PWS High Speed Dynamometer control system upgrade_Final.pdf

Performance Work Statement

High-Speed Dynamometers Control System Upgrades

C.1 GENERAL:

C.1.1 SCOPE. This is non-personal services contract to design, build, and integrate a state-of-the-art speed and force dynamometer control system. The control system shall be integrated on two government owned high-speed dynamometers, a SuperFlow TD-2500 and a Taylor RS-25K of the Automotive Instrumentation Division of Aberdeen Test Center for two systems. The Government shall not exercise any supervision or control over the contract service provider performing services herein however the contract service provider will coordinate scheduled engineering and installation efforts with the COR, COTRs, or other government technical points of contact and provide all documentation for all engineering and manufacturing/installation functions. The Contractor shall provide all required certified factory trained labor, documentation, schematics, integration supplies, tools, test equipment, transportation and integrate control system.

C.1.2 BACKGROUND. The Automotive Instrumentation Division of the Aberdeen Test Center (ATC) uses the high-speed dynamometers, to conduct automotive performance tests of tracked and wheeled combat and tactical vehicles. The high-speed dynamometers are used to closely control the speed or load of a test item while measurements of drawbar force or speed and other pertinent powertrain characteristics are obtained using independent on-board data acquisition. Typical performance tests conducted with the dynamometer include grade simulation, high-speed cooling, and fuel consumption.

The TD-2500 high-speed dynamometer has a maximum drawbar pull of 2,500 lbf and a continuous 200 hp curve to 71 mph. The RS-25K high-speed dynamometer has a maximum drawbar pull of 5,620 lbf and a continuous 350 hp curve to 70 mph.

The TD-2500 and RS-25K both utilize Eddy Current absorbers to create the resistance. The TD-2500 has one absorber and a single axle. The power is supplied by a battery bank that is charged by a belt-driven alternator. The belt and absorber are driven off the input side of the differential, with 5.29:1 gears and LT235/85R16 tires setting the belt RPM. The TD-2500 is currently controlled via the original tethered analog hand-held unit. The dynamometer was delivered to ATC in 1999 and has been in continuous service at the test center since. The RS-25K has two absorbers and two axles. The power is supplied by an Onan Diesel Generator. The absorbers are driven off the input side of the differentials, 4.10:1 gears, and LT285/60R18 tires. The RS-25K is currently controlled via a Windows-based tablet. The dynamometer was delivered to ATC in 2017 and has been in continuous service at the test center since.

C.1.3 PERIOD OF PERFORMANCE. The period of performance shall be specified by the contractor’s proposal, from contract award start date not to exceed one year. The upgraded control system will be integrated into the existing dynamometer chassis and be ready for acceptance testing ninety (90) days after the government accepts the preliminary design proposal. Acceptance testing will be completed within thirty (30) days after the integration of the new speed control system. ATC will provide the dynamometer crew (driver, dynamometer operator and engineer) to execute the acceptance tests described. ATC will also provide the test vehicles.

C.1.4 PLACE OF PERFORMANCE. The contractor shall provide onsite demonstration and acceptance testing services at the U.S. Army Aberdeen Test Center (ATC), Aberdeen Proving Ground, MD. The installation services shall be completed at their facility and shipped back to ATC at the contractor’s expense. The cost estimate shall provide the line item for the cost.

C.1.5 HOURS OF NORMAL OPERATIONS.

C.1.5.1 Principal Period of Maintenance (PPM): ATC is currently operating under an alternative work schedule. The contractor shall perform the maintenance within the government alternative work schedule and that work schedule will be known as the PPM for this contract. The PPM will be 8 workdays of 9 hours each, 1 workday of 8 hours, and every other Friday known as the Regular-Day-Off (RDO) as shown below. All workdays commence at 0700.

M T W T F

Week 1 9hrs 9hrs 9hrs 9hrs 8hrs

Week 2 9hrs 9hrs 9hrs 9hrs 0hrs

C.1.5.2 Integration and demonstration work shall not be scheduled during the following Federal Holidays:

New Years Day, M.L. King Birthday, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Day, Thanksgiving Day, and Christmas Day.

C.1.5.3 The Government reserves the right to postpone services based on sensitive work activities occurring at the facility. The COR will provide 24 hour notification of the requirement and advise the duration, up to 5 business days.

C.1.5.4 The Government has the option to permanently change the hours and days of operation if the contractor is provided two weeks’ notice.

C.1.6 PERSONNEL. All services under this contract shall be performed by competent personnel, experienced and highly qualified to provide the required services in accordance with the equipment manufacturer’s maintenance and repair procedures, without unnecessary delays or interference with government mission.

C.1.6.1 The contractor shall provide at minimum, one lead certified and factory trained technician with a minimum of 4 years experience and demonstrated knowledge in dynamometer control systems.

Personnel must have solid technical experience to maintain, troubleshoot and repair electrical/electronic and mechanical dynamometer equipment.

C.1.6.2 Program Management and Key Personnel. N/A

C.1.6.3 Identification of Contractor Personnel. The contractor shall provide a 2” x 1” nametag (black lettering with white background) with the company name and the word Contractor below it. The contractor shall ensure all personnel prominently display their nametags at all times while in a work. In addition to that, the contractor shall ensure all personnel identify themselves as a contractor employee (with the name of their company) when answering the telephone, using the email system, and when attending meetings.

C.1.6.4 Personal Protective Equipment (PPE). All contractor personnel shall wear the appropriate PPE when in the following work areas: range areas where entrance is controlled by the Range Operations Team, industrial buildings, at construction sites, test sites and test facilities. Other areas may be reviewed to determine if hazards are present which necessitate the use of PPE. Failure to wear/use PPE may cause removal from the job site and/or seizure of non-compliant equipment/items.

C.1.7 SAFETY. The Contractor agrees will abide by all ATC Safety Policies at no additional cost to the government.

C.1.7.1 Hazardous Conditions. Contractor personnel may be exposed to the following conditions during performance of work:

C.1.7.2 High noise levels (impulse and steady state);

C.1.7.3 Proximity to electric power sources of high voltage and/or amperage;

C.1.7.4 Working with lead acid batteries, radioactive materials, and ammunition;

C.1.8 SECURITY. The Contractor will abide by all ATC Security policies at no additional cost to the government.

C.1.8.1 Escorted access into Restricted Areas: The Contractor is responsible for hiring personnel eligible for escorted access to service equipment in the APG Restricted Areas (RAs). The Contractor shall advise employees that the SAC will be used to review criminal history records and that adverse information may result in an employee being denied access into the RA.

All employees working on this contract will be US citizens, non US persons are not authorized to work on this contract.

C.1.8.2 Restricted Area (RA) Security Identification Credential. Contractor personnel will be granted escorted access provided a visit authorization letter being sent directly to the ATC Visitor Control Desk from the contracting company, the contractor employee will be issued an organizational credential to be used while in the RA. This credential identifies that the employee has an official need to be in the RA.

Contractor personnel shall wear their security credential above the waist at all times when in the restricted areas of APG with the following exceptions: (a) when photography is ongoing and the employee is likely to be in the photograph, and (b) when the employee is actually working with a piece of equipment that could catch the security credential and endanger the safety of the employee.

C.1.8.3 Reports of Adverse Information. The contractor shall report to the ATC Security Manager all adverse information on contractor personnel such as security violations, arrests, bankruptcy, wage garnishments and denial, suspension, or revocation of security clearances. The ATC Security Manager may deny employees’ access into APG restricted areas based upon the adverse information.

C.1.8.4 Installation Access. All contractor personnel will comply with the requirements of APG Regulation 190-4, Movement Control within the Installation, for entry, exit, and internal control of personnel, material and vehicles on APG. To gain access to APG, DA Form 1602, Civilian Identification Card, shall be issued to contractors who do not require computer access or do not travel on official Government business upon written approval from the COR. All vehicles and personnel are subject to search and seizure of contraband and/or unauthorized Government property in accordance with Army Regulation 190-13, The Army Physical Security Program.

C.1.8.5 Safeguarding Government Information and Property. The contractor shall be responsible for safeguarding all Government information and property provided for contractor use. Government-furnished property will be secured in accordance with AR 190-51, Security of Unclassified Army Property (Sensitive and Non-sensitive).

C.1.8.6 Usage of Privately Owned Personal Electronic Devices (PEDs) Within the Restricted Area (RA).

A privately owned personal electronic device (PED) is defined as a civilian multifunction cell phone, iPhone, personal digital assistant, tablet, blackberry, digital inventory devices and electronic recording/storage devices. Contractor personnel shall not use the PED’s photographic/recording capability within the ATC RA. The contractor shall not install or connect a privately owned PED to any government-owned computer or network system. Also, a PED that has the capability to store data cannot be connected to a government computer for purposes of charging the device’s battery. Contractor employees must use the appropriate wall adapter to charge a privately owned PED. PEDs are authorized for private, non-work related matters. Under no circumstances will a privately owned PED be used to photograph or record images while in the ATC RA(s).

C.2 APPLICABLE DOCUMENTS AND AVAILABILITY.

C.2.1 Documentation which includes the following will be made available to the contractor to aid in their proposal development:

a. Electronic (scanned) copies of original drawings and schematics

b. Test Operating Procedures (TOP) used for acceptance testing

C.3 REQUIREMENTS. The primary requirement is to design, build, integrate and demonstrate a modern, state-of-the-art, reliable speed and force control system for the existing TD-2500 and RS-25K dynamometer chassis and to reuse the bodywork, battery pack-alternator/generator, and absorbers where practical. Any existing vehicle components that are retained as part of the speed control upgrade project should be evaluated by the Original Equipment Manufacturer (OEM) or a certified repair facility to determine their functional condition and whether any repair, rebuild, or upgrades are needed. In no circumstance should the current drawbar performance of the dynamometers be degraded by the new control system.

C.3.1 Speed Control. The dynamometer, when equipped with the new speed control system, shall control the test vehicle speed to + 0.2 mph of the speed set point for true ground speeds between 0.5 to 70 mph.

Control of the test vehicle speeds will be demonstrated on paved level (within 1.0 %) test courses at Aberdeen Test Center. To provide for safe operation, the dynamometer operator can override the speed setting using an emergency stop button.

C.3.2 Force Control. The force control feature shall control the dynamometer to + 0.5% of the force set point for speeds between 0.5 mph and 70 mph. Force control shall be an option when operating the high-speed dynamometer. Force selection will be controlled by the dynamometer operator and will have a maximum resolution of the force set point of 5 lbf. The force control feature for the dynamometer mode will be demonstrated on paved level (within 1.0 %) test courses at Aberdeen Test Center. To provide for safe operation the dynamometer operator can override the speed setting using an emergency stop button..

The current load cells included on the dynamometers are a 3k lbf capacity on the TD-2500 and a 5k lbf capacity on the RS-25k load cell mounted in the tongue.

C.3.3 Programmable DAC Output. The high-speed dynamometers shall be wired with three programmable Digital to Analog Convertor (DAC) linear, conditioned 0-10 volt range outputs. The three outputs shall be located at the front of the dynamometers for ease of connection to the test item. Two of the options available for programming shall be load and speed from the speed and force measured signals into the control system.

C.3.4 CAN BUS Output. The dynamometer data shall be output in a CAN BUS format via a standard D-sub 9-pin connector which can be enabled/disabled by the dynamometer operator. The dynamometer data shall have an accompanying Interface Control Document (ICD) with a CAN bus DBC file and shall be transmitted from the controller tablet or electronics enclosure.

C.3.5 Engineering Design Documentation. The speed and force control upgrade shall require the contractor development and an ATC review of a technical design package. The proposed control system design is required to be fully documented to include wiring diagrams, schematics, theory of operation, parts lists, source code and sources of supply for all major components. Any special tools or processes will be identified. A theory of operation document will be provided to assist ATC engineers in the understanding of the updated system operation. Troubleshooting, recommended maintenance intervals/procedures, and calibration procedures will also be provided.

C.3.6 Electrical Upgrade. The existing electrical control panel shall either be replaced in its entirety or fitted with a new subpanel. The upgraded electrical cabinet shall contain new and modern discrete components along with new power and control system wiring. Any associated electrical control components located outside of the electrical control cabinet shall be replaced and rewired with new power and control wiring. The control systems shall be protected from water and prevailing weather conditions, as appropriate.

The wired controls and analog indicators shall be replaced on the TD-2500 with a new and reliable software package. The package shall run on a tough or ruggedized computer tablet that is similar to the RS-25K. The existing RS-25K tablet shall be upgraded with the new software package as well. Units for software package readouts and displays should be in U.S. customary units but shall be adjustable to SI units if required for a specific test. A wireless, point-to-point communication connection shall be standard between the dynamometer and the controller tablet. A 25-foot Cat 5e cable and weather-resistant connection point, mounted in a convenient location at the front of the dynamometer, shall be provided on the TD-2500 in the event that wireless control has interference issues. The wireless and wired connections on the RS-25K shall be maintained.

C.3.7 Commonality of Hardware. Main hardware board and other hardware components shall be common between the two high-speed dynamometers. ATC desires as much commonality as possible between the two for maintenance and ease-of-use purposes even though the hardware might be substantially greater in the RS-25K over the TD-2500.

C.3.8 Warranty: 2-year parts and labor of system modifications, excluding normal wear items, effective from Date of Local ATC Commissioning).

C.3.9 Service: 2-year service plan consisting of free technical phone/email support and 48-hour rush spare parts service.

C.4 PROPOSAL DEVELOPMENT/EVALUATION:

C..4.1 Each technical proposal is required to have sufficient detail to enable a comprehensive evaluation of the proposed control system modifications and its impact on acceptable dynamometer operation to determine whether the design will meet the essential requirements of the government. Proposals should be specific, complete and demonstrate a thorough understanding of the requirements.

C.4.2 Acceptability of proposals will be based on meeting all of the requirements of the government specification. Failure to address every requirement will result in the proposal being rated unacceptable.

Contractors submitting unacceptable technical proposals will be notified upon completion of the government’s technical review process. If a proposal is not clear in its response to a requirement, that proposal will be rated susceptible of being made unacceptable and at the government’s sole discretion may or may not request further clarification.

C.4.3 In order to facilitate the evaluation process each proposal should contain sufficient detail with respect to the following:

a. Basic design approach

b. Adherence to the requirements of the government specification

c. Use of state-of-the-art technologies

d. Component selection and commercial availability

e. Overall dynamometer performance

f. Adequacy of software

g. Familiarization and training plans for government personnel (end user)

h. Documentation, troubleshooting, and schematics

C.5 CONTROL SYSTEM COMMISSIONING

C.5.1 The commissioning of the high-speed dynamometer to complete the control system upgrade will be performed on-site at ATC. Prior to final commissioning, the dynamometer may be shipped at the contractor’s discretion for inspection, rebuild or modification as required to support the control system upgrade. All shipments requested by the contractor will be completed at the contractor’s expense. The cost estimate shall provide the line item for the cost.

C.5.2 Dedicated shop space and a prime mover will be provided by ATC to facilitate the control system tuning and commissioning. A trained vehicle operator will be provided by ATC when the high-speed dynamometers need to be moved.

C.6 ACCEPTANCE TESTING

C.6.1 After completion of the control system upgrade, component overhaul and wiring improvements, the high-speed dynamometers will be subjected to a series of acceptance tests to insure the dynamometer operation meets the government specifications. Contractor personnel are expected to be on-site during the acceptance tests to make any adjustments, modifications or repairs that may be needed during the course of the acceptance test.

C.6.2 The acceptance of the high-speed dynamometer control system upgrade will be based on its ability to meet the speed and force control requirements for each intended mode of operation. Government personnel at ATC will execute the acceptance tests after completion of the control system integration.

Evaluation of the speed and force controls will be conducted on ATC’s paved test courses. The test course gradient for all tests will not exceed 1.0 percent. Tests will be conducted on ATC’s Dynamometer Test Course and/or Automotive Test Evaluation Facility (ATEF). Descriptions of the test courses are provided in reference [b].

C.6.3 High-speed, grade simulation tests will be conducted using the U.S. Army Test and Evaluation Command (ATEC) Test Operating Procedure (TOP) 2-2-604, Drawbar Pull, reference [b] as a guide.

Specifically, “Drawbar Pull on Hard Surface”, paragraph 4.2 will be followed during the acceptance tests.

Several test vehicles will be used so that the speed and load range of the dynamometer will be adequately covered. Tracked and wheeled vehicles (e.g. FMTV, HMMWV, Bradley Fighting Vehicle) will be used as needed. Sustained stabilized speed runs will be conducted for a minimum time interval of one minute each. The speed intervals selected will not exceed 2 mph and the minimum test speed will be 0.5 mph.

Speed and force data will be recorded at a minimum sample rate of 100 Hz using a calibrated. The filtered (20 Hz) speed data will be compared to the speed control requirements. The speed control requirement on a level paved surface is + 0.2 mph of the speed set point for speeds between 0.5 to 70 mph for all load conditions.

C.6.3.1 Sustained stabilized force runs will be conducted for a minimum time interval of one minute each.

Force values will be selected based on typical gradeability and tractive effort requirements. Force values that simulate ascending 2-, 3-, 5-, and 10-percent grades will be determined for a light wheeled vehicle (e.g. HMMWV) and a heavy tracked vehicle (e.g. Bradley Fighting Vehicle). Speed and force data will be recorded at a minimum sample rate of 100 Hz using a calibrated, ATC-installed data acquisition package.

The filtered (20 Hz) force data will be compared to the force control requirement. The force control feature shall control the dynamometer to +0.5% of the force set point for speeds between 0.5 mph and 70 mph.

C.6.4 The contractor shall have personnel on-site to witness all acceptance tests and should be ready to make any required adjustments, modifications or repairs needed to the new control system to ensure conformance to the government specifications. The contractor will be responsible for the data collection and data presentation. Acceptance tests will be documented in a formal written report and supplied to the government fifteen (15) days after completion of the acceptance test phase.

C.7 Submission Procedures:

Please submit proposals in the following format:

Address all elements of the performance work statement in the proposal. On a separate document submit the firm fixed pricing information. Do not submit pricing and technical proposals in the same document.

C.8 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 performance work statement (PWS). 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.9 CONTRACTOR MANPOWER REPORTING (CMR).

The Office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) has established a secure data collection site, entitled Contractor Manpower Reporting System, for the purpose of capturing contractor (and subcontractor) manpower utilized during the performance of this contract. As a result, the contractor shall report all the information required by the Contractor Manpower Reporting System. The information requiring completion by the contractor includes, but may not be limited to the following:

Contracting Office, Contracting Officer, Contracting Officer's Technical Representative, Contract number, Requiring activity identification code (UIC), Command, Obligated Dollars, Fund cite information, Contractor name, address, phone number, e-mail address, Direct labor hours, Direct labor dollars, Federal Service Code (FSC) and Locations of service. The contractor shall submit all required information before final invoice. The contractor shall access the Contractor Manpower Reporting System database on the internet and fill-in the required data entry fields. The system can be accessed at the following internet address: https://cmra.army.mil.

C.10 The contractor shall utilize the Wide Area Work Flow (WAWF) system for requesting payment for all CLIN from the Government. The Contractor shall submit 2:1 combos (Invoice and Receiving Report) into Wide Area Work Flow each month for the labor hours CLIN that reflect all services rendered for the COR to review and approve payment.