PR 1301102208 Performance Work Statement (PWS).pdf

PERFORMANCE WORK STATEMENT (PWS)

Digital Image Correlation System: Hardware, Software, and Training

1.0 DESCRIPTION/BACKGROUND: The Welding, Processing, and Nondestructive Evaluation branch

(C611) of the Naval Surface Warfare Center Carderock Division (NSWCCD) performs research and development on technologies of interest and provides engineering, research, and technical support to NAVSEA technical warrant holders, various program offices, and other Department of Defense (DoD) organizations. A particular program supported by C611 is the Office of Naval Research (ONR) funded 10Ni Technical Candidate program. Mechanical testing is essential in order to evaluate the performance of materials. Traditional individual strain gauges can be inaccurate at very small and very large strains and can only measure one specific area at a time. This digital image correlation (DIC) system will enable NSWCCD to obtain full field surface strain measurements of mechanical test specimens. Data using this new technical capability will immediately support the ONR 10Ni Technical Candidate program in addition to SSBN and SSNX program office projects and many more.

2.0 OBJECTIVE: The objective of this contract is to procure a fully functioning turn-key digital image correlation (DIC) system which meets the performance requirements for all supplies and services per this specifications document. The system must be tested and tuned to achieve the required strain resolution and maximum frame rate at full camera resolution prior to delivery. Additionally, the vendor must come on-site to unpack, set up, perform a test run to check accuracy following shipping and assembly, and provide training to Carderock employees.

3.0 MINIMUM SPECIFICATIONS

The contractor shall provide a turn-key digital image correlation system that includes 3.1 through 4.5.

The components and specifications as listed below.

3.1 3D Digital Image Correlation System Requirements

3.1.1 Full-field non-contact measurement including 3 dimensional positions, 3 dimensional displacements, 3 dimensional velocities and 2 dimensional surface strains for the black and white speckled surface of interest

3.1.2 System must also include necessary software to perform 2 dimensional DIC with one of the cameras provided

3.1.3 Must be able to measure surface strains between 0.005% (global) to 2,000% or higher

3.1.4 Must be able to achieve a surface strain accuracy of 50 microstrain or less

3.1.5 Must be able to achieve an in-place displacement accuracy of 1/200,000 * field of view or better

3.1.6 Must be able to achieve an out-of-place displacement accuracy of 1/100,000 * field of view or better

3.1.7 Perform synchronized capture of at least 4 cameras at once

3.1.7.1 The option to integrate all 4 camera images and results into one common coordinate system during calibration and post-processing without manual stitching

3.1.7.2 The option to record and analyze each stereo system (pair) separately but simultaneously

3.1.8 Display real time full-field live strain data

3.1.8.1 User can choose the data density for processing rates between 2-10 Hz

3.1.8.2 Display over 10,000 data points

3.1.8.3 User can choose to display data in an unlimited number of user specified 3D plots, 2D contour image overlays, and point extractions displayed graphically.

3.1.9 Synchronize image capture for fatigue and vibration applications

3.1.9.1 Accurate triggering of vibration events up to 5 KHz

3.1.10 System must be tested and tuned to achieve the required strain resolution and maximum frame rate prior to delivery

3.1.11 No Wi-Fi cards in any components

3.1.12 No wireless parts included in any components

3.1.13 Made and built in the United States (required to decrease equipment repair and technical support response time when problems occur) each individual component (example camera lens) is not required to be made in the USA but it is preferred

3.2 Image Acquisition Software Requirements. To assist in acquisition and setup, image capture software must include or be able to:

3.2.1 View all live and connected cameras at once

3.2.2 Compute image histograms

3.2.3 Setup/alignment aids such as cross hairs overlaid on each camera image

3.2.4 Tool to assist in lighting level that indicates overdriven/saturation locations in the images

3.2.5 Zoom in on camera images to view individual pixel level details

3.2.6 Adjust exposure time for each camera

3.2.7 Calibrate intrinsic (focal length, aspect ratio, sensor center) and extrinsic

(displacement and angles between cameras) stereo parameters at the same time

3.2.8 Quantify noise floors in the test setup prior to testing i.e. confidence estimates on matching performance for the speckled surface and calibration parameters

3.2.9 Ability to record up to 4 external BNC signals time synchronized with the DIC images

3.2.10 Ability to perform system calibration before or after test images have been collected and apply the calibration to previous data sets

3.2.11 Includes a calibration correction feature that automatically recalculates camera orientations after a disturbance (floor vibration) occurs before or during testing.

The feature eliminates the need to perform another calibration if a disturbance occurs during testing.

3.2.12 Includes a calibration to correct for changes in the refractive index (e.g., viewing specimen trough glass or liquid) between the speckle pattern and a stereo camera pair

3.2.13 Automatic lens distortion calibration feature that corrects optical distortions due to lenses

3.2.14 Ability to generate new variables based on equations applied to the calculated data (ex. compute stresses from calculated strains or volume conservation during plastic deformation)

3.2.15 Report all camera trigger times to ensure image pairs are synchronized

3.2.16 Software must be an approved software in the NAVY DADMS system

3.3 Post-processing Software Requirements. To assist in post-processing speckled surface images into position, displacement and strain information the post-processing software be able to:

3.3.1 Process a test sequence of 2000 image pairs, each containing 50,000 data points in 10 minutes on a single Intel Quad-core processor

3.3.2 User defined area of interest selection

3.3.3 Calculates a suggested data density (solution unit and percent overlap between solution units)

3.3.4 Analyze data with a user defined data density (number of pixels per repeating solution unit and percent of overlap between repeating solution units)

3.3.5 Tool to search for analysis solution unit start point using advanced predictive algorithms for both spatial and temporal start point generation

3.3.6 Ability for the user to define their own start point

3.3.7 Ability to use multiple start points in one solution

3.3.8 Calculate uncertainty measures for position and displacement data

3.3.9 Include multiple calculation options including interpolation, criterion, solution unit weights, and thresholding (ex. spline solution, optimized 8-tap filter, normalized square difference, Gaussian)

3.3.10 Ability to isolate and remove rigid body motion from the solution

3.3.11 Change coordinate system to a user defined coordinate system

3.3.12 Ability to query minimum/maximum, mean and standard deviation of the calculated data

3.3.13 Ability to perform time-slice extractions, stress-strain curve generation, data extraction along lines

3.3.14 Export point data for the entire surface or area of interest

3.3.15 Display and export strain/displacement surface contour images

3.3.16 Ability to modify surface contour plot scales to user defined values

3.3.17 Overlay strain/displacement contours on original sample images with user defined transparency

3.3.18 Select and export region of interest statistics

3.3.19 Export animations of contour plots over time

3.3.20 Export recorded external signal data

3.3.21 Discrete marker tracking in three dimensions of a user defined point of interest

3.3.22 Full-field experimental data can be directly compared to FEA data.

3.3.23 Unlimited installations of the post-processing software to any operating system compatible computers

3.3.24 Software must be an approved software in the NAVY DADMS system

3.4 Licensing, Technical Support and Training Requirements

3.4.1 One permanent acquisition license (no annual licensing fees)

3.4.2 Two permanent post-processing licenses (no annual licensing fees)

3.4.2.1 One of the permanent post-processing license must be able to float (be shared) between multiple users and computers

3.4.3 Shipping, on-site system assembly, and training included (as described in Section 4.5)

3.4.4 Unlimited United States based technical support via telephone and email (no annual fee)

3.4.5 System maintenance with software upgrades for 1 year

3.5 Camera Requirements

3.5.1 Two 2.3 Megapixel (1920 x 1200 @ 140 fps) Digital Cameras

3.5.2 Two 12.3 Megapixel (4096x3000 @ 30fps) Digital Cameras

3.6 Lens Requirements

3.6.1 Includes pairs of camera compatible lenses required to achieve the full range of

FOVs and high temperature applications

3.6.1.1 Two f2.8/50mm lenses

3.6.1.2 Two Extension Ring Sets (includes 0.5, 1, 2, 5, 10, 20, 40mm rings)

3.6.1.3 Two 100mm f/2.8 lenses with adapters

3.6.1.4 Two Blue 30.5mm filters

3.6.1.5 Two Blue 55mm filters

3.6.1.6 Two M30.5 x 0.5 Mounted Linear Glass Polarizing filters

3.6.1.7 Two M55 x 0.75 Mounted Linear Glass Polarizing filters

3.7 Hardware Requirements

3.7.1 Ruggedized aluminum cart workstation with rack-mounted PC to capture and post-process DIC images:

3.7.1.1 Rack-mount tower with workstation and drawers

3.7.1.2 Must meet or exceed ruggedized requirement in MIL-STD-81 OG

3.7.1.3 Must meet or exceed the EM shielded requirement in MIL-STD-461 F

3.7.1.4 Integrated rear panel connections for USB, Ethernet, firewire (if app), and analog data connections (BNC)

3.7.1.5 Windows 10 operating system

3.7.1.6 Processor with similar or better specifications as Intel Core i7 3.2GHz

Quad-core

3.7.1.7 64 GB RAM or better

3.7.1.8 8 TB hard drive & 1 TB solid-state drive or better

3.7.1.9 Comparable or better OpenGL® Graphics card with 30 acceleration

3.7.1.10 No Wi-Fi card

3.7.1.11 Two 24” LCD monitors

3.7.1.12 Integrated universal power supply

3.7.1.13 No wireless components (keyboard, mouse, etc.)

3.7.1.14 No integrated webcam

3.7.1.15 All drivers necessary to run the software, cameras, and data acquisition system

3.7.1.16 One analog data acquisition system compatible with

hardware/software, external BNC outputs and DIC acquisition system to synchronize trigger and record external signals with the camera images up to 1MS/s / 8 channels

3.7.1.17 Two year replacement warranty for defects in materials and/or workmanship on all non-consumables

3.8 Accessory Requirements

3.8.1 Stereo mounting system with fine adjustment and tripod for camera placement

3.8.2 Calibration targets and fixtures to support the full range of field of views with tolerances and certificates if available (ex. NIST certificate)

3.8.3 Software to generate and print replacement calibration targets

3.8.4 Two LED lighting systems with adjustable mounts and polarizing filters to achieve lighting requirements for all required field of views

3.8.5 All cabling required to connect and power entire system (cameras, computers and lights)

3.8.6 Speckle pattern ink application kit

3.9 Manuals

3.9.1 Reference CDRL A001, the contractor shall provide the manufacturer’s manuals, in English, for the system.

4.0 SERVICE REQUIREMENTS

The contractor shall provide services related to purchase and delivery of the DIC system including delivery/shipment; rigging/offloading and emplacement; installation and assembly; initial startup and acceptance testing; and onsite training.

4.1 Installation and Assembly. The contractor shall:

4.1.1 Perform all necessary anchoring and leveling of the system and all associated equipment.

4.1.2 Complete all required assembly of the system and associated equipment prior to commencing the startup and acceptance testing process.

4.1.3 Install power conversion equipment, as needed, and cabling to power the system from the government’s electrical drop(s) location.

4.1.4 Include all requirements and related costs associated with the installation and assembly in the proposal.

4.2 Initial Startup, Inspection, Demonstration and Acceptance

4.2.1 The contractor shall be responsible for the initial startup of the system and all associated equipment supplied under this agreement.

4.2.2 As part of the initial startup, the Government TPOC or technical representative will perform a pre-operational inspection of the system.

4.2.3 The contractor shall demonstrate to NSWCCD personnel that all key functions are operational prior to equipment acceptance. The demonstration shall at a minimum include measurement of a test component article. The component will then be inspected by Code 61 personnel to ensure the analyzed data is adequate within the required specifications. After successful completion of the demonstration phase, the Government TPOC or technical representative will accept the system.

4.3 Warranty

4.3.1 Two year replacement warranty for defects in materials and/or workmanship on all non-consumables

4.3.2 This warranty shall begin the day after final acceptance of the machine by

NSWCCD. The cost for all repairs conducted under the warranty including but not limited to parts, labor, travel and shipping shall be covered under the warranty. All troubleshooting and repair work shall commence within 48 hours of the reported problem and is to be conducted onsite at NSWCCD in West Bethesda, Maryland.

4.4 Technical Support

4.4.1 The contractor shall provide engineering support over the phone as needed to answer technical questions arising for the first twelve (12) months after final acceptance of contract requirements.

4.4.2 Upgrades to the latest software will be covered for the first twelve (12) months after final acceptance of contract requirements.

4.5 Training

The contractor shall provide onsite training to a minimum of three (3) NSWCCD employees or NSWCCD contractors. The training is to be held in Building 60 at NSWCCD, Room 172. The training will be 2 days, and will cover the DIC setup (calibration, speckling, etc.), data analysis, theory and best practices. The purpose of the on-site training is to ensure users have the knowledge to setup and use the system correctly to achieve the most accurate data possible and understand the systems capabilities and full-potential. Any training handouts and materials needed for the training will be provided by the Contractor.

4.6 Option: Additional Technical Support

Four (4) out-year maintenance and technical support where:

4.6.1 The contractor shall provide engineering support over the phone as needed to answer technical questions arising up to 4 years after the end of one year after final acceptance of contract requirements.

4.6.2 Upgrades to the latest software will be covered up to 4 years after the end of one year after final acceptance of contract requirements.

4.7 Option: Advanced Training

The contractor shall provide onsite training to a minimum of three (3) NSWCCD employees or NSWCCD contractors. The training is to be held in Building 60 at NSWCCD, Room 172. The training will be 2 days, and will cover NSWCCD specific advanced applications using the DIC system. The purpose of the on-site training is to set up and run through more complicated testing scenarios than the initial training. Any training handouts and materials needed for the training will be provided by the Contractor.

5.0 DELIVERABLES

The Contractor shall deliver the requirements specified in the Contract Data Requirements Lists (CDRLs), below.

5.1 CDRL A001 – Commercial Off-The-Shelf (COTS) Manuals and Associated Supplemental Data.

The contractor shall provide at least one paper copy and one digital copy of manuals.

6.0 SECURITY REQUIREMENTS: Unclassified

7.0 SCHEDULE, SHIPPING, AND DELIVERY

The contractor shall arrange for shipment and delivery of the machine complete with equipment and accessories/features described above to the NSWCCD, 9500 MacArthur Blvd, Building 60, Rm 172, West Bethesda, MD 20817.

8.0 PERIOD / PLACE OF PERFORMANCE

8.1 Required period of performance: The contractor shall deliver the DIC system no more than 20 weeks after receipt of contract award or not later than Dec 15th, 2023, whichever occurs earlier. Subsequent to delivery, the performance period for installation services will not exceed 30 days. Full period of performance through 2029 as the warranty does not begin until after installation.

8.2 Place of performance: The contractor shall provide and perform contract services at the NSWCCD, 9500 MacArthur Blvd, Building 60, Rm 172, West Bethesda, MD 20817.

9.0 CLEAN UP

9.1 In general, the Contractor shall remove debris and rubbish from work areas, and shall remove debris and rubbish that may accumulate. The Contractor shall be responsible for disposal of all debris and rubbish in accordance with local regulations regarding hauling and disposal.

9.2 During this project, walk ways shall be kept clear at all times from construction materials, trash debris, equipment, or any hazard that could cause safety hazards to government and/or non-government personnel.

9.3 Empty cans, rags, rubbish, unused materials and other discarded materials shall be removed from the site at the end of each workday.

10.0 SAFETY REQUIREMENTS

The Contractor shall insure that the following safety measures are adhered to by all personnel during these services, and any subsequent phases:

10.1 Provide, erect, and maintain barricades, rails, as required to protect the general public, workers, and adjoining property.

10.2 Provide personal protective equipment (safety shoes, hardhat, hearing protection) for contractor personnel which shall be worn at all the times. Insure proper access to the work area shall be maintained throughout the working period. Insure proper ventilation of fumes and airborne particles, as necessary, to provide a safe work environment.

11.0 SECURITY/SITE ACCESS REQUIREMENTS

11.1 Contractor personnel working at NSWCCD must be fully identified. To initiate the site access process (for both personnel and vehicles), the Contractor will contact the Carderock Visitor Center (301-227-1500). The Visitor Center personnel will provide further instructions/information (procedures, forms, etc.).

11.2 Contractor personnel are expected to perform most work during normal NSWCCD duty hours.

When work must be performed outside normal working hours, permission must be obtained from the Security Office through the Project Manager.

11.3 Contractor personnel must confine themselves to the work sites specified in their contract.

Visiting other areas is prohibited. Identification issued by the Visitor Center must be displayed at all times. Access to Carderock buildings will not be allowed without proper identification.

11.4 Pursuant to federal regulations, all personnel and vehicles on NSAW property are subject to search by authorized personnel at any time.

11.5 Alcoholic beverages, weapons, cameras, sound recorders, proscribed drugs and explosives are prohibited on NSWCCD property.

11.6 Use of Government property without prior written approval of the Contracting Officer is prohibited.

11.7 The Visitor Center will arrange for special contractor parking, if required. Contractor personnel shall not park in numbered/reserved spaces, areas reserved for car pools, or other prohibited areas. Posted speed limits and traffic restrictions must be observed at all times.

11.8 No Contractor personnel shall be allowed to operate a privately owned vehicle on station other than for ingress and egress. All private vehicles shall be parked in the designated areas and remain until the end of the work shift at which time they shall be driven directly to the gate for exit from the station. Any desired transportation of personnel, supplies or equipment on station by the contractor shall be accomplished by the use of one (1) registered vehicle furnished by the contractor and operated by an assigned driver appointed by and responsible to his supervisor.

11.9 Accidents or problems of a security/safety nature must be reported to the NSWCCD Security and Safety Offices immediately.

12.0 SMOKING RESTRICTIONS

The use of lighted cigarettes, e-cigarettes, cigars, pipes, or any tobacco product is not permitted except in designated areas.

13.0 STATION PERMITS

Permits are required for, but not necessarily limited to, welding and burning. Permits must be requested by the Contractor in accordance with the current NSWCCD procedures on a daily basis.

14.0 ENVIRONMENTAL PROTECTION REQUIREMENTS

14.1 The Contractor shall comply with Federal, state, and local regulations pertaining to the environment, including but not limited to the following: water, air, soil and noise pollution.

14.2 The Contractor shall prevent oily or other hazardous substances from entering the ground, drainage areas, storm drainage system, or local bodies of water.

14.3 The Contractor shall pick up solid wastes daily and place in covered containers which are regularly removed by the Contractor from Government property. Prevent contamination of the site or other areas when handling and disposing of wastes. At project completion, leave the areas clean.

14.4 The Contractor shall handle generated hazardous waste in accordance with 40 CFR 262. Take precautions to prevent spills of oils and hazardous material. In the event of a spill, immediately notify the Project Manager, USACE Official, USACE Safety Office/ USACE Environmental, and initiate containment operations utilizing personnel properly trained and protected for such situations.

14.5 The Contractor shall make the maximum use of low-noise emission products, as certified by the EPA. Blasting or the use of explosives is prohibited.

15.0 GOVERNMENT TECHNICAL POINT OF CONTACT (TPOC)

TBD at time of Award