I. 8 1300835912_TTF Specificaiton Document Rev 03.pdf

Towed Array Tension Test Facility Upgrade

1.0 GENERAL DESCRIPTION

This specification covers the salient design and performance requirements for one (1) control system to be used for tension testing samples up to 180-feet in length and recording pertinent test data. Capabilities must provide testing and data recording abilities as detailed below.

2.0 BACKGROUND

The Towed Array Tension Test Facility (TTF) is comprised of two mirrored opposite tensioning sections (puller subassemblies) attached to a 180 foot test trough. The puller subassemblies are comprised of dual drive screws with a drive head, driven by control equipment (figure 1). The TTF Control System is comprised of the control equipment, control console, and the control software. The control equipment consists of a motor, motor controller, and pulley system. The control console is the interface between the operator and the control equipment. The control software allows the operator to command the control equipment from the control console. The testing software allows the operator send commands to the control equipment to execute tension testing to a Unit Under Test (UUT).

The limit switches prevent equipment damage by limiting the system from moving the drive heads to the ends of the drive screws. Each puller subassembly has two pairs of optical and mechanical limit switches, one pair at the inner travel limit and the second pair at the outer travel limit. Personnel are not allowed within 4 feet of the TTF during operation. The load cells are Honeywell Model RF tension load cells and are paired with Honeywell Model SC1000 and SC2000 load cell indicators. The load cells and indicators use RS-232 and RS-485 serial communications. The optical sensors are Eaton Photoelectric Sensors E58 Harsh Duty Series 18mm Diameter Perfect Prox®, four inch sensors. There are two marquee displays – at the north end and the south end of the test trough. The marquee displays are industrial LED marquee displays which use RS-232 and RS-485 serial communications. The TTF utilizes emergency stop buttons and emergency stop street trolley break lines. There is an emergency stop button located by each motor controller and an emergency stop button located in the control room by the current control console. The emergency stop street trolley break lines are located along the east and west side of the test trough.

This document provides the requirements for the replacement of the control equipment and control console (red boxes, figure 1). The contractor shall install control software within the control console of one (1) HP 420 Z3 Windows 10 computer provided by the Government.

Figure 1. NUWCDIVNPT Tension Test Facility Diagram

3.0 APPLICABLE DOCUMENTS

The contractor shall perform the tasking required in Section 4.0 in accordance with the below Applicable Documents (AD).

3.1 3.2 3.3 3.4 3.5 3.6 3.7

4.0

MIL-PRF-28800, Test Equipment for Use with Electrical and Electronic Equipment, General Specification for Honeywell Model RF Rod End In-line Tension Load Cell data sheet Honeywell Sensing and Control SC Instrumentation SC Series Instruction Manual EATON Cutler-Hammer Photoelectric Sensors E58 Harsh Duty Series data sheet 15-1176-S02, Standard Operating Procedure for the Tension Test Facility TTF Drawing Data Package MIL-HDBK-46855, Human Engineering Guidelines for Military Systems, Equipment, and Facilities MIL-STD-1472, Human Engineering

REQUIREMENTS

4.1 Physical

4.1.1 The puller subassembly mechanisms shall be compatible with the existing tension bed frame.

4.1.2 Control equipment shall fit in a space as shown in the TTF Drawing Data Package, provided by the Government.

4.1.3 The TTF Control System shall provide for a drive screw throw/active travel/stroke length of no less than 17 feet for each puller subassembly.

4.2 Performance

4.2.1 Each puller subassembly shall provide a minimum working load of no less than 60,000 pounds tension.

The TTF Control System shall be:

4.2.2 Capable of holding a constant tension (+/- 3% of working load) for up to 24 hours.

4.2.3 Capable of advancing or retracting the drive head at a variable rate between 0.01 inches per second and 1.0 inches per second.

4.2.4 Capable of measuring drive head position data to +/- 0.001 inches.

4.2.5 The software shall be able to process precise tension data at a resolution of 0.01 pounds tension.

4.2.6 Designed to complete no less than 20,000 tension cycles over its service life.

4.2.7 Designed to withstand the shock and vibration associated with catastrophic failure of

UUTs at 60,000 pounds and at full extension up to 200 times over the life of the system.

4.3 Hardware

4.3.1 The Control System shall utilize optical and mechanical limit switches in the active travel area for inner and outer travel limits of each puller subassembly.

4.3.2 The optical limit switch shall be a software interlock to prevent movement past the ends of the drive screws when tripped.

4.3.3 The drive head rate shall automatically ramp down to 0.1 inches per second when the drive head is within 2 inches of an optical limit switch and traveling faster than 0.1 inches per second.

4.3.4 The control console shall provide a warning indication when the drive head is within 2 inches of an optical limit switch.

4.3.5 One Computer shall control both sets of Control Equipment via the control console.

The Control System shall:

4.3.6 Allow both puller subassemblies to be controlled independently or concurrently.

3.8

4.3.7 Allow the drive heads to move towards the outer optical limit switch when the inner optical limit switch is tripped and allow the drive heads to move towards the inner optical limit switch when the outer optical limit switch is tripped.

4.3.8 Utilize current marquee displays to display the current tension of the UUT in pounds at both ends of the facility when the system is powered on.

4.3.9 Be designed with appropriate guards and other electrical features to promote safe operation with minimal risk to personnel. Guidance for this requirement can be found in GFI 15-1176-S02, Standard Operating Procedure for the Tension Test Facility.

4.4 Control Console

4.4.1 The Control Console shall be compatible with Windows 10 (or newer) operating system.

4.4.2 The Control Software shall prompt the operator for a data file name upon software initialization.

4.4.3 The Control Software shall have a default file naming system for use if the operator declines to input a file name.

4.4.4 The Control Software shall create and save a data file for every test.

4.4.5 The Control Software shall record all data during testing.

4.4.6 Data sampling rate shall be adjustable either by samples per second or by a change in tension.

4.4.7 The sample rate shall be variable with a minimum of one sample per second to at least twenty samples per second or from one pound tension to 100 pounds tension.

4.4.8 The Control System shall include a report generator.

4.4.9 The report generator shall allow the operator to generate custom reports compatible with

Microsoft Office and/or Adobe Acrobat PDF viewer/generator.

4.4.10 Reports generated by the Control System shall at a minimum have the following options:

• Graphical representation of test

• Zoom-in on points of interest in the test

• Written description of test commands/scenario

4.4.11 The Control System shall be able to export generated report files.

4.4.12 Report files shall be less than 4.7GB.

4.4.13 The Control System shall be able to export recorded data to a comma separated variable

(CSV) file.

4.4.14 The Control System shall create multiple raw data files when the size of the test file is greater than 4.7GB.

4.4.15 The Testing Software shall provide a test scenario generation capability that allows the operator to generate a file that will run up 500 commands for a single test.

4.4.16 The Testing Software shall allow test scenarios to be saved and retrieved.

4.4.17 The Testing Software shall use a graphical user interface (GUI) when creating scenarios and while testing.

4.4.18 The GUI shall display the following while testing:

• Current tension

• Drive head speed/rate

• Elongation

• Location of each drive head in its respective puller subassembly

• Graphical representation of tension over duration of test

• Enable/disable motor(s) button

4.4.19 The GUI shall allow the operator to drag and drop graphical icons to create testing scenarios. MIL-STD-1472 (Human Engineering) and MIL-HDBK-46855 (Human Engineering Guidelines for Military Systems, Equipment, and Facilities) shall be used as guidelines.

4.4.20 The Control System shall allow test commands to be run individually.

4.4.21 The testing software shall include the commands listed in section 5.

4.4.22 The Testing Software shall allow test results to be filtered by the user to show specific portions/segments of a test.

4.4.23 The Control System shall allow custom reports to be created for filtered portions/segments of a test.

4.4.24 The Testing Software shall be capable of varying data sampling rate throughout the test.

4.4.25 The software shall require the operator to input a warning tension limit and maximum tension limit for each test.

4.4.26 The Control Console shall sound an audible alarm when the test warning tension limit is reached.

4.4.27 The Control Console shall sound an audible alarm when the test maximum tension limit is reached.

4.4.28 The Control Console shall halt drive head movement when the maximum tension is reached.

4.4.29 A pop-up warning shall display on the control console when the maximum tension is reached.

4.4.30 The Control Software shall allow for the maximum tension warning pop-up to be cleared without reducing the tension.

4.4.31 Continuation of the current scenario/testing profile shall be allowed by Government user after the maximum tension warning has been cleared, which Government personnel shall be allowed to clear.

4.4.32 The control console shall allow the user to remotely enable, disable, and manipulate each set of control equipment individually or concurrently.

4.4.33 The Control Console shall emit an audible alarm when the north or south set of control equipment is enabled.

4.4.34 The Control Console shall emit an audible alarm when testing commences.

4.4.35 The control software shall contain programmed tension limits that do not allow the TTF to exceed the system’s maximum capability.

4.4.36 The Control Console shall display the current tension of the puller subassemblies on the marquee displays.

4.4.37 If only one puller subassembly is in use, the Control Console shall display the tension of that puller subassembly on both marquee displays.

4.4.38 The power-up condition of the TTF shall not allow for movement of the drive heads in the puller subassemblies.

4.4.39 The Control Console shall include battery backup with power conditioning.

4.5 Interfaces

4.5.1 The control system shall be compatible with canister-type tension load cells from various manufacturers that use RS-232 and RS-485 Serial Communications.

4.5.2 The control system shall be compatible with marquee displays that use RS-232 and RS- 485 Serial Communications.

4.5.3 The control equipment shall use 230 volt 3 phase power.

4.5.4 The control console shall use 120 volt power.

4.6 Safety

4.6.1 The mechanical limit switches shall remove the power to the motor when tripped.

4.6.2 Power shall be restored to the motor after the mechanical limit switch has been reset.

4.6.3 The Control Console shall halt the movement of the drive heads when the maximum tension is reached.

4.6.4 The Control System shall incorporate emergency stop buttons and/or street trolley brake lines.

4.6.5 The control system shall remove power to the drive motors and halt movement of the drive head immediately when emergency stop buttons and/or street trolley brake lines are activated.

4.6.6 Emergency stop buttons and street trolley brake lines shall be located at each puller subassembly, in the control room, at the main energy source(s), and continuously along the east and west sides of the test trough.

4.6.7 The Control System shall be able to withstand power interruptions IAW MIL-T-28800 (revision F section 3.5.1.2.3).

4.6.8 The Control System shall return to power-up condition when power has been restored IAW MIL-T-28800 (revision F section 3.5.1.2.3).

4.6.9 Power-up condition of the control system shall be as follows:

• Initialization of software;

• System health checks;

• Display current sensor readings;

• Drive heads/puller subassemblies are disabled/unable to move; and

• In the event of a power outage, the control system shall immediately engage brakes and halt all movement of the puller subassemblies.

5.0 TTF Commands:

Command Description ACTIVE DRIVE PRIMARY Activate north end control equipment

ACTIVE DRIVE

SECONDARY

Activate south end control equipment

CYCLE ELONGATION

FROM {%} TO {%} {count}

TIMES

Alternate from (user specified elongation)% to (user specified location)% (user specified integer) of times

CYCLE HOLD TENSION

FROM {tension} TO {tension} {count} TIMES

Alternate from (user specified tension) pounds for (user specified time) seconds to (user specified tension) pounds for (user specified time) seconds (user specified integer) of times

CYCLE TENSION FROM

{tension} TO {tension} {count}

TIMES

Alternate from (user specified tension) pounds to (user specified tension) pounds (user specified integer) of times

DISABLE Stop movement of control equipment until "enable" command is given ELONGATION TO {%} Elongate UUT to (user specified) percent elongation ELONGATION + {%} Increase elongation by (user specified) percent ELONGATION - {%} Decrease elongation by (user specified) percent ENABLE Enable movement of control equipment HEAD TO INNER OFFSET Move drive head to zero position HEAD TO OUTER OFFSET Move drive head to outer most position HOLD TENSION Keep constant tension HOLD TENSION AT {tension} Keep constant tension at (user specified) tension LENGTH TO {distance} Change the length of the UUT to (user specified) length LENGTH + {distance} Increase length by (user specified amount) LENGTH - {distance} Decrease length by (user specified amount) LOOP {count} Repeat previous commands (user specified integer) of times PAUSE {time} Set (user specified time) seconds dwell/pause between two commands POSITION TO {distance} Move drive head (user specified distance) inches POSITION + {distance} Move drive head (user specified distance) inches right POSITION - {distance} Move drive head (user specified distance) inches left

RAMP TENSION FROM

{tension} TO {tension} OVER {time}

Increase tension from (user specified pounds) tension to (user specified pounds) tension over (user specified amount of time) seconds

REPEAT Repeats the previous set of commands

SET CYCLE PAUSE FROM

{time}

Set cycle dwell time at low tension/elongation for (user specified time) seconds

SET CYCLE PAUSE TO

{time}

Set cycle dwell time at high tension/elongation for (user specified time) seconds

SET DATA SAVE

RESOLUTION {tension or time}

Set data sampling rate

SET HEAD RATE {rate} Set speed at which dead head moves for (user specified speed) inches per second

SET HOLD TENSION HEAD

RATE {rate}

Set speed at which dead head moves when holding constant tension for (user specified speed) inches per second

SET HOLD TENSION

RESOLUTION {tension}

Set range of tension while holding constant tension (example +/- 5 pounds)

SET HOLD TIME {time} Hold tension for (user specified) time SET LENGTH {distance} Insert initial UUT length

SET MAXIMUM TENSION

{tension}

Set test maximum tension limit

SET WARNING TENSION

{tension}

Set test warning tension limit

TENSION TO {tension} Tension to (user specified) pounds TENSION + {tension} Tension (user specified) pounds more TENSION - {tension} Tension (user specified) pounds less TENSION TO BREAK Increase tension until UUT brakes, then stop movement of drive head