Performance Work Statement Profilometer.pdf

PERFORMANCE WORK STATEMENT

Mobile Off-road Terrain Measurement System

C.1 GENERAL. The objective of this contract is to provide U.S. Army Aberdeen Test Center (ATC) a stand-alone highly mobile off-road test course and terrain measurement system, consisting of a prime mover with integrated sensor suite, data collection hardware and software. The system shall meet the technical, training, and documentation requirements as described in this document.

C.1.1 SCOPE. This is a non-personal services contract to provide ATC a stand-alone highly mobile off-road test course and terrain measurement system, consisting of a prime mover with integrated sensor suite, data collection hardware and software. The Government shall not exercise any supervision or control over the contract service provider performing services herein.

C.1.2 BACKGROUND. The test facilities at the U.S. Army Aberdeen Test Center (ATC) contain approximately 64 km (40 mi) of automotive test courses on more than 1320 hectares (3300 acres) of land. Each automotive test course is designed to meet a particular military vehicle specification, and many exceed commercial standards. The courses are divided into two classifications, endurance courses and performance courses. The ATC Profilometer, also called the Profiler, regularly traverses each of the ATC test courses and collects measurements to ensure that they are within roughness specifications. Results from data collected from the Profiler ensure test course consistency over time and provide maintenance recommendations.

C.1.3 PERIOD OF PERFORMANCE (POP). The POP shall be 10 months from contract award date. Any changes shall only be approved by the contracting officer.

C.1.4 CONTRACT TYPE. This will be a Firm Fixed Price (FFP) or Mixed FFP and T&M] contract.

C.2 APPLICABLE DOCUMENTS AND AVAILABILITY.

C.2.1 APPLICABLE DOCUMENTS.

Refer to TOP 01-1-010 Appendix A for a description of the system to be replaced.

C.2.2 AVAILABILITY OF DOCUMENTS. The government will be responsible for providing the contractor all ATC and/or Department of the Army SOPs or regulations.

C.3 REQUIREMENTS. The ATC Profilometer will be a highly mobile off-road test course and terrain measurement system, consisting of a prime mover and data collection hardware and software. The prime mover will be a rugged off-road capable vehicle. The data collection system will consist of micro-terrain measurement (scanning) instrumentation and an Inertial Navigation System (INS). The INS will be used to determine the position and orientation of the scanning hardware as the prime mover traverses the terrain, allowing the correlation of scan data frames to a common earth-referenced coordinate system. The INS consists of a high-grade Inertial Measurement Unit (IMU) which produces triaxial accelerations and triaxial rotational measurements, and a differential Global Positioning System (GPS). The Profilometer will produce a scan in post-processing by merging the INS solution with the surface scanning data. The Profilometer will include an end-to-end software package for controlling the system, processing, and analyzing data. Many of the test courses contain very soft soils that become significantly softer when saturated with water. The current profiler scanner cannot distinguish course features that will compress without significant input to the suspension. The intention of the system is to measure inputs into the vehicles under test.

To mitigate the compressibility of the soil, the current version of the Laser Profilometer only uses a single line of data points from behind the wheels for course evaluation.

Refer to TOP 01-1-010 Appendix A for a description of the system to be replaced.

The Profiler shall have a comprehensive software package, which may be composed of one or multiple programs. The program(s) shall perform the equipment operation, with stages for data collection, merging, reduction and analysis, and results reporting. The programs will be collectively referred to as the software package.

The software package will have user accessible outputs at the different stages of data collection and analysis. At each stage the software must generate outputs in formats which can be read by widely available programs such as MATLAB or Python. The outputs from the different stages will be used for diagnostic and verification purposes, confirming instrumentation functionality and analysis accuracy. The outputs will include:

Surface scanner outputs INS position and orientation solutions Differential GPS data XYZ points of the merged surface scan Distance vs. elevation profiles for selected paths through the surface scan Feature identification to include:

o Potholes (size and count) o Washboarding o Ruts o Amount/location of water on course or in potholes

A record of any edits made to scan data

The selected vendor will be required to demonstrate how their proposed design meets system requirements in a design review. They will next conduct a demonstration of their prototype in an initial system test and a final system test. The initial system test may occur at the vendor facility, the government facility, or a third-party facility. The objective of the initial system test demonstration will be to demonstrate the surface measurement system’s ability to collect the appropriate raw data needed to perform the reporting functions outlined in this document. The final system test shall take place at the government facility where the profiler will scan ATC Endurance and Performance test courses. The profiling system will scan six (6) specified test courses. This data shall be processed using the software package and results will be output in formats meeting the reporting requirements.

1 PROFILOMETER System Requirements

Each requirement maps to an associated qualification method(s) and has traceability to system requirements. Each requirement includes thresholds and objectives as applicable where:

1. Threshold (T) - Level of performance that is considered achievable at low-to-moderate risk.

2. Objective (O) - Level of performance which is the ultimate desired operational goal.

T = O Threshold and Objective are the same requirement level. Therefore, when T = O, there is no contractual obligation to exceed the Threshold requirement.

This section specifies the requirements, that is, those characteristics of the system that are conditions for acceptance. Requirements are sub organized under three overall categories: Prime Mover, Sensors, and Data. Each system element, defined as a group of related requirements, is itemized using a project unique identifier to support testing and traceability. Each system element is annotated by a unique Requirement Identifier (REQ-Category-##). Individual requirements represent constituent capabilities to enable functionality in each system requirement.

Category Summary Description I. Prime Mover Requirements

REQ-PM-01 The prime mover with integrated sensors must be able to traverse difficult off-road terrain

T = 24o breakover angle, 27o approach & departure angle, and 280mm of ground clearance.

O = > 25o breakover , > 30o approach & departure angle and >300mm ground clearance

REQ-PM-02 The prime mover must be able to traverse secondary and cross-country roads as defined in TOP-01-1-010 and TOP 01-1-011 with integrated sensors

T = 4WD with locking transfer case, low range, and front and rear locking differentials

T = O

REQ-PM-03 Prime mover must be protected from course debris and features on secondary and cross-country roads as defined in TOP 01-1-010 and TOP 01-1-011.

T = Prime mover must have comprehensive skid plates protecting the oil pan, transmission, transfer case, fuel tank, and vehicle body

T = O

REQ-PM-04 Prime mover interior must accommodate an operator and trainee in all season conditions

T = Cab space for 2 occupants without removing any sensor equipment. Climate control must be available and operable without compromising power to sensors or operation of prime mover. Ambient noise in the prime mover must be less than 75 dB while the vehicle is operating.

O = Cab space for 3 occupants without removing any sensor equipment, climate control must be available and operable without compromising power to sensors or operation of prime mover, ambient noise in the prime mover must be < 60 dB.

REQ-PM-05 Prime mover and mounted equipment must be operable on public roads to move between test courses without special considerations.

T = Prime mover complies with all sections of Subtitle 1 of Maryland Title 24 Vehicle Laws with all sensors in place including an overall width of 8 feet or less.

T = O

REQ-PM-06 Prime mover must be cleanable after use in wet, muddy, or dusty conditions

T = Exterior of prime mover can be washed in a military wash rack using water at a pressure of 75psi at a flow rate of 25 gallons per minute without ingress.

T = O

REQ-PM-07 The system, including prime mover and sensors, must be operable given storage year round in a non-climate controlled facility.

T = Prime mover must start after up to 3 months storage in a non climate controlled facility.

O = Prime mover must start after more than 3 months storage in a non climate controlled facility.

REQ-PM-08 Prime mover maintenance tasks limited to services provided by ATC fleet maintenance facility.

T = Prime mover is a consumer vehicle that has a naturally aspirated gasoline powered engine.

T = O

REQ-PM-09 Prime mover must meet and maintain test course speed requirements for all ATC Endurance and Performance test courses

T = Prime mover must traverse the following courses of International Roughness Index (IRI) values (in in/mi) while maintaining these minimum speeds while making valid scans without damage to the equipment.

- Paved (70-150 IRI) at 55mph

- Secondary Roads (250 -700 IRI) at 35 mph

- Cross Country Roads (800 – 1500 IRI) at 20 mph

- Trails (5000 + IRI) at 5 mph

REQ-PM-10 Operators must be able to safely navigate the laser profilometer in tight difficult terrain.

T = Prime mover must include a backup camera if rear visibility from driver seat is impeded.

T = O

REQ-PM-11 Prime mover must have robust recovery provisions.

T = Prime mover must include recovery provisions that comply with STANAG 4478 wheeled vehicle towing lugs.

T = O

REQ-PM-12 Prime mover will be fitted with off road tires capable of traversing ATC terrain.

T = Prime mover will be fitted with 35-inch diameter mud terrain tires and will have any necessary driveline or suspension modifications to retain the vehicles performance and warranty including but not limited to axle gearing, springs, shocks, bump stops, fender flares, and wheel offset.

T = O

II. Sensor Requirements

REQ-SR-01 Controls including arming/ disarming sensors, Graphical User Interface (GUI) for software control, and Emergency Stop (E Stop) must be operable from driver’s seat if required due to sensor safety concerns.

T = System arm, disarm, software control GUI, and E Stop must be operable from the driver’s seat by a 95th percentile male and a 5th percentile female.

REQ-SR-02 External warning indicators must be visible to personnel outside of the prime mover when the system is armed.

T = Proper signage and indicators IAW ANSI Z136.1 or similar regulatory documents relating to any type of hazardous sensor.

T = O

REQ-SR-03 Scanning instrumentation shall be securely mounted to prime mover. Equipment must stay rigidly in place while traversing off road courses which induce strong shocks and vibrations.

T = The system will be robustly mounted to withstand severe off-road driving as outlined in MIL 810H Large Assembly Transport. The instrumentation and mounting hardware shall not negatively impact off road performance of prime mover including, but not limited to, approach and departure angles, overall width, and ground clearance.

T = O

REQ-SR-04 Assembly and disassembly of scanning instrumentation for prime mover maintenance tasks must be completed with reasonable effort.

T = Assembly and disassembly of scanning instrumentation that would interfere with prime mover maintenance must be able to be completed by 2 people within a 4 hour window with standard tools, or specialty tools must be provided.

O = Assembly and disassembly of scanning instrumentation that would interfere with prime mover maintenance must be able to be completed by 1 person within a 4 hour window with standard tools, or specialty tools must be provided.

REQ-SR-05 Scanning instrumentation must be able to measure continuously over multiple test courses.

T = Scanning instrumentation must record for 4 hours continuously.

O = Scanning instrumentation must record for > 5 hours continuously.

REQ-SR-06 Scanning instrumentation must function without a software connection to internet and be transferable to online workstations.

T = Scanning instrumentation and software must not require a network connection to operate and will record to removable media.

T = O

REQ-SR-07 The current profilometer only uses the points behind the wheel path of the prime mover to calculate course roughness. This compensates for compressible soil that does not significantly affect the suspension.

T = Scanning instrumentation must include a mechanism to compensate for compressible soil along two wheel paths.

O = Scanning instrumentation must include a mechanism to compensate for compressible soil across the entire test course width.

REQ-SR-08 Scanning instrumentation must output a common time basis reference signal at 1 kHz for integration of future equipment and software.

T = Scanning system provides an accessible common time basis signal (such as an electrical pulse, TTL, etc.).

T = O

REQ-SR-09 Scanning instrumentation must produce valid scans at slow speeds to allow measurement of the most severe ATC test courses.

T = Scanning instrumentation produces valid scans at speeds down to 5 mph.

O = Scanning instrumentation produces valid scans at speeds down to 1 mph.

REQ-SR-10 The processed scan data must compensate for any motion of the mounted sensor relative to the road surface.

T = Scanning instrumentation must include a differential GPS and inertial navigation system with instrumentation mounted on the scanning sensor platform to correct for platform movement.

REQ-SR-11 Scanning equipment and software must be easily maintainable by operators.

T = Operation manuals, parts lists, tool lists, and sources of supply are included at time of delivery.

T = O

REQ-SR-12 The scan width must be sufficient to cover the width of endurance and performance courses at ATC.

T = The scan width will be 12 feet or greater.

O = The scan width will be variable between 12 and 20 feet.

REQ-SR-13 Scanning instrumentation must resist ingress of mud, dust, and other environmental hazards common on ATC test courses.

T = IP65 compliant.

O = IP67 compliant.

REQ-SR-14 The instrumentation must have a sufficient sampling rate to achieve the desired resolution at a variety of speeds.

T = The scanning frequency ranges will be sufficient to achieve 40 samples per foot at speeds between 5 and 55 mph.

O = The scanning frequency ranges will be sufficient to achieve 80 samples per foot at speeds between 1 and 65 mph.

REQ-SR-15 Scanning instrumentation shall be easily operable by one engineer in the driver’s seat of the prime mover.

T = All scanning instrumentation is operable using a provided GUI at the driver’s seat.

T = O

REQ-SR-16 Scanning instrumentation must establish a common reference point to monitor test course height changes over months to years.

T = Instrumentation must establish a common reference point based on existing features at the government facility.

REQ-SR-17 The scanning resolution must be sufficient to detect small but relevant course features including ruts, rocks, pebbles, and grout lines between cobblestones.

T = The vertical and horizontal precisions must be within 1 mm for relative vehicle position changes less than 3 m at speeds down to 10 mph.

O = The vertical and horizontal precisions must be within

0.5 mm for relative vehicle position changes less than 3 m at speeds down to 5 mph.

REQ-SR-18 The scanning resolution must be sufficient to detect larger course features such as potholes, large rocks, and humps.

T = The vertical and horizontal precisions must be within 10 mm for relative vehicle position changes between 3 and 10 m at speeds down to 5 mph.

O = The vertical and horizontal precisions must be within 5 mm for relative vehicle position changes between 3 and 10 m at speeds down to 5 mph.

REQ-SR-19 The tolerance of scanning equipment must be sufficient to detect course grades and long distance features.

T = The vertical and horizontal precisions must be within 20 mm for relative vehicle position changes between 10 and 3000 m at speeds down to 5 mph.

O = The vertical and horizontal precisions must be within 10 mm for relative vehicle position changes between 10 and 3000 m at speeds down to 5 mph.

REQ-SR-20 Safety equipment required for safe operation of the system must be included.

T = Safety equipment including but not limited to any personal protective equipment and covers for any hazardous sensors.

O = T

III. Data Requirements

REQ-DR-01 Data recorded or reduced by provided software is exportable in a non-proprietary format to be readable by other software including Python or MATLAB.

T = All data recorded is exportable in a non proprietary format such as .csv.

REQ-DR-02 Data will be visualized and processed within a quick turnaround time.

T = Data visualization, processing, and result reporting must not take longer than 24 hours to complete from the end of scanning to the production of the final reports.

O = Data visualization, processing, and result reporting must not take longer than 10 hours to complete from the end of scanning to the production of the final reports.

REQ-DR-03 Data from inertial measurement instrumentation must be used to correct scan data for vehicle motions.

T = Software is provided to post-process GNSS corrections, combine GNSS and inertial measurements into an integrated position and orientation solution, and translate scan sensor data to earth-referenced coordinates.

T = O

REQ-DR-04 Data recorded by the Profilometer produces equivalent metrics to the current Laser Profiler.

T = Data collected includes:

- GPS Time

- Latitude

- Longitude

- Ellipsoidal height

- Northing

- Easting

- Roll Angle

- Pitch Angle

- Kappa Angle

- Heading Angle

- Euler Angles

- Distance from scanning equipment to ground

- X, Y, and Z displacement coordinates of prime mover compared to a reference point

- X, Y, and Z coordinates measured by scanning instrumentation

O = Additional data is provided.

REQ-DR-05 Users must be able to visualize data to make corrections for errors caused by difficult course conditions such as deep water, heavy mud, and dust.

T = Using provided software or tools, can visualize and correct erroneous measurements from the full scan.

REQ-DR-06 Provided software must be able to generate 3D renderings of course scans capable of being viewed and edited.

T = 3D renderings can be made of full course width and at least 100 ft in length.

O = 3D renderings can be made of full course width and full course length.

REQ-DR-07 Provided software must allow for automated or user defined detection of course features.

T = Software can identify and count potholes, wash boarding, ruts, and bumps in test courses using user defined parameters such as height, depth, length, width, and shape.

O = Software can identify and count potholes, wash boarding, ruts, and bumps in test courses using user defined parameters such as height, depth, length, width, and shape. Software can detect if potholes or other course features are filled with water.

REQ-DR-08 Provided software for data analysis and reporting must be Army Golden Master (AGM) Compliant.

T = All provided software is AGM Compliant.

T = O

REQ-DR-09 Provided software shall have features to indicate that data is being collected and have verification tools to preliminarily check data in the field.

T = Data collection state, including errors that impede accurate data collection, INS solution health, and scanner activity shall be indicated on the GUI at the driver’s seat.

2 PROFILOMETER System Validation

2.1 Pre-proposal Requirements Meeting

Prospective vendors will meet at the government facility to visit and traverse the test courses, meet government personnel, and gain a better understanding of system requirements.

2.2 System Requirements Review

The System Requirements review shall be conducted to ensure that system requirements have been completely and properly identified and that a mutual understanding between the Government and vendor exists.

2.3 Design Review

This is a technical review to ensure that a system can proceed into fabrication, demonstration, and test that can meet stated performance requirements. The vendor shall conduct the design review. The design review assesses the system final design as captured in product specifications and will ensure that the system has been captured in detailed design documentation. The design review shall be scheduled by the vendor prior to the beginning of the integration of the scanning system into the prime mover.

2.4 Initial System Test

The initial system test may be conducted at a government facility, vendor facility, or third-party facility. The system shall measure a variety of obstacles to verify that it can accurately capture the 3D profile of test course features. The software shall be able to control the system in the prime mover and process collected data. Scan results shall be compared with existing measurements.

2.5 Final System Test

The final system test will be conducted on ATC test courses. The system will measure 2 test courses each of primary, secondary, and cross-country terrain with a variety of permanent obstacles including but not limited to half rounds, potholes, and ATC Profile IV. The results will be compared to existing measurements and course profiles to ensure the scanning is accurate and all required data is capturable. To ensure the system hardware is robust enough to survive many years and miles of offroad courses the vehicle will perform 5 laps of ATC vibration courses as per MIL 810H Large Assembly Transport without damage to the equipment.

2.6 Training

The vendor shall develop and provide system operation and maintenance training through a combination of classroom, written instructions, and hands-on operation. The vendor shall develop and conduct training for users/operators and local maintainers to understand the functional and operational capabilities. The vendor shall provide local support maintenance training and training system documents required to support troubleshooting and maintenance, diagnostics, fault isolation, calibration, adjustments, removal and replacement procedures, use of built in test, and repair, and other tasks associated with local support maintenance. The vendor shall develop a complete training support package that integrates training products, materials, and other necessary information to train the system operation and functionality.

C.4 DELIVERABLES AND DELIVERY SCHEDULE:

Vendor shall deliver a highly mobile off-road test course and terrain measurement system, consisting of a prime mover with integrated sensor suite, data collection hardware and software. Vendor shall deliver complete documentation of the system, system operations, software instructions and system maintenance. Vendor shall supply the system 10 months after contract award.

Deliver to Dominic Fonseca US Army Aberdeen Test Center 6850 Lanyard Road, Bldg 358 Aberdeen Proving Ground, Maryland 21005-5059 520-708-0940 dominic.r.fonseca.civ@army.mil

C.5 GOVERNMENT FURNISHED FACILITIES, EQUIPMENT, AUTOMATION

SYSTEMS, MATERIALS AND SERVICES

None

C.6 CONTRACTOR-FURNISHED FACILITIES, EQUIPMENT, AUTOMATION

SYSTEMS, MATERIAL AND SERVICES

The contractor shall provide all facilities, equipment, automation systems, materials and services required for satisfaction of the contract terms.

C.7 QUALITY ASSURANCE SURVEILLANCE PLAN (QASP)

Attached as a separate document.

C.8 CONTRACTING OFFICER’S REPRESENTATIVE (COR) AND TECHNICAL

POINT OF CONTACT (TPOC): Name, phone, email

C.9 NON-PERSONAL SERVICE STATEMENT

Contractor employees performing services under this order will be controlled, directed, and supervised at all times by management personnel of the contractor. Contractor management will ensure that employees properly comply with the performance work standards outlined in the statement of work. Contractor employees will perform their duties independent of, and without the supervision of, any Government official. The tasks, duties, and responsibilities set forth in the task order may not be interpreted or implemented in any manner that results in any contractor employee creating or modifying Federal policy, obligating the appropriated funds of the United States Government, overseeing the work of Federal employees, providing direct personal services to any Federal employee, or otherwise violating the prohibitions set forth in Parts 7.5 and 37.1 of the Federal Acquisition Regulation (FAR).

C.10 CONTRACTOR MANPOWER REPORTING (CMR).

The Office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) has established a secure data collection site, Contractor Manpower Reporting Application (CMRA), for the purpose of capturing contractor (and subcontractor) manpower utilized during the performance of this contract. The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via CMRA. The contractor is required to completely fill in all required data fields using the following web address: https://cmra.army.mil

Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year. Contractors may direct questions to the help desk by clicking on “Send an email” which is located under the Help Resources ribbon on the right side of the login page of the Contractor Manpower Reporting website.