SATPC0036110 Tab 07 SOW_Redacted.pdf

STATEMENT OF WORK

1. Objective/Requirements

This requirement is for the acquisition of an Isojet 2k Resin Injection System for NASA Langley Research Center (LaRC) for use in the Hi-Rate Composite Aircraft Manufacturing project.

2. Characteristics, Scope, and Specs

The manufacturer shall provide the following items:

LINE PRODUCT QTY.

1 IsoJet 2K Resin injection system DPE RTM Installation &

Training

2 Isojet 2k Resin Injection System DPE RTM variable ratio /variable flow

Global System Specifications

The system shall include all necessary components for safe operation of the system including resin pumps, vacuum pump, resin storage tanks, heating and cooling apparatus, flow meters, mixing head, and control system.

The system shall be mounted on a mobile platform with lockable wheels.

The system shall be a single in-line unit that does not require manual movement of the resin between stages (e.g., resin can be degassed, mixed, and injected without operator intervention).

The system shall be a meter-mix injection system designed for resin transfer molding

(RTM).

The system shall include tanks capable of degassing, agitation, and heating of each component of the resin prior to mixing and injection.

The system shall include heated lines between all components to ensure that the resin remains at a set temperature throughout the system.

The maximum operating temperature of the system shall be at least 130 °C (266 °F) unless otherwise noted.

The maximum injection pressure of the system shall be at least 10 bar (145 psi).

The system shall be designed to operate with either one-part or two-part resin systems.

The system shall allow for operation at flow rates of 5 mL/min to 400 mL/min and resin component mix ratios of 100:2 to 100:100. The system shall use two separate resin infusion pump systems to cover this range. Specifications for the two pump systems are

All resin tanks shall include a pneumatic agitation system with variable speed control, a temperature probe for measuring resin temperature, and a low resin level sensor.

A safety relief valve shall be included on all resin tanks to prevent over-pressure of the system.

The system shall include a drain catch to lower the humidity of the atmosphere (i.e., air) in the resin tanks.

The temperature of each resin tank shall be controllable to at least 130 °C (266 °F) with a resolution of at least 1 °C (1.8 °F).

The system shall include a scale under a resin tank for monitoring resin flow in the one-component configuration.

The system shall include a vacuum pump with connections to the resin tanks and the infusion mold.

The vacuum pump shall be capable of pumping at a rate of at least 16 m3/hour and achieving a vacuum pressure of at least 1 mbar (0.8 torr).

The system shall include a stainless-steel resin trap to protect the vacuum pump from resin or other volatile components.

A vacuum gauge reading from 0 to 30 inHg shall be included to measure vacuum pressure on the mold and the resin tanks.

The system shall include a controllable temperature mixing head to combine and mix the two resin components.

The maximum operating temperature of the mixing head shall be controllable to at least 130 °C (266 °F) with a resolution of at least 1 °C (1.8 °F).

The mixer shall be a disposable static mixer housed in a heater block.

The manufacturer shall include at least twenty (20) disposable static mixers.

An in-line pressure sensor shall be located downstream of the mixing head for monitoring and controlling the injection pressure with a resolution of at least 1 psi.

The system shall use two separate mixing heads for use with the low-flow and high-flow pump systems.

The system shall include a heated injection hose to transfer mixed resin from the static mixer to the mold.

The heated injection hose shall be at least 6.5 ft (2 m) long with an internal diameter of at least 0.55 in (14 mm) and allow for a disposable inner lining (e.g., copper or Teflon tubing) to be inserted into the injection hose prior to each infusion.

The temperature of the heated injection hose shall be controllable up to the maximum temperature of at least 130 °C (266 °F) with a resolution of at least 1 °C (1.8 °F).

The system shall include a control system and user interface for programming infusion runs with defined parameters and automatic operation of all components of the system.

The system shall be capable of controlling temperature set points and status of the pots, resin lines, mixing head, and metering pump, injection flow rate, injection pressure, mix ratio, vacuum pumps, valves, and mixing head.

The system shall allow the user to manually control/override set parameters during an infusion run.

The controller shall display system status and monitor for errors including resin pot life, low resin level, motor inverter failure, and resin line heater failure.

The control system and user interface shall consist of a dedicated Windows 10 PC and at

The control system shall be a standalone unit capable of operation without connection to the internet.

The control system shall be capable of recording and displaying data for at least six (6) thermocouple sensors and two (2) pressure sensors connected to the mold.

The control system shall be capable of transferring all recorded data (for both infusion system and mold) to a usb drive in a non-proprietary format readable by common office and laboratory computers equipped with standard software suites. Formats may include but are not limited to *.txt, *.csv, *.xlsx.

The system design submitted shall include site requirements to support the proper installation and operation of the equipment such as space requirements, floor load requirements for the equipment, utilities, and any other additional equipment, apparatus or services needed for the safe and proper use of the equipment.

The system shall use standard utility hookups for power (up to 240 V, 3-phase, 60 Hz, 15 amps) and pneumatics (<90 psi). All utility requirements shall be submitted to NASA Langley Research Center for approval prior to contract award.

Information Technology Acquisition Management (ITAM) and safety offices prior to contract award.

An operation manual as well as mechanical, pneumatic, and electrical systems drawings shall be included.

Installation and training on the system shall be provided by the manufacturer and take place at NASA Langley Research Center.

Pump System Specifications

The system shall include two separate resin infusion pump systems with both sharing a common control unit.

High-Flow Pump System Specifications

One pump system (high-flow system) shall be capable of mix ratios of 100:15 to 100:100 at flow rates of 40 mL/min to 400 mL/min.

The high-flow system shall consist of two gear pumps capable of high-precision volumetric metering with an accuracy no greater than 1% of set value.

The high-flow system gear pumps shall be driven by asynchronous electric motors with electronic speed regulation.

The high-flow system shall be capable of processing resins with viscosities up to 15000 cps.

The high-flow system shall include two resin tanks for the separate resin components with capacities of 20 liters (5.3 gallons) and 9 liters (2 gallons).

The high-flow system gear pumps shall be equipped with pressure sensors with a resolution of at least 1 psi to monitor the inline pressure and automatically shut down the pumps in the event of an over-pressurization event.

Flow meters with a resolution of at least 1 mL/min shall be installed on the high-flow system pump outlets to allow for data collection and control of the mix ratio of the two components.

An enclosure shall surround the high-flow system pumps and be mounted on the moveable frame. A door shall be installed on the enclosure for easy access to the pumps.

Low-Flow Pump System Specifications

The low-flow pump system shall be capable of mix ratios of 100:2 to 100:100 and flow rates of 5 mL/min to 100 mL/min.

The low-flow system shall use progressive cavity pumps.

The low-flow system shall be capable of processing resins with viscosities up to 50000 cps.

The low-flow system shall include two addition resin tanks for using lower volumes of the separate resin components and each shall have a capacity of 1 liter (0.26 gallons).

The low-flow system shall operate with a maximum resin temperature of at least 50 °C (122 °F).

3. Place of Performance

NASA Langley Research Center, Hampton, VA 23681

4. Period of Performance

22-24 weeks + 1 month for sea delivery to NASA site

5. Payments transfer, Installation & training service will be due/invoiced at completion.