Salient Characteristics.doc

Salient Characteristics (Requirements Document) Commercial Availability Certification:

I have evaluated the commercial marketplace and determined that all of the salient characteristics documented below are available in products/services offered in the commercial marketplace.

Signature (typed name): Constandinos M. Mitsingas Contracting Officer’s Representative (COR) The Army Research Laboratory is standing up a Hybrid-electric Integration, Validation and Experimentation (HIVE) facility within the Vehicle Technology Directorate with goals to experiment on different hybridization and electrification architectures and technologies. As part of these efforts, several units of equipment have already been procured: an Alternating Current (AC) dynamometer, an electric motor, regenerative variable frequency drive (VFD) and a battery emulator. The goal of this Salient Characteristics (Requirement Document) is to procure the remaining equipment. The Contractor shall provide all necessary equipment and materials (e.g. load absorbing dynamometer, not limited to the combining gearbox, and relevant sensor suite) to finalize the design and integration of the HIVE facility to the Vehicle Technology Directorate of the Army Research Laboratory in Building 4603, Aberdeen Proving Ground (APG), MD 21005 with the following minimum Government specifications:

1. Load absorbing dual-ended AC dynamometer:

· The dynamometer shall have air-Cooled capabilities

· The dynamometer shall have a continuous torque of at least 900 pounds per foot (PPF) from 0 to 1,160 revolutions per minute (RPM)

· The dynamometer shall have a continuous power of 200 horsepower (HP) from 1,160 to 5,000 RPM

· The dynamometer shall have a minimum power of 170 HP at 6,000 RPM

· The dynamometer shall have a shaft mounted digital encoder for speed measurement

· The dynamometer shall have a precision inline non-contact torque flange for torque measurement up to 1,475 PPF with 0.05% of full-scale accuracy

· The dynamometer shall have low inertia of no greater than 7 pounds per square foot (PSF), with high transient acceleration capability and inertia simulation.

· The dynamometer shall have a load accuracy within 0.2% of Full Scale between 10%-90% of range.

· The dynamometer shall have Resistance Temperature Detectors (RTDs) included for the bearings in order to measure temperature and be used for over temperature protection

· The dynamometer shall be capable of remote control from an adjoining room via Ethernet communications and have a hard-wired emergency stop.

· Electrical Specifications

· The dynamometer shall accept Input Voltage: 480 voltage alternating current (VAC) (3 phases)

· The dynamometer shall accept input frequency: 60 hertz (Hz)

· The dynamometer shall include up to 25 feet of phase-balanced VFD power cables to connect motor drive to dynamometer

· The dynamometer shall be configured to deter loss of alternating current (AC) mains and isolate within 100 milliseconds (MS).

2. Two-Input One-Output Combining Gearbox

· The gearbox shall have a decreasing gear ratio of 2:1 (Input:Output).

· The gearbox shall have an operational range of 0 to 12,000 RPM for inputs and 0 to 6,000 RPM respectively for the output.

· The gearbox shall have input shafts rated for 270 PPF continuous torque.

· The gearbox shall have center-to-center distance of input shafts approximately 30’’.

· The gearbox shall have output shaft rated for 540 PPF continuous torque.

· The gearbox shall have temperature measurement on the high speed bearings

· The gearbox shall have a separate oil lubrication system that can be monitored and controlled by the user

3. Constant-Velocity (CV) Shafts:

· CV shafts shall be used between the input Government Furnished Equipment (GFE) AC dynamometer, Unit Under Test (UUT), and the combining gearbox.

· The CV shafts shall be rated for 300 PPF up to 12,000 RPM

· Zero torsional bearing joints shall be used

· Maximum of 5 degrees of parallel offset operation shall be allowed

4. Heavy-Duty Shaft Guards:

· Heavy-Duty shaft guards shall be included where rotting shafts are present.

5. Heavy-duty sub-base weldment for dynamometer and gearbox mounting.

· The weldment shall have T-Slot mounting so that it can be mounted on an alignment baseplate.

· The weldment shall have mounting holes that will allow for bolting, connections and alignment of the aforementioned dynamometer, torque transducers, combining gearbox, shaft guards and sensors and sensor cables.

· The weldment shall be designed to have the minimum footprint possible.

6. Non-regenerative- Insulated Gate Bipolar Transistor (IGBT) controlled VFD

· The VFD shall be National Electrical Manufactures Association (NEMA) 12 Rated

· The VFD shall be wall mounted with maximum 17’’ Wide x 10’’ deep x 47’’ tall dimensions

· The VFD shall have Electromagnetic Interference/Radio Frequency Interference (EMC/RFI) filters included

· The VFD shall have a top-exit blower, with front faced filtered air entry.

· The VFD shall have Modbus/ Transmission Control Protocol (TCP) interface connections

· The VFD shall include a High Speed Motor Safety Input:Output (IO)

· The VFD shall be capable of set point ramp of 10%-90% torque/speed commands within approximately 3ms

· The VFD shall power a 200 HP Government Furnished dynamometer

7. Miscellaneous sensors:

· Type-K thermocouples shall be used to measure all necessary temperature for safety operation minimum quantity of six (6))

· Accelerometers shall be used to measure vibrations of gearbox, shafts and relevant equipment (minimum quantity of six (6))

· Flow meters shall be used to measure two (2) coolant and one (1) oil lubrication flows

· Voltage and current transducers shall be provided to measure power consumption of the UUT.

8. Government Furnished Equipment (GFE):

· Input 200 HP Air-cooled AC dynamometer

· UUT mounting tombstone weldment

· Regenerative dual-IGBT AC Foreign Voltage Detector (FVD)

· PowerNet Dynamometer control and Data Acquisition System for Real time Control

· Process chilled water at 40-60 oF and 40-80 pounds per square in gauge (psig) supply is available for cooling

· 120 VAC, 208 VAC, 277 VAC and 480 VAC electrical service is available.

9. Installation and Control

· The UUT mounting tombstone weldment (Item 8) shall be used and modified as needed to accommodate the use of the new equipment, combining gearbox (Item 2) and load absorbing dyno (Item 1).

· The contractor supplied non-regenerative VFD (Item 6) shall be used to supply power to the GFE AC dyno (Item 8)

· The GFE regenerative VFD shall be used to power the contractor supplied load absorbing dyno (Item 1).

· The GFE control system (Item 8) shall be modified to accept communication of the aforementioned contractor supplied equipment and sensors (Items 1 through 7) as well as be able to control the contractor supplied load absorbing dynamometer (Item 1).

· The contractor shall make all mechanical connections between the GFE and contractor supplied equipment.

· The Government shall make all electrical connections between the equipment and the facility.

AT – OPSEC REQUIREMENTS

The following AT – OPSEC requirements apply:

AT Level I Training. This standard language is for contractor employees with an area of performance within an Army controlled installation, facility, or area. All contractor employees, to include sub-contractor employees, requiring access to Army installations, facilities and controlled access areas shall complete AT Level I awareness training within 14 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or the contracting officer, if a COR is not assigned within 7 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website: http://jko.jten.mil.

Access and general protection/security policy and procedures. This standard language is for contractor employees with an area of performance within Army controlled installation, facility, or area. Contractor and all associated subcontractors employees shall provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshall Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204.9, Personal Identity Verification of Contractor Personnel) as directed by DoD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

iWATCH Training. This standard language is for contractor employees with an area of performance within an Army controlled installation, facility, or area. The contractor and all associated subcontractors shall brief all employees on the local iWATCH program (training standards provided by the requiring activity (ATO)). This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR. The training shall be completed within 14 calendar days of contract award and within 14 calendar days of new employees commencing performance with the results reported to the COR NLT 14 calendar days after contract award.

DISTRIBUTION STATEMENT A

Approved for public release; distribution is unlimited.

Contracting Officer:

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