PD09WRGBGBEB12.DOC

PD09WRGBGBEB12

8 February 2010

CAGE 98752

Purchase Description

Common Multi-Platform Boresight System (CMBS)

1.0 SCOPE

1.1 Scope. This effort shall include procurement of a fully mature, common multi-platform boresight system (CMBS) including operation manuals with Illustrated Parts Breakdown (IPB). The measurement equipment shall be common support equipment compatible with, and work in conjunction with, the F-15 and F-16 aircraft specific adapters and software.

1.2 Background. Boresight procedures on aircraft are performed to verify and align the critical weapons' systems used by the pilot and aircraft avionics. Boresighting is performed when excessive G-Ioads or unusually violent maneuvers occur, where there is a hard landing, where there has been aircraft structural damage or repairs performed, where the pilot reports a discrepancy, when timed scheduled boresighting is required, or where the local aircraft maintenance chief has determined there is a need. The present manual optical boresight system requires complex calibration procedures to insure instrument readiness and executing alignment of weapon systems on aircraft. The aircraft mission sortie rate is very high and weapon system alignment and accuracy requirements become more necessary under such conditions. Therefore, there exists the common need for synchronization of the aircraft weapons' systems with clear and precise procedures within aggressive environments using the most expeditious methods possible.

2.0 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in section 3 and 4 of this specification. This section does not include documents in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this specification, whether or not they are listed. If tests were accomplished and passed by a previously released version of the referenced documents on identical items, then the contractor shall submit the test results as compliance to the requirements in question.

2.2 Government Documents.

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation.

FEDERAL

FED-STD-595

Colors Used in Government Procurement

MILITARY SPECIFICATIONS & STANDARDS

MIL-STD-130N

US Military Property, Identification Marking of

MIL-STD-461F

Control of Electromagnetic Interference Emissions and

Susceptibility, Requirements for

MIL-STD-810G

Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-889B

Dissimilar Metals

MIL-STD-1472F

Human Engineering

MIL-PRF-23377J

Primer Coatings: Epoxy, High-Solids

MIL-PRF-26915D

Primer Coating, for Steel Surfaces

MIL-PRF-85285D

Coating: Polyurethane, Aircraft and Support Equipment

HANDBOOK

DEPARTMENT OF DEFENSE

MIL-HDBK-808

Finish, Protective and Codes for Finishing Schemes for Ground Support and Equipment

MIL‑DTL‑0053030

Intermediate Primer MIL-STD-882D System Safety

MIL-STD-889B

Dissimilar Metals

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available are available online at http://assist.daps.dla.mil/quicksearch/ or www.dodssp.daps.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D Philadelphia, PA 19111-5094)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DoDISS are the issues of the documents cited in the solicitation.

NFPA Pamphlet 70

National Electrical Code

NIST

National Institute of Standards Technology

NSTL

National Standards Testing Laboratory

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from: NFPA/ National Fire Protection Association, Battery March Park, Quincy MA 02269 Phone (617) 770-3000 (Ext 240)

2.4 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 General. The contractor shall provide a system of common boresighting equipment, one set for F-16C/D Blocks 30, 40 and 50 aircraft and one set for F-15E aircraft. All hardware shall be in new/un-used condition manufactured from latest technology materials. System architecture as detailed herein is provided as a single example of proven boresight industry equipment presently used by the United States military for the boresighting of military aircraft weapons systems using a common hardware concept. This system architecture shall meet or exceed the performance and repeatability standards of the existing telescope-based boresight systems’ accuracies as stated herein. The hardware shall be factory calibrated to industry standards and to the tolerances as set forth within this document. The contractor shall provide all technical data calibration procedures, including calibration reference point drawings showing critical parameters, and training aids and materials to the Government prior to hardware delivery to completely familiarize Air Force military personnel in the operation and application of the hardware on both the F-15 and F-16 aircraft's weapons and avionics systems. The CMBS shall interface with the aircraft using the alignment fixture points already established for the aircraft. Contractor shall research, develop and verify aircraft interface data to ensure the fit and accuracy of the CMBS. The contractor shall provide the Government with the verified data. No aircraft modifications shall be required. The Contractor shall perform all necessary testing and analysis of the boresight systems in a real-world application to determine suitability as a replacement to the original aircraft manufacturer's boresight systems.

3.1.1 Growth Provisions. The CMBS shall be capable of measuring positional accuracy in aircraft coordinates (x, y, and z).

3.2 Preproduction samples. Two samples shall be subjected to preproduction inspection in accordance with 4.3; one F-16 sample and one F-15 sample.

3.3 CMBS Description

3.3.1 Common Boresight System Configuration. The CMBS shall be a computerized measurement system that will be used in the alignment of the aircraft weapons systems and avionics. It shall consist of a common measurement system and aircraft-specific fixtures that will attach to specific aircraft alignment points already established by the aircraft manufacturer on the aircraft for the present manual system. The CMBS boresight system shall have a computer control feature that can be used in varying climates with consideration of the user climate appropriate gear (See 3.3.3 & 3.3.4). The CMBS system shall have no target board requirements.

3.3.1.1 System Accuracy. The CMBS shall have an accuracy no less than the existing legacy system.

a. Measurement Accuracy: No less than 0.3 milliradians

b. Total System Accuracy: No less than 0.5 milliradians

3.3.2 Measurement System. The CMBS measurement system shall be composed of common hardware and sensing equipment to all aircraft configurations listed in 3.1. The components of the measurement system, with the exception of the computing resource, shall be captive to the aircraft. The measurement system shall provide step-by-step computer generated information to the operator on the alignment procedure to be performed. The measurement system shall also store aircraft weapon system misalignment values for later retrieval. Parameters such as operator's name, aircraft tail number, and time/date will be stored with the data. When the weapon system is determined to be misaligned, the CMBS shall provide the operator with real-time information regarding the misalignment value in all three axes (pitch, roll, and yaw) on the computer display. If applicable, the information shall be continuously displayed and reveal changes as adjustments are being made to realign the system or mount. Total system accuracy of the measurement system shall not be affected by the operation of internal components while providing continuous and real-time feedback of 3-axis position. The CMBS shall have the capability to support angular pitch, roll, and yaw measurements. The CMBS shall also have the capability to support positional measurements relative to the aircrafts’ x, y, and z coordinate system. The CMBS measurement system shall not drift or require resynchronization during boresight operations.

3.3.2.1 Illumination. The CMBS control panel shall be arranged and adequately illuminated so that all controls, switches, and displays shall be legible and may be operated in any ambient lighting conditions to include bright sunlight and darkness. The control panel shall have variable illumination to allow easy readings of all instruments and controls on the control panel.

3.3.3 Environmental Conditions and Limits. The CMBS shall be designed and tested to meet the requirements specified herein. The CMBS shall be fully functional, outdoors, in climates ranging from inside the Arctic Circle to SWA Deserts.

3.3.3.1 Operating Temperature Range. The CMBS shall be capable of operating in ambient temperatures ranging from 22o F to 122o F.

3.3.3.2 Storage Temperature Range. The CMBS shall be capable of storage in ambient temperatures ranging from -40ºF to 180ºF without system failure; objective -80oF to 224oF.

3.3.3.3 Altitude. The CMBS shall be capable of operating at any altitude from sea level to 8,000 feet without de-rating; objective is 12,000 feet. The CMBS shall be capable of storage and transportation at any altitude from sea level to 12,500 feet; objective is 25,000 feet. De-rating of the CMBS shall be allowed at altitudes above 25,000 feet.

3.3.3.4 Humidity. The CMBS shall be subject to natural high humidity conditions that randomly vary the temperature between 79° and 95°F with the relative humidity reaching between 85% and 95% over a 24 hour period. Immediately following the humidity cycling without drying or allowing the unit to dry, perform the test as specified in 4.10.7. The CMBS shall be inspected during the test, and there shall be no leakage, damage, evidence of degradation, failure, or impending failure of any portion of the system.

3.3.3.5 Fungus Resistance. All materials used shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The CMBS shall be suitable for operation and storage as specified in 4.10.11.

3.3.3.6 Rain. The CMBS shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10-inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6-inches of rain per hour impinging on the CMBS at angles from vertical to 45°. Examine the item and conduct a visual inspection and test as specified in 4.10.15. The system shall be inspected during the test, and there shall be no leakage, damage, evidence of degradation, failure or impending failure of any portion of the system.

3.3.3.7 Salt Fog Exposure. The CMBS shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance as specified in 4.10.12.

3.3.3.8 Sand and Dust Resistance. The CMBS shall be capable of storage and operation during exposure to 1400 milligrams per cubic meter wind-blown sand (particle size 150-1000 microns) for 90 minutes or dust (particle size 10-150 microns) at wind speeds up to 60 miles per hour (mph) for 12 hours without damage or deterioration of performance as specified in 4.10.13.

3.3.3.9 Explosive Atmosphere. The CMBS shall be capable of operation in a fuel-air atmosphere without ignition as specified in 4.10.14.

3.3.3.10 Vibration, Loose Cargo. The CMBS shall be capable of operation following exposure to vibration as specified in 4.10.8. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the CMBS.

3.3.3.11 Shock, Transit Drop. The CMBS shall be capable of operation after sustaining a drop, based on its size, as specified in 4.10.10. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the CMBS.

3.3.3.12 Shock, Bench Handling. The CMBS shall be capable of operation after sustaining a 4” drop onto a hard surface as specified in 4.10.9. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the CMBS.

3.3.3.13 Electromagnetic interface (EMI). The CMBS shall be tested in accordance with accordance with MIL-STD-461F as specified in 4.10.16.

3.3.3.14 Solar Radiation. The CMBS shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments.

3.3.4 Human engineering. The CMBS shall be designed in accordance with MIL-STD-1472F for ease of operation, inspection, and maintenance, including but not limited to the use of arctic mittens and Mission-Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

3.3.5 System Components. Each aircraft boresight kit shall be designed and manufactured for that specific type of aircraft and shall include all accessories required by the CMBS to boresight the same aircraft boresight stations detailed herein for the F-15 and F-16 aircraft with the accuracies as detailed herein.

3.3.5.1 CMBS Common Hardware. The contractor shall provide CMBS common hardware, cables, all other associated accessories and handling enclosures. Any special tools and calibration equipment required by the field for calibration or operation of this boresighting system shall be furnished by the contactor as part of the CMBS system common hardware. The system shall be able to be calibrated by regional PMELs. System shall provide a reference in three axes: elevation (pitch), azimuth (yaw), and roll, with respect to the aircraft reference line as well as positional accuracy in aircraft x, y, and z coordinate system. The system circuits shall incorporate Built-In-Test (BIT) architecture for power-on, background and initiation modes. An indicator shall indicate system is functional and input power is available. BIT shall detect malfunctions that cause a failure to operate under its normal conditions. The system design shall insure accurate, reliable, temperature stable, noise immunity and time stable performance. When commanded, the sampled data is converted and serialized for output to the computer.

3.3.5.1.1 System Computer. The CMBS computer shall control the operation of the sensing equipment in the CMBS system. The computer coordinates BIT operations, initiates operations, and accepts acquired data from the sensors for further processing. The computer display shall allow the operator to get real-time feedback in all three axes. The computer shall permit the injection of or measure specific aircraft weapons systems CMBS measurement offsets, identified in Air Force Precision Measurement Equipment Laboratories (PMEL), into the computer. These offsets, stored in memory within the computer processor, shall insure precise detection and measurement of linear and angular differences of the weapons stations to the Aircraft Boresight Reference Line (ABRL) and allow the operator to continuously measure the three axes of the modified boresight mounting point station (hard-points on aircraft). The sensing equipment shall be used to continuously measure the ABRL offset, allowing the computer to compensate for aircraft movement within a range until such movement will affect computer accuracy, thus insuring stable accuracy and consistency in boresight performance. The computer shall allow for the translation of axis of operation to the axis of the aircraft (if required) without operator involvement. Internally, the computer shall contain storage of software, required accuracy data and aircraft boresight results. The computer microprocessor shall be current or next generation processor in architecture, and shall perform noise immunity and immunity to ambient light. The computer shall perform roll-pitch-yaw and x, y, and z calculations in aircraft coordinates. The computer shall allow for data download and transfer to include, but not limited to, a minimum of two USB 2 ports. The computer shall operate on AC (85-265 VAC @ 47-440 Hz) or DC power (26.5-32 VDC). The input power circuits shall automatically sense input power and select the internal processing circuitry without operator action, and shall be filtered to meet EMI susceptibility and emission requirements. The sensor shall be interfaced to the computer using industry standards.

3.3.5.1.1.1 Software. The computer software shall operate in the most current Microsoft Windows environment and compatible with not-yet released software versions. The software shall include aircraft independent operations and aircraft specific software. Aircraft-specific software is to be written in “script” to be viewed and used with instructions for operator instructional purposes during boresight procedures. There shall be a help menu to assist the operator during boresight procedures.

3.3.5.1.2 Reliability. Common CMBS Hardware shall have a calculated mean time between failure (MTBF) of not less than 1500 hours. (Objective: greater than 1750 hours) CMBS shall incorporate an elapsed time meter as the means to measure MTBF. A failure is defined as the event or inoperable state in which any item or part of an item does not perform as specified. Common wear items such as light bulbs shall not be considered as chargeable failures.

3.3.5.2 F-16C/D Aircraft Boresight Kit. The contractor shall furnish a complete F-16C/D aircraft boresight kit, as detailed and necessary hardware for mounting on the various weapons stations as detailed within Table 2. The kit shall be compatible with the aircraft and CMBS systems. Additionally, the kit shall include all associated hardware and CMBS computer software necessary for the proper and complete CMBS system boresight verification, calibration and adjustments to the F-16C/D (multi-block configurations).

3.3.5.3. F-15E Aircraft Boresight Kit. The contractor shall furnish a complete F-15E aircraft boresight kit, as detailed and necessary for mounting on the various weapons stations as detailed within Table 4. The kit shall be compatible with the aircraft and CMBS systems. Additionally, the kit shall include all associated hardware and CMBS computer software necessary for the proper and complete CMBS system boresight verification, calibration and adjustments to the F-15E.

3.3.6. Transit Cases. The CMBS shall be housed in ruggedized transportation cases to protect the fixtures from contact with any object which could affect the boresight equipment accuracy in interface or functional characteristics. The cases shall be equipped with handles for two-man lifting as required per Mil-Std-1472F and a pressure relief valve.

3.3.7.

CMBS Basic Operation. The CMBS shall ensure that the boresight operators will not have to remove the external fuel tank for the boresighting process. The aircraft will not require jacking, leveling or repositioning and the established aircraft reference centerline shall be used. Furthermore, any aircraft movement during the boresight and alignment process shall be detected by the CMBS and will be automatically compensated for misalignment in the weapons component boresight alignment readings.

3.3.8. System Size. The size and weight shall be as small as practically possible consistent while meeting the performance requirements specified herein. Each CMBS case shall be no more than two-man lift capable. Complete CMBS shall fit on one 463L pallet; 88”x 108” with usable space of 84”x104”. Total CMBS weight including adapters shall not exceed 800 lbs and 102” high; objective: total system weight of 500 lbs or less.

3.3.9. Task Operations. The CMBS shall require no more than two operators to boresight the aircraft. The boresight process shall take no more than eight hours or sixteen man-hours from set-up to aircraft returned to mission-ready condition; plus potting cure time(objective: boresight completion time shall be no more than four hours or eight man-hours). The CMBS shall also have the capability to perform boresight alignment confidence checks or minor boresight alignments without LRU removal.

3.3.10. Calibration. The CMBS shall maintain a calibration cycle no less than 24 months. PMEL training shall be included in order to be able to calibrate the system at regional PMELs.

3.3.11. Rechargeable Battery. If a rechargeable battery is incorporated in the CMBS, the battery shall be maintenance free and have an operation time of not less than five hours, with an objective of eight hours. Additionally, the rechargeable battery must be easily replaced without disassembling the measurement housing and if there is an internal recharge circuit it must be designed to operate from the power sources as noted in 3.3.5.1.1.

3.4 Materials, Protective Coatings, and Finish.

3.4.1 Materials. Components and materials shall be selected with consideration given to the minimum acceptable service life and the environmental conditions stated herein. The use of recovered or recycled materials is highly encouraged. Materials defined as Class 1 or Class 2 Ozone Depleting Compounds/Substances (ODC/ODS) shall not be used.

3.4.2 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during service shall not be used or shall have a means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Ferrous structures and surfaces shall be primed with zinc rich primer or equivalent in accordance with MIL-PRF-26915D, Type II. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with strontium chromate based corrosion inhibitor or equivalent, Type I, Class C2 of MIL-PRF-23377J Amendment 1. Raw metal edges shall be coated with the primer before topcoating. Topcoat shall be polyurethane in accordance with Type I, Class H of MIL-PRF-85285D; Chemical Agent Resistant Coating (CARC) shall not be used. Fasteners, handles, and fittings used in the assembly of the CMBS shall also be primed and painted. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications.

3.4.3 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889B, shall not be in contact with each other. The use of dissimilar metals only when separated by suitable protective material is permitted.

3.4.4 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130M. Painted markings shall be one inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than one-half inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of FED-STD-595B, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of FED-STD-595B.

3.4.5 Identification plate. An identification plate in accordance with MIL-STD-130M shall be securely attached to the CMBS including each adapter in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). In addition the identification plate shall include three (3) blank lines across the bottom for future etching by the USAF. Universal identification (UID) information in accordance with MIL-STD-130M shall also be permanently affixed to the CMBS, near the identification plate.

3.4.6 Finish. The exterior finish color of the storage cases shall be Gray, color 26173, per FED-STD-595/MIL-PRF-85285.

3.4.7 Shock meter. The CMBS shall include a 100G accelerometer (shock meter) to determine abuse in the field or during shipping.

3.5. Transportability. The CMBS shall be transportable via all modes of shipment: rail, sea, road, air and shall be capable of withstanding mechanical shock and vibration characteristics of rail, sea, air and road transport.

3.6 Life expectancy. The CMBS shall be designed to have a service life of no less than 20 years and shall be suitable for extended storage in an outside environment for no less than 25 years.

3.7 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

3.8 Workmanship. The CMBS, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include, but are not limited to, freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of soldering, welding, brazing, painting, wiring, and riveting; marking of parts and assemblies; alignment of parts and tightness of assembly fasteners.

3.9 Welding. Welding procedures shall be in accordance with American Welding Society code. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings.

3.10 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.11 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.12 Cleaning. The CMBS shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

Table 1 Existing F-16 Aircraft Boresiqht System Fixtures

(Used at aircraft centerline stations)

(2 each)

Fixture

Forward ABRL

Boresight Fixture

HUD Alignment

Boresight Tool

Boresight Fixture

Adapter Assembly Fixture

INU Mount

Rate Sensor Unit (RSU)

Positioning Fixture

Boresight and

Positioning Fixture

Left Pod Mounts

Boresight Transfer

Fixture

Right Pod Boresight

Check Fixture

Left Pod

Boresight Check Fixture

Right Pod Mount

Positioning Fixture

Left Pod Mount

Positioning Fixture

Left and Right Pod

Fixture

Boresight Checking

Fixture

General:

The CMBS shall support the F-16 C/D versions of aircraft. It shall provide aircraft sensors for the following weapon systems: Radar, Heads-Up-Display (HUD), Gun, Rate Sensor Unit (RSU), Inertial Navigation Unit (INU), Left and Right Angle-of-Attack (AOA), and Left and Right hard point pods. Mounting fixtures required for positioning the weapons system mounts shall also be provided as part of the CMBS and will attach to the already established alignment mounting points on the aircraft. The overall CMBS tolerances shall be no greater than the legacy system tolerances.

Table 2.

The F-16 Aircraft Boresight Accuracy

Required Measurement Accuracies

0.5 mr

0.5 mr

1.7 mr

1.7 mr

2.5mr

1.7 mr

1.7 mr

2.5 mr

Note: 1 mr = 3’-26.26”

PDR=Purchase Description Performance Requirement

Table 3 Existing F-15 Aircraft Boresight System Fixtures

Optical Alignment Collimator

Adapter with Clinometers Platform

Adapter

20MM M61A1 Gun Alignment Adapter

Alignment Telescope Adapter

Mount Alignment Adapter

Attitude Heading Reference Set

Alignment Adapter (for AHRS Gyro)

RADAR Antenna Mount Alignment

Adapter

Fixture

Left Pod Mount Positioning

Fixture

Mount Alignment Adapter

MAD Mount Boresight Adapter

F-15 Aircraft

The CMBS shall support the F-15E aircraft. It shall provide aircraft adapters for the following weapon systems: Radar, HUD, Gun, INU, JHMCS Cockpit Mapping Robot and LANTIRN pods. Mounting fixtures required for positioning the weapons system mounts shall also be provided as part of the CMBS and will attach to the already established alignment mounting points on the aircraft. The overall CMBS tolerances shall be no greater than the legacy system tolerances.

Table 4.

The F-15E Aircraft Boresight Accuracy

Required Measurement Accuracies

2.0

3.0

HUD

Optical Ver (Upper Ret)

2.0

Yaw

Roll

Yaw

Roll

**Note: All figures are in milliradians (mr) unless otherwise stated. 1 mr = 3’-26.26” PDR=Purchase Description Performance Requirement

4.0

VERIFICATION

4.1 General.

The operational characteristics of the CMBS shall meet all performance and function requirements specified in Section 3. All contractor inspections and testing requirements as specified herein, except as otherwise noted, may be proposed by the contractor. Inspection shall be performed on the F-15 and F-16 aircraft. The Contractor shall submit all test plans and procedures for Government approval. Government reserves the right to be present during all testing and shall be notified 30 days before start of testing. Government acceptance of test and inspection results is required before CMBS is fielded.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Preproduction inspection (see 4.3).

b. Operational inspection (see 4.4).

c. Conformance inspection (see 4.5).

4.3 Preproduction inspection. The preproduction CMBSs shall be subjected to the examinations, tests, and analyses described herein. The contractor shall provide or arrange for all test equipment and facilities. No further testing will occur until the preproduction inspection is completed and the results are reviewed and approved by the Government.

4.4 Operational inspection. An operational test and evaluation (OT&E) shall be performed following the successful completion of the preproduction inspection. No further testing will occur until the inspection is completed and the results are reviewed and approved by the Government.

4.5 Conformance inspection. Each preproduction CMBS shall be subjected to the examinations and tests described herein.

4.6 Government Furnished Equipment for Testing. The Government shall provide access to operational aircraft for contractor testing and functional use of the CMBS and shall provide all technical assistance necessary for operation.

4.7 Inspection Requirements

4.7.1 Apparatus and Instruments. Apparatus and instruments used in conjunction with the contractor-conducted calibration and testing specified herein shall be of laboratory precision-type, calibrated at proper intervals to ensure laboratory accuracy and traceable back to National Institute of Standards Technology, National Standards Testing Laboratory, or other Standards laboratory.

4.7.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data and/or shorter intervals shall be provided as appropriate for any specific test. The Contractor shall submit the resulting test report for Government approval.

a. Date

b. Time started

c. Time finished

d. Ambient temperature

e. Ambient light

f. Aircraft tail number

g. Fixture name and part number

h. Test performed

i. Test Standard (commercial/military) call out

4.7.3 Test rejection criteria. Throughout all tests specified herein, the CMBS shall be closely observed for the following conditions, which shall be cause for rejection:

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Structural failure of any component, including permanent deformation, or evidence of impending failure.

c. Evidence of excessive wear.

d. Poor fit or misalignment of components.

e. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

f. Computer or software failure or inaccuracy.

g. Evidence of corrosion.

A failure during Government functional testing is described as the CMBS unit not being able to perform its full operational capabilities as prescribed by the specification. Failure shall be documented in the area of aircraft type and boresight station. If a failure is correctable, documentation shall be furnished on what action was taken to correct it and prevent it from reoccurrence.

4.8 Test Conditions

4.8.1 Standard Atmosphere Conditions. Contractor-conducted testing shall be conducted at atmospheric pressure (approximately 29.92 inches Hg) and at ambient temperature

(22°F to 122°F +/-10°F) conditions. When tests are conducted with atmospheric pressure or ambient temperature differing materially from the above values, proper allowance and documentation shall be made for the difference from the specified conditions. The Contractor shall perform its calibration on the instruments comprising the CMBS in accordance with each instrument’s original equipment manufacturer’s recommended calibration instructions. All test equipment used during the testing of the CMBS shall be calibrated or have been calibrated and is current.

4.8.2 Contractor-conducted Preliminary Run In. Any preliminary run-in of the CMBS hardware as recommended by the manufacturer shall be performed by the manufacturer prior to submission of the boresight system for performance testing. A calibration date, list of standards used, calibration test points, as found and as left data, uncertainties, environmental conditions at time of calibration and a traceability statement stating that the calibration is traceable to NIST or other nationally recognized standards, etc shall be included in the calibration report. The calibration certificate requirements can be found in AF Technical Order 00-20-14, Section 4.5.1.4

4.9 Detailed inspection requirements.

4.9.1 Examination of product. Each CMBS shall be examined to verify compliance with the requirements herein. A contractor-generated, Government-approved checklist that identifies each relevant requirement not verified by a test or analysis and the inspection results shall be used. Particular attention shall be given to materials, workmanship, dimensions, surface finishes, protective coatings and sealants and their application, welding, fastening, and markings. Proper operation of each CMBS function shall be verified. Compliance with the human engineering requirements of 3.3.4 shall be demonstrated.

3.6 Life expectancy.

Contractor analysis of life of the CMBS major components (see 4.14).

4.10 Environmental testing.

4.10.1 High temperature storage test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 501.5, Procedure I, to demonstrate operational functionality following storage in a high temperature environment with a maximum temperature of at least 180˚F; objective 224ºF. Test duration shall be a minimum of seven 24-hour cycles as specified by test method.

4.10.2 High temperature operation test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 501.5, Procedure II, to demonstrate operational functionality in a high temperature environment with a maximum temperature of at least 122˚F. Test duration shall be a minimum of three 24-hour cycles as specified by test method.

4.10.3 Low temperature storage test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 502.5, Procedure I, to demonstrate operational functionality following storage in a low temperature environment with a minimum temperature of at most -40˚F; objective -80˚F. Test length shall be a minimum of 6 hours following stabilization at minimum specified temperature.

4.10.4 Low temperature operation test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 502.5, Procedure II, to demonstrate operational functionality in a low temperature environment with a minimum temperature of at most 22 ˚F. Test length shall be a minimum of 2 hours following stabilization at minimum specified temperature.

4.10.5 Altitude storage test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 500.5, Procedure I, to demonstrate operational functionality following storage in a low pressure environment equivalent to an altitude of at least 12,500 feet; objective 15,000 feet.

4.10.6 Altitude operation test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 500.5, Procedure II, to demonstrate operational functionality in a low pressure operation environment equivalent to an altitude of at least 8,000 feet; objective 10,000 feet.

4.10.7 Humidity test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 507.5, to demonstrate operational functionality in a high humidity environment of at least 95% relative humidity. Test duration shall be a minimum of ten 24-hour cycles.

4.10.8 Loose cargo vibration test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 514.6, Procedure II, to demonstrate operational functionality following exposure to vibration profile as specified by MIL-STD-810G, Method 514.6, Category 5.

4.10.9 Bench handling shock test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 516.6, Procedure VI, to demonstrate operational functionality following exposure to shock impulses as specified by test method.

4.10.10 Transit drop shock test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 516.6, Procedure IV, to demonstrate operational functionality following exposure to shock impulses as specified by test method.

4.10.11 Fungus resistance test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 508.6, to demonstrate resistance to fungal growth as specified by test method.

4.10.12 Salt fog exposure test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 509.5, to demonstrate operational functionality and resistance to corrosion following exposure to a salt fog environment as specified by test method.

4.10.13 Sand and dust resistance test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 510.5, Procedure I, to demonstrate operational functionality following exposure to an environment of blowing dust as specified by test method.

4.10.14 Explosive atmosphere test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 511.5, Procedure I, to demonstrate operational functionality in a fuel-air explosive atmosphere without ignition as specified by test method.

4.10.15 Rain test. A preproduction CMBS shall be tested in accordance with MIL-STD-810G, Method 506.5, Procedure III, to demonstrate operational functionality and resistance to water penetration as specified by test method.

4.10.16 Electromagnetic interference test. A preproduction CMBS shall be tested in accordance with MIL-STD-461F, to demonstrate operational functionality and limited electromagnetic interference under conditions for Air Force Ground Equipment as specified by MIL-STD-461F, Table V.

4.11 Contractor-conducted Calibration.

The Contractor shall calibrate each component of the common hardware and each aircraft interface adapter prior to delivery of all systems. The contractor-conducted calibration procedures shall indicate existing fixture required accuracies and the contractor's replacement adapter's requirements clearly verifying those accuracies are equal to or being higher in accuracy and repeatability than those required by the existing boresight hardware system. The contractor-conducted calibration and verification shall be witnessed by Government representatives from HQ AFMETCAL Det 1 and WR-ALC/GBEB or their designated representatives. Failure to meet existing accuracy requirements shall be cause for rejection. Any repeat of boresight fixture calibration/verification failure shall be cause for rejection and remanufacture.

4.12 CMBS Testing

4.12.1 F-16 Boresiqht Acceptance Testing. The Contractor shall conduct a thorough operational testing and comparison-based analysis of the CMBS relative to the telescope-based boresight procedures in as near-as-possible deployed conditions for the F-16C/D aircraft. Testing shall be conducted under the direction and control of HQ-ACC and WR-ALC or their delegated representative organization. The testing shall consist of complete boresight verification and adjustment of all weapons stations as detailed within Table 2. Furthermore, accuracy of the boresight shall meet all aircraft limits as detailed in Table 2. Failure to meet limits on any station during the period of field testing shall be cause for system rejection, unless such failure can be attributed to outside factors and eliminated upon further testing. After verifying the boresight kit meets accuracy requirements, two additional sets of data points shall be taken. Between each test run, the boresighting equipment shall be completely removed and reinstalled on the aircraft. The three sets of data collected shall be provided to the Government for review and acceptance to determine if system measurements are repeatable to contractor specifications.

4.12.2 F-15 Boresiqht Acceptance Testing. The Contractor shall conduct a thorough operational testing and comparison-based analysis of the CMBS relative to the telescope-based boresight procedures in as near-as-possible deployed conditions for the F-15E aircraft. Testing shall be conducted under the direction and control of HQ-ACC and WR-ALC or their delegated representative organization with the contractor support. The testing shall consist of complete boresight verification and adjustment of all boresighted aircraft systems as detailed within Table 4. Furthermore, accuracy of the boresight shall meet all aircraft limits as detailed in Table 4. Failure to meet limits on any aircraft system during the period of field testing shall be cause for system rejection, unless such failure can be attributed to outside factors and eliminated upon further testing. After verifying the boresight kit meets accuracy requirements, two additional sets of data points shall be taken. Between each test run, the boresighting equipment shall be completely removed and reinstalled on the aircraft. The three sets of data collected shall be provided to the Government for review and acceptance to determine if system measurements are repeatable to contractor specifications.

4.12.3 BIT and fault system test. The CMBS shall be tested to verify compliance with 3.3.5.1. Fault conditions shall be induced on the CMBS and the control system shall detect these faults as required by the respective sections herein. Correct operation of all controls associated with the fault system shall be verified.

4.12.4 System Computer and Software. The CMBS shall be tested to verify compliance with 3.3.5.1.1 and 3.3.5.1.1.1. Correct operation of all controls associated shall be verified.

4.13 Physical examination

4.13.1 Ozone, dissimilar metals, and material certification. The contractor shall provide certification that no ozone depleting substances are used in the construction of the CMBS, any dissimilar metals are suitably isolated or treated, and no explicitly prohibited materials are utilized. Verify compliance with requirements of 3.4.1, 3.4.3 and 3.7.

4.13.2 Riveting, welding, assembly, and workmanship inspection. The CMBS shall be inspected to verify compliance with the requirements of 3.8, 3.9, 3.10, and 3.11.

4.13.3 Paint certification. The contractor shall provide certification that all parts are treated, primed, and painted in accordance with the requirements of 3.4.2 and 3.4.6.

4.13.4 Markings inspection. The CMBS shall be inspected to verify compliance with the requirements of 3.4.4 and 3.4.5.

4.13.5 Weight and dimension measurement. The CMBS shall be measured, weighed and lifted to demonstrate compliance with the requirements of 3.3.8.

4.14 Functional Testing

4.14.1 Transportability. An engineering analysis shall be performed to demonstrate compliance with 3.5. The engineering analysis shall utilize the data for rail, sea, air, and road transportation modes referenced in MIL-STD-810G.

4.14.2 Life expectancy. An engineering analysis shall be performed to demonstrate compliance with the CMBS life expectancy requirement of 3.6 (20 years).

4.14.3 Reliability analysis. An engineering analysis shall be performed to demonstrate compliance with 3.3.5.1.2. See Appendix A herein for additional reliability definitions and clarification. Actual reliability testing is not required.

5.0 PACKAGING.

5.1 For acquisition purposes, the packaging requirements shall be as specified in the contract or order. When actual packaging of materiel is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command. Packaging data retrieval is available from the managing Military Department's or Defense Agency's automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6.0 NOTES.

(This section contains information of a general or explanatory nature which may be helpful, but is not mandatory.)

6.1 Acquisition requirements.