Item Cross-Reference Matrix - Shot Peen Machine.pdf

ITEM SOW Para.

REQUIRED COMPONENTS, SYSTEMS,

OR DELIVERABLES

REQUIRED CONSTRUCTION OR DESIGN

CHARACTERISTICS

SUBFACTOR REFERENCE

3.4.1

Certification in ISO 9001:2015, AS 9100, or

Other Equivalent QMS

A

Proof of certification in ISO 9001:2015, AS 9100, or Other Equivalent QMS S1:E1

B

If a certificate other than ISO 9001:2015 and AS

9100, demonstrates equivalency by basis of the

QMS on the following principles:

S1:E1

B

i. Customer Focus – Meet the needs of customers and strive to exceed their expectations to attract and retain them.

S1:E1

B

ii. Leadership – Leaders at all levels of the organization must set goals, direction, and create conditions for engaged people to achieve these goals.

S1:E1

B

iii. Engagement of People – Employees at all levels of the organization must be competent and involved to raise the organization’s ability to create and deliver products that meet and exceed customer expectations.

S1:E1

B iv.Process Approach – Determining the organization’s core processes S1:E1

B

v. Improvement – Commitment to continuous process improvement.

S1:E1

B vi.Evidence-based decision making – Decisions are based on data and information.

S1:E1

B vii.Relationships – An understanding of the influence of internal and external stakeholders.

S1:E1

011 3.2.1 Machine has a blade peening system

012 A Peens a minimum of two blades at a time

013 B A minimum of two blades can be loaded/unloaded while machine is performing a peening cycle

014 C Two blades can be peened simultaneously at the same intensity and at the same peening process parameters

015 D Process air pressure ranges between 90-110

PSI

016 3.2.1.1 Blade Positioning System

017 A. Sealed driving components to prevent damage from peening media.

018 B. Index or rotate a minimum of 2 blades and fixtures simultaneously.

019 C. Position and rotate blades using the same degree of rotation and to predetermined system positioning locations.

020 D. Positions each blade at the same angle in relation to the peening nozzles.

021 E. The blade rotation axis shall be capable of coordinating simultaneously with all other axis motion.

022 F. Machine processing shall stop and provide a fault with the specific cause if actual position values deviate from the program value.

023 3.2.1.2 Indexing Table

024 A. Allows for loading and unloading of multiple blades outside the peening chamber while blades are being processed within the peening chamber.

COMMENTS

Item Cross-Reference Matrix - SHOT PEEN MACHINE

RFQ # FA8132 20 Q 0019

IAW FAR Provision 52.212-2

Contractor:

025 B. Includes interlocks so the table cannot index when the work door(s) are not fully open or during a peening cycle.

026 C. Table indexing should not be affected by the use of air hoses located on the outside of the machine.

027 3.2.1.3 Pressure Peening System

028 A. Includes a continuous media flow pressure pot system for each size of media specified for the machine.

S2:E1; S2:E2

029 B. Capable of peening with each size of media specified for the machine. Each media type specified shall include its own:

S2:E1; S2:E2

030 a. Dedicated pressure pot assembly, and S2:E1; S2:E2

031 b. Dedicated media classifier. S2:E1; S2:E2

032 C. Capable of continuous peening on a single program for a minimum of 8 consecutive hours.

S2:E1; S2:E2

033 D. Capable of using different media sizes other than those originally specified.

S2:E1; S2:E2

034 E. If a different media size or substitution is made, it shall not compromise the system from being able to do any of the items listed in the specification.

S2:E1; S2:E2

035 3.2.1.3.1 Air Drop The machine shall include a single, pressurized air drop

S2:E1

036 A. Supplies air to the entire system. S2:E1

037 B. Includes a supply shutoff valve. S2:E1

038 a. Located at operator height, 4'9" to 6'5", from the floor and meet all applicable OSHA and JIC codes.

S2:E1

039 3.2.1.3.2 Main Air Regulator The machine shall include a main air regulator with a 4 pressure gauge. The main air regulator shall be a Proportion Air 2"

R000 pilot operated regulator with a

DSY100 pressure transducer, and a

QB2TFEE100S305S1038 electronic air pressure regulator

S2:E1

040 A. The 4" pressure gauge shall have a range of

0-100 psig, an accuracy of ±1% across the entire range, and a liquid filled case.

S2:E1

041 B. The machine shall be configured to allow pressure transition during a CNC program, and does not require nozzle movement to make the pressure transition happen.

S2:E1

042 3.2.1.3.3 Pressure Pots S2:E1

043 A. Constructed in accordance with ASME

BPVC.VII.1-2017.

S2:E1

044 B. Includes external air pressure gauges in both upper and lower pressure pots to assist with troubleshooting.

S2:E1

045 C. There shall be external air pressure gauges in both the upper and lower pressure pots to assist with trouble shooting.

S2:E1

046 D. There shall be external air pressure gauges on pinch valves, air pressure boosters, and any other locations that would be necessary for trouble shooting purposes.

S2:E1

047 E. Air pressure gauges shall be properly rated for the pressure range they are governing.

S2:E1

048 F. The lower pressure pot shall have a separate media valve located on the outside of the pot which allows all media to be drained from the system when repairs are necessary.

S2:E1

049 3.2.1.3.4 Media Shifting S2:E1; S2:E2

050 A. Ensures a minimum amount of media is supplied from the pressure pot to the peening nozzles so that the intensity is consistent.

S2:E1; S2:E2

051 B. Shuts down and displays an alarm when the system runs out of media.

S2:E1; S2:E2

052 C. Media shifting shall not interrupt a peening cycle, or change the intensity of the shot stream.

S2:E1; S2:E2

053 D. Reclaims acceptable media while the pressure pot refills.

S2:E1; S2:E2

054 E. Prevents media backing up into the media classifier, dust collector, or cyclone separator during a pressure pot refill.

S2:E1; S2:E2

055 3.2.1.3.5 Media Switching Valves S2:E1; S2:E2

056 A. The peening system shall use durable valves that can easily be changed and maintained in locations where media comes in contact with the valves to minimize maintenance frequency and valve wear.

S2:E1; S2:E2

057 B. All valves shall be mounted on the outside of the pressure pots for ease of maintenance.

S2:E1; S2:E2

058 3.2.1.3.6 Media S2:E1; S2:E2

059 A. Capable of using different sizes of Cut Wire or Cast Shot media, including but not limited to CCW 12, CCW 14, CCW20, CCW

28, SAE 70, SAE 110, SAE 170, or SAE 230.

The system shall be capable of operating with all of the shot sizes listed with either

Cast Steel Shot of high hardness (55 to 62

HRC), or regular (45 to 52 HRC) hardness, and Conditioned Carbon Steel Cut Wire shot of high hardness (55 to 62 HRC) or regular hardness (45 to 52 HRC).

S2:E1; S2:E2

060 B. The system shall be tested with both CCW

14 and CCW 20 of regular hardness with one type of media being used for one pressure pot system and the other media type being used for the other pressure pot system on the dual media system. One pressure pot system shall be calibrated exclusively for size fourteen (14) conditioned carbon steel cut wire shot with a regular hardness and the other shall be calibrated exclusively for twenty (20) conditioned carbon steel cut wire shot with a regular hardness.

S2:E1; S2:E2

061 3.2.1.3.7 Media Switching S2:E1; S2:E2

062 A. Does not require switching media screens or emptying the peening system of media to switch from one type of media to another.

S2:E1; S2:E2

063 B. Does not cross-contaminate between the different types of media.

S2:E1; S2:E2

064 C. Switches from one media size to another within 5 minutes.

S2:E1; S2:E2

065 D. All components are accessible for maintenance.

S2:E1; S2:E2

066 E. Displays the media type selected by a peening program on the operator information screen.

S2:E1; S2:E2

067 F. Shuts down the peening program when the wrong type of media is selected for that program.

S2:E1; S2:E2

068 G. Displays a fault on the operator information screen when the wrong media is selected for a particular program.

S2:E1; S2:E2

069 H. All programmable commands are done in G code.

S2:E1; S2:E2

070 3.2.1.3.8 Media Flow Valves and Monitoring This machine shall include an installed

Electronics Inc. (EI) 578-24 MagnaValve (PN

999290) with an EI FC-24 (PN 999331) Flow

Controller for each media type.

S2:E2

071 A. The EI media valve shall be accurate to ±5% of full scale rating of 3-30 lb/min.

S2:E2

072 B. The media flow range shall match what is displayed on the computer operator interface.

S2:E2

073 3.2.1.3.9 Pressure Blast Hose S2:E1; S2:E2

074 A. The inner diameter shall be 3/4" (19.0mm), and an outer diameter of 1.5" (38.1mm).

S2:E1; S2:E2

075 B. Goodyear Plicord 4 Ply or equivalent S2:E1; S2:E2

076 C. A minimum of 15 feet (4.6m) long. S2:E1; S2:E2

077 D. Capable of operating with a minimum of

150 PSI (10.2 bars).

S2:E1; S2:E2

078 E. Hoses and piping on each peening gun shall be the same length from the point of pressure control to the end of each nozzle, so that the pressure is passively balanced between the peening guns.

S2:E1; S2:E2

079 F. A quick coupling on the air supply end shall be provided to accommodate attachment and detachment. A 1-1/4" (31.8mm) NPS female fitting on the opposite end of the air supply will provide for attachment to a standard blast nozzle.

S2:E1; S2:E2

080 3.2.1.3.10 Media Peening Nozzles S2:E1; S2:E2

081 A. Straight nozzles with an internal diameter of either 5/16" or 3/8".

S2:E1; S2:E2

082 B. Made of boron carbide. S2:E1; S2:E2

083 C. All peening nozzles in the system shall be the same whichever internal diameter is selected.

S2:E1; S2:E2

084 D. The system shall use a minimum of one nozzle per blade spindle attached to the gantry robot head for peening the parts.

S2:E1; S2:E2

085 E. Ability to peen within ±5% of each other. S2:E1; S2:E2

086 F. Pointed away from the work door used for programming.

S2:E1; S2:E2

087 G. Physically located between the programmer and the blade spindle.

S2:E1; S2:E2

088 3.2.2 Media Recovery System S2:E3

089 A. No media shall be allowed to escape via the media recovery system.

S2:E3

090 B. The machine shall be equipped with a cyclone type reclaim system that separates reusable media meeting AMS2431 from spent media and dust

S2:E3

091 C. The reclaimed media shall be returned to the media hopper/pressure pot.

S2:E3

092 D. A filter or guard system in the bottom of the peening cabinet shall be used to keep larger objects, such as screws, bolts, Allen wrenches, tape, etc. from entering into the reclaim system and any moving parts.

S2:E3

093 E. Reclaim system shall be capable of moving at a minimum of 100 pounds of media per minute to the cyclone.

S2:E3

094 3.2.2.1 Dust Collector S2:E3

095 A. The peening cabinet shall house an integral dust collector.

S2:E3

096 B. The dust collection system shall draw contaminated air out of the cabinet.

S2:E3

097 C. This air shall be filtered and returned to the plant atmosphere. It shall use multiple cartridge filters that are 99% plus efficient at 0.5 micron at 250 cubic feet per minute

(CFM).

S2:E3

098 D. Filters shall be mounted in a way that are easy to change, properly align, and seal.

S2:E3

099 E. The dust collector shall have a differential pressure gauge to monitor pressure drops across the filters and indicate when filters need replacement.

S2:E3

100 F. The system shall also include a purging system that removes dust from the filters with a timed air pulse through the filters.

Larger dust shall fall freely into a trash receptacle.

S2:E3

101 G. The dust collector and the ductwork leading to the dust collector after the cyclone separator shall be capable of passing a fluorescent dust inspection test.

S2:E3

102 3.2.2.2 Media Classifier Two SWECO® vibratory media separators/classifiers shall be provided, one for each media types, to classify the peening media specified for the machine

S2:E3

103 A. It shall come with the appropriate sized screens for the specified media to ensure proper classification of media per AMS2430 and AMS2431.

S2:E3

104 B. Easily and safely accessed for maintenance, including but not limited to, changing out screens and accessing the auto lubrication devices.

S2:E3

105 C. All non-conforming media shall be discarded into a government provided fifty five (55) gallon re-sealable drum.

S2:E3

106 3.2.2.3 Media Adder System S2:E3

107 A. This system shall add media to the reclaim system when low media is detected.

S2:E3

108 B. When the media adder system is turned on, it shall have no effect on the peening cycle or desired intensity.

S2:E3

109 C. Media adder system shall be external to the cabinet and hold between 150 pounds and

200 pounds of media.

S2:E3

110 D. Media adder system shall be placed on the ground, with the top between 36 and 48 feet above the ground.

S2:E3

111 3.2.2.4 Media Cleaning System S2:E3

112 A. The cleaning system shall be designed so that it will clean all of the shot off of the blades, fixtures, and table when table is indexed. No media shall be blown into the operator load/unload area.

S2:E3

113 B. Media cleaning system shall be a high enough pressure to clean off the media, but a low enough pressure to avoid inadvertently peening the part.

S2:E3

114 3.2.3 CNC System S2:E4

115 A. The machine shall conform to NAS 995 sections 3.1 and 3.2.

S2:E4

116 B. The control station shall be equipped with an industrially hardened keyboard.

S2:E4

117 C. The control shall be the latest FANUC control Series 31i that can simultaneously control motion of all axes of motion on programmed paths.

S2:E4

118 D. Shall utilize G code to control the process. S2:E4

119 E. The ladder logic for the FANUC control for this system shall be provided and shall be unlocked.

S2:E4

120 F. The CNC shall receive all the process instructions such as nozzle movement, dwell time, total cycle time, nozzle selection, media flowrate, air pressure etc.

from the operator PC.

S2:E4

121 G. The control system shall be housed in a mounted enclosure adjacent to the robot control. The enclosure shall be rated

NEMA12/IP55 to provide protection against oil and dirt.

S2:E4

122 H. The entire controller shall be integrated in accordance with NEMA 250, NFPA 79, NEMA ICS 1, NEMA ICS 6, ISO 13849 and

ISO 12100.

S2:E4

123 3.2.3.1 CNC Controller S2:E4

124 A. The CNC controller shall receive process parameter set points, alarm limits, shutdown limits, and recipe numbers which shall be passed to the control system for immediate implementation.

S2:E4

125 B. The system shall be designed so that the shot stream stabilizes off the part before moving into position to peen the part.

S2:E4

126 C. Each parameter shall have programmable high and low limits. If a warning or shutdown alarm occurs, a message describing the condition and the time of occurrence shall be displayed. Process tolerances to shut down the system shall be able to be set so that they will comply with

AMS2432D for Computer Monitored Shot-peening process.

S2:E4

127 D. CNC shall not execute any un-commanded movements or actions, including but not limited to robot movement, air or media flow to the nozzle, parts door(s) opening or closing, table indexing, reclaim system turning on or off, etc. (see NAS 995 3.6.4.)

S2:E4

128 E. The system shall be capable of interrupting the peening cycle within one second, when excursions outside set tolerances are detected for shot flow, air pressure, nozzle motion speed, and/or turntable speed, and shall display actual values during processing.

S2:E4

129 F. Each alarm condition shall be supported with alarm and diagnostic messages.

S2:E4

130 3.2.3.2 Control Hardware S2:E4

131 A. A large scale integration (LSI) and surface mount technology design for reliability.

S2:E4

132 B. TFT-LCD color display for ONG-type keyboard with a 10.4" screen.

S2:E4

133 C. Machine operator's panel (portable teach pendant) equipped with an LCD and manual pulse generator as described in 3.5.3.4.

S2:E4

134 D. Shall store a minimum of 300k Program steps. It shall also have a minimum of 512

KB (1280 meters) of motion program storage for the part programs .

S2:E4

135 E. 4GB Random Access Memory (RAM) S2:E4

136 F. 500 GB HDD storage Capacity. S2:E4

137 G. Fiber optic FSSB connection to servo drives. S2:E4

138 H. Program test function as described in

3.5.3.5.

S2:E4

139 I. Graduated speed adjustment as described in 3.5.3.6.

S2:E4

140 J. Over travel override function as described in 3.5.3.7.

S2:E4

141 3.2.3.3 CNC Operation S2:E4

142 A. Shall provide extensive help messages for the operator.

S2:E4

143 B. Shall allow the operator to edit programs while executing motion programming

S2:E4

144 C. Shall conform to RS-274 format for compatibility with existing programs.

S2:E4

145 D. Shall include "paramacro" programming features that shall allow the user to include operator G-codes to be used in a part program.

S2:E4

146 E. A security clearance device shall be implemented to prevent unauthorized users from changing any of the critical process parameters on the CNC.

S2:E4

147 F. Shall not skip any lines in program execution when program is cycle stopped and restarted again, or when the door is opened and closed again during a program stop.

S2:E4

148 3.2.3.4 Operator Control Pendant S2:E4

149 A. An operator control jog/teach pendant shall be incorporated into the system to allow the operator to perform all jogging functions on the control system.

S2:E4

150 B. The control pendant shall be constructed to meet or exceed the following characteristics:

151 a. The pendant shall have an illuminated display for ease of viewing.

S2:E4

152 b. A dead man switch shall be installed on the jog pendant. The switch shall be a "positive break normally closed" contact. The switch shall change state when an actuator turns a positive mechanical linkage within the switch. This design eliminates false signals that could otherwise be caused by broken springs or welded contacts. The switch shall be tamper resistant and mounted with tamper resistant screws.

S2:E4

153 C. This hand-held teach pendant shall include but not be limited to the following items:

S2:E4

154 a. Jogging All Axes in both Positive and

Negative Directions

S2:E4

155 b. Selectable High, Medium, and Low Jog

Speeds

S2:E4

156 c. Incremental Jog Speeds S2:E4

157 d. Homing of All Axes S2:E4

158 e. Cycle Pause Button for Program Execution S2:E4

159 f. Cycle Run Button for Program Execution S2:E4

160 g. Store Button to Insert the Current Position into the Motion Program

S2:E4

161 h. Jog Pendant cord between 7-15 ft long and located near the programming area

S2:E4

162 i. Convenient pendant holder on side of machine that protects the pendant and minimizes the probability that it will be bumped onto the floor.

S2:E4

163 j. Emergency Stop Push-Button (mushroom type, push to activate, twist to reset)

S2:E4

164 k. Incremental positioning wheel, for precise robot positioning

S2:E4

165 3.2.3.5 Program Test Function S2:E4

166 A. The program test function mode shall allow a nozzle to move with the door open but only when the Jog Pendant dead-man switch is engaged.

S2:E4

167 B. The program test function mode shall operate without air pressure or media flow

S2:E4

168 C. The program test function mode shall be able to operate without engaging the

S2:E4

169 D. The program test function mode shall run at programmed speeds and shall not continuously run at 100% possible speed like a "Dry Run" function.

S2:E4

170 E. When the dead-man switch is released, the cycle stop is pressed, or an "E-stop" button is pressed, the program shall stop and the robot will cease movement. However, when the program is resumed, it shall be able to continue from the point at which the robot stopped without skipping any lines of code.

S2:E4

171 3.2.3.6 Graduated Speed The system shall have a manually operated graduated speed adjustment dial on the

CNC control panel and the jog pendant. The graduated speed adjustment dial shall be easily accessible on the CNC and/or the jog pendant. It shall allow the programmer to quickly slow down the speed of the gantry robot and resume normal speed without stopping the program.

S2:E4

172 A. The graduated speed control shall conform to NAS 995 paragraph 3.1.8.

S2:E4

173 B. The graduated speed adjustment shall be capable of adjusting the speed of the program, when necessary, to increase or decrease the speed for programming purposes and resume it to regular speeds for checking points.

174 C. The graduated speed adjustment shall have a range of no less than 0% to no less than

120% of the programmed speed.

S2:E4

175 3.2.3.7 Over Travel Override S2:E4

176 A. It shall either be located on the control panel or the jog pendant.

S2:E4

177 B. The system shall prevent the over travel override button from allowing the gantry robot to continue to travel beyond the working envelope in the direction it over traveled.

S2:E4

178 C. The system shall not allow the axes to extend beyond the hard stops, it shall only be capable of traveling past the hard stops by forces external to the system and not by programming errors, or pendant operational errors.

S2:E4

179 3.2.3.8 Power On/Off S2:E4

180 A. A plastic guard to protect from inadvertently pressing the button.

S2:E4

181 B. Separate from the breaker installed on the machine.

S2:E4

182 C. Removes all power from the machine safely and in a controlled manner to de-energize the system before the breaker needs to be shut down.

S2:E4

183 3.2.3.9 Emergency Stop (E-STOP) Buttons S2:E4

184 A. The system shall have a manually-operated

E-STOP button that shall terminate the peening cycle, which includes: stopping all moving parts, all robot movement, the dust collector, reclaim system, air flow, and media flow.

S2:E4

185 B. This sequence shall have no effect on the established program.

S2:E4

186 C. The E-STOP button shall be readily available to the operator at all remote control panels, pendants, main control panel, and any other point on the machine tool frequently requiring the operator's presence per NAS

995 Paragraph 3.4.9.

S2:E4

187 D. All E-STOP shall be mushroom type, push to activate, and twist to reset buttons. When a

E-STOP is reset, the machine shall not resume any part of the peening cycle, including but not limited to: all motion, air flow to the nozzle, media flow to the nozzle, the dust collector, or the reclaim system until a start command is given.

S2:E4

188 3.2.4 Gantry Robot S2:E4

189 A. Variable frequency or variable speeds drives for all axes.

S2:E4

190 B. The gantry robot shall require a rigid frame during movement for stability of nozzles with no visible signs of oscillation after quickly coming to a stop or during robotic arm traversing for any of the axes including the spindle axis.

S2:E4

191 C. The gantry robot does not oscillate when stopping or traversing any axis.

S2:E4

192 D. Minimum display resolution of 0.001 for linear axes and 0.01 for angular axes.

S2:E4

193 a. All axis values display on the CNC screen during programming and during program execution.

S2:E4

194 E. The robot shall at a minimum operate at the parameters specified in Table I.

S2:E4

195 F. The system shall meet the alignment and accuracy requirements as specified in Table

II. These requirements are in place to ensure that nozzles will be capable of peening blade airfoils for a wide variety of blades with sufficient precision.

S2:E4

196 3.2.4.1 Motors Motors for all axis movement shall be

Fanuc servo motors

197 A. Motors shall be sized appropriately for the system to move the components at the rates specified.

S2:E4

198 B. Any motors that are not sealed and permanently lubricated shall have means to lubricate the motor without personnel having to climb on, under, or around the equipment.

S2:E4

199 3.2.4.2 Axes S2:E4

200 A. The "home" position for all axes shall be the furthest the nozzles can be from the work spindles and blades.

S2:E4

201 B. The "home" position for each axis will display as 0 (with the designated number of significant digits for the specified axis).

S2:E4

202 C. When the nozzles move toward the part and away from "home," they move in the positive direction.

S2:E4

203 D. Axes may be designed so that the center of the axis is the "home" position.

S2:E4

204 E. Nozzle Rotational Axes shall have "home" positions centered in the middle of their range with zero (0.0000) positioned with the nozzle level and pointing in the direction of the part. Rotational Axes shall have the positive direction be up from the specified home position or to the right from the specified home position as required for the designated axis.

S2:E4

205 F. The machine shall be capable of peening all features on a part and fixtures at an angle of 90°, including the top and bottom of a blade mid span when a part is in the holding fixture.

S2:E4

206 G. The standoff distance shall be adjustable from no less than 2" to 12" from the center of the spindle axis across all axes orientations.

S2:E4

207 H. Axis description shall conform to EIA-267C. S2:E4

208 3.2.4.2.1 Axes Over Travel Limits S2:E4

209 A. All axes, excluding the spindle rotational axis, shall have both programmed stops and hard stops so that the axis will stop if it travels beyond the range specified in 3.4.17

Table I.

S2:E4

210 B. The system shall not allow the axes to extend beyond the hard stops, unless the machine is under repair.

S2:E4

211 C. Only forces external to the machine can move it past the hard stops.

S2:E4

212 D. The machine shall have a way to travel the robot back into the working envelope from the operator control panel if it has traveled past programmed stops, either by jogging the robot or having an over travel override button.

S2:E4

213 3.2.4.2.2 Axis Ball Screws and Bearing Surfaces S2:E4

214 A. Accept antifriction type way bearings of a precise fit.

S2:E4

215 B. Include adjustable gibs, guides, or bearings for alignment of the table to the ways and to prevent excessive loading of the feed drive motor.

S2:E4

216 C. All axis ball screws and bearing surfaces leveled and aligned within:

S2:E4

217 a. 0.001" flatness and parallel for the X and Y axis with reference to the base, and

S2:E4

218 b. 0.001" flatness and perpendicular for the Z axis.

S2:E4

219 3.2.5 Cabinet Design

220 A. The cabinet shall prevent any media from escaping the cabinet.

221 B. Cabinet design shall be such that it minimizes shot from being stored in places within the cabinet where it cannot be reclaimed.

222 C. An E-stop shall be provided in the operator loading/unloading area and clearly labeled as such.

223 D. An E-stop shall also be located in the vicinity of the programing service door so that during programing and program testing the E-stop is easily accessible.

224 3.2.5.1 Base

225 A. Minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine.

226 B. Easily and accurately level the machine by the contractor when the machine is delivered and installed.

227 3.2.5.2 Operator Platform

228 A. A platform shall be provided to allow the operator access to the blade loading/unloading area, parts door(s), and operator station.

229 B. The steps shall meet all applicable OSHA specifications. The platform shall ensure that operators that are 4' 9" and taller shall be capable of loading/unloading the blades without additional assistance.

230 3.2.5.3 Media Peening Cabinet

231 A. Minimum ½" steel plate with all weld seams ground to a radius.

232 B. Rounded or beveled edges unless sharpness is required to perform a necessary function.

233 C. Inside walls protected from the peening media blast by means of at least 1/8" thick replaceable SB60 rubber liners or equivalent abrasion-resistant gum rubber.

234 D. Minimum ¼" thick urethane blast wear plates mounted on the cabinet wall directly in front of the nozzles to absorb energy from overspray and ricochet.

235 a. These plate(s) shall be replaceable.

236 b. These plate(s) shall cover the 1/8" thick replaceable SB60 rubber liners within the peening cabinet.

237 E. Sealed to reduce noise, contain media, and prevent safety hazards.

238 3.2.5.3.1 Work Lights

239 A. At a minimum, two (2) light emitting diode

(LED) light fixtures complete with dust tight, abrasive resistant covers shall be mounted in the ceiling of the media peening cabinet to illuminate the entire work area.

240 B. The lighting shall produce a well-lit cabinet interior with a minimum 80 foot-candles

(861 lux) of light intensity.

241 C. Lighting shall allow for easy bulb replacement.

242 D. Lighting shall comply with NFPA 79 requirements.

243 3.2.5.4 Doors, Covers and Panels The machine shall include doors, covers, and panels as necessary. Doors, covers, and panels shall be easily accessible for removal and maintenance egress.

244 3.2.5.4.1 Door Interlock Switch The machine shall have a keyed interlock switches on all doors leading into the peening cabinet

245 A. Verifies all doors that provide access to the peening chamber are securely closed.

246 B. Stop all processing if the door is opened during a peening cycle. Processes to include, but not limited to: air flow, media flow, spindle rotation, and gantry arm movement.

247 C. Prevent a peening cycle from starting when the door is open. No processes shall resume until all door(s) are closed and the peening cycle is restarted by the operator.

248 D. Deactivate when the machine is in a "Test" status and while the jog pendant is engaged. This will allow the robot to move to programmed points without running a cycle.

249 E. Ensure that while a peening chamber door is open, the machine will not make un-commanded movements or while the jog pendant is disengaged.

250 3.2.5.4.2 Light Curtain

251 A. Light curtains shall be placed in loading and unloading area(s)

252 B. If the light curtain is obstructed, the doors shall not open or close, and the work table shall not index.

253 C. A fault shall be displayed on the operator computer that the light curtain is obstructed.

254 D. Once the light curtain is cleared, the fault shall be easily and quickly cleared to resume indexing/closing the doors on the machine

255 3.2.5.4.3 Parts Door(s)

256 A. The door(s) shall be sealed so no media can escape. No media shall be allowed to exit the machine during a peening cycle.

257 B. An abrasive resistant rubber coating on the inside surface to protect from the peening process.

258 C. Quick exchange between parts inside the cabinet and parts in the loading zone.

259 D. Safe loading and unloading outside of the peening cabinet while blades are processed within the cabinet.

260 E. Table can only index when the part door(s) are verified open and the machine is not in a peening cycle.

261 3.2.5.4.4 Service Door(s)

262 A. Sealed to contain media entirely within the machine.

263 B. A minimum of 3' tall and 4' wide.

264 C. Placed at eye level for a person between 5' and 6' tall.

265 D. Allows for retrieval of small objects if dropped into the media peening chamber.

266 E. Includes a magnetic door stop to keep the door open when programming.

267 3.2.5.4.5 Window

268 A. Constructed with clear safety glass.

269 B. Be a minimum of 12in high and 12in wide.

270 C. The window shall include a urethane slide plate.

271 a. Is open or closed using a lever on the side of the machine

272 b. The slide plate shall be made of 1/8" urethane

273 c. The slide plate shall completely protect the widow from being peened, or peening ricochet when it is covering the window.

274 d. The slide plate shall be capable of partially concealing the window while peening, and staying in place without external assistance from an operator.

275 D. The viewing window shall be placed in a location on the machine that optimizes the viewing angle of the operator to the part while operating the nozzle and spindle axes, for automatic peening.

276 E. The window shall have a removable film which can be reapplied to protect the glass surface.

277 3.2.5.6 Manual Blow Off The machine shall have manual blow off air nozzles around the machine where operators or maintenance personnel will perform routine tasks

278 A. At a minimum, one manual, self-coiling blow-off nozzle shall be near the part loading/unloading area, one nozzle near the pressure pots and their components, and one near the media classifiers.

279 B. Use of the blow-off nozzles during the peening process shall have no effect on the air pressure being used to peen the part or while indexing the table.

280 3.2.6 Operator Computer Station The operator computer station shall have a computer with an operator interface system.

281 A. The computer station will be located within reach of the parts loading and unloading door(s)

282 B. The computer station will be located within reach of the CNC controller

283 3.2.6.1 Operator Computer The operator computer shall house all the necessary features to create files, edit, and store them for future use.

284 Operator computer shall run the operator interface system and Almen intensity software.

285 A. High End Modern Workstation: E5-2367 3.5

Ghz dual processors

286 B. Windows 10 operating system

287 C. 16GB DDR4-2133 Memory

288 D. 8GB Video Card

289 E. 500GB Hard Drive

290 F. DVDRW Disc Drive

291 G. 19" Industrial sealed LCD touchscreen monitor with cable

292 H. Industrial sealed keyboard

293 I. Wired mouse

294 J. Industrial sealed jog pendant

295 K. 4 USB ports

296 L. Uninterruptable Power Supply (UPS), minimum 1 hour PC runtime with power off

297 M. PC shall run strictly offline

298 3.2.6.2 Programming Screen The programmer shall be capable of viewing and editing programs on the operator interface while viewing the peening chamber

299 A. The screen(s) used to program the nozzle position with relation to the parts shall be positioned near the peening chamber and service door used for programing and observing part programs and is available at the load/unload station for operation.

300 B. If a single screen shall be used, the programing screen shall be set up on a robust positioning mount to allow it to rotate to either side of the machine or otherwise configured to easily be able to be used at the operator station and programing location.

301 C. As a safety precaution the system shall be designed such that when the programming screen is not in the part loading/unloading station location no air pressure or media will flow through the nozzles.

302 3.2.6.3 Operator Interface System The operator interface system shall be used to display process control data information during a shot peen cycle.

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303 A. The operator interface shall display all process instructions including, but not limited to:

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304 a. nozzle movement S2:E5

305 b. dwell time S2:E5

306 c. total cycle time S2:E5

307 d. media selection S2:E5

308 e. air pressure S2:E5

309 f. media flow S2:E5

310 g. program number S2:E5

311 h. any other information as required by other sections

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312 B. The equipment shall shut the process down when required parameter limits are exceeded.

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313 C. The operator interface shall be responsible for axes motion programming, full process control, process monitoring, and process/systems diagnostics ability.

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314 D. The operator interface shall have an extensive diagnostic capability including but not limited to:

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315 a. Help messages for all parameters shown on the display screens

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316 b. Information on the limits and operations of a parameter

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317 c. Information about displayed/active alarms S2:E5

318 d. Machine and system alarm conditions, such as equipment malfunctions, shall also be supported by alarm and diagnostic messages

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319 E. Necessary support services and peripheral equipment shall also be linked to the operator interface including, but not limited to:

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320 a. Media probes S2:E5

321 b. Manga Flow Controller S2:E5

322 c. Proportion Air Pressure Transducer S2:E5

323 d. Fanuc CNC Controller S2:E5

324 F. Operator interface system shall have no input lag, and take less than 1s to implement inputs including, but not limited to:

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325 a. making program selections S2:E5

326 b. editing programing S2:E5

327 c. changing the view of active process parameters

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328 d. Setting new set points or alarm limits S2:E5

329 3.2.6.3.1 Parts ID Page S2:E5

330 A. The user shall be able to enter a known part number or display a sortable list of all entered/programmed parts.

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331 B. Along with each part recorded in the system, a minimum of 4 part pictures

(entered by the customer) per part program shall be available to aid in selecting the correct program for each part.

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332 C. Documentation such as nozzle selection, setup description, fixturing requirements, and user specific data shall also be shown on the part identification screen.

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333 D. The Serial Number of the part(s) must be entered into this screen in order to authorize a program run, and stored with the part information and operation parameters in the part tracking database.

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334 3.2.6.3.2 CNC Programs The operator interface will be used to select, view and edit the CNC programs

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335 A. Programs shall be written by the programmer on the PC interface using G-code programming language.

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336 B. When a part is selected by the operator, the associated part program shall automatically be sent to the CNC and made active.

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337 C. Each part program must have a minimum of twelve (12) optional motion control or process functions that can be defined. This feature shall be used when certain areas of the part need to be processed and for

Almen test locations to be run on the same program.

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338 D. The operator shall be able to select each function required. This data shall then be passed to the CNC which will only perform the selected functions/areas.

339 E. Process set points and process actual values shall be displayed in an easy-to-read format on a monitor screen.

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340 F. When the programmer enters a parameter inconsistent with the process or not within the range of a particular variable, a message indicating the valid range shall be displayed.

This screen shall display the critical process parameters.

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341 G. All program "Save" buttons shall save the program when commanded. Before leaving the programming screen, program shall prompt the programmer to save their work if any changes have been made in the program since the program was last saved.

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342 3.2.6.3.3 Login Security System The Operator interface shall have multi-level security system to control access to certain functions.

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343 A. The controller shall have a minimum of three levels of security, which enable the administrator of the system to lock out specific parties and operations as desired.

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344 B. Each process parameter shall be protected by a multi-level security system.

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345 C. The security system shall safeguard the program from unauthorized/accidental deletions, additions, or modifications to any of the program recipes, part programs, part pictures, program run time, or reports.

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346 D. The security system shall be capable of locking out operators from all computer programs that are not peening/process related while otherwise allowing access to the full function of the PC.

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347 3.2.6.3.4 Program Recipes S2:E5

348 A. Recipes shall be identified by an independent address (part number or some other form of identification) that can be recalled during program execution.

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349 B. The system shall store all desired recipe process values that are manually input by the programmer during recipe setup.

Parameters could include all spindle speeds, media flow rate for each media type, air pressure, and any other parameter critical for peening.

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350 C. Each parameter shall have programmable high and low limits.

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351 D. Different recipes shall be selectable from this system to process different parts.

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352 E. The system shall allow a programmer to edit recipes while executing motion programming.

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353 3.2.6.3.5 Data Logger The system shall be equipped with a data logger to monitor and log critical process parameters

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354 A. The data logger shall provide a record of all process parameters (i.e set point, minimum, maximum and average values, time to process), alarms, and shutdowns.

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355 B. The data logger shall have a reporting data function that allows operator to set a schedule. The data logger file shall store part names, part numbers, and serial numbers.

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356 C. The data logger shall exist to provide information on troubleshooting based on specific alarms which occur, and the frequency with which they appear.

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357 3.2.6.3.6 Reports S2:E5

358 A. All data shall be stored and done through an integrated database nested within the operator interface.

359 B. Reports shall provide the following: S2:E5

360 a. Process summary reports - providing the summary of all key parameters (i.e set point, minimum, maximum and average values, time to process)

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361 b. Alarm logs which show all alarms and shutdowns generated over a given time period

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362 c. Recipe print-outs S2:E5

363 d. Part log reports that show all parts processed for a given time period

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364 e. Strip chart records which show second-by-second data.

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365 D. All data shall be reported by date, part noun, part number, serial number, or any other user specified data.

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366 E. Reports shall be exportable in a wide variety of formats such as Lotus 123, Excel, Word, RTF, Text, Dbase, etc.

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367 3.2.6.3.7 Preventive Maintenance Schedule S2:E5

368 A. The PM scheduler shall track the elapsed hours or days on a minimum of 100 items.

This will allow maintenance to be recorded for each unique item based on its usage rather than on an hour basis for the complete machine.

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369 B. Each item shall be assigned an elapsed time/cycle for the "maintenance due" alarm to alert the operator .

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370 C. Each maintenance item shall have help available at the push of a button.

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371 3.3 Construction The machine shall be constructed of parts that are new, without defects, and free of repairs.

372 The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion

373 The moving components shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion, or inconsistencies in movement.

374 3.3.1 Castings and Forgings All castings and forgings shall be free of defects, scale, and mismatching.

375 No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

376 3.3.2 Fastening Devices All screws, pins, bolts, and other fasteners shall be installed in such a way as to prevent unintentional loosening.

377 Fastening devices subject to removal or adjustment shall not be permanently installed.

378 3.3.3 Threads All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein.

379 3.3.4 Gears All gears of axis drive trains shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

380 Gears in drive trains shall be hardened and ground steel.

381 Working surface hardness shall be not less than a Hardness of Rockwell C (HRC) of 48.

382 3.3.5 Surfaces All surfaces shall be clean and free of harmful or extraneous materials

383 All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function

384 The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

385 3.3.6 Welding Brazing, or Soldering Welding, brazing, or soldering shall be employed only where specified in the original design.

386 None of these operations shall be employed as a repair measure for any defective part.

387 3.3.7 Painting All machine components shall be coated with a high quality industrial epoxy paint.

388 3.3.8 Workmanship Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

389 3.3.9 Measuring and Indicating Device

Graduations

All measuring and indicating devices on the machine shall be graduated in U.S.

customary units.

390 3.3.10 Controls All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located on the operator's control panel(s).

391 3.3.11 Safety and Health Requirements All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

392 3.3.11.1 Safety Guarding Covers, guards, or other safety devices shall be provided

393 The safety devices shall not interfere with the operation of the machine

394 The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

395 All enclosures and covers requiring preventive maintenance shall be secured with turn type, flush mount, quick fasten locks or industry standard common size and type fasteners. NOTE: Interlock bypass shall be installed for maintenance personnel use.

396 3.3.12 Audible Noise Level Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the "A" weighted scale of a standard

Type II sound level meter, at the operator's work position or any point at a distance of 3 feet from the equipment.

397 Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

398 Sound levels shall be measured with a calibrated sound level meter set on "A" scale and "Slow" response. When tested at the facility it will be accepted as long as the noise levels do not test higher than 90 dB(A) at any point in the process and shall be located in a hazardous noise area.

399 3.3.13 Mercury Restriction The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

400 3.3.14 Asbestos Restriction Asbestos and materials containing asbestos shall not be used on or in the machine.

401 3.3.15 Lead Lead and materials containing lead shall not be used on or in the machine unless otherwise stated.

402 3.3.16 Use of Polychlorinated Biphenyl (PCB) The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

403 3.3.17 Environmental Protection Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

404 3.3.18 Lubrication All parts of the machine requiring continuous lubrication shall be automatically lubricated by a system that will ensure adequate lubrication of parts

405 Parts or mechanisms requiring periodic lubrication shall be provided with adequate means for grease or oil lubrication.

406 Systems using recirculated oil shall be equipped with a replaceable or washable filter element.

407 Each oil reservoir shall have an oil level gage.

408 Automatic processes of lubrication shall have a warning device to indicate when lube oil is low or system failure

409 All oil holes, grease fittings, and filler caps shall be easily accessible not requiring personnel to climb onto, around, or under the machine.

410 3.3.19 Replacement Parts All parts subject to replacement shall be manufactured to definite dimensions and tolerances per ASME Y14.5, and shall be listed in the provided equipment manuals.

411 Replacement parts shall be interchangeable without requiring modification.

412 Replacement parts are those that are subject to wear or failure such as but not limited to wear plates, rubber lining, gears, bearings, shafts, feed screws, drive belts, pumps, screens, hoses, and seals.

413 Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices.

414 Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

415 3.3.20 Hydraulic System The hydraulics system shall conform to ISO

416 The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

417 All sight glasses and pressure gauges shall be visible without removal of any covers or panels.

418 3.3.21 Pneumatic System The pneumatic system shall conform to ISO

419 The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

420 3.3.22 Electrical System

421 A. The machine shall conform to all OSHA, NEMA and NFPA 79 standards and regulations.

422 B. The power source at the intended Tinker Air

Force Base facility is 480 volt, 3-phase, 60

Hertz (Hz). The machine's electrical system shall be able to work with the provided facility power source and shall be tolerant to ± 10 percent fluctuation.

423 C. The electrical system shall be complete:

including fuses, electrical contacts, and any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment, etc.

424 D. No wire nuts shall be utilized in the electrical system.

425 E. All wires in the electrical system shall be correctly labeled and referenced in the electrical drawings and maintenance manuals provided.

426 F. All electrical components shall be secured to prevent hazards caused by unsecured wires.

427 G. The electrical system shall be properly grounded and all wires shall be appropriately sized for the intended current and voltage.

428 H. All unused electrical card slots for Inputs and Outputs shall be filled with blank cards.

429 I. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only.

430 J. Contractor shall notify the government of the specific Amperage requirements of the machine at time of contract award.

431 3.3.22.1 Electrical Enclosures

432 A. Conform to NEMA ICS 6 standards. The enclosure shall be NEMA 250 type 12, provide for ventilation of components, and designed for an indoor non-hazardous location.

433 B. The machine shall be provided with interlocks on its electronic cabinet that instantly remove power from the equipment when the door is opened in accordance with NFPA 79.

434 C. The controller cabinet shall be cooled by means of a thermostatically controlled…