FEDS V250 Dyno Overhaul_SOW Rev -_06 Jun 24.docx

06 June 2024

Statement of Work For:

FEDS V250+ Dynamometer Overhaul

Rev - 06 June 2024

REVISION HISTORY

Table of Contents

1.0 Scope.

This Statement of Work (SOW) defines the effort required to upgrade the V250 Dynamometer (Dyno) for Flexible Engine Diagnostics Systems (FEDS). The V250 Dyno absorbs engine output for high-speed torque measurements to test engine performance test system for rotary aircraft engines and has used the original design since 1985. V250 Dyno is used globally at both United States and their allies’ sites for aircraft engine maintenance and testing. This system upgrade, known has the enhanced V250 Dyno or the V250+, replaces all existing V250’s with a modernized system with increase the reliability and maintainability. A redesigned V250+ dyno with a 2-piece plenum rather than current 1-piece design will reduce warping and weld cracking, making the unit more maintainable by the onsite FEDS operators, and increase the current Mean Time Between Overhaul (MTBO) from 1,000 hours to 5,000 hours.

The objective for this effort shall be to provide hardware design, architecture, and best practices for the design and development using lessons learned from a similar redesign of the V35 dyno. The V35 upgrade project (V35/85) was funded by the ATE, ITEP office to redesign the V35 dyno to handle the performance of the new T901 engine and is a similar effort to upgrading the V250 Dyno. The Contractor shall be considered an Expert in V250 Dyno hardware, plenum, rotary unit design and air flow modeling.

2.0 Applicable Documents.

Applicable top-level documents are contained in the Document Summary List (DSL). The document versions specified on the DSL take precedence over the generic references (without revision letters) cited in the SOW.

3.0 Requirements.

The Contractor shall provide services for the design, development, procurement, integration, and testing of the enhanced V250, known as V250+ Dynamometer. The V250+ Dyno re-design shall include the following:

Project kickoff meeting, establish Plans, clarify technical requirements, and schedules for the task, milestones, and product necessary for the V250+ DYNO project. Includes: Project kickoff meeting, establish Plans, clarify technical requirements, and schedules for the tasks, milestones, periodic project reviews and product delivery necessary for the success of the V250+ DYNO improvement effort. The cost of this proposal covers the non-recurring engineering (NRE) efforts, including design, analysis, and creation of manufacturing drawings. The effort will occur in three stages of analysis and design as detailed below:

Task 1: Kick-off Meeting The contractor shall hold a kick-off meeting with the U.S. Army to exchange project information. The plans and schedules for the project, periodic project meetings, and communication shall be discussed at the kick-off meeting. Further information provided in paragraph 3.1.

Task 2: Rotating Group and Analysis Modifications The Aerodynamic performance will be evaluated using Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) will be used to evaluate the structural capacity and stress levels of the rotor, at higher operating speeds, resonance/vibration, and deflections. A report of Rotating Group Analysis of flow path aerodynamics, rotor design, attachment and rotodynamic (including bearings and seals) and include the results of the CFD, FEA and rotodynamic analysis. A report of the aerodynamic performance will be delivered upon completion of testing approximately 3 months after the kickoff meeting.

Task 3: Static Structure Analysis The static structure design will be reviewed, analyzed, and modified as needed for improvements in the areas of mechanical reliability, and serviceability. Finite Element Analysis (FEA) will be used analyze the following static structure sub-components: the chassis, bearing housings, plenum, bearings and bearing lubrication system. The analysis of these components for stress levels (for life calculations) and deflections. Modal analysis will be performed to predict resonant frequencies of said parts. A report documenting the design and analysis of the new V250+ chassis and collector will be delivered at the end of structural analysis, approximately seven (7) months after the kickoff meeting.

Task 4: CAD Models and Manufacturing Drawings The final deliverables will consist of a CAD assembly model, assembly drawings, and a BOM reflecting the final V250+ configuration and design changes. The CAD models will include models and drawings for new or modified manufactured components, manufacturing components, manufacturing drawings. A final report for the project incorporating the interim reports from the earlier Rotating Group and Static Structure analyses shall also be delivered at this time, 12 months after the programs kick-off.

Task 5: Project Management, Client Liaison, and Reporting\ The Contractor shall provide Project Management, Client Liaison, and Reporting throughout the life of this effort. The contractor shall maintain internal management of the project per their ISO and/or AS9100 procedures. The contractor shall hold monthly progress review (PR) meetings, and shall include a brief status report. The contractor shall prepare technical reports at the end of each Task 2, 3, and 4. These reports shall be in Powerpoint PDF format, can be discussed in monthly PR meetings, or at stand-alone meetings as required. The report generated after Task 4 shall serve as the final report of this effort (as stated previously).

The contractor shall assist in modeling, analyzing, and designing the appropriate configuration and architecture based on the System Specification for the V250+ Dyno. The contractor shall assist with air flow and temperature modeling and determination of mechanical stresses. The Contractor shall review the design and provide suitable drawings for a product ready for manufacture and testing. Recommendations shall be made to improve maintainability and reducing repair time and of the V250+ Dyno.

3.1 Kick-off Meeting.

The Contractor shall participate in a kick-off meeting virtually, at the PIF, or at the Contractor’s facility, with a teleconference capability, at a mutually agreed upon date no later than (NLT) 15 calendar days after task award.

3.1.2

3.2 Travel.

No travel is expected. All activities are expected to take place in the greater River Junction, VT area at contractor facility, thus no travel expenses are expected or authorized.

4.0 Government Furnished Information.

The Government will provide the following GFI:

· None.