Performance_Work_Statement.docx

FA8601-16-R-0056 | Attachment 1

FA8601-16-R-0056 Attachment 1

SPECIFICATION FOR

Servo-Hydraulic Material Test Frame Controller Upgrade

AFRL/RQVV FIRST Laboratory Structural Validation Branch Aerospace Vehicles Directorate Wright Patterson Air Force Base

2790 D ST. BLDG 65

WPAFB, OH, 45433

(TEL) 937-904-6811

August 3, 2016

SPECIFICATION FOR

Servo-Hydraulic Material Test Frame Controller System Upgrade

1. PURPOSE

· Application: This specification is intended to define the hardware, software, data acquisition and control requirements for multiple Servo-Hydraulic Material Test Frame Controller System Upgrades. System use includes static, fatigue, block or random spectum fatigue, multi-step ramping.

· Objectives: This specification is intended to ensure the following characteristics of the Servo-Hydraulic Material Test Frame Controller System Upgrade:

· Minimum Mission Impact

· Capability

· Minimum Facility Configuration Impact

· Safety

· Maintainability

· Minimum Purchase and Operational Costs

2. EXISTING SYSTEMS DESCRIPTION

· Controller #1 MTS FlexTest GT, operating 4 test frames with PC Per Station Control including Force, LVDT and Extensometer

· Qty 2 11kip (50kN) capacity MTS Landmark MN: 370.10

· Qty 2 22kip (100kN) capacity MTS Landmark MN: 370.10

· Controller #2 MTS FlexTest GT, operating 4 test frames with PC Per Station Control including Force, LVDT and Extensometer

· Qty 1 5kip (25kN) capacity Local manufacture with MTS load cell, and actuator with integrated LVDT.

· Qty 1 220kip (1000kN) capacity MTS MN: 311.31

· Qty 1 500kip (2272kN) capacity MTS MN: 311.41

· Qty 1 55kip (250kN) capacity MTS MN: 318.25

· Controller #3 MTS FlexTest GT, operating 3 test frames with PC Per Station Control including Force, LVDT and Extensometer

· Qty 2 110kip (500kN) capacity, MTS 810 MN: MTS 380.50

· Qty 1 55kip (250kN) capacity MTS Landmark MN: 370.50

· Controller #4 MTS FlexTest GT, operating 3 actuators with one PC

· Qty 3 11kip (50kN) capacity Shore Western (SW) Actuators

· Integrated LVDTs

· Interface Load Cells

· Mounting: Shore Western Swivel Base

· Controller #5 MTS TestStar IIs operating 1 test frame including Force, LVDT and Extensometer

· Qty 1 22kip (100kN) capacity MN: MTS 312.31

· Controller #6 MTS TestStar IIs operating 1 test frame including Force, LVDT and Extensometer

· Qty 1 5.5kip (25kN) capacity MTS 858 Tabletop MN: 359 L/F

· Load Cell 1Kip capacity

· Existing Test Frame Computer System (Qty. 14)

· INTEL CORE i7-4770 @3.4GHz

· MEMORY, 8GB (2 x 4GB), 240-PIN, DDR3 SDRAM

· 1TB 7200 RPM 64MB CACHE SATA INTERNAL HARD DRIVE

· ASUS MAXIMUS VI HERO LGA INTEL MOTHERBOARD

· PNY GeFORCE GT 610 1GB 64-BIT DDR3 PCI EXPRESS VIDEO CARD

· INTEL 10/100/1000Mbps PCI-EXPRESS NETWORK ADAPTER

· Window 7 operating system

· Alignment System

· Model 709.20D-01 Alignment Data Acquisition and Conditioning System

· Model 709.20D-01 Alignment Data Acquisition and Conditioning System

· Model 609 Alignment Fixtures are only installed on test frames with capacities from 5.5kip through 55kip.

· Software

· Current control/data acquisition software and optional components includes the following:

· MTS FlexTest GT 793 basic software

· MTS 793.10 Multi-Purpose Testware (MPT)

· MTS 793.04 PC per Station (MPC)

· MTS 793.11 Profile Editor

· MTS 793.08 Peak-Valley Phase Control (PVP)

· MTS 793.07 Arbitrary End –Level Control (ALC)

· MTS 793.03&02 Calculations with Outputs & Inputs

3. PROPOSED CONTROLLER ATTRIBUTES

· The existing 6 controllers shall be replaced with than no less than 4 multi-channel controllers. The ideal configuration based upon current facility configuration and is represented below.

· Controller #1 – operates qty. 2 - 11kip & qty. 2 - 22kip MTS Landmarks

· Controller #2 – operates 5kip, 22kip, 220kip & 500kip MTS test frames

· Controller #3 – operates qty. 2 - 55kip & qty. 2 - 110kip MTS test frames

· Controller #4 – operates qty. 3 - 11kip SW actuators & 1.1kip MTS 858 Tabletop test frame

· The existing wiring to the 4 controller locations shall be used to the greatest extent possible.

· The 2 test frames with MTS TestStar IIs controllers are not currently cabled to the “Ideal” configuration. These 2 test frames required cabling lengths are approximately 25ft (8m).

· Each channel shall be operated from individual computer stations (existing and provided by the government)

· Handset remote controls shall be provided for each channel/test frame.

· Handset functionality shall include; zeroing/offset signal channels, start/stop tests, hydraulics on/off control, actuator position adjustment.

· Please note the qty. 3 11kip (50KN) capacity Shore Western Actuators, has only one operator computer station but shall have a handset for each actuator.

· Handsets shall be wired. Wireless handsets will not be acceptable.

· Control loop frequency shall be a minimum of 4kHz, 16bit

· Each test frame/channel must have dedicated sensor I/O of load, position, and extensometer (strain)

· Each test frame/channel must have dedicated hydraulic servo and hydraulic service manifold controls.

· Controllers shall incorporate existing emergency stop and safety features.

· Additional Integrated Data Acquisition

· Each controller shall have a minimum of 64 channels available to be distributed among the test frames/channels from 0 to 64 channels on a single test frame.

· Sampling rate range shall be at a minimum 1Hz to 6kHz

· Multiple sampling rates shall be definable per test frame.

· The 64 channels/controller shall be capable of ¼, ½, full bridge with shunt capability, high level voltage inputs (±10 volts), and high level voltage outputs (±10 volts).

· Thermocouple inputs are desired but not required. Thermocouple types if offered should at a minimum be K-type, J-type, and T-type

· ¼ -bridge completions shall accommodate 120OHM, 350OHM, and user defined. (1V, 5V, and 10V Excitation)

· Excitation, Filtering, Bridge type, Bridge completion, limit detections programmable on a per channel basis

· Shall be clock syncing with controller

· Alignment System shall follow and adhere to ASTM E1012

· The system shall be integrated with controllers for force control and/or feedback.

· If a separate PC is provided, both the hardware and software shall be operating and compliant with Windows 10

· The system shall be portable to each test frame/channel.

· The system shall be compatible with existing MTS 609 Alignment Fixtures

· The system shall be compatible with 8 and 12 gage alignment specimens.

· An instrumented alignment specimen shall be provided.

· Specimen shall be a flat, rectangular cross section rated to a safe stress between 10 KSI and 60 KSI

· Specimen shall have a minimum of 8 strain gages

· Video Extensometery system shall adhere to ASTM E83

· Shall be integrated with controller and provided software.

· If a separate PC is provided, both the hardware and software shall be operating and compliant with Windows 10

· Shall follow and adhere to ASTM E83 with a minimum B-2 classification

· Measurements shall include as a minimum, displacement, axial strain & transverse strain (Possion’s ratio), shear strain and rotation.

· Calibration devices processes shall be provided for both axial and transverse directions.

· Shall have necessary lenses to accommodate Working Distances (WD) from 100mm to 500mm

· Shall have necessary lenses to accommodate Fields of Views (FOV) from 50mm to 400mm

4. PROPOSED SOFTWARE ATTRIBUTES

· Software shall be Windows 10 compliant.

· Software shall run on existing computers. See Section 2 Existing System Description

· Software shall be Commercial Off The Shelf (COTS) with technical and update support.

· The basic core software shall operate the test frames and collect data from the test frames.

· The basic core software and additionally proposed software shall be equivalent and/or more capable than existing controller software. See section 2 Existing Systems Description, Software

· Error Checking/A-B compare with configurable action control shall be included as a basic feature.

· The reuse of existing software is desirable as it has the lowest training requirement and impact on mission.

· Any software proposed not in the Existing System Description shall be accompanied with training. See section 8 Installation and Training.

· Preferred software set-up shall follow a graphical test flow.

· Data shall be able to be exported as ASCII, CSV, Tab Delimited, Excel and fully customizable reports.

5. PROPOSED ACCESSORIES

· Provisions shall be provided to mount controllers and necessary hardware into standard 19” rack consoles.

· Necessary cabling, adapters and components shall be provided.

6. AVAILABILE POWER AND UTILITIES

· 115VAC, 20A (unconditioned)

· 115VAC, 20A (conditioned)

· Compressed air (100psi max)

7. WARRANTY

· Minimum 1 year coverage on parts and workmanship.

· Minimum 1 year of software maintenance, to include upgrades as they become available across all packages and optional software components.

· Phone technical support shall be available during standard business hours 365 days a year excluding federal holidays

· On-site support including parts, labor, and travel

8. INSTALLATION AND TRAINING

· Installation

· Vendor technician/representative shall install setup, verify operation and provide NIST traceable calibration of controllers with their respective test frames and components.

· Installation and Calibrations shall be completed within 10 business days to minimize Mission Impact.

· All travel and living expenses shall be included.

· Training

· Training shall be provided in a laboratory/classroom environment at a vendor site for up to 6 personnel.

· Travel and living expenses will be at the expense of the government.

AFRL/RQVV FIRST Laboratory Structural Validation Branch Aerospace Vehicles Directorate Wright Patterson Air Force Base

2790 D ST. BLDG 65

WPAFB, OH, 45433