13.1. LOAD HEIGHT SENSORS

3.2.14. LIGHTING

3.2.15. FIRE SUPPRESSION

3.2.16. SECURITY DOOR

3.2.17. SOFTWARE CONTROLS

3.2.17.1. SYSTEM COMPATIBILITY

3.2.17.2. CONTROLLER

Appendix A (309 MMXG), Hill AFB, - Page ii

3.3 DELIVERY AND ASSEMBLY

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

4.2. REMEDIAL & SUSTAINMENT MAINTENANCE

4.3. TESTS

4.4. CERTIFICATIONS

4.5. WARRANTY

5. DATA

5.1. CDRLS

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for one (1) vertical lift module (VLM) for the 581st MMXS, Building 850 at Hill Air Force Base, (AFB) Utah. The work shall be completed in accordance with this appendix, the cover purchase description (PD), and applicable Air Force (AF) Drawings if any. This appendix covers equipment, materials, and labor necessary to complete installation of the required VLM systems.

Due to the end use of the VLM and footprint limitations (3.2.1), tray size of the VLM is a critical requirement (3.2.5.2). The 581st MMXS has multiple individual workloads that are refurbished by the shop. Each workload has a collection of parts creating a kit that is ordered and billed to individual serialized assets. The 581st MMXS needs to keep each collection of parts together for financial accountability.

One (1) VLM is required as this whole effort is to store all parts for a workload, based on work in progress (WIP), on to the minimum number of trays, creating a single kit while optimizing the available footprint. A tray size any smaller and the whole space will not be fully utilized, and kits could be displaced onto other trays. A tray much deeper was also found to be unsafe for potential users.

1.2. DEFINITIONS

Extractor - A fabricated metal structure attached to a lift mechanism used to transport trays between storage locations and pick window.

Tray live load capacity - Actual amount of load supported by a tray, not including tray weight.

Tray - A container in which items are stored.

VLM - Vertical Lift Module

Depth - Measurement from front to back when looking at the front of the VLM.

Width - Measurement from side to side when looking at the front of the VLM.

Height – Measurement from bottom to top inclusive of top cover.

Storage positions - The number of tray storage locations available within a Vertical Lift Module.

VLM System – Description of an operational VLM in fully automated configuration.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

3. REQUIREMENTS

Contractors shall submit technical design drawings/diagrams and other pertinent information describing proposed VLM that complies with mandatory specifications/requirements stipulated in the Cover Purchase Description and this Appendix A document.

Appendix A (309 MMXG), Hill AFB - Page 2

3.1. SYSTEM DESCRIPTION

The Contractor shall provide one (1) VLM that shall store and retrieve individual small to large sized items located on respective storage trays. Personnel shall retrieve parts, tools, materials, or components by entering data information into the Air Force Material Processing System (MPS).

The VLM shall then respond to appropriate MPS commands and retrieve respective trays where needed components are stored and delivered at the pick window. This also applies to parts binning functions for storage actions.

The VLM shall consist of and not limited to the following major components:

a. Extractor

b. Trays

c. Storage locations

d. Pick window

e. Electronic Controls & Respective Hardware

f. Conduit, wiring, mechanical fasteners, and all other items needed to install a fully operational VLM system.

g. Operational sensors that monitor all functions of the VLM as it applies to safety and automated processes.

3.2. CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

The external dimensions VLM shall fit within a nominal space of 162 inches deep, 210 inches wide, and 240 inches high.

3.2.2. STRUCTURE

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

The VLM shall have a steel structure that supports the fully loaded system without the use of enclosure panels for structural support. Vertical closed section racking corner posts with a minimum of 4” X 4” X 12’square structural tubing shall be used. Tray Rails shall be a minimum of 13-gauge CR Steel formed and welded to vertical frame members. Horizontal spreaders shall be a minimum 3.5” X 3.5” X 12’ square structural tubing. Tray supports shall be factory welded.

The VLM shall be securely anchored to the concrete floor in a manner that unit distortion shall not occur. The VLM shall be designed such that the weight of a fully loaded unit shall be distributed over the warehouse floor with a maximum live load capacity of 300 pounds per square foot. Base plates shall not extend past the external dimensions of the VLM.

Appendix A (309 MMXG), Hill AFB - Page 3

3.2.3. DEFORMATION

No VLM structural member shall exhibit elastic deformation greater than 0.10 percent of the distance between the ends of the member when loaded to capacity. No portion of the VLM shall exhibit permanent deformation.

3.2.4. EXTRACTOR

The extractor shall be used to extract and transport trays between storage locations and the pick window, also known as a pick and pull system.

3.2.4.1. EXTRACTOR SAFETY FACTOR

Each extractor lift mechanism shall have a minimum 6 to 1 safety factor based on yield strength.

3.2.4.2. EXTRACTOR TRAY SENSORS

Sensors shall be used to ensure that tray movement operations are loaded onto or off the extractor in such a manner that it will not move vertically unless the tray being stored or retrieved is outside of the extractor movement envelope.

3.2.4.3. EXTRACTOR LOADING

The extractor shall be capable of supporting the live load capacity of a loaded tray. Uneven loading shall have no effect on extractor speed or movement operations. Rack & Pinion vertical lifting mechanism shall be utilized.

3.2.4.4. EXTRACTOR FREE FALL

The extractor shall be prevented from free falling in a manner such that tray components will not be damaged in any event, such as power failure.

3.2.4.5. EXTRACTOR CALIBRATION

The extractor shall automatically calibrate its location as necessary to ensure continuously accurate storage and retrieval of trays. The extractor shall be easily recalibrated if tray locations are changed or in the event the unit loses electrical power.

3.2.5. TRAYS

There shall be a minimum of 21 trays, requiring 15 trays @ 12” clearance for each, and 6 trays @ 14” clearance for each.

3.2.5.1. TRAY CONSTRUCTION

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

Appendix A (309 MMXG), Hill AFB - Page 4

All trays shall be welded box steel 2” X 6” construction with corrugated floors, to provide continuous support for the capacity stated in 3.2.5.3. The rails and stiles shall be a minimum of 11 gauge CR Steel formed and welded. Tray bottom shall be a minimum of 16-gauge corrugated steel. Additionally, each tray shall have a protective coating over all surfaces to prevent metal to metal component storage contact. Trays must be fully assembled and completed at the manufacturing facility.

3.2.5.2. TRAY DIMENSIONS

Tray dimensions are based on inside dimensions. Dimensions are considered to be usable space.

The depth of each tray shall be 40 ± 1 inch. The minimum width of each tray shall be 192 inches.

The height of all tray side walls shall be a minimum 3-inch perimeter walls.

3.2.5.3. TRAY CAPACITY

Each tray shall have a minimum live load capacity of 2,000 pounds with no deformation greater than 0.10 percent.

3.2.5.4. TRAY MARKINGS

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

Each tray shall be marked with its associated number beginning with number "1" and progressing through all VLM trays. The number shall be contrasting to the tray color and shall be located in a position which is visible to personnel on a fully loaded tray. The numbers shall be located such that normal operations do not damage the labels. The numbers shall be permanently affixed to the trays.

3.2.5.5. TRAY PARTITIONS

N/A

3.2.5.6. TRAY CROSSWISE DIVIDERS

The following requirement needs to be as stated, or functional equivalent, to be considered technically acceptable.

There shall be a quantity of twenty-one (21) 192X40 96 Cell 6”H storage dividers.

3.2.6. STORAGE LOCATIONS

technically acceptable.

Appendix A (309 MMXG), Hill AFB - Page 5

Metal storage rails shall be used to support stored trays and be configured with rollers or glides including the pick window. The storage rails shall allow tray placement on a minimum of 4” center locations. The storage rails shall enable safe storage of trays loaded to maximum capacity without deformation.

3.2.7. STORAGE WINDOW

The storage window width shall be the width of the tray plus a minimum of 1 inch on either side.

The lower edge of the storage window shall be located between 36 + 2 inches from the floor.

The storage window shall be located on the front of the VLM.

3.2.8. PANELS

3.2.8.1. ENCLOSURE PANELS

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

VLM outer panels shall be bolted solid metal to ensure security protection and fire suppression.

The panels shall be bolted from the outside to permit removal for maintenance, shelf adjustment or emergency access. Solid metal panels shall be installed to enclose the top of each VLM.

3.2.8.2. MAINTENANCE SERVICE PANEL

technically acceptable.

A removable or hinged service panel shall provide maintenance access to operating parts such as motors, brakes, and other respective components. The panel shall be equipped with safety interlock switches to prevent the VLM from operating when the service panel is open. The bottom of the service panel shall be located a minimum of 18 + 6 inches above the floor.

3.2.9. MAINTENANCE ACCESS

All parts requiring periodic maintenance shall be easily accessible either by way of service panel or other access point.

3.2.10. SERVICE LIFE

All equipment furnished shall be new and of high quality to ensure the complete VLM system is designed to operate for a minimum of 20 years. This shall be demonstrated from historical verifiable performance data respective to vendor specific operational VLM in the private sector or government.

3.2.11. DRIVE COMPONENTS

Appendix A (309 MMXG), Hill AFB - Page 6

3.2.11.1. MOTORS

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

Vertical lift motors must be a minimum dual 7.5 HP motor configuration for 30 inches per second retrieve/store time under maximum load at continuous duty. Motors shall not exceed their fully rated load when at specified maximum capacity under the most severe conditions likely to be encountered. All motors shall be designed for continuous duty at an ambient temperature, 40 to 110 degrees Fahrenheit. Motors shall be drip proof and designed to operate on 480 VAC, 40 Amp, 3 phase electrical power. Motors shall have an electronically controlled soft start-stop & shall be equipped with an overload device. Additionally, all motors & controls shall be located 18” above the floor required under explosive applications.

3.2.11.2. GEAR REDUCERS

Gear reducers shall not permit oil to leak. The maximum input horsepower rating of the gear reducer shall not be less than the horsepower of the attached drive motor. Motor and reducer frames shall be compatible.

3.2.12. CONTROLS

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

VLM shall have a permanent control cluster that is either a push button or membrane type. The control cluster shall be located on a swivel arm attached to either side and shall be no higher than 42 inches from the floor. As a minimum, the control cluster shall contain an alpha numeric keypad to activate movement of the extractor, maintenance functions, and operational status.

Emergency stop buttons shall be located on each side of the VLM. The control cluster shall have a visual display which indicates the current tray number on the extractor. The VLM shall have an "on/off" key lock switch to control the unit's electrical power.

3.2.13. OBSTRUCTION SENSORS

Sensors shall be mounted on the VLM at the pick window to stop movement of the extractor if an object extends through the sensor plane opening, or the extractor movement area. If this condition occurs, operations shall abort and either an audible tone or error message shall be visually displayed on the control panel.

3.2.13.1. LOAD HEIGHT SENSORS

Sensors shall be mounted at the pick window to measure the load height of the tray. This shall be used by the VLM controller to ensure there is adequate height clearance to store the load. If there is not adequate height to store the load, the storage procedure shall be aborted and an error message transmitted either audibly or visually displayed on the control panel.

Appendix A (309 MMXG), Hill AFB - Page 7

3.2.14. LIGHTING

The VLM shall have overhead lighting, which shall measure not less than 50 foot-candles at the pick window. The lighting shall be continuous along the length of the pick window.

3.2.15. FIRE SUPPRESSION

Two sprinkler heads shall be installed on the VLM top cap. The sprinkler heads and piping shall be designed to provide a minimum of 180 GPM with a single connection point. Piping for VLM located side-by-side shall utilize the same piping. Fire suppression drawings and calculations shall be provided and approved before the installation of the VLM. Drawings shall show an installation diagram and connection point to existing fire suppression system. Contractor is responsible for installation of complete fire suppression system throughout VLM and shall provide a stub for facility connection.

3.2.16. SECURITY DOOR

The following requirements need to be as stated, or functional equivalent, to be considered technically acceptable.

A motorized Roll-Up type metal security door shall be provided to enclose the pick window opening when the VLM is not in use. When closed, the door shall prevent access to components inside the unit. It shall be of sufficient strength and durability such that extraordinary means are required to gain access to the VLM when the door is closed. The security door shall be lockable using a key lock switch for up and down control. A minimum of two sets of keys shall be provided for each lock. The door shall be an integral part of the VLM and shall allow unobstructed access to the pick window. The opening mechanism shall be motorized dual chain driven inclusive of sprockets and other mechanical devices to support smooth operation of the doors opening and closing.

3.2.17. SOFTWARE CONTROLS

3.2.17.1. SYSTEM COMPATIBLITY

An optional feature where the VLM could accept retrieve & store commands from Air Force Material Processing System MPS/D230. Additionally, if operational error codes occur resulting from a malfunction, they shall be transmitted to MPS with status information.

3.2.17.2. CONTROLLER

The controller shall be a programmable modular configuration. The controller shall have a command driven interface capable of asynchronous responses. Commands shall include status, retrieve/move and store/move. In addition, if a tray is currently at the pick window, a retrieval command for a new tray will cause the existing pan to be automatically stored and the new tray retrieved. A command to store a tray currently in the pick window without retrieving a tray shall be supported. The controller shall respond when commands are completed and not require continuous polling to determine completion status. Inclusion of the error code in the completion

Appendix A (309 MMXG), Hill AFB - Page 8 message is required. The actual failure or completion code shall be available for lookup through the interface.

3.3. DELIVERY & ASSEMBLY

The Government shall be responsible for all necessary facility preparation work. The Contractor shall provide the Government drawings, asset/facility location, and/or requirements related to electrical power, plumbing, and fire suppression no later than 60 days prior to scheduled delivery date.

The Contractor shall provide all necessary equipment and personnel to receive and offload materials. At the delivery, a representative from the VLM manufacturer shall be on-site to ensure all components are free from defect and undamaged after unloading. Assembly shall be performed by manufacturer-trained installers. The Contractor shall provide all manuals in accordance with CDRL A003 (DI-TMSS-80527), Commercial Off-The-Shelf (COTS) Manuals & Associated Supplemental Data, at the time of delivery.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

The VLM shall be inspected to verify each meets all requirements of sections 1, 2, and 3 of this appendix and cover purchase description. These inspections shall be completed as part of the system checkout and again as a part of the quality conformance testing. Acceptance is inclusive of all inspections and operational tests for conformance to Appendix A and cover documents as the final approval for acceptability of the VLM.

4.2. REMEDIAL & SUSTAINMENT MAINTENANCE

Remedial and ongoing maintenance sustainment of the VLM, Carousels, and other types of storage aids at Hill Air Force is performed by a specific servicing repair contractor under contract agreement. All new storage aids delivered to Hill Air Force Base are subject to repair and maintenance under the provisions of this contract. The Manufacturer shall agree to provide access support inclusive of technical maintenance data, replacement parts, and VLM processor control software. Additionally, training shall be provided for the incumbent servicing repair entity inclusive of all operational and maintenance aspects of the VLM.

4.3. TESTS

The following tests shall be performed on the system as part of the system acceptance testing and again as a part of quality conformance testing for final acceptance.

A) Upon completion of installation, the Contractor shall perform a functional acceptance test demonstrating full performance per manufacturer’s specification(s) on the VLM. Prior to acceptance testing, the Contractor shall provide a written copy of the acceptance test procedures for government approval in accordance with CDRL A001 (DI-QCIC-80553), Appendix A (309 MMXG), Hill AFB - Page 9

Acceptance Test Plan. Upon approval of the acceptance test procedures, the Contractor shall schedule an acceptance test meeting with the PM and other Government technical representatives. All testing shall be completed until the VLM passes all tests to the satisfaction of the Government team. Once the acceptance process is complete, the Contractor shall provide an acceptance test report for the VLM in accordance with CDRL A002 (DI-QCIC-81891), Acceptance Test Report.

No. Paragraph Testing

3.2.4.2., 3.2.13., 3.2.13.1.

All safety interlock switches, sensors, touch bars, and stop buttons shall be tested to ensure that they are functionally operational.

4.4. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with CDRL A004 (DI-MISC-81356), Certificate of Compliance.

No. Paragraph Certifications

1 3.2.2.

The Contractor shall certify that the weight of the fully loaded VLM is adequately distributed to not exceed the capacity of the floor as specified.

2 3.2.4.1.

The Contractor shall certify that all extractor support mechanisms have a minimum

6-to-1 safety factor based on yield strength.

3 3.2.10.

The Contractor shall certify that the Vertical Lift Modules are designed to function a minimum of 20 years.

4.5. WARRANTY

The Contractor shall ensure a standard commercial warranty is included with the VLM. A copy shall be provided to the Government upon asset acceptance.

5. DATA

5.1. CDRLS

The contractor shall provide a minimum of two (2) copies of contract information data, one (1) hard (paper) copy and one (1) electronic copy, in accordance with the corresponding requirement for each Data Item below:

CDRL Title Data Item

Description PWS / Appendix

Paragraph A001 Acceptance Test Plan DI-QCIC-80553 Appendix A, 4.3A A002 Acceptance Test Report DI-QCIC-81891 Appendix A, 4.3A

A003 Commercial Off-The-Shelf (COTS) Manuals &

Associated Supplemental Data DI-TMSS-80527 Appendix A, 3.3

A004 Certificate of Compliance DI-MISC-81356 Appendix A, 4.4