Updated_Purchase_Description.pdf

PURCHASE DESCRIPTION

L6WC01 – ADVANCED METAL FINISHING FACILITY BLAST

BOOTH ROBOT BLASTERS

1. Scope: Currently there are four (4) manual blast booths in building 20128, Robins AFB; two

(2) booths are for blasting using walnut hull blast media, one (1) uses aluminum oxide media, and one (1) uses glass bead media. This contract requires installation of one (1) blast system in each of these booths. The systems shall consist of a robotic arm that will be suspended from the ceiling of the existing booths, manipulate the existing blast nozzle and hoses, and control the starting and stopping of blast media and air independently. The system shall function in two (2) modes: One mode shall run pre-programmed teach pendant programs, where the item to be blasted is placed in a fixture or presented to the robot in an expected orientation. In this mode, the blast start and stop will be programmatically controlled. The second mode shall allow the operator to “drive” the robot using joystick control and start and stop media with a button on one of the joysticks. When using the “manual drive” mode, the operator shall utilize a camera and monitor system to view/verify the robot motion.

1.1. The purchase price shall include the system itself, delivery, all listed accessories/options, installation, testing/verification, training/familiarization, and warranty.

1.2. The contractor shall provide all materials, equipment, and labor necessary to deliver and install the AMFF Blast Booth Robot Blasters.

1.3. All work shall be completed in accordance with this purchase description and subject to the terms of the contract.

1.4. The first system shall be installed in one of the walnut hull booths, training completed, and Government approval obtained before beginning work to install the remaining systems. The first system to be installed shall be in one of the two walnut hull booths. The contractor shall complete installation and training on the first system and obtain government approval before begining installation of the remaining systems. Government approval/disapproval shall be given within two (2) weeks after installation and training on the first system.

A. Installation of the first system shall begin no later than 12 months after contract award.

B. The total Period of Performance shall not exceed 30 months.

C. At no time during contract performance shall both the aluminum oxide booth and the glass bead booth be out of operation at the same time.

2. Design: The AMFF Blast Booth Robot Blasters shall be new and complete, custom built to meet our application, and ready for immediate operation after installation, acceptance testing and training are completed.

3. Equipment Description: The AMFF Blast Booth Robot Blasters shall consist of the following subsystems.

3.1. Robot Hardware/Software:

A. The system shall consist of a Fanuc robot with a payload greater than or equal to 70kg.

B. The robot shall reach any location with an area bound by the booth’s inner walls offset inward by 1.5 ft and a lower and upper plane separated by 7ft. See Appendix A.

C. The system shall employ Handling Tool.

D. RoboGuide shall be loaded on the PC.

E. The robot controller shall be of type R-30iB or later with an i pendant.

F. The robot controller shall not be located in the booth.

G. The robot teach pendant shall reach all areas in the booth for teaching/programming parts.

H. The robot and any other electrical devices/systems installed in the booth shall have Class II

Division 1 Classification issued by a Nationally Recognized Testing Laboratory.

I. The robot shall employ Fanuc DCS and Collision Guard.

J. The robot shall employ a halo/wire guard to prevent part collisions.

K. Any axis in addition to the six (6) robot axes shall be included as an extended axis in

Group 1, thus allowing coordinated motion with the robot.

3.2. Robotic Blasting Modes:

A. The system shall have two (2) distinct modes of operation, program execution and manual drive mode.

(i). Program Execution

1). The system shall allow the operator to select a part and start the blasting sequence from the HMI.

(ii). Manual Drive 1). The contractor shall provide an intuitive control interface for controlling the robot motion and media control, for example joystick control.

3.3. Programming:

(i). The system shall allow teach pendant programming.

(ii). The system shall have the option of employing an algorithm to automatically create motion paths based on the four (4) corners of flat parts (points identified by the operator) and based on the four (4) corners and additional mid-points (points identified by the operator) for curved parts.

(iii). The system shall allow for the addition of future part programs and recipes.

(iv). The system shall allow a part program to be run anywhere within the work envelope.

1). The part(s) shall be located in the booth by the operator “touching off” three corners of the part(s). As an option, the part(s) shall be located in the booth automatically by a laser scanner.

2). The system shall allow multiple copies of the same program to be run within the same production run.

(v). The contractor shall provide two (2) non-consecutive weeks of programming support.

This shall be in addition to the programming training.

(vi). Any models created shall become property of the Government.

(vii). The motion path overlaps shall be based on the media pattern, to ensure uniform stripping.

3.4. Robot Support Structure:

A. The robot shall be mounted from the ceiling of the booth. A sketch of the booth is located in Appendix A.

B. If required to support the robot and associated hardware, the contractor shall design and install a structure external to the existing booth to support the selected robot and hardware.

3.5. Subsystem Hardware:

A. The existing media on/off switch shall be incorporated into and controlled by a single

Allen-Bradley PLC (Logix 5000 family).

B. The HMI hardware shall consist of a PC with a 21” monitor. This shall be on UPS backup.

C. The PC shall be configured with RAID 1 hard drives.

D. The PLC/HMI shall interface with the robot controller, in order to restore/backup TP programs and initiate robot motion/process (program start).

E. The communication protocol used for communication between the robot, PLC, HMI, and any remote I/O shall be Ethernet/IP.

3.6. Subsystem Software:

A. The OS for the PC shall be the latest version on Windows supported by the HMI, PLC, and

Robot software.

B. The HMI software shall be latest version of Rockwell Automation RSView SE (local) and shall be loaded on the PC. Factory Talk View Studio shall also be loaded on the PC.

C. The PLC software shall be latest version of Rockwell Automation Logix 5000 Pro Edition and shall be loaded on the PC.

D. The Government shall be provided and shall own the PLC and HMI source code (.ACD and .APA files) and no parts of the code shall be password protected, unless the Government will be given the password. This code will not be sold to 3rd parties, rather it will be used to troubleshoot the system and provide a backup in case of program loss.

3.7. Camera System:

A. The contractor shall provide a camera system with a minimum of three (3) cameras, one on the robot and two in the booth, to provide the operator with multiple views of the part being blasted. This system shall include a 21” monitor for viewing.

3.8. Data Recording:

A. The contractor shall provide a DVR for recording video of the process. The system shall store two (2) or more weeks of data. This video shall be time stamped for comparison to key strokes and in-process testing.

B. The key strokes from the pendant and keyboard shall also be recorded and time stamped.

C. There shall be a database of sensors with an automated report generation.

4. Acceptance Testing:

4.1. The complete factory and site acceptance plans shall be developed by the contractor;

reviewed and modified/approved (as appropriate) by the government contract technical representative; and mutually agreed upon prior to conducting any test. Documentation verifying the acceptance testing and verification shall be provided to the Government.

4.2. Factory Acceptance Testing

A. The contractor shall build a mock booth and completely setup robot hardware/software, subsystem hardware/software, and data recording at their facility.

B. Once the mock setup is completely assembled, working and the Government has approved the test plan, the contractor shall notify the Government POC via email and within forty five (45) days the Government shall send representative(s) to verify the following:

(i). The contractor shall demonstrate the ability to mock strip (no media) an un-programmed part with the use of the intuitive control interface.

(ii). The contractor shall demonstrate the ability to mock strip (no media) a programmed part started via the HMI.

(iii). The contractor shall demonstrate the creation of a program.

(iv). The contractor shall demonstrate the data collection.

(v). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

C. Upon successful demonstration of the above the Government will approve the system to be shipped to WR for installation.

4.3. Site Acceptance Testing

A. Once installation is completed and the Government has approved the test plan, the contractor shall notify the Government POC via email and within one (1) week the Government representative(s) shall verify the following:

(i). The contractor shall demonstrate the ability to strip an un-programmed part with the use of the intuitive control interface.

(ii). The contractor shall demonstrate the ability to strip a programmed part started via the

HMI.

(iii). The contractor shall demonstrate the creation of a program.

(iv). The contractor shall demonstrate the data collection.

(v). The Government representative(s) shall verify the robot hardware/software and subsystem hardware/software.

5. Installation:

5.1. The robotic blast booth system shall be installed by the contractor/vendors qualified representative(s) in the government’s designated facility/location in building 20128 on Robins AFB, GA. All items shall be assembled and installed utilizing best commercial practices and manufacturer’s installation procedures. The government shall supply all required utilities within ten (10) feet of the installation site.

A. The contractor shall provide a list of all required utilities three (3) months after contract award.

6. Training:

6.1. Within fifteen (15) days of installation and the completion of site acceptance testing;

operator, maintenance, and programming training will be provided for up to ten (10) Air Force civilian equipment operators and service technicians by the contractor’s qualified representative at no additional cost to the government. Training shall be provided for each system installed.

6.2. Training shall include:

A. Two (2) weeks of operator training, to include production runs on condemned assets and review of the operation manual.

B. One (1) week of maintenance training, to include a complete preventive maintenance cycle, basic troubleshooting, and review of the electrical/mechanical drawings and maintenance manual.

C. Two (2) weeks of programming/engineering training, to include a complete part creation sequence and review of the programming manual.

7. Additional System Requirements:

7.1. The robotic blast booth system shall include all of the necessary consumables required for initial operation.

7.2. The contractor shall provide three (3), one (1) week production support visits, scheduled as required throughout the year. The contractor shall be onsite within two (2) weeks of being notified that onsite support is required.

7.3. A final walk through inspection shall be conducted with the Government Technical Representative after the installation has been completed. Any components damaged, missing, or installed improperly will be identified and corrected by the contractor in a timely manner prior to completion of the contract. Only the Contracting Officer is authorized to make changes to the resulting award document and/or contract on behalf of the Government.

7.4. SAFETY REQUIREMENTS:

A. The contractor shall establish and maintain a safety and health program in accordance with the elements listed in the Appendix C (Safety Requirements). The contractor shall submit a Safety and Health Plan 10 days after award for review and acceptance by the WR- ALC/SE (Safety Office). The contractor shall ensure their Safety and Health Plan addresses, in detail, the items listed in the Appendix C. If task specific procedures are incorporated into a company local document, ensure those procedures are included/attached to the company's Safety and Health Plan. Referencing the company's local procedure/ document in the safety plan is not adequate. If the company's local procedure/document is not attached; Safety Plan will be returned "Not acceptable".

(Safety and Health Plan CDRL A001-DI-MGMT-81580/T, Contractor's Standard Operating Procedures)

B. The contractor Safety Plan shall address in detail the items listed in the Contract Appendix C, Part II through Part IV as applicable. For task specific procedures identified in the Contract Appendix C, the contractor's internal procedures for those tasks must be identifiable within the submitted Safety Plan or shall be provided in an amendment or addendum to the company's Safety Plan. If task specific procedures identified in the Contract Appendix C, are not submitted with the contractor's Safety Plan, the submitted

Safety Plan will be returned as NOT ACCEPTED. The contractor will have 5 working days to resubmit the Safety Plan, amendment or addendum to address or correct issues identified for non-acceptance. The WR-ALC Safety Office will provide acceptance or non-acceptance of the resubmission within 5 workings days of receipt to the COR who will notify the CO.

C. Mishap/Incident Reporting. The contractor shall report all mishaps/incidents in accordance with the contract Appendix C. The contractor shall immediately secure the mishap scene and damaged property and impound pertinent maintenance and training records until released by the Government's Safety Office (WR-ALC/SE). Such release shall be accomplished through the CO. The contractor shall cooperate and assist Government personnel in the investigation of the incident and submit an Accident/Incident Report within 24 hours of the accident/incident. The Contractor shall require all subcontractors to comply with required safety, health and fire standards. (CDRL A002, Accident/Incident Report, DI-SAFT-81563/T)

7.5. Contractor shall provide signs, barricades, and lights as required to protect base personnel.

7.6. Schedule. The contractor shall schedule and perform the work as to minimize negative impacts on production.

7.7. The contractor shall perform the required work during the following normal business hours:

6:00 AM – 6:00 PM, Monday – Friday. Work performed on weekends and holidays shall be approved by the Contracting Officer before work commences. A Government Representative shall be present in the event of weekend/holiday work schedule.

7.8. The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

7.9. Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc., during equipment installation.

7.10. The systems shall include all of the necessary consumables required for initial operation.

7.11. The contractor shall provide equipment capacity/emissions information and booth manuals as required by WR-ALC Environmental Management to modify the Robins AFB Title V Air Permit. This information is due to the Government POC three (3) months after contract award.

Permit modification shall be in place and verified by WR-ALC Environmental Management prior to any equipment installation.

7.12. Three (3) months after contract award, the contractor shall provide a single Gantt Chart showing the project schedule from contract award through final inspection for each of the three systems.

7.13. The contractor shall perform the required work during the following normal business hours: 6:00 AM – 6:00 PM, Monday – Friday. Work performed on weekends and holidays shall be approved by the Contracting Officer before work commences. A Government Representative shall be present in the event of weekend/holiday work schedule.

7.14. The contractor shall remove all packing materials and residue from the area and properly dispose of these off base. The work area shall be maintained in an uncluttered and safe condition at all times or work will be terminated until the conditions are corrected.

7.15. Under no circumstances shall the contractor use Government equipment such as forklifts, ladders, stools, tools, etc., during equipment installation.

7.16. Three (3) months after contract award, the contractor shall provide a single Gantt Chart showing the project schedule from contract award through final inspection for each of the four systems.

8. Warranty: All standard warranty provisions shall be included with the bid package but as a minimum shall include one (1) year parts and labor from the time of acceptance (for each system) for defects in material and workmanship.

9. Data Deliverables/Contract Data Requirements Lists (CDRL):

CDRL # Ref. Para. Description A001 7.4.A, 7.4.B Contractors Standard Operating Procedures A002 7.4.C Mishap Report A003 3 Commercial Off the Shelf Equipment Manuals and

Associated Documents (Operator/Maintenance Manuals, Sparte Parts List, Schematics)

A004 7.12 Project Gantt Chart A005 6 Training Material A006 4 Acceptance Test Plan

10. Government supplied items:

10.1. The government will supply basic drawings of largest and smallest parts to verify reach and booth configuration.

11. Government Technical Representatives: The on-site Government points of contact are:

Primary: Alternates:

Shane Groves Jim Cunningham Zack Wallace

402 CMXG/MXDQBE 402 CMXG/MXDQBE 402 CMXG/MXDQBE

Robins AFB, GA Robins AFB, GA Robins AFB, GA Comm 478-335-6482 Comm 478-222-4083 Comm 478-222-5930

Appendix A – Booth Layout

20’

10’

Door

Top View

Front View

10’

12’

12’

20’

Side View

Work Envelope

Work Envelope 7’ 1.5’

1.5’

Work Envelope 7’ 1.5’ 1.5’

1.5’

1.5’

1.5’

1.5’

C. Upon successful demonstration of the above the Government will approve the system to be shipped to WR for installation.

11. Government Technical Representatives: The on-site Government points of contact are: