LHTS_Specification.docx

Specification for Upgrade of the Linear HydraulicTest Stand

1.0 SCOPE

1.1 Definition. This specification defines the minimum essential requirements for the upgrade of (1) Linear Hydraulic Test Stand, Part Number 9770-0708, Asset 65923035326, used to test H-53 Dual Input Servovalves, located in Building 133 at Fleet Readiness Center East (FRC East), Marine Corps Air Station (MCAS) Cherry Point, NC. The test stand consists of Linear Hydraulic Test Stand, Part Number 9770-0708, Asset 65923035326, Servo Components Test System Electronic Test Console, Part Number 9840-0088, and the Servo Valve Test Cart, Part Number 2350-0321. The upgrade shall replace the test stand computer, peripherals, software, and Data Acquisition and Control System (DACS). These items are located in the Electronic Test Console (ETC). The software shall be replaced with Windows based software. The Data Acquisition and Control System (DACS) shall be replaced with a Commercial of the Shelf (COTS) Data Acquisition and Control System. The test stand is composed of three items and is used to test dual input servovalves. The upgraded test stands shall test dual input servovalves per their associated overhaul manual as listed in paragraph 1.2.

1.2 Component list.

1.3 Automatic Test Program Sets (TPSs) List.

2.0 APPLICABLE DOCUMENTS

2.1 General. While every effort has been made to ensure the completeness of these listings, document users are cautioned to reference the latest revision of the following specifications; and meet all of the specified requirements of this specification, whether or not they are listed in this section.

2.2 Government Documents

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a portion of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto.

FEDERAL STANDARDS

FED-STD-H28 Screw Thread Standard for Federal Service

MIL-STD-461 Electromagnetic Interference Requirements

MIL-STD-1472 Human Engineering

DEPARTMENT OF DEFENSE HANDBOOKS

Synthetic Hydrocarbon Base, Metric, NATO Code Number H-537

NAVAIR 17-35TR-04 Requirements for Preparation of Instrument Calibration Procedures

Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.

OTHER PUBLICATIONS

Federal Communications EMI Regulation Commission (FCC) Part 18, Subpart A through C

U.S. Department of Labor

OSHA 29 CFR 1910 General Industry

OSHA 29 CFR 1926 Construction Industry

OSHA 29 CFR 1910.147 The Control of Hazardous Energy

OSHA 29 CFR 1910.1200 HazCom Standard & Emergency Planning Community Right-to-Know

EM 385-1-1 Safety and Health Requirements Manual, U.S. Army Corps of Engineers

When requesting specifications and standards, refer to both the title, and the document number. Copies of specifications and standards required in connection with specific procurement functions should be obtained as specified below.

Copies of federal and military specifications required by the prospective suppliers may be obtained from the Business Service Center, General Services Administration, Washington DC 20405. Copies of all other referenced Government publications may be obtained upon application to the Superintendent of Documents, Government Printing Office, Washington DC, 20402.

2.3 Non-Government Standards and Guidelines.

AMERICAN SOCIEITY OF MECHANICAL ENGINEERS (ASME)

AMERICAN NATIONAL STANDARDS INSTITUTE.

ANSI/ASQC D1160-1995 American National Standard for Formal Design Reviews

Applications for copies should be addressed to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036.

ELECTRONIC INDUSTRIES ASSOCIATION (EIA)

RS-232-C Computer Interface

Application for copies should be addressed to the Electronic Industries Association, 2001 Eye Street NW, Washington, DC 20006.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS

Application for copies should be addressed to the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08854-4141

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

250 Enclosures for Electrical Equip.

ICS-1 General Standards for Industrial Controls and Systems

ICS-2 Industrial Control Devices, Controllers and Assemblies

KS-1 Enclosed and Miscellaneous Distribution Equipment Switches

Application for copies should be addressed to the National Electrical Manufacturers Association, 155 East 44th Street, New York, NY 10017.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Codes

NFPA 79 Electrical Standards for Industrial Machinery

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 101 Life Safety Code

NFPA 423 Standard for Construction and Protection of Aircraft Engine Test Facilities

Application for copies should be addressed to the National Fire Protection Association, Publication Sales Division, One Battery March Park, Quincy, MA 02269.

Copies of the above document may be obtained from National Instruments 11500 N. Mopac Expressway Austin, TX 78759-3504

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE ARP490F Electrohydraulic Servovalves

SAE ARP4904A Capability Guidelines for Computer Controlled Test Equipment For Hydraulic Components

Application for copies should be addressed to the SAE, 400 Commonwealth Drive, Warrendale, PA 15906-00

2.4 Unit Reference and Test Publications.

TEI-00062205

Temporary Engineering Instruction, Dual Input Servo Valves Test Procedures

Additional test information is provided in Cherry Point Local Engineering Specification CP 68-23-CC-8227. Cherry Point TEI-00062205 provides updated test procedures.

Copies of the above publications are available upon request from the Contracting Officer.

2.5 Other Government Documents, Drawings, and publications. The following other Government documents, drawings and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited herein.

(Copy available from Contracting Office upon request)

FRCEASTINST 5000.1A, enclosure (1) Visitor/ Contractor Site Specific Rules and Compliance Brochure (Copy available from Contracting Office upon request)

FRCEASTINST 11100.1M Environmentally Controlled Facilities (Copy available from Contracting Office upon request)

2.6 Order of Precedence. In the event of conflict between the text of this specification and the references cited herein, the text of this document shall take precedence. However, nothing in this specification supersedes applicable laws and regulations unless a specific exemption has been obtained from the Government.

3.0 REQUIREMENTS

3.1 General Information and Coverage. The linear hydraulic test stand upgrade shall be of the contractor's design except as otherwise specified and capable of performing its intended function in accordance with the operation and performance requirements within this document, and with no loss of capability of the current system. No loss of capability is intended to mean all measurements and data currently collected by the system shall be measured by the upgraded system. It is further intended that no shift of measured data shall occur as a result of this upgrade, except for minor variations within instrumentation calibration tolerances.

3.2 Definition. The upgrade shall replace the test stand computer, peripherals, software, and Data Acquisition and Control System (DACS). The software shall be replaced with Windows based software. The programming language shall be National Instruments LabVIEW or equivalent as specified I section 3.7.2 of this specification. The DACS shall be replaced with a Commercial of the Shelf (COTS) Data Acquisition and Control System. The preferred DACS hardware shall be National Instruments. The contractor supplied linear hydraulic test stand upgrade shall integrate with the existing test stand sensors to automatically, semi-automatically, and manually test all performance characteristics of the servovalves in accordance with the applicable technical manuals and references listed in Section 2.4 of this specification. The linear hydraulic test stand upgrade shall integrate with the existing linear hydraulic test stand to successfully perform all data acquisition, processing, and control functions necessary to complete production overhaul tests. The linear hydraulic test stand upgrade shall interface with the existing system with no loss of current capability. The linear hydraulic test stand upgrade shall be designed for ease of maintenance, operation, and calibration.

3.3 Configuration and Design. The linear hydraulic test stand upgrade shall be designed for installation in the existing test stand electronics test console (ETC), in the hydraulics shop of Building 133 at FRC East, MCAS, Cherry Point, NC. The system installation by the contractor shall be performed in the hydraulics shop. FRC East Drawing No. PED-19396F (Attachment 1) identifies the layout of the existing test stand location. The contractor shall meet the requirements of FRCEASTINST 11100.1M Environmentally Controlled Facilities, when performing the installation.

3.4 Permits. The contractor shall be responsible for obtaining all permits required for the scope of contractor supplied services. Examples of permits may include but are not limited to: hot work permits and North Carolina building permits. Permits requiring environmental consideration shall pass through the FRC East Environmental Division office prior to application. The Government will direct the contractor in how to apply for and resolve any environmental items that arise. This direction shall not relieve the contractor of the financial responsibility of environmental permitting. Contractors shall comply with all federal, state, and local laws. The Government will supply Points of Contact (POCs) that can provide assistance in, obtaining the required permits. NOTE: all permits shall be the contractor’s responsibility. Permits for hot work shall be obtained by calling the fire department at (252) 466-2241.

3.5 Removal of Existing Equipment. The contractor shall be responsible for the removal of any equipment required for the upgrade. The contractor shall be responsible for the safe and proper removal, disposal, and site restoration in the handling of hazardous materials. The contractor shall remove instrumentation and valves non-destructively. Construction debris shall be disposed of properly. The Government shall approve the disposal method of all equipment removed and reserves the right to retain any equipment or wiring for internal use.

3.6 Upgrade Characteristics. The Linear Hydraulic test stand upgrade shall meet or exceed the following performance and physical characteristics. All technical wiring and existing system layout shall be the responsibility of the contractor.

3.6.1 Computer System. The following detail the Government’s minimum requirements for the computer system. It remains the contractor’s responsibility to provide a computer system capable of meeting the performance requirements of all installed software, even if such a system would exceed the requirements of this document. The computer system shall have the following minimum characteristics:

3.6.1.1 Operating System. The host computer operating system shall be Microsoft Windows 7 Professional or the latest version of Microsoft Windows 100% supported by LabVIEW. The contractor shall install all service packs. The contractor shall provide a copy of the physical installation media.

3.6.1.2 Processor. The system shall use an x86 based architecture. The system shall have minimum of four processors or processing cores. The processors shall each have a minimum clock speed of 3.0 GHz.

3.6.1.3 CPU Usage. The overall average CPU usage, as defined by the Windows Task Manager, shall not exceed 35 %, with the test application active while testing a UUT. In addition, no individual processing core shall exceed an average of 50% with the test application active, while testing a UUT. Verification of performance will be tested during acceptance.

3.6.1.4 Memory. The system shall have a minimum of 16 Gb of Random Access Memory (RAM).

3.6.1.5 Memory Usage. The system shall keep at least 50 % of its Physical Memory available with the test application active, while testing a UUT, as defined by the Windows Task Manager. Verification of performance will be tested during acceptance.

3.6.1.6 Form Factor. The computer system shall be a rack mount type. The computer system shall be housed in a 19 “rack which is part of the test stand Electronic Test Console (ETC). Cable connections shall be installed that allows the computer to be pulled out for servicing.

3.6.1.7 Optical Disk. The optical disk shall have a speed of 16x (or greater), with CD/DVD burner (DVD+/-RW), and with double layer DVD+RW write capability.

3.6.1.8 Storage. The system shall employ dual hard drives. The hard drives shall have a minimum of 70% free disk space after all applications have been loaded or 500 Gb, whichever is greater. The hard drives shall not be installed in a Raid configuration.

3.6.1.9 Displays. The system shall provide at least 1024 x 768 resolution and 24 bit color.

3.6.1.10 USB Ports. The system shall have three or more USB ports, with at least one remaining unused

3.6.1.11 Warranty. The computer shall include at least the Standard Commercial Warranty consisting of, three year, Next Business Day On-Site Service, including parts and labor. The contractor shall provide a placard detailing the computer warranty details and expiration date. The contractor shall affix the placard to the computer.

3.6.2 Computer Peripherals. The computer system shall be equipped with a minimum of the following peripherals:

3.6.2.1 Keyboard. The keyboard shall be suitable for use without damage in an environment where MIL-PRF-83282D hydraulic fluid is present. The keyboard shall be rated NEMA 4X, UL60950, and FCC Part 15 Class B.

3.6.2.2 Mouse/Keyboard. The Mouse/Keyboard may be combined into a single unit.

3.6.2.3 Monitor. The contractor shall replace the existing touch screen monitor. The monitor shall be a LCD touch screen type with RS-232-C interface. The monitor shall be factory sealed against dirt, dust and liquids. The monitor shall be suitable for use without damage in an environment where MIL-PRF-83282D hydraulic fluid is present. The replacement touch screen monitor shall be 17 inches diagonally.

3.6.2.4 Printer. The contractor shall replace the existing LaserJet printer located in the test stand Electronic Test Console Printer drawer. The replacement printer shall be a LaserJet type. The printer shall have a print speed of 15 pages per minute. The printer shall have a resolution of 1,200 dots per inch (dpi). The contractor shall provide a second complete set of printer cartridges.

3.6.2.5 Test Program Set (TPS) Development Computer. The contractor shall provide a Test Program Set (TPS) Development Computer. The purpose of the computer shall be to perform maintenance of the software Test Program Sets. The computer shall be a Laptop. The computer shall be capable of creating, saving, editing and deleting Test Program Sets (TPS). The computer shall also be capable of creating, saving, editing and deleting Manual Mode Test Programs. The software shall be capable of Setting up, creating, saving, editing and deleting UUT’s and test definitions.

3.6.3 Data Acquisition and Control System. The contractor shall replace the existing Data Acquisition and Control System (DACS) with a Commercial off the Shelf (COTS) Data Acquisition and Control System software and hardware for the linear hydraulic test stand to be upgraded. The DACS shall be composed of COTS hardware components. The preferred DACS hardware shall be National Instruments Compact DAQ, PCI (Peripheral Component Interface) PCI express, PXI (PCI-eXtensions for Instrumentation), PXI express, or equivalent. The contractor shall remove and replace all existing DACS components. The existing removed DACS components shall be retained and provided to the Government. The new DACS shall be comprised of a computer system, application software, and hardware used to control and measure devices required to test the components listed in sections 1.2 and 1.3. The scope and accuracy of testing of each component shall conform to the requirements set forth in their associated manual listed in sections 1.2. and 1.3. The mode of testing for components listed in section 1.2 shall be manual. The contractor shall also provide separate application software test program sets (TPS) that enable the DACS to perform semi-automatic and automatic mode testing for each component listed in section 1.3. Manual, Semi-automatic and automatic modes shall be as defined in SAE ARP4904A, Capability Guidelines for Computer Controlled Test Equipment for Hydraulic Components. The DACS with the exception of the application software for the components listed in section 1.3 shall be a complete commercial off the shelf hardware and software product designed for the purpose of testing hydraulic components. New wiring to the DACS is required. All current capability for testing servovalves shall be maintained in the Linear Hydraulic Test Stand as part of the upgrade. All new wiring shall include but not be limited to, connections, cables, and harnesses as required. All wiring shall be clearly identified at origin and termination. All cables and connections shall be made of material that can tolerate MIL-PRF-83282D Hydraulic Oil, temperatures up to 130 degrees Fahrenheit. Wiring and cables shall be routed in a manner that allows maintenance and accessibility. All connections shall be made of corrosion inhibitive anti-electrolysis material. The DACS shall meet the following requirements for equivalency:

3.6.3.1 Analog to Digital Converter. The DACS shall include an Analog to Digital Converter to convert analog signals into digital data. The Analog to Digital Converter shall have a minimum of 16-bit resolution. The Analog to Digital Converter shall have a minimum of 16 differential input channels. The Analog to Digital Converter shall have programmable gains. The Analog to Digital Converter shall have a sampling rate of 100 KHz minimum. The Analog to Digital Converter shall have an accuracy of +/- 0.003 %.

3.6.3.2 Analog Inputs. The Data Acquisition system shall provide signal conditioning modules and shall interface to all existing test stand sensors.

3.6.3.3 Signal Conditioning Modules. The following signal conditioning modules shall be replaced. Maintain spare channels.

Spare

Spare

Spare

Reserved

Spare

3.6.3.3.1 Spare Signal Conditioning Modules. Spare signal conditioning module configuration shall be maintained to accommodate additional analog input channels.

3.6.3.4 Digital to Analog Converter. The DACS shall include a Digital to Analog Converter to convert digital data into analog signals. The Digital to Analog converter shall have a minimum of 16-bit resolution. The Digital to Analog converter shall have a minimum of 8 channels. The Digital to Analog Converter shall have programmable output ranges. The Digital to Analog Converter shall have a relative accuracy of +/- 0.003 %.

3.6.3.5 Analog Outputs. The DACS shall have the following Analog Outputs:

3.6.3.5.1 Servo Amplifier #1. The DACS shall include a Servo Amplifier. The Servo Amplifier shall have programmable Gain and Feedback. The Servo Amplifier shall provide up to +/- 100 mA Servo Current. The Servo current at zero shall be 0.00+/- 0.05 mA. The Servo Current at 80 mA shall be 80.00 +/- 0.02 mA. The Servo Current indication shall agree within +/- 0.01 mA of the actual servo current. The Servo Amplifier shall be capable of operating in the open and closed loop modes.

3.6.3.5.2 Servo Amplifier #2. The DACS shall include a second Servo Amplifier. The Servo Amplifier shall have programmable Gain and Feedback. The Servo Amplifier shall provide up to +/- 100 mA Servo Current. The Servo current at zero shall be 0.00+/- 0.05 mA. The Servo Current at 80 mA shall be 80.00 +/- 0.02 mA. The Servo Current indication shall agree within +/- 0.01 mA of the actual servo current. The Servo Amplifier shall be capable of operating in the open and closed loop modes.

3.6.3.5.3 Servo Amplifier #3. The DACS shall include a third Servo Amplifier. The Servo Amplifier shall have programmable Gain and Feedback. The Servo Amplifier shall provide up to +/- 100 mA Servo Current. The Servo current at zero shall be 0.00+/- 0.05 mA. The Servo Current at 80 mA shall be 80.00 +/- 0.02 mA. The Servo Current indication shall agree within +/- 0.01 mA of the actual servo current. The Servo Amplifier shall be capable of operating in the open and closed loop modes.

3.6.3.5.4 Signal Generator #1. The DACS shall include a Signal Generator for driving the Servo Amplifiers. The generator shall have programmable frequency, amplitude and waveform. The signal generator shall have sine, triangle and square waveform outputs. The frequency range shall be 0.0006 to 15.999 KHz minimum. The amplitudes of the positive and negative portions of the sine wave should be equal to each other within 0.20 vdc, smooth (no steps) and continuous. (Check at 50 Hz and 25 Hz).

3.6.3.5.5 Manual Control Potentiometer The DACS shall interface to the Test Stand Manual Control Potentiometer to allow for manually setting of the Servo Currents.

3.6.3.5.6 Programmable DC Power Supply. The test stand programmable power supply shall be replaced. The DACS shall interface to the replacement test stand programmable power supply. The DACS shall allow for remotely controlling and programming the Solenoid voltage and current to the test stand front panel connectors. The power supply shall be capable of providing 30 VDC, 10 A maximum.

3.6.3.5.7 Spare Analog Output Channels. The DACS analog output channels shall have a minimum number of 10 % spare channels for expansion or maintenance replacement.

3.6.3.6 Digital Inputs and Outputs. The DACS shall include the following Digital Inputs and Outputs:

3.6.3.6.1 TTL Inputs and Outputs. The DACS shall include a minimum of 48 Buffered TTL Inputs/Outputs.

3.6.3.6.2 Digital I/O - Solenoids. The DACS shall have ON/OFF control capability of solenoid channels.

3.6.3.6.3 Digital I/O – Relay Servo Currents. The DACS shall have ON/OFF control capability of Servo Currents.

3.6.3.6.4 Digital I/O - Spare Channels. The DACS digital I/O shall have a minimum number of 10 % spare channels for expansion or maintenance replacement.

3.6.3.7 Test Stand Electronic Test Console Connections Used. The DACS shall interface to the following Electronic Test Console connectors:

Used

3.6.3.8 Test Stand Electronic Test Console Connections not Used. The DACS shall interface to the following Electronic Test Console connectors:

Not Used

COM 2

X

3.6.4 Test Stand Sensors.

3.6.4.1 Replace Test Stand Sensors. The contractor shall replace all existing test stand sensors.

3.6.4.2 Test Stand Sensor Interface. The Data Acquisition System shall interface to all test stand sensors.

Accuracy: +/- 0.5 % iv

Accuracy: +/- 0.25 % fs

Accuracy: +/- 0.5 degrees F

Tolerance: +/- 0.002 inches

3.6.4.3 Pressure Transducers. The DACS shall interface to the strain gauge type pressure transducers listed below.

Drawing Reference #

3.6.4.3.1 Spare Pressure Transducers. The DACS shall have (2) two spare channels configured to accommodate strain gauge type pressure transducers.

3.6.4.4 Flow Measuring Cylinder. The DACS shall interface to the LO Q flow cylinder.

3.6.4.5 Servovalve Current Measurement Channels. The DACS shall interface to the servovalve Current Measurement Channels.

3.6.4.6 Fluid Temperature Transducer. The DACS shall interface to the Fluid Temperature Transducer.

3.6.4.7 Variable DC supply The DACS shall interface to the Variable Power Supply drawing (reference 100-001) Voltage and Current sensors.

(******need to find these******)

3.6.4.8 Displacement Measurement Channel. The DACS shall interface to the Displacement Measurement Channel.

3.6.4.9 Instrumentation Accuracy. All instrumentation accuracies after the upgrade shall be equal to or better than current instrumentation.

3.7 Computer System Software. The contractor shall replace the computer system software for the upgrade.

3.7.1 Computer System Software Characteristics. The linear hydraulic test stand computer system software shall include the operating system and application software to perform data acquisition, control, operation, display, and reporting of all servovalve units under test. The existing operation, reporting, calibration, and data capabilities shall be maintained. There shall be no loss of test capability with the existing servovalves. All of the existing reporting structure and data capture capability shall be maintained with the upgraded systems. All current software capabilities shall be maintained with the upgraded system.

3.7.2 Programming Language. The programming language shall be National Instruments LabVIEW 2015 or equivalent. The programming language shall be the latest stable version compatible with the operating system and appropriate hardware drivers. LabVIEW Virtual Instruments (VIs) also termed Test Program Sets (TPS) shall be written using National Instruments LabVIEW Development Guidelines. Each LabVIEW VI (front panel) and programming structure (block diagram) shall be visible in one computer display window.

3.7.2.1 Programming Language Equivalent. If a programming language other than LabVIEW is provided, the programming language shall have the following characteristics:

3.7.2.1.1 Visual Language. The programming language shall be a visual type of programming language (VPL). Programming shall be accomplished by manipulating program elements graphically.

3.7.2.1.2 Graphical Programming Language. The programming language shall be a graphical type of programming language (GPL). Programming shall be accomplished by manipulating program elements graphically. The source code shall be graphical.

3.7.2.1.3 Dataflow Programming. The programming language shall be a dataflow type of language. The flow of data shall determine the execution order of program elements.

3.7.2.1.4 User Interfaces. The programming language shall allow for the creation of Graphical User Interfaces (GUI).

3.7.2.1.5 Device Interface. The programming language shall interface to multiple devices.

3.7.2.1.6 Virtual Instruments. The programming language shall allow the creation of Virtual Instruments.

3.7.2.1.7 Device Drivers. The programming language shall include an extensive library of device drivers.

3.7.2.1.8 Compiler. The programming language application development environment shall include a compiler to convert the graphical code into executable machine code.

3.7.2.1.9 Function Library. The programming language shall include large libraries of functions for data acquisition, signal analysis and control.

3.7.2.1.10 Text Programming. The programming language shall include a text-based programming component for math functions.

3.7.2.1.11 Multithreading. The programming language shall include multithreading to allow multiple tasks to execute in parallel.

3.7.3 Commercial Application Software. All commercial computer software shall be licensed to FRC-East, MCAS, Cherry Point, NC.

3.7.3.1 Microsoft Office. The contractor shall provide a licensed copy of the current version of Microsoft Office Home/Business, at lease Home/Business version of the suite.

3.7.3.2 Sysmantec Ghost Solution Suite. The latest version of Sysmantec Ghost Solution Suite or equivalent shall be provided to backup and restore the computer system.

3.7.3.3 Windows Desktop Security Manager. A Windows desktop security manager shall be installed to restrict access.

3.7.4 Test Stand Application Software.

3.7.4.1 Requirements. The test stand application software shall allow the linear hydraulic test stand to perform all tests required by each servovalve listed in paragraph 1.2. SAE ARP490 Revision F, Electrohydraulic Servovalves, provides definitions and background information for understanding the physical performance and test procedures of electrohydraulic flow control servovalves.

3.7.4.2 Modes of Operation. The test stand application software shall provide for the automatic, semi-automatic and manual modes of operation. The modes of operation shall be as defined in SAEARP4904, Revision A, Capability Guidelines for Computer Controlled Test Equipment for Hydraulic Components. In automatic and semi-automatic modes the linear hydraulic test stand is controlled by TPSs. In manual mode, the operator selects the transducers to be displayed, the desired plotting parameters, the pressure controls and pressure settings, the hydraulic circuit valve patterns, and all parameters required to control the UUT. All modes of operation shall provide for both on screen plotting as well as printed data plots. Automatic and semi-automatic modes shall provide plotted and printed results, including pass/fail evaluations and a data sheet summary at the end of testing. In manual mode the data plot shall be available in real time.

Purpose

3.7.4.3 System Control.

3.7.4.3.1.1 Automatic Mode. The Upgrade shall include automatic mode software. The automatic mode software shall allow the test stand to automatically set-up and control test functions. The automatic mode software shall allow the test stand computer to perform complete tests for the servovalves listed.

3.7.4.3.1.2 Automatic Mode Test Program Sets. The contractor shall provide automatic Test Program Sets (TPS) for the following servovalves:

Automatic Test Program Sets (TPSs) List.

3.7.4.3.1.3 Semi-Automatic Mode. The upgrade shall include semi-automatic mode software The Automatic Mode Test Program Sets shall operate in the Semi-automatic mode to enable the operator to select a subset of the Automatic Mode TPS

3.7.4.3.1.4 Manual Mode. The Upgrade shall include Manual Mode Software. The Manual Mode software shall allow the test stand operator to manually set-up and control test functions. The Manual Mode software shall allow the test stand operator to perform individual tests, displays, plots and setups for the listed servovalves and servocomponents. The Manual Mode software shall control, measure and display parameters.

3.7.4.3.1.5 Manual Mode Test Program Sets. The contractor shall provide manual mode test programs for the following servovalves:

Manual Mode Test Program List.

Part Number

H-53

H-53

H-53

3.7.4.3.1.6 The contractor shall provide the following Manual Mode test programs for each of the listed servovalves.

02) Displacement

03) Press. Plot

05) 303 FLOW

12) Int. Leak

15) Mech. flow

02) Displacement

03) Press. Plot

06) 304 FLOW

02) Displacement

03) Press. Plot

07) 305 FLOW

3.7.5 Test Stand Application Software. The application software shall provide for servovalve testing in accordance with SAE ARP490, Revision F.

3.7.6 Test Stand Application Software Functions. The test stand application software shall provide all functions currently provided. The test stand application software shall meet the following requirements:

3.7.6.1 Electronic Console. The Software shall interface the test stand operator to the electronic Console Touchscreen, keyboard, Manual Potentiometer and Emergency Stop button.

3.7.6.1.1 Touchscreen. The touchscreen shall allow the test stand operator to select menu buttons and configure tests.

3.7.6.1.2 Keyboard. The keyboard shall allow menu selections and input of numerical data. The Keyboard and Mouse can perform operator functions without the Touchscreen operational.

3.7.6.1.3 Manual Potentiometer. The Manual Potentiometer shall allow adjustment of parameters

3.7.6.1.4 Emergency Stop Button. The Emergency Stop button shall allow all testing to be immediately terminated with all valves and controls set to a safe state.

3.7.6.2 Deleted.

3.7.6.3 Units of Measurement. The application software shall be capable of defining the test units of measurement.

3.7.6.4 Measurement Sample Filtering. The application software shall be capable of defining measurement sample filtering. The Measurement Sample Filtering shall include a Moving Average Filter, with number of samples from 0 (no filtering) to 1000.

3.7.6.5 Valves. The application software shall be capable of creating, deleting and activating test stand valve patterns.

3.7.6.6 Current. The application software shall be capable of selecting and controlling current settings in open or closed loop control to allow setting current to the UUT..

3.7.6.7 Voltage. The application software shall be capable of selecting and controlling voltage settings to allow setting voltage to the UUT using the Programmable Power Supply.

3.7.6.8 Solenoids. The application software shall be capable of configuring and selecting individual or groups of solenoids (relays), and to allow changing the state of the solenoids, to select and set parameters for solenoid groups. Relays shall allow switching on and off electrical signals to the UUT.

3.7.6.9 Signal Generator. The application software shall be capable of selecting servos and to configure and control current, voltage and waveforms for a signal generator, to define waveforms, and the associated parameters such as wave type, amplitude, and frequency.

3.7.6.10 Plot. The application software shall be capable of setting up, configuring and displaying plots during tests, including plot features and triggers, to plot multiple measurement parameters in the plot area of the screen.

3.7.6.10.1 Overlay. The application software shall be capable of constructing overlays to be displayed on the screen, concurrent with plotted data.

3.7.6.10.2 Print Plot. The application software shall be capable of printing the plotted data.

3.7.6.11 Monitor. The application software shall be capable of setting up, configuring and displaying real-time measurements using digital displays and bar graphs.

The digital displays and bar graphs shall be larger than the normal digital displays and shall be large enough to enable the test stand operator to easily view from a distance.

3.7.6.11.1 Digital Displays. The application software shall display the digital display current reading.

3.7.6.11.2 Limits. The application software shall show the parameter limits. The application software shall show characters green in limits, red out of limits, yellow no limits set

3.7.6.11.3 Bar graphs. The application software shall be capable of displaying bar graphs. The bar graph shall provide an indication if the parameter is in tolerance. Green and red color coded bars provide shall provide an indication if parameter is out of tolerance.

3.7.6.12 Device Management. The application software shall be capable of creating, coping, deleting and viewing all available control and monitoring devices.

3.7.6.13 Real Time Display. The application software shall be capable of displaying real-time measurements of selected parameters.

3.7.6.14 Front Panel Controls. The application software shall have the capability of selecting, enabling and disabling, coarse and fine adjustment of the front panel controls. The front panel controls shall include:

3.7.6.14.1 Current Control.

3.7.6.14.2 Signal Generator Control.

3.7.6.14.3 Voltage Control.

3.7.6.14.4 Solenoid Groups Control.

3.7.6.15 Functions. The application software shall include the following functions:

3.7.6.15.1 Printer. The print function shall enable/disable the printer and allow the printing of test data reports and graphs.

3.7.6.15.2 Filter. The filter function shall turn on and off the measurement filter.

3.7.6.15.3 Solenoid. The solenoid function shall allow the turning on and off of groups of solenoids.

3.7.6.15.4 Feedback. The feedback function shall allow the opening and closing of the feedback loop control.

3.7.6.15.5 Plot Pen. The plot pen function shall allow for raising and lowering of the plot pen. When the plot pen is lowered the test data is displayed on the graph.

3.7.6.15.6 Clear. The clear function shall clear the graph.

3.7.6.15.7 Options. The options function shall set the options.

3.7.6.15.8 Stop. The stop function shall set the servovalve test stand to a safe state.

3.7.7 User Interface. The Computer system monitor with touch screen shall be the primary user interface for the linear hydraulic test system. The operator shall have the capability to select mode of operation, select TPS to be run, select output format and interrupt test in progress from computer monitor touch screen. Status of testing and test results shall be displayed on the computer monitor. During testing the transducer data are displayed and continuously updated on the computer system monitor.

3.7.8 System Boot and Initialization. The application software shall include system boot and initialization routines that configure the linear hydraulic test system after power up. These routines shall not require operator input. Initialization shall conclude with the display of the main system menu.

3.7.9 System Support. The application software shall provide the DACS with high level application programs that are required to support self-test, calibration, diagnostics, and utilities.

3.7.10 Self-Test Software. The contractor shall provide Self Test Software. The Self Test Software shall include Built in Test (BIT) Software and Maintenance Diagnostics Software.

3.7.10.1 BIT Software. The BIT software shall run automatically on system startup to determine if the DACS and test stand sensors are operating within defined operating parameters. The BIT software shall provide a visual indication to the test stand operator of the results of each test. After completion of the BIT, the BIT software shall automatically print a report with the results of each test.

3.7.10.2 Maintenance Diagnostics Software. Maintenance diagnostics software shall be provided. The diagnostics software shall be menu driven. The diagnostics software shall allow detailed troubleshooting of the entire system by maintenance and calibration personnel. The diagnostics software shall have a graphical display that can isolate controls, transducers, sensors and interfaces to check out the entire system or system components independent of a servovalve. The diagnostics shall include analog input, diagnostics graph, analog output frequency input, digital input, digital output, calculated values. The software shall help determine if input signals are being processed properly from the data acquisition hardware. The test executive diagnostics shall include diagnostics to allow maintenance to view all data values for each parameter type.

3.7.11 Calibration Software. Calibration software shall be provided to enable calibration of all servovalve test parameters. The application software shall provide the calibration personnel with an easy to use method to calibrate and align all system transducers and signal measurement hardware. The calibration programs shall provide all of the prompting required for calibration of the specified devices. The calibration algorithms shall compute new scale factors. The calibration software shall be menu and icon driven from the main menu. The calibration software shall perform a minimum of two-point linear calibration. The calibration software shall provide multiple point calibrations, such as ten-point Linear, polynomial curve fit and look up table. The calibration software shall have a calibration display screen which includes, but is not limited to raw signal, processed signal, calibration coefficients, and date of current calibration. The calibration software shall maintain a calibration history with a minimum of two previous calibration cycles. The calibration software shall provide a calibration report. The calibration software shall have provisions for printing a calibration report for each channel or a summary of all channels, which shall be suitable for filing for future reference. The calibration software shall provide a graphical display of the applied calibration data. The calibration software shall have resolution of parameters on the calibration display page at least 10 times the resolution of parameters on the test display pages. The calibration software shall provide a means of saving and restoring of the calibration data. The calibration software shall perform both software and hardware calibration. The system software shall provide an alarm to the operator of an upcoming Calibration Due date. The controlled access to this Date, will be to engineering and Calibration personnel.

3.7.11.1 Displacement Calibration. The calibration software shall include a 10 point calibration of the displacement transducer, hardware and software.

3.7.12 Software Utilities. The application software shall provide utility functions that enable the test stand operator to perform the miscellaneous tasks required to support the DACS operation, which are not included in another category. These tasks include but are not limited to:

3.7.12.1 Download System Archive. The application software shall have the capability downloading the system archive of test data. The application software shall be capable of storing and retrieving servovalve test data.

3.7.12.2 System Backup and restore. The application software shall provide the means to completely backup and restore the application software.

3.7.12.3 Reset Clock and Calendar. The application software shall provide a means to reset the computer clock and calendar.

3.7.12.4 System Security. Passwords and System Access. The application software shall be capable of controlling system security. The application software shall control passwords and system access for security. The application software shall be capable of adding/modifying or deleting used access and passwords.

3.7.12.5 Software Configuration. The application software shall have capability to generate test specific calculations. The test executive software shall have capability to change channel configuration. The test executive shall have the ability to define calculated parameters. The test executive software shall have defined parameters for use in testing with the ability to edit, copy and delete configurations.

3.7.12.6 Configuration Management. The application software shall provide the means to manage the configuration of the software. The software shall log personnel access, files, and date of changes made.

3.7.13 Creation of Test Program Sets. The application software shall be capable of creating, saving, editing and deleting Test Program Sets (TPS).

3.7.14 Creation of Manual Mode Programs. The application software shall be capable of creating, saving, editing and deleting Manual Mode Test Programs.

3.7.15 UUT’s and test definitions. The application software shall be capable of creating, saving, editing and deleting UUTs and test definitions.

3.7.16 Data Storage and Retrieval After Test. The application software shall be capable of storing and retrieving UUT test data after testing has been completed.

3.7.17 Application Software Functions. The application software shall have the following functions to support application the servovalve testing:

3.7.17.1 Reports. The application software shall be capable of creating, saving, editing and deleting UUT test reports.

3.7.17.2 Data Displays. The application software shall be capable of creating, saving, editing and deleting data displays.

3.7.17.3 Graphs and Plots. The application software shall be capable of creating, saving, editing, and deleting graphs and plots.

3.7.17.4 Overlays. The application software shall be capable of adding graphical overlays to plots to visually determine when parameters are out of limits.

3.7.17.5 Data Storage and Retrieval During Test. The application software shall be capable of storing and retrieving UUT test data while testing.

3.7.18 Software development Tools. The contractor shall provide all software development tools used to develop the software. The COTS software shall include the LabVIEW Professional Development System.

3.7.19 Software Quality Assurance (SQA). The contractor shall have a pro-active Software Quality Assurance program in conformance with IEEE/EIA 12207 and the Software Engineering Institute (SEI) Capability Maturity Model Integration (CMMI) Level II and the applicable Key Process Areas (KPAs) from Level III. Selected areas (KPAs) in Level III, include Technical Solution, Product Integration, Verification, and Validation. The contractor shall provide artifacts from the Specific Practices of the KPAs to the government monthly to ensure Software Quality Assurance IAW the SEI-CMMI Levels. The SQA process shall extend to any system or device that integrates with system software or is a software configurable item. The scope of the SQA process will be throughout the life of the project until the end of the warranty period.

3.7.20 Electronic Test Console. The contractor shall reuse the existing Servo Components Test System Electronic Test Console, Part Number 9840-0088.

3.8 Control Functions. The existing control functions shall be maintained as part of the upgraded system. No loss of current control capability shall occur.

3.9 Electrical. The upgraded system shall be furnished complete with all accessories such as, controls, relays, and switches pre-wired for operation upon connection to the main power source. To facilitate tracing of circuits, all control circuit wiring shall be identified by sequential alphanumeric markings that correspond to the schematic diagram. Labels shall be of a permanent design and shall be stamped or printed on a base material or covered with a clear shrink wrap material to facilitate durability within the test stand environment. Graphic symbols for logic diagrams shall be IAW applicable requirements of NEMA ICS-l. All electrical components shall conform to the requirements of NFPA No. 79, 423, or 70 as required. Electrical Enclosures shall meet requirements of NEMA 250.