PD_Rev1_21M_222A_GA_Short_Gage Block Comparator Upgrade.pdf

21M-222A-GA

19 October 2020

Rev 1

PURCHASE DESCRIPTION

FOR

Short Gage Block Comparator Upgrade

1. SCOPE: This is a procurement to upgrade P/N 130B-24 Short Gage Block Comparators. The short gage block comparators are used by the Air Force Primary Standards Laboratory (AFPSL) and the Precision Measurement Equipment Laboratories (PMEL) to calibrate gage blocks that range in length from 0.01 to and including 4.0 inches (0.25 to 100 mm). The upgrade shall replace the current digital and computer interfaced measurement systems with an electronic measurement system that is interfaced to a laptop controller.

2. PERFORMANCE REQUIREMENTS: The Upgraded Short Gage Block Comparator (USGBC) shall include the following characteristics:

2.1. Dual Contact Comparator with Floating Head design.

2.2. Gage Block Capacity: 0.010 to 4.000 inches (0.25 to 100 mm).

2.3. Warm-Up Time: Shall not exceed 30 minutes.

2.4. Adjustable Upper Contact and Lower Contact Gaging Force.

2.4.1. Nominal Upper Contact Gaging Force: Approximately 3 oz (85 g).

2.4.2. Nominal Lower Contact Gaging Force: Approximately 1 oz (28 g).

2.5. Measurement Units: Inch (µin) and Metric (µm).

2.6. Amplifier Range: +/- 500.0 µin, (+/- 10.0 µm).

2.7. Amplifier Resolution: 0.1µin, (0.001µm).

2.8. Amplifier Uncertainty:

2.8.1. Linearity: +/- 1.0 µin, (0.025µm) in the central +/- 50.0 µin (1.25µm) range of amplifier.

2.8.2. Linearity: +/- 1.0 µin, (0.025µm) in any 50.0 µin (1.25µm) range of amplifier.

2.8.3. Repeatability: Shall not exceed 1.0 µin (0.025 µm).

3. FUNCTIONAL REQUIREMENTS:

3.1. The USGBC shall mechanically operate the same as the original design: floating head, adjustable upper gaging force, and adjustable lower gaging force. The gage head shall be able to be lowered and/or lifted using the lifting lever. Dual Stylus Design; one fixed stylus and one electronic gage head.

3.2. Replace the staging table.

3.3. Replace internal components associated with the adjustable vertical spindle/head. The adjustable vertical spindle head shall be move up and/or down smoothly.

3.4. Replace all reed springs.

3.5. Replace the upper and lower stylus contacts.

3.6. Replace the electronic gage head.

3.7. Interface USGBC to Laptop Controller.

3.8. If missing, replace circular bubble level.

3.9. If missing, replace the adjustable feet.

3.10. Calibration Requirements: The USGBC shall be calibrated/aligned using U.S. Air Force owned gage blocks. When the USGBC does not meet calibration requirements, alignment shall be accomplished using the Alignment Software. Gaging force shall be adjusted manually.

3.11. Assign a new U.S. Air Force System Part Number.

Rev 1

4. ANCILLARY EQUIPMENT: The USGBC shall include:

4.1. Dynamometer with pointer, for measuring Upper and Lower Gaging Force.

4.1.1. Dynamometer Specifications:

Range: 0 to 100 grams.

Resolution: 1 gram.

Accuracy: Not To Exceed: +/- 2 grams.

4.2. Electronic Weigh Scale, for measuring Upper Gaging Force.

4.2.1. Electronic Weigh Scale Specifications:

Range: 0 to 100 grams.

Resolution: 1 gram.

Accuracy: +/- 2 grams.

4.3. Electronic Depth Gage, for measuring Lower Stylus Protrusion Height.

4.3.1. Electronic Depth Gage Specifications:

Range: +/- 0.040 inches.

Resolution: Not to exceed 0.0005 inches.

Accuracy: Not to exceed +/- 0.0005 inches.

4.4. Test Indicator and Holder for measuring Lower Stylus Collar Setting.

4.4.1. Test Indicator Specifications:

Range: +/- 0.005 inches Resolution: 0.00025 inches.

Accuracy: +/- 0.0005 inches.

4.5. Electronic Temperature Measuring Device: The electronic temperature measuring device shall be interfaced to the system and will monitor and correct gage block length when measuring dissimilar materials based on the materials coefficient of thermal expansion.

4.5.1. Electronic Temperature Measuring Device Specifications:

Number of Platinum Resistance Probes: 2.

Range: 68 +/- 15 degrees Fahrenheit.

Resolution: 0.05 degrees Fahrenheit.

Combined Accuracy (display and probes): Not To Exceed +/- 0.05 degrees Fahrenheit.

4.6. Double Sided Optical Flat, for inspecting gage block surfaces.

4.6.1. Optical Flat Specifications:

Range: 2.0 inch Diameter.

Accuracy: Flatness not to exceed 1.5 µin TIR.

4.7. Toolmakers Square for inspecting the perpendicularity of the vertical spindle.

4.7.1. Toolmakers Square Specifications:

Perpendicularity shall not exceed 0.0005 inches TIR.

Material: Stainless Steel or Tooled Steel.

4.8. Tongs for picking up and moving gage blocks.

4.9. Air Bulb/Brush for cleaning gage blocks.

4.10. Serrated Aluminum Oxide Deburring Stone with case (approximately 1”x2”x3”).

4.11. Shall include the Gage Block Positioner kit and Templates.

4.12. All cables, connectors, electronic interfaces, operating software, calibration software and other equipment necessary to operate and/or calibrate the USGBC.

5. MECHANICAL & PHYSICAL REQUIREMENTS:

5.1. Model and Serial Number Identification: A metal plate shall be attached to the USGBC. The metal plate shall identify the Air Force System Part Number, the USGBC Part Number, Serial Number, and Manufacturer.

5.2. UID Label: This item shall be clearly labeled with a model number, serial number, and manufacturer’s name. Unique item identification labeling shall follow Item Identification and Valuation requirements as stated in the contract.

Rev 1

5.3. The USGBC shall meet all requirements of this purchase description when it within the following Operating Environment/Storage conditions:

5.3.1. Laboratory Temperature: 68 +/- 1° F.

5.3.2. Relative Humidity: 20 to 50%.

5.4. Electrical and Facility Requirements:

5.4.1. Electrical Power and Connections: The USGBC must operate using 110 volts AC at

50/60 Hz, 15 amps.

5.4.2. Electrical Safety: The USGBC must be grounded.

5.4.3. Fuse: The USGBC must have a fuse.

6. CONTROLLER REQUIREMENTS:

6.1. The USGBC shall be interfaced with a Laptop Controller that includes Gage Block Calibration Software and Gage Block Comparator Alignment Software.

6.2. For USGBC owned by PMEL: Shall include Gage Block Calibration and Gage Block Comparator Alignment Software that uses the similar measurement processes, techniques, corrections, calculations, etc. as the Mahr developed software identified as V 4.0A, Build 3 (08.16.2011).

6.3. For USGBC owned by AFPSL: Shall include Gage Block Comparator Alignment Software that uses similar measurement processes, techniques, corrections, calculations, etc. as the Mahr developed software identified as V 4.0A, Build 3 (08.16.2011).

6.3.1. Shall include Special Gage Block Calibration Software that will only be used by the

AFPSL. The Special Gage Block Calibration Software shall use measurement processes, techniques, corrections, calculations, etc. as described in Paragraph 8.0 and Paragraph 9.0 of this Purchase Description.

6.4. A Laptop Controller is required that can efficiently operate under Microsoft Windows 10 Professional 64 bit operating system. All major components of the system must be commercially available and fully supportable by commercial sources. Where specific brands are identified in this specification, no substitutes are allowed without prior approval from the AFMETCAL. The Controller must meet or exceed Microsoft Windows 10 Professional hardware requirements.

6.5. Laptop Controller Salient Characteristics:

6.5.1. Memory: Minimum 8 GB system Memory.

6.5.2. USB: Minimum of two integrated USB 3.0 ports not being utilized by other components.

6.5.3. External Video Support.

6.5.4. Display Panel: 14.1-inch (diagonal) or larger viewable display.

6.5.5. Hard Drive: 120 GB (Minimum).

6.5.6. DVD-ROM: Internal or External DVD +/- RW dual layer or Blue-Ray.

6.5.7. Lenovo brand controller will not be acceptable.

6.5.8. Operating System and Software: All software must run under Microsoft Windows 10

(Professional operating system or greater 64bit, latest version release). All software must run Windows 10 as a non-elevated user.

6.6. Additional Hardware: Additional hardware required to make this system function as identified by this purchase description shall be required.

6.7. Software Identification: All software used in conjunction with instrument shall be identified by Name, Version, and Date; to be displayed upon startup or located in an “About” menu in the software.

6.8. Warranty:

6.8.1. The contractor shall warrant that the software product meets this purchase description and is free from defects in design and operation and will perform to stated specifications within this purchase description.

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6.8.2. The contractor shall (at no additional cost) update, or replace the software product as necessary to correct any deficiencies identified in the software. Replacement software shall meet or exceed the requirements in this purchase description.

6.8.3. When firmware or software upgrade is anticipated by a manufacturer during the life cycle of this contract, the contractor shall contact AFMETCAL for concurrence. If AFMETCAL concurs with the proposed upgrade, all previous units shall be updated to this upgrade.

6.8.4. All firmware or software provided under this contract shall be at the same version, revision, build number, and revision date at the completion of the contract.

6.8.5. Since AFPSL Gage Block Comparator Calibration Software and the Gage Block Calibration Software is new, the contractor shall provide software upgrades when errors or other issues are found within a timely manner to reduce downtime.

7. SOFTWARE, GAGE BLOCK CALIBRATION for USGBC Owned by PMEL:

7.1. All raw and processed measurement data shall be exportable to an Excel File, Access File, and Text File. Measurement Data shall include, but not limited to, all of the raw data required for all measurement runs, temperature for each raw measurement if the temperature monitoring system is turned on and all master gage block file information and test gage block file information.

7.2. Software shall allow all raw and processed data to be exported to Access, Excel, and Text File.

7.3. Software shall use the same measurement processes, techniques, corrections, calculations, etc.

as the Software described in Par 6.2.

7.4. Software shall allow master gage block set files with set p/n, set id#, set s/n, material, and deviations to be developed and saved so the master gage block files can be recalled to calibrate test gage blocks.

7.5. Software shall allow test gage block set files with set p/n, set id#, set s/n, material, individual gage block s/n’s to be developed and saved.

7.6. Software shall allow a Gage Block Set or Individual Gage Block to be calibrated.

7.7. Software shall follow a sequence that compares each test gage block in the set to a master gage block. The measurement sequence can be stopped and resumed at any time. Software shall save measurement data automatically.

7.8. After all test gage blocks in the set have been compared to a master gage block once, the sequence described in Par 7.7 is repeated for a second set of measurements.

7.9. After the two measurement sequences described in Par 7.7 and Par 7.8 are completed, the software calculated deviations for each test gage block in the set are compared and must agree within the specification input into the Spread Value contained within the Configuration Menu.

7.10. If the two calculated deviations for any test gage block in the set, exceed the Spread Value, the those particular test gage blocks are flagged and must be compared to a master gage block for third time.

7.11. Once all test gage blocks in the set meet the Spread Value, the software shall direct technician to print a certificate of calibration and case card.

7.12. Certificate of Calibration shall identify the set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

7.13. Case Card: The software shall allow case cards to be printed. Case cards are small card sized charts that fit into the gage block set. The case card shall identify set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

7.14. Software Configuration shall allow the technician select units for length, deviations, and temperature.

Rev 1

7.15. Software Configuration shall allow the technician to select laboratory temperature, gage block temperature, or manual entry.

7.16. Software Configuration shall allow the technician to select the expansion coefficients for various gage block materials such as, but not limited to ceramic, steel, tungsten, and chromium carbide. The numerical expansion coefficient value for each material must be identified.

7.17. Software Configuration shall allow the technician select the penetration coefficient for various gage block materials such as, but not limited to ceramic, steel, tungsten and chromium carbide or a manually entered value. The numerical penetration coefficient value for each material must be identified.

7.18. Software Configuration shall allow the technician to select the master gage block set being used, enter the test gage block variation in µin, enter the spread value in µin, and the allowed column edits for test gage block data for dev 1 and dev 2.

7.19. Software shall save all final test gage block calibration data.

7.20. Software shall allow a replacement test gage block to be added to a previously calibrated test gage block set. The replacement test gage block s/n and deviation shall be able to be input into the test gage block file and a new certificate of calibration and case card to be printed.

8. SOFTWARE, GAGE BLOCK CALIBRATION for USGBC Owned by AFPSL:

8.1. All raw and processed measurement data shall be exportable to an Excel File, Access File, and Text File. Measurement Data shall include, but not limited to, all of the raw data required for all measurement runs, temperature for each raw measurement if the temperature monitoring system is turned on and all master gage block file information and test gage block file information.

8.2. Prior to delivery, the vendor shall provide this software to AFMETCAL for testing.

8.3. Software shall allow master gage block set files with set p/n, set id#, set s/n, material, and deviations to be developed and saved so the master gage block files can be recalled to calibrate test gage blocks.

8.4. Software shall allow test gage block set files with set p/n, set id#, set s/n, material, individual gage block s/n’s to be developed and saved.

8.5. Software shall allow a Gage Block Set or Individual Gage Block to be calibrated.

8.6. This primary difference between the AFPSAL Gage Block Calibration Software and the PMEL

Gage Block Calibration Software is the AFPSL will calibrate each test gage block set or each individual gage block using up to three sets of master gage blocks using up to three measurement sequences as described below.

8.7. Software shall follow a sequence that compares each test gage block in the set to a master gage block. The measurement sequence can be stopped and resumed at any time. Software shall save measurement data automatically.

8.8. After all test gage blocks in the set have been compared to a master gage block once, the sequence described in Par 8.7 is repeated for a second set of measurements using a second master gage block set.

8.9. After the two measurement sequences described in Par 8.8 and Par 8.9 are completed, the software calculated deviations for each test gage block in the set are compared and must agree within the specification input into the Spread Value contained within the Configuration Menu.

8.10. If the two calculated deviations for any test gage block in the set, exceed the Spread Value, the those particular test gage blocks are flagged and must be compared to a third set of master gage blocks for third time.

8.11. Step 8.7 is repeated until the two calculated deviations for any test gage block in the set does not exceed the Spread Value.

8.12. Once all test gage blocks in the set meet the Spread Value, the software shall direct technician to print a certificate of calibration and case card.

Rev 1

8.13. Certificate of Calibration shall identify the set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

8.14. Case Card: The software shall allow case cards to be printed. Case cards are small card sized charts that fit into the gage block set. The case card shall identify set p/n, set s/n, set id#, date of calibration, technician’s name, accuracy, s/n for each individual gage block and the calculated deviation from nominal length in microinches (example: -3 µin) and micrometers (example: +5 µm).

8.15. Software Configuration shall allow the technician select units for length, deviations, and temperature.

8.16. Software Configuration shall allow the technician to select laboratory temperature, gage block temperature, or manual entry.

8.17. Software Configuration shall allow the technician to select the expansion coefficients for various gage block materials such as, but not limited to ceramic, steel, tungsten, and chromium carbide. The numerical expansion coefficient value for each material must be identified.

8.18. Software Configuration shall allow the technician select the penetration coefficient for various gage block materials such as, but not limited to ceramic, steel, tungsten and chromium carbide or a manually entered value. The numerical penetration coefficient value for each material must be identified.

8.19. Software Configuration shall allow the technician to select the master gage block set being used, enter the test gage block variation in µin, enter the spread value in µin, and the allowed column edits for test gage block data for dev 1 and dev 2.

8.20. Software shall save all final test gage block calibration data.

8.21. Software shall allow a replacement test gage block to be added to a previously calibrated test gage block set. The replacement test gage block s/n and deviation shall be able to be input into the test gage block file and a new certificate of calibration and case card to be printed.

9. SOFTWARE, GAGE BLOCK COMPARATOR ALIGNMENT for USGBC Owned by PMEL and the AFPSL:

9.1. Software alignment process and techniques should be the same as the Software described in

Para 6.2.

9.2. The comparator alignment software shall guide or prompt the technician through the entire measurement process.

9.3. The comparator alignment software shall allow the technician to enter the number of gage blocks being used, the deviation of each gage block and if necessary the spread between the gage blocks.

9.4. The comparator alignment software shall guide or prompt the technician through the entire alignment process.

9.5. The comparator alignment software shall provide quantifiable measurement data to determine if the alignment process is acceptable or if it should be repeated.

9.6. The comparator alignment software shall allow the technician to accept and save the new alignment data or reject it and repeat the alignment process.

10. OPERATOR’S MANUAL:

10.1. Shall include at least one printed manual and an electronic copy of the manual.

10.2. Cover Page: Shall identify the Air Force System P/N, Contract Number, Noun, Mfg, Rev

Number, and Date.

10.3. Shall include an index, a description that identifies the system and its various parts, components and display. Graphics and technical description of the comparator and how it works. Graphics and technical description of the display, menu bar, function buttons, sensor positon readout, measurement readout, etc.

Rev 1

10.4. Shall include the technical specifications such as capacity, upper and lower gaging forces, contact radius and material, range of signal, range of sensor positon, resolution (inch and metric), linearity accuracy, repeatability, thermometer p/n, thermometer mfg, thermometer range, thermometer resolution and thermometer accuracy for the provided thermometer.

10.5. Shall identify Warm-Up Time.

10.6. Shall identify Fuse requirements and instructions.

10.7. Shall include instructions for un-packing, set-up, installation instructions, interfacing all electrical connections and thermometer, and installing software.

10.8. Shall include instructions for measuring and adjusting the upper and lower gaging forces using the dynamometer and weigh scale.

10.9. Shall include instructions for checking and adjusting the cam clearance, for measuring and adjusting the lower contact stylus protrusion height.

10.10. Shall include maintenance instructions for cleaning, replacing upper and lower stylus contacts, electronic gage head replacement and alignment, over-travel stop screw check and adjustment, adjusting the staging table perpendicular to the spindle, measuring contact protrusion height and adjustment using depth gage, checking and aligning contacts.

10.11. Shall include instructions for adjusting comparator to obtain the full amplifier range.

10.12. Shall include instructions for using the comparator and software to calibrate gage blocks. The instructions shall discuss the menu’s, setting up test and master files, entering individual gage block serial numbers, setting up the configuration, units, environment, expansion coefficients, penetration coefficients, measuring mode, the two run comparison measurement process, re-running a gage block a third time if the two first runs exceed the Spread Value requirement, how to print certificates and case cards.

10.13. Shall include instructions for calibrating and aligning the comparator using gage blocks. The instructions shall provide guidance for determining if the alignment process measurement results are acceptable or un-acceptable.

10.14. Shall include description and calculations used to determine the Penetration Coefficients.

10.15. Shall include description and calculations used to determine the Coefficient of Thermal

Expansion constants.

11. SOFTWARE MANUAL:

11.1. Shall include at least one printed manual and an electronic copy of the manual.

11.2. Cover Page: Shall identify the Air Force System P/N, Contract Number, Noun, Mfg, Rev

Number, Software Version, and Date.

11.3. Shall include installation and log-in instructions.

11.4. Shall include a description of all main screen menus, buttons, and other components associated with each menu.

11.5. Shall provide instructions for setting coefficient of thermal expansion, material environment, units, etc.

11.6. Shall include instructions for setting up master gage block set files: How to input information such as set part number, set serial number, material, nominal gage block sizes and certified deviations.

11.7. Shall include instructions for setting up test gage block files: How to input information such as set part number, set serial number, material, nominal gage block sizes, and individual gage block serial numbers.

11.8. Shall include instructions for calibrating a test gage block set: How to select a test and master gage block set. A description of the measurement process and sequence. Description of measurement runs and how to compare measurement results (allowable variation) to determine if the two measured test gage block deviations are acceptable.

11.9. Shall provide instructions for measuring variation in length.

Rev 1

11.10. Shall include instructions for re-measuring test gage blocks when the measurement results are not acceptable.

11.11. Shall include instructions for measuring single test gage blocks.

11.12. Shall include instructions for printing measurement results, certificates, and case cards.

11.13. Shall provide instructions for developing new certificates and case cards.

12. SHIPPING and SHIPPNG CONTAINERS

12.1. For PMELs that have two Gage Block Comparators: The contractor shall provide and ship to the PMEL, two shipping containers, two sets of bolts, shims, tie-down plates and instructions.

This will ensure the Gage Block Comparator is packed and attached to the shipping container correctly.

12.2. For PMELs that have one Gage Block Comparator: The contractor shall provide and ship to the PMEL, one shipping container, one sets of bolts, shims, tie-down plates and instructions. This will ensure the Gage Block Comparator is packed and attached to the shipping container correctly.

12.3. The contractor shall pay all shipping costs as described below:

The cost to ship the empty shipping container(s) from Mahr to the PMEL.

The cost to ship the packed shipping container(s) from the PMEL to Mahr.

The cost to ship the USGBC from Mahr to the PMEL or AFMETCAL.

PMELs located at Kadena AB, Japan and RAF Feltwell, United Kingdom: All shipping will go through AFMETCAL.

All other PMELs including Elmendorf AFB, Alaska will be directly shipped.

13. INSTALLATION and TRAINING: The contractor shall coordinate with PMEL, set-up the comparator, and provide at least one day of training (excluding travel time) for each destination site.

Training shall include operation, calibration, and maintenance of the gage block comparator.

14. TESTING: Installation and system operation overview by the contractor shall take place at the customer’s premises. The contractor shall spend a minimum of one day on site. The USGBC will be inspected and accepted at a destination specified elsewhere in this contract. The item will be checked with test equipment and parameters equal to or better than those required assuring specified performance requirements are met. Test equipment has first echelon certification directly traceable to the National Institute of Standards and Technology (NIST) or other approved equivalent international laboratory where required. Test will be performed to assure the USGBC meets or exceeds all of the requirements of this purchase description. Such testing does not relieve the contractor of performing all inspections and quality control checks at the point of fabrication as necessary to assure performance as specified.

Attachment:

Data Requirements

Attachment to Statement of Work

Short Gage Block Comparator Upgrade

DATA REQUIREMENTS

MANUALS: A complete user and service manual and calibration procedure shall be provided with each unit in contractor format. Manuals shall be on CD/DVD‐ROM in Indexed Portable Document Format

(iPDF). The manuals shall comply with Data Item Description (DID) DI‐TMSS‐80527C and the Contract

Data Requirements List (DD Form 1423).

SOFTWARE USER MANUAL: The software user manual shall contain instructions to execute one or more related computer software configuration items. The software user manual shall be on CD/DVD‐ ROM in

Indexed Portable Document Format (iPDF) and prepared in accordance with Data Item Description DI‐

IPSC‐81443A and Contract Data Requirements List (DD Form 1423).