NRL_CCOAST_Hydraulic_System_Requirements_final.docx

NRL-KW Hydraulic Structures/Material Test System Requirements

CCSE (6130)

DESCRIPTION OF NEED

The Naval Research Laboratory (NRL) in Key West is setting up an outdoor marine test environment in order to provide flexible testing for materials, coatings, aircraft, and marine structures. This will consist of a hydraulic system which will provide for mechanical loads to be applied to the materials and structures. These loads may be static or dynamic for the purpose of fatigue testing.

The hydraulic structures and materials test system consists of:

· Hydraulic Power Unit (HPU) that provides pressure and flow of hydraulic fluid

· Support Equipment: valves, pipes, and fittings to move pressurized hydraulic fluid to the test area

· Hydraulic Cylinders and Electronically Controlled Valves (Servovalve, or equivalent) and Instrumentation that provide for force on samples and structures within an NRL supplied load frame

· A Controller that provides command to the Servovalves and interfaces with vendor supplied Software user interface and Data Collection System

· A Data Collection System that consists of all signal acquisition hardware and a PC based software interface, which may be integral to the Controller, and which receives signals in various forms, conditions them, and interfaces with the vendor supplied PC based software to record them (NRL will supply the PCs)

· Software which run the Controller and Data Collection System and provide user interface with test parameters and control and allows for real-time viewing of data, post-processing, and export of data

Figure 1. Depiction of test site layout

DESCRIPTION OF TEST ENVIRONMENT

This system will be exposed to natural outdoor marine environment, being located next to the ocean. During testing, salt water may be sprayed on equipment that is located out of the air-conditioned buildings. Hydraulic cylinders, servovalves, and fittings/hoses specifically will see this salt spray. The outdoor system will be exposed to full sunlight.

Equipment internal to air-conditioned spaces will see incidental exposure to saltwater laden air. Also, periodic loses in air-conditioning may occur.

The Hydraulic Cylinders and Servovalves shall be constructed of marine compatible materials and/or coated/painted in marine compatible coatings/paints.

Wiring and electronics shall be protected from exposure. Equipment located in conditioned environment shall be NEMA 12 (NEMA 4 preferred) and equipment located outdoors shall be NEMA 4 (IP65).

OVERALL SYSTEM REQUIREMENTS

The hydraulic test system shall provide for testing of 12 independent control channels, each with a separate Hydraulic Cylinder and Servovalve.

Three (3) of these independent control channels shall be capable of testing to 50 kip force in both tension and compression.

Nine (9) of these independent control channels shall be capable of testing to 20 kip force in both tension and compression.

All independent control channels shall be capable of fully reversing force in a variety of modes which will be discussed with the Controller Software.

If calibration is required, the Controller and Data Recording System shall have an automated calibration method that can be performed by trained NRL personnel or by the offeror under the service contract.

The equipment shall be new. No remanufactured or "gray market" items will be acceptable or considered.

Prospective vendors must be original equipment manufacturers (OEM), authorized dealers or distributors or resellers of any proposed equipment or systems.

All physical equipment, control systems, data acquisition systems, firmware, and software shall be self-compatible and “turnkey” in operation. No NRL labor shall be required to integrate hardware, control systems, data acquisition systems, firmware or software.

HYDRAULIC POWER UNIT

The HPU shall be capable of providing a minimum of 60 GPM at a minimum of 3000 psi maximum working pressure. All aspects of the system shall be capable of an industry accepted safety factor above this maximum working pressure.

This HPU shall interface with a NRL supplied 306 BTUH (Filtrine PCP-3000S-330A-WP) chiller with a liquid-liquid heat exchanger supplied by the offeror.

The HPU shall fit within 11 ft x 11 ft floor space. (The double doors allow 6’ clearance into the Hydraulic Shed.)

The HPU shall have valves to disconnect hydraulic power from each of twelve (12) separate hydraulic cylinder lines.

The HPU shall have built-in reservoir, accumulator(s), fill valve, filters, recirculating pump, heat exchanger, manifolds for connection of the 12 independent lines, and anything else that is necessary to provide for a safe and easily maintainable hydraulic test system.

Operation of the HPU in the enclosed Hydraulic shed shall meet OSHA permissible exposure limits.

The HPU shall have equipment maintenance and health monitoring to assist users in trouble-free operation.

The HPU shall interface with the Hydraulic Controller to provide for user input and monitoring from a separate control building.

SUPPORT EQUIPMENT

Hydraulic hoses, fittings, valves, and associated connectors needed to meet the operational requirements of the system shall be provided by the vendor.

Compatible hydraulic fluid shall be provided.

Hoses and lines shall be flushed clean and sealed with hydraulic fluid.

Hydraulic hoses will see full sun exposure and preventative measures will be included to address survivability of hoses in UV exposure environment.

It is preferred that external metal components on the hydraulic hoses are constructed of corrosion resistant steel.

HYDRAULIC CYLINDERS, SERVOVALVES, AND INSTRUMENTATION

The Hydraulic Cylinders shall meet the force requirements in Section 3. They shall be capable of a minimum of 6.0 inches of stroke. NRL will provide column support for compression loading.

The Hydraulic Cylinders and Servovalves, individually, shall be able to meet the no-load frequency response in Table 1.

Table 1 Cylinder/Servovalve Frequency Response Requirement (no-load, zero phase lag)

The Hydraulic Cylinders/Servovalves shall have integrated measurements of Force, Displacement, and Pressure. Figure 1 depicts this integrated setup.

Figure 2 Depiction of Hydraulic Cylinder, Servovalve and instrumentation The integrated measurements shall be NIST calibrated.

The load cell measurement accuracy shall be 0.25% of full scale rating.

The displacement measurement accuracy shall be within 0.5% over the full stroke and 0.25% within a 1 inch range.

The load and displacement instrumentation shall be integrated with the Hydraulic Cylinder/Servovalve assembly. Pressure instrumentation may be located in the Hydraulic Shed.

All components shall be fatigue rated and not require replacement.

Cylinders and Servovalves must be flushed and sealed with hydraulic fluid. NRL does not intend to leave all cylinders out in the environment at all times, so appropriate storage cases or crates shall be provided for long term storage. It is preferred that these cases/crates can be sealed/desiccated.

Load cells and displacement transducers, with connector installed, shall be IP65 or equivalent.

CONTROLLER

The Controller shall be capable of closed-loop feedback control of 12 independent Axes.

These Axes shall be capable of being controlled by force, displacement, velocity, pressure, conditioned strain, or any other customizable analog input. With the exception of strain input, all other signals must be appropriately conditioned for the controller. NRL will provide conditioning for strain input.

Analog inputs shall include voltage and current proportional signals.

Digital control signals may include Quadrature Encoders, Synchronous Serial Interface (SSI) and Pulse Width Modulation (PWM).

The Controller shall interface with the Software and HPU in an integrated system.

In addition to the input channel, other channels shall be capable of providing for triggers and abort criteria, such as displacement outside of a user-input range.

The Controller shall provide digital discrete output of 12 channels minimum, configurable within the Software.

The Controller shall be capable of closed-loop feedback control up to 500 Hz.

The Controller shall be able to have basic on/off, start/stop, and jogging controlled at the load frame via external remote control.

The Controller shall have manual and automatic tuning functionality, adaptive tuning and control as well as cascade control functionality.

The Controller shall provide for a minimum of three (3) users running three (3) independent tests from independent workstations simultaneously.

The Controller shall include digital filters for filtering signals.

The Controller shall be expandable to provide voltage and current proportional analog output.

The Controller shall have an E-stop located in the Control Shed and an E-stop that can be remotely located.

DATA COLLECTION SYSTEM

The Data Collection System shall interface with the Controller and Software in an integrated system. The data collection hardware/firmware may be part of the Controller hardware/firmware. The data collection system will have PC based control software. (NRL will provide the PCs.)

The Data Collection System shall record all signals used by the Controller for closed loop feedback.

In addition to the signals used by the Controller, the data collection shall be capable of recording:

· 12 minimum analog channels, expandable up to 96 minimum analog channels

· 12 digital input channels The Data Collection System shall be expandable to allow for ¼, ½, and Full-bridge completion for 36 strain gage measurement channels. These channels are included in the analog channels in the bullets above.

The Data Collection System shall be capable of sampling rates up to 2000 Hz, storing of 30 Billion samples in internal memory/storage, and a data resolution of single-precision floating point (32 bit) minimum.

Minimum A/D conversion shall be 24-bits.

Perform cycle counting on signals (of great importance for fatigue testing).

The Data Collection System shall include digital filters for filtering signals.

The Data Collection System shall provide for exporting data into multiple formats including Excel and CSV.

SOFTWARE

NRL will provide computers for interfacing with the Controller/data collector. These will be Windows 7 64-bit or Windows 10 64-bit computers.

The Software shall be in an environment that is tailored for materials/structures testing and provide a graphical user interface where the user can:

· Design test sequences

· Set up all aspects of the Controller and data collection system

· Customize the environment to view real-time test data in a way that is useful to test monitoring and is mechanical-test centric

· Run tests controlling the Controller, data recorder, and HPU

· Be provided real time data and graphs of any and all signals

· Store, open, view, and export of current and past test data

· Record and reset cycle counts for fatigue testing of hardware/materials

· Design and display data in custom units that are formulaic and calculated from measured signals The Software shall be capable of providing for sine, step, square, triangle, ramp, sine-sweep, random (or pseudo-random), and user time-history input.

The Software shall meet requirements “out-of-the-box” and require no labor from NRL to program.

The Software shall be capable of executing multiple user-defined test sequences simultaneously. Licenses to operate 3 computers simultaneously in a testing/data collection mode shall be provided. If a separate license to design tests is required, a single Software license to design tests shall be provided.

The Software shall have capability to have calculated signals/channels.

The Software shall be capable of receiving an external input command.

INSTALLATION AND TRAINING

The offeror shall install the system on-site, calibrate sensors, and check out all equipment under supervision and support of NRL personnel. NRL personnel will provide support for heavy material handling and interface with NRL equipment.

The offeror shall provide on-site training on all user-accessed functions of the system as well as maintenance.

Full technical documentation, system schematic, and manuals of operation shall be provided to NRL personnel.

SERVICE AND SUPPORT

The offeror shall provide a service and support contract to troubleshoot issues and service the equipment if required.

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