Salient Characteristics - 19 MXS - Water Jet.pdf

Salient Characteristics

General requirements - The waterjet shall be new (not a rebuilt or remanufactured) and one of the manufacturer's standard current production models (not a prototype) capable of operations in accordance with the requirements herein. The waterjet shall be constructed from materials with sufficient mass and strength and configured in a shape and size that supports the workpiece and machine components while minimizing element deflections and initiated and/or transmitted vibration during operation. Designs with a separate catcher tank (independent of cutting unit) shall not be allowed. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, and repair. Access doors or removable panels shall be provided for servicing all components located within the waterjet.The waterjet shall be delivered as a complete system so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. As such, delivery of the waterjet must include all tooling, accessories, internal and external hardware, software, and components required for installation and operation.

Components - The waterjet shall consist of, but not be limited to, the principal components, attachments, and accessories necessary to meet the operational and performance requirements as defined below:

a. Cutting Assembly Support

b. Machine Table

c. Controller

d. Operating/Cutting Software

e. Cutting & Movement Operations

f. Pump with Pump Rebuild Kits

g. Garnet Storage Hopper

h. Cutting Head

i. Chiller System

j. Water Recycling System with Rebuild Kit

k. Garnet and Solid Removal System

l. Remote Keypad

m. Water Level Control

n. Nozzle Assembly with Replacement Nozzle Assemblies

Cutting Assembly Support - The cutting head/nozzle assembly shall be mounted above the machine table in a manner maintains the tolerances and repeatability established in section "Performance". The support structure for the cutting head/nozzle assembly shall be rated a minimum of two times the static and operational loads based on the yield strength of all load-bearing components. The support components shall support precision movement of the cutting head/nozzle assembly and rigidly hold the cutting head/nozzle assembly in place, preventing unintended movement due to normal machine operations or bumping of the equipment by operating personnel. The cutting assembly support shall have 360 degree wrap-around bellows to prevent garnet and water entry into the drive system.

Movement of the cutting support assembly shall be controlled via closed-loop, digital drives with brushless servo motors that require no periodic tuning.

Head Assembly - The cutting head/nozzle assembly shall be supported in a cantilever configuration where the assembly is attached to only one side of the machine table.

Machine table - The machine footprint, working envelope, maximum load and cutting travel shall meet the specifications listed below. The bed shall have four inch x 14 gauge (minimum thickness) galvanized steel support slats. The bed shall have means for leveling the machine on a flat mounting surface. The system must be of unitized design to eliminate misalignment due to an operator bumping either the cutting head or table during material loading. The base shall have access doors or removable plates as necessary for servicing components housed within. The contractor shall provide the necessary leveling hardware to insure compliance with machine specifications. All structural components for the table shall be made of material or coated/painted to prevent corrosion.

Minimum X-Y Travel: 8'4" x 4'7"

Minimum Table Size: 10'6" x 5'5"

Max Waterjet Footprint (includes control station; excludes pump, garnet storage, and other accessories):

13' x 8'

Max Operating Weight: 25,000 lbs

Max Supported Material Load: 400 lbs/sq. ft.

Minimum Z-axis Travel: 7.0"

Minimum Traverse Speed: 180 inches per minute

Controller - The waterjet shall be provided with a fully automatic, solid-state, integrated circuit, 64-bit, multiple microprocessor PC-based controller that runs on Windows® 10 operating system. The controller shall include a minimum 17-inch, LCD, LED, OLED, or similar flat panel display, standard mouse and keyboard inputs, and a minimum of two additional USB ports not utilized by the mouse or keyboard. The controller and screen shall be located in a water-resistant housing that is attached to the waterjet frame at a height suitable for operating while standing. The controller shall be capable of saving, storing, and recalling all associated operating files to/from an internal hard drive. The controller shall be capable or reading/importing all associated operating files from an external disk drive (CD/DVD) connected via USB.

The controller shall be capable of full operations without an internet or network connection.

Software - The waterjet shall ship from the vendor with all software required for operations installed on the controller. The software shall provide full operational control of all waterjet machining functions. The software shall be fully integrated into the controller. The software shall be capable of update/upgrade without the controller requiring an internet or network connection. The vendor shall provide three (3) additional sets (with operating licenses) of the associated software.

2-D Functionality - The software shall provide full cutting/jetting functionality in two dimensions (2-D, flat) across the machine table. These functions shall include: automatic and manual lead in/out, parametric shape generator, automatic collision prediction and correction, support tool path fonts, Windows® true type fonts, automatic raster-to-vector conversion, and comer and piercing optimizations.

The software shall provide the ability to resize, rotate, mirror, align geometric features (individually or as part of a group), and alignment with other features. The software shall automatically select default cut/jet parameters (i.e. - nozzle speed, jet pressure, tool path, pierce locations, over/undercuts, etc) based on input geometry, material type, thickness, and desired finish. The software shall allow for programming/modification of all cut/jet parameters. The software shall calculate cut/movement paths prior to machining operations and provide machine time estimates correct with 1 percent of actual operations, and shall allow for customizable pause and alert based on machine parameters. The software shall be capable of importing models and geometries in the following file formats/extensions:

DWG (.dwg), DXF (.dxf,) Initial Graphics Exchange Format (.igs, .iges), g-code (.n), Numerical Control

Machine Instructions (.nc), Computer Numeric Control File (.nee), Portable Document Format (.pdf), and

AutoDesk (.ps).

Automated material standoff - The system shall include integrated capabilities (software and hardware) to automatically adjust the standoff distance to compensate for changes in the material height once the standoff distance has been set at the start of a machining cycle. The system shall also detect potential collisions between the waterjet hardware (i.e., nozzle assembly, etc.) and material and pause the machine to prevent collision.

Pump requirements - The pump shall be capable of obtaining and maintaining the designed operating pressure, 60,000 pounds per square inch (psi), without the use of hydraulic assistance or pressure attenuators. The design shall support a minimum 500 operational hours between pump rebuilds with a minimum design life of 1,000 operational hours between rebuilds under normal operating conditions.

Pumps shall meet the requirements listed below. The pump shall include an integrated variable frequency drive that is controlled by the waterjet controller that allows for reduction or modification of pump operating parameters below the maximum threshold to meet cutting/jetting requirements while maximizing efficiency. The pump shall include a 1 IOV, single-phase electrical outlet to power controller and table operations.

Operating Power: 50 horsepower

Full Load Power Draw: 65A at 480VAC (60Hz)

Output Pressure: 60,000 psi

Orifice Opening: 0.016 inch

Flow Rate (in gallons per minute) with Orifice Opening and at Output Pressure: 1.2 gpm

Pump Dimensions in inches (length x width x height): 66 x 36 x 38.5

Pump Rebuild Kits - The waterjet shall be delivered with all special tooling required to disassemble, service, and rebuild the pump for continued use due to wear/tear from normal operations. The waterjet shall be delivered with two (2) pump rebuild kids that shall include all filters, lubricants, seals, single-use connectors, and all other items to reset the service life of the pump to zero (0) hours when rebuilt.

Garnet Storage Hopper - A garnet storage hopper capable of holding a minimum of 600 pounds of garnet/abrasive shall be included and incorporated into the design. The tank shall be capable of being pressurized up to 125 psi. The garnet storage hopper tank shall include the appropriate air valves and pressure regulators to provide pressure sufficiently and consistently needed to move garnet from the tank to the cutting head/nozzle assembly. The garnet storage hopper operations shall be fully compatible and integrated with the waterjet controller and software.

Cutting Head - The waterjet cutting head shall have a rotating/angling capability for the purpose of offsetting lead-in taper at the onset of the cut. Taper offset functionality shall be integrated into the system ( controller and software). The cutting head tilt from perpendicular to the machine table surface shall be a minimum of ±9 degrees. The cutting head shall also include fully integrated, motorized motion in the Z-axis (vertical) for a total movement no less than 7 inches.

Chiller System - The system shall be provided with a water chiller system for cooling water prior to entering the high-pressure pump. The water chiller system shall be capable of a minimum cooling rate of

60,000 BTU/hour and maintaining pump inlet water temperature of 65 °F or below. The water chiller system shall utilize refrigerant R-407c. The chiller system shall operate at a rated load of 11 amps on

480V AC, 60Hz, 3-phase power. The chiller shall not exceed the dimension of 48 inches long by 30 inches wide by 66 inches high.

Water recycling system - The waterjet shall include a water recycling system that allows for the reuse of water and eliminates the need for constant water supply and drain for operations. The water recycling system shall draw water from the machine table/tank and shall filter and condition the water using the following: mechanical filtration to remove solid particles, nano filtration to remove dissolved solids, and bacteria elimination. The water recycling system shall function as an integrated system with the machine table/tank, pump, and chiller system. The system shall include a settling tank with a clean-out of 1 inch

National Pipe Thread (NPT) for service The settling system within the water recycling system shall include a submersible sediment pump with ground fault circuit interrupter (GFCI) that moves sediment laden water to a hopper or catcher tank ( also included). The water recycling system shall operate at a rated load of 6 amps on 480V AC, 60Hz, 3-phase power. The water recycling system shall not exceed the dimension of 80 inches long by 36 inches high by 74 inches high.

Water recycling rebuild kit - The waterjet shall be delivered with all special tooling required to disassemble, service, and rebuild the water recycling system for continued use due to wear/tear from normal operations. The waterjet shall be delivered with two (2) water recycling filter kids that shall include all cartridges, filters, lubricants, seals, single-use connectors, and all other items to return the water recycling system to optimal performance.

Garnet and Solid Removal System - The waterjet shall include a system capable of removing garnet, solids, and other sediment from the bottom of the machine table/tank. The removal system shall utilize programmable controls that allow customization of the garnet evacuation rate, run time, and the ability to reverse flow. The garnet evacuation rate shall be capable ofreaching a rate of up to 5.6 pounds per minute. The removal system shall evacuate all garnet, solids, and other sediment into a mobile hopper, which is also included. The removal system shall operate at a rated load of 10 amps on 220/240VAC, 60Hz, single-phase power.

Remote Keypad - The waterjet shall include a remote keypad/pendant that allows the operator to precisely locate the nozzle and cutting head observing their exact location in relation to the material and standing away from the control panel. The remote keypad shall not provide a method to begin cutting.

Cutting shall be initiated only at the controller.

Water Level Control - The waterjet shall include methodology to adjust the water level in the machine tank relative to the machine table. There shall be at least 3 inches difference between the minimum water level and the maximum water level. The water level control shall be an independent hardware control (switch, lever, buttons, etc.) and not imbedded in software or programming.

Support and Nozzle Assembly with Replacement Nozzle Assemblies - The cutting head shall be supplied with a one-piece nozzle body and shall be warranted to last 500 hours (min). The waterjet shall be supplied with five (5) replacement nozzle bodies, all of which are one-piece bodies and warranted to 500 hours.

Electrical System - All electrical equipment shall comply with NFPA-79. The machine shall be designed to operate from a single 125-135A, 440-480V, 3-phase, 60-Hz (±1 Hz) power source. The system shall have a distribution/transformer panel that receives the facility power and transforms, conditions, and distributes appropriate power to the individual systems/components. The panel shall be certified and stamped by Underwriters Laboratory (UL) and shall have a breaker to stop power to all waterjet systems/components. It is acceptable for the panel to be located separate from the waterjet systems/components.

Construction - The abrasive waterjet cutting machine shall be constructed of parts which are new, without defects, and free of repairs. The cutting axes and tank shall be one unit to guarantee the cutting accuracy listed herein. The machine structure shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion. Processes such as welding, plugging, or filling with solder or paste shall not be used for reclaiming any defective part(s).

All screws, pins, bolts, and other fasteners shall be installed in a manner as to prevent change of tightness.

Castings/Forgings - All castings/forgings shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solders or paste shall not be used on casting or forgings for reclaiming any parts of the machine.

Welding, Brazing or Soldering. Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

Surfaces - All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt, fins, sprues, flux, and other harmful or extraneous materials. External surfaces shall be smooth, and all edges shall be either rounded or beveled unless sharpness is required to perform a function.

Gears - All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit repeated, full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

Painting - The machine shall be painted in accordance with the manufacturer's commercial practice.

Yellow or orange safety color-coding shall be used for designating physical hazards.

Threads - All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28.

Interchangeability - All replaceable parts shall be manufactured to common, published standards (i.e., ASTM, SAE, NEMA, etc.) with tolerances and clearances such that said parts components can be replaced or adjusted without modification of the equipment.

Maintainability - The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, and repair of parts.

Equipment Training - A complete overview of the machine controller, graphics display, and machine function and operation shall be provided at the installation location. Training shall be coordinated with the training point of contact (POC) at the installation location no later than seven (7) calendar days after setup/commissioning at the installation location. The training POC will be provided by the government at the time of order. Training shall follow installation of the equipment and last no more than three (3) days for a maximum of five (5) technicians. Training shall provide the necessary skills and knowledge to operate the machine safely, execute Manual Data Input functions, manual operation of machinery, load tooling into tool changer, conduct tooling offsets, and importing manufacturing files. Electronic versions of training materials shall be accessible to training participants for a minimum of three (3) years after completion of the training. Training shall also include how to properly service and maintain the main pump, water recycling system, and nozzle assembly.

Warranty - A minimum one (1) year warranty shall be provided to protect against defects, breaks, or component failures during normal operations. The warranty shall include the replacement and installation of components/assemblies at the installation location by an OEM-certified technician. The warranty does not cover consumable items such as nozzles or rebuild kits. For equipment located in austere operating environments, an OEM-certified technician may oversee the repair by a government representative; however, replacement components will still be provided as part of the warranty.

Support - Technical support for the equipment and software shall be provided for a period of three (3) years after the date of purchase. Technical support shall be accessible, at a minimum, via phone and email.

Performance - When tested, the waterjet shall meet the precision or standard performance category requirements as follows.

Positioning X, Y, & Z Linear Axes: +-0.001"

Repeatability X, Y, & Z Linear Axes: +-0.001"

Ball Bar Test 12" Circle: +-0.003"

Safety and Health Requirements - Covers, warning signs, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards and shall prevent unintended contact with the guarded component/area. The safety devices shall not interfere with operation of the machine.

Safety devices shall be removable to facilitate inspection, maintenance, and repair of the parts. All machine parts, components, mechanisms, and assemblies furnished on the machine shall comply with

US Department of Labor 29 CFR 1910.

High Pressure Tubing - The tubing that supplies pressurized water from the pump to the cutting head shall be stainless steel and shall have a pressure rating at least 2.5 times the normal operating pressure of the system.

Caution-Warning Plates - Corrosion resistant "Caution" or "Warning" plates shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

Audible noise - Audible noise emitted by the equipment under no load shall not exceed 81 dBA at the operator's workstation or at any other point at a distance of three (3) feet from the equipment as measured on the "A" weighted scale of a standard Type II sound level meter.

Prohibited Materials - Asbestos, mercury, lithium or polychlorinated biphenyl (PCB) shall not be used in any part or component of the system. Lithium batteries used in the computer system are exempt from this requirement.

Environmental Protection - The machine shall be so designed and constructed that under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prescribed by federal, state, or local statutes in effect at the location of installation.

Stop Switch - An emergency stop switch/button shall be provided that when pressed will instantly stop all motion of the machine and will cease flow through the nozzle.

System of Units - All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine shall be graduated in inch-pound (IPS) units. Dual markings with metric and IPS units is acceptable provided the IPS units are clearly discernable. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place.

Nameplate. A corrosion-resistant, metal nameplate shall be securely attached to the machine and contain the following information:

a. Nomenclature.

b. Manufacturer's name.

c. Serial number.

d. Machine model designation.

e. Power Input (volts, total amps, phase, and frequency).

f. Short-circuit/overcurrent rating.

g. Contract number or order number.

h. Date of Manufacture

Item Unique Identification Marking - An Item Unique Identification (IUID) plate shall be provided in accordance with MIL-STD-BON. The IUID plate shall be permanently affixed to the machine and shall include, at a minimum, the information specified above. This data on the IUID shall be Machine Readable

Information (MRI) for item identification and automatic data capture. It is permissible to combine the nameplate and the IUID provided both Human Readable Information (HRI) and MRI are present.

Lubrication plate or chart - A lubrication plate or chart shall be permanently and securely attached to the machine. The information provided on the plate or chart shall include:

a. Points of lubricant application.

b. Servicing interval.

c. Type of lubricant(s) with SAE number or lubricant identifier.

Manuals/Drawings - The vendor shall furnish one (1) hard copy of all technical manuals/drawings containing all information necessary for the programming, operation and maintenance (parts lists, electrical schematics, ladder logic and 1/0 diagrams) of the waterjet. One (1) complete set of manuals/drawings shall be sent to the receiving activity concurrent with machine delivery.

Installation Drawings - The vendor shall provide to the receiving facility, engineering installation drawings showing the necessary compressed air, water, and electrical utilities of the waterjet.

Documentation - All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct.

Regulatory Requirements:

Recovered Materials - The offeror/vendor is encouraged to use recovered materials to the maximum extent practicable, in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

Environmental Protection - The item shall meet all applicable Environmental Protection Agency (EPA) restrictions in effect on the date of the contract. These regulations apply to the emission of materials hazardous to the environment or the user's health and shall be adhered to during the manufacturing, service, transportation, storage, and operational use of the item.