FEDS V250 Dyno_SOW Rev - 10 Apr 25.docx

10 April 2025

Statement of Work For:

Flexible Engine Diagnostics System (FEDS) Variable-Geometry, Radial Outflow Compressor (VAROC) Air Dynamometer 250 (V250+) Dynamometer

Rev - 10 April 2025

REVISION HISTORY

Table of Contents

1.0 Scope

This Statement of Work (SOW) defines the effort required to upgrade the Variable-geometry, Radial Outflow Compressor (VAROC) Air Dynamometer (Dyno) 250 for the Flexible Engine Diagnostics Systems (FEDS). The contractor shall fabricate and assemble an enhanced V250 Dyno, to be known as a V250+. The contractor shall be considered an expert in V250 Dyno hardware, plenum, rotary unit design, and air-flow modeling.

The Dynamometers are utilized by the FEDS for aircraft engine maintenance. The V250 Dyno absorbs engine output for high-speed torque measurements to test engine performance for rotary aircraft engines. The FEDS requires an upgrade to the V250 Dyno for the Army to test Chinook T55-GA-714A engines. The V250+ Dyno will replace all existing V250’s with a modernized system that provides the reliability and maintainability needed by the FEDS.

A redesigned V250+ dyno will have a two-piece plenum rather than the current one-piece design. This will reduce warping and weld cracking, making the unit more maintainable by the onsite FEDS operators, and is estimated to increase the current Mean Time Between Overhaul (MTBO) from 1,000 hours to 5,000 hours.

2.0 Requirements

2.1 Base

The contractor shall provide the non-recurring engineering (NRE) for the development of an enhanced V250 Dyno, to be known as a V250+. The contractor shall provide the following:

1) Procure a forged rotor billet.

2) A fully assembled inner housing assembly for the V250+ Dyno to include the inner housings, bearings, shrouds and seals.

3) A Lubrication Cart Prototype.

4) A written review of the assembly NRE of the 250+, including the design, analysis, and creation of manufacturing drawings. This shall include an Assembly Readiness Report and a Rig Test Readiness Report.

The contractor shall assist in analyzing and testing the appropriate configuration and architecture of the Inner Housing Assembly and Lubrication Cart based on the System Specification for the V250+ Dyno. The contractor shall review the design and provide suitable drawings for the manufacturing and testing of the V250+ Dyno. Recommendations shall be made to improve maintainability and reducing repair time of the upgraded V250+ Dyno.

2.1.1 Inner Housing Assemblies

The inner housing assemblies shall include all required inner housing, bearings, shrouds, and seals based on the design provided as Government Furnished Information (GFI) that has been reviewed, analyzed, and modified as needed to improve the areas of mechanical reliability and serviceability. These parts shall be made based on previous Finite Element Analysis (FEA) used to analyze the static structure sub-components: the bearing housing, plenum, bearings and bearing lubrication system. The analysis of these components for stress levels (for life calculations) and deflections.

The contractor shall provide an interim report documenting the completed inner housing assembly with respect to the design and analysis of the V250+ Dyno shall be delivered by the contractor upon final assembly.

2.1.2 Lubrication Cart Prototype

The lubrication cart shall include a V250+ Lube Oil system, drawings and manuals. The new or modified manufactured components will be documented against the original Computer-Aided Design (CAD) models and manufacturing drawings.

The contractor shall provide an interim report upon completion of the Lube Oil Cart production.

2.1.3 Project Management and Reporting

The contractor shall provide a final report incorporating the interim reports from SOW paragraph 2.1.1 and 2.1.2. The contractor shall hold monthly progress review (PR) meetings and include a brief status report, as well as prepare technical reports as required. These reports shall be in PowerPoint PDF format, which will be discussed in monthly PR meetings, or at stand-alone meetings as required.

The contractor shall provide project management, client liaison, and reporting through the life of this effort. The contractor shall maintain internal management of the project per ISO and/or AS9100 procedures.

2.1.4 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. The kick-off meeting shall be 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.

2.2 Option

The contractor shall fabricate and assemble an enhanced V250 Dyno, to be known as a V250+. The contractor shall provide the following:

1) A complete rotor and associated rotary parts.

2) A fully assembled static structure with inner housing assembly as defined in SOW paragraph 2.1.1 and the chassis, collector, and all components required for the integration of the rotary components.

3) An assembled Dyno with rotor assembly, frame, inner housing assembly and all ancillary components. This includes the lubrication cart ready for testing.

4) An assembled Dyno ready for a low load, full-speed test based on the Readiness Review reports from SOW paragraph 2.1. The Rig Test shall be done by the contractor if it is achievable without major rebuilding of the test rig.

5) A written report on the assembly of the V250+ Dyno.

The contractor shall assist in analyzing and testing the appropriate configuration and architecture of the Dyno and the Lube Cart based on the System Specification for the V250+ Dyno. The Contractor shall review the design and provide suitable drawings for a first product ready for manufacture and testing. Recommendations shall be made to improve maintainability and reducing repair time of the upgraded V250+ Dyno.

2.2.1 Rotor Assembly

The Rotor Assembly will be completed, tested and ready for installation into the Dyno.

The Rotor Assembly shall include a bladed rotor disk, shaft, bearings and a V-toothed Hirth interface. The rotary assembly will be built based on the design reviewed, analyzed, and modified as needed to improve the areas of mechanical reliability, and serviceability provided as GFI. The rotor blades, Hirth interface and other rotary subcomponents shall be made based on previous FEA, crack propagation and centrifugal stress analysis. The analysis of these components for centrifugal and other relevant stress levels and deflections shall be reported for life of service calculations.

An interim report documenting the completed rotary assembly with respect to the design and analysis of the new V250+ will be delivered at the completion of the assembly.

2.2.2 Static Structure (Inner Housing, Chassis and Collector) All the static structures such as the frame, chassis collector and ancillary components shall be fabricated and integrated. Inner housing assemblies and all its associated parts (including all parts and assemblies needed such as inner housing, bearings, shrouds, and seals) produced in SOW paragraph 2.1.

The contractor shall provide an interim report on the completion of the static structures and their progress toward final integration with the rotary elements.

2.2.3 Complete Dynamometer Assembly and Testing

The contractor shall provide a complete V250+ two-piece plenum design Dyno with Lube Oil system, assembly drawings and an operator’s manual. This final deliverable will consist of a Dyno fully assembled from all components and subcomponents produced. The new or modified manufactured components will be documented against the original CAD models and manufacturing drawings. A Dynamometer ready for a low load, full-speed test based on Readiness Review Assessment from SOW paragraph 2.1 A final report for the project incorporating the interim reports from the V250+ production and the results of the rig testing shall also be delivered at this time.

2.2.4 Project Management 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 interim technical reports as requested in SOW paragraph 2.2.1 and 2.2.2, and a final technical report as requested in SOW paragraph 2.2.3.

2.2.5 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. The kick-off meeting shall be 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. The following shall be discussed: material corrective action, rework assessment, and rework of any first article components, if necessary, and manufacture of assembly tooling/fixturing, as identified.

2.3 Travel

The Contractor personnel shall travel only when travel is the most efficient and timely means of performing contract tasks. All travel requires Government approval/authorization and notification to the COR. The Government anticipates travelling to the following location:

3.0 Government Furnished Information

The Government shall provide the following GFI:

· System Specifications for the enhanced V250 Dynamometer (250+)