SOW_GTWiringCalibration-CS Calibration_16Mar2023.pdf

US Consumer Product Safety Commission - National Product Testing and Evaluation Center 5 Research Place, Rockville, MD 20850

March 16, 2023

Statement of Work/Requirements for the Grand Tower & Crib Shaker:

Wiring, Commissioning and Calibration

I. Background:

The U.S. Consumer Product Safety Commission (CPSC) has a need for a large lifecycle testing device (the Grand Tower or GT or CYCLIC TESTER) with multiple electrical components to be wired and calibrated. The Crib Shaker (CS or SMALL CYCLIC TESTER), built into the GT, also needs maintenance and calibration.

The GT will be used to test various components such as switches, doors, handles, levers, and other consumer products in order to examine wear and other life-related issues. The specific requirements listed below are the minimum requirements for the Grand Tower wiring and calibration.

CPSC also has a need for the CS, intended for performing cyclic testing cribs, as well as various components such as chairs, furniture structures, and other consumer products in order to examine wear and other life-related issues. Periodic calibration (annual) will be necessary for proper functioning of the equipment.

The specific requirements listed below are the minimum requirements for the Crib Shaker calibration.

In its current state, the GT is not functional. Various error messages are triggered when attempting to operate the GT. Most of the physical hardware is present.

The hardware drives, motors, controllers and sensors have been installed previously on the GT test system. A survey / inspection will need to be completed for the contractor to determine what remains to be installed and wired on the GT.

The Keyence SZ-01 and SZ-V Laser Safety Scanners are existing on the GT / CS (CYCLIC TESTERS) test system and will need to be removed along with the associated wiring, safety relays, safety relay contact expansions, etc. All hardware removed from any and all installations shall remain in possession of the U.S. Government. The system-level software controller for the GT currently installed on the control computer is the MTS Multi-Purpose Test Suite Elite (mpe).

The CS is functional, but position, velocity, and force values on the control computer’s data acquisition graph and virtual gauges appear to be inaccurate.

This system will also need a survey / inspection for maintenance and calibration services.

II. Requirements:

A.) Contractor’s certifications and experience

a) Powerful magnets can damage equipment and injure personnel. The contractor must have the following certifications by 1 June 2023.

i. Baldor’s Linear Motor Safety Briefing training class.

b) The contractor must have at least 6 years of experience working with

Baldor Linear Motor Iron Core (LMIC) motors and integrating those motors into equipment.

c) The contractor must have at least 20 years of experience working with the

Baldor motor drives or ABB motor drives and integrating the components into test equipment.

d) The contractor must have at least 2 years of experience working with the MTS FlexTest series of servo-hydraulic controllers and integrating the controller into test equipment.

i. If the contractor does not have 2 years of experience working with the FlexTest 60 series of controllers, then the contractor must sub- contract the installation, set-up, and integration of the FlexTest directly to MTS.

e) The lead electrical/Mechanical engineer on the project must have at least 20 years of experience in machine controls design.

f) The contractor must provide documentation for all of the above requirements.

B.) Standards and Regulations

a) The [CYCLIC TESTER] was designed to meet the guidelines set forth in

NFPA 70, National Electrical Code, Edition 2014, and the National Electrical Safety Code (NESC), Edition 2014.

New work on the [CYCLIC TESTER] must meet the latest version of the

NESC. The current standard is NESC 2020 for work on the [CYCLIC TESTER], which is to finish the wiring to get the unit completely functional. The [CYCLIC TESTER] work shall be to 2020 standards. The affected areas per the NESC 2020 standard include but are not limited to:

- Ground Fault Circuit Interrupter (GFCI) protection.

- Termination torque procedures.

- Disconnect identification.

- Arc Flash protection

C.) [CYCLIC TESTER] Components (Existing) General Hardware (the following features must be part of the final functioning [CYCLIC TESTER] design)

a) Enclosure

i. The system shall include an electrical enclosure to protect the equipment and employees. The enclosure shall be rated to at least

IP4X.

ii. All components including the enclosure, and within the enclosure, shall be UL listed for the type of service intended.

iii. Each signal entering or exiting the enclosure shall be provided with reasonable protection against damage at the pass through.

iv. The enclosure shall have an external Power Off switch to disconnect power to the enclosure.

v. The enclosure shall include all components recommended by the drive and motor manufacturer, which may include:

1. Line filters.

2. Circuit breakers.

3. Power supplies.

4. Junction blocks.

5. Exhaust fan.

6. Power switch.

7. Relays.

8. PLCs or auxiliary industrial microcontroller.

vi. All penetrations through the enclosure shall use strain-relief connectors.

b) Cable Trays

i. The cable trays shall be compatible with Cabofil model CF105.

D.) [CYCLIC TESTER] Components (Existing) Safety (the following features must be part of the final functioning [CYCLIC TESTER] design)

a) The system shall have a warning light on a 20 ft cable that can be mounted to the test cell’s metal structural beams for each actuator identifying each actuator’s state. The function of the Signal Light shall be written into each individual application program. The following signals and requirements shall be part of the system design.

i. Solid Green: test complete.

ii. Blinking Green: test in process.

iii. Solid Red: user input required.

iv. Blinking Red: emergency stop or system fault.

v. The [CYCLIC TESTER] and [SMALL CYCLIC TESTER] control system shall have push button emergency stop switches (E-Stop switches) located a minimum of 6 ft from the [CYCLIC TESTER]/[SMALL CYCLIC TESTER] actuators. A secondary action shall be required for restart (system will not restart by the sole action of clearing the E-Stop switch).

vi. The [CYCLIC TESTER] and [SMALL CYCLIC TESTER] control systems shall have integrated safety limit switches or stops.

E.) CPSC provided Utilities

a) Electrical

i. CPSC can provide 480V 3ph 4 wire 60A.

ii. The electrical power shall be shared between the lifting system

(Contract # CPSC-S-15-0049) and the Linear Motor and Controls (Order # HHSP233201300184A).

iii. If the machine requires different electrical power, the contractor shall request written approval from the Contracting Officer’s Representative (COR).

b) Pneumatic

i. CPSC can supply 80 psi at less than 0.5 SCFM.

ii. If the machine requires different pneumatic power, the contractor shall request written approval from the COR.

F.) Service

a) [CYCLIC TESTER] Set-up

i. The contractor shall perform the wiring required for the [Cyclic Tester] to achieve a fully functional state such that the verification tests and calibrations below can be demonstrated and completed (see Sections G & H).

ii. The contractor shall provide on-site set-up and functional verification using all equipment associated with these systems, including equipment procured and installed under this contract and the equipment purchased through the following contracts.

1. MTS FlexTest 60 and Multi-purpose Test Suite Elite (mpe) software

a. Contract # CPSC-S-12-0055

2. Linear Motor

a. Order # HHSP233201300184A

3. Linear Motor Fixture

a. Order # HHSP233201400076A

4. Lifting System

a. Contract # CPSC-S-15-0049

b) Technical Service

i. The contractor’s technical service agents shall be available via phone between 10AM – 3PM EST Monday – Friday. The technical service agents shall be able to troubleshoot hardware and software problems.

All customer service questions answered via the phone shall be at no-charge.

ii. [Contractor] shall provide a one year warranty on all new parts and labor provided under this contract. Not on already existing parts. Any existing parts that is determined to be nonfunctional during development shall be purchased by CPSC separately from this agreement and shall be installed by the contractor.

iii. The quote submitted for this SOW shall provide four option years for calibration and maintenance services, each as a separate line item.

G.) Calibration The term, measurement, in the calibration requirements below refers to values read with the control computer’s scope plotting function using the MTS software

a. [CYCLIC TESTER] Calibration

i. Calibrate to a total force of 500 lbs.

ii. Calibrate displacement measurements to within 0.125 in. (±0.0625 in.).

iii. Calibrate force measurements to within 0.25 lbf (±0.125 lbf).

b. [SMALL CYCLIC TESTER] Calibration

i. Calibrate to a total force of 38 lbs.

ii. Calibrate displacement measurements to within 0.125 in. (±0.0625 in.).

iii. Calibrate force measurements to within 0.25 lbf (±0.125 lbf).

c. All calibration services shall be recorded in a report and submitted to CPSC for review, approval, and record.

H.) Commissioning and Verification Testing

All external weights and fixturing used to test the system shall be provided by CPSC. The contractor shall provide a report for all testing. Samples used for the testing procedures in this section are to-be-determined between the contractor and CPSC. The test is designed to evaluate the performance of the systems. The system passes if it performs the test, the results are displayed and recorded accurately by the HMI, and the test systems’ structural, power and control components maintain their integrity. The following tests will be performed in addition to any other commissioning and verification tests deemed necessary by CPSC and the contractor, to evaluate performance.

a) Test: Motor Brake.

i) Rotate the motor so that is downward-facing.

ii) Attach a 1100+ lbm static mass to the end of the motor.

iii) Cut power to the system.

iv) The motor shall not extend more than 2.5 inches before the pneumatic clamps stop the motor.

b) Test: Y-axis Rotational Brake.

i) Rotate the motor so that it is pointed horizontally.

ii) Attach a static mass to the motor back plate to create a torque of at least

2000 in-lbf.

iii) Cut power to the system.

iv) The motor back plate shall not rotate more than 2 degrees.

c) Test: Z-axis Vertical Brake.

i) Attach a 500 lbm static mass to the fixture.

ii) Cut power to the system.

iii) The fixture shall not drop more than 5 inches.

d) Test: Cyclic Testing of Pneumatic Brakes.

i) Place 25 lbm at the end of the motor.

ii) Confirm that all pneumatic brakes are actively braking.

iii) Command the motor to conduct a +/- 6 inch saw-tooth waveform at maximum speed and acceleration.

iv) After 1000 cycles, there shall be no observable movement in the Y-axis rotation brake or the Z-axis rail brake.

e) Test: Motor Soft Stop

i) Plate the motor in a horizontal orientation.

ii) Command the motor to move beyond the soft stop locations in both extension and retraction.

iii) The switches shall stop the motor from extending or retracting past the switches.

f) Test: Motor Hard Stop

i) Place the motor in a horizontal orientation.

ii) Disable the soft stop switches.

iii) Extend the motor at a rate of 4 inches per minute.

iv) The motor must automatically shut-off after contacting the hard stop and not cause any damage to the fixture or the motor itself.

g) Test: Rotational Hard Stop

i) The end-use operator must be capable of rotating the lever to rotate the motor back plate.

ii) This criterion is met if no excessive force is needed to operate the lever and no part of the system is damaged throughout the full rotational range.

h) Test: Cable Length and Routing.

i) Move the fixture through all degrees of freedom.

ii) In any orientation, the pneumatic and electrical cables shall not inhibit the movement.

i) [CYCLIC TESTER] Static Test #1

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

** (Transducer Electronic Data Sheet ~ IEEE1451.4) **

ii. Apply tensile force on the sample at a rate of 5 lbf per minute.

iii. End the test when the load exceeds 25 lbf.

iv. The test is successful if the load is accurately applied, measured and recorded with no damage to the [CYCLIC TESTER] test system. No permanent damage or changes should be present.

j) [CYCLIC TESTER] Static Test #2

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

ii. Apply a tensile force on the sample at a rate of 5 lbf per minute.

iii. The test should shut down when the force achieves 900 lbs.

k) [CYCLIC TESTER] Dynamic Test #1

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

ii. Attach a 25 lbm drop mass to the actuator using nylon rope. The actuator shall be mounted in a vertically downward orientation.

iii. Accelerate the actuator downward. Wait 2 seconds.

iv. Quasi-statically retract the actuator to the initial position.

v. Repeat a total of 20 times.

vi. Using the load cell mounted in-line with the actuator, the test should result in the drop mass being in free fall within 0.125 inch of the starting position in all cycles.

l) [CYCLIC TESTER] Dynamic Test #2

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

ii. Attach a 25 lbm drop mass to the actuator using nylon rope. The actuator shall be mounted in a vertically downward orientation.

iii. Quasi-statically lower the drop mass to the sample. Identify the actuator displacement value where the full drop mass weight is hanging on the load cell attached to the actuator.

iv. Quasi-statically, move the actuator up 1 inch from the location identified in the previous step.

v. Accelerate the actuator downward. Wait 2 seconds.

vi. Quasi-statically retract the actuator. Identify the actuator displacement value where the full drop mass weight is hanging on the load cell attached to the actuator.

vii. Quasi-statically, move the actuator up 1 inch from the location identified in the previous step.

viii. Repeat a total of 20 times.

ix. Using the load cell mounted in-line with the actuator, confirm that the drop mass is in free fall within 0.125 inch of the starting position in all cycles.

x. Using the load cell and the actuator displacement, confirm that the drop height is 1 inch above the sample, even if the sample compresses over time.

xi. When the test is complete, the system shall email AHowie@CPSC.gov and include all test and system data. The email’s subject shall be “Testing automatic email functionality.” The text of the email shall be “Dynamic Test #2 complete.” If a system fault or E-Stop condition were to occur, the text of the email shall be “Dynamic Test #2 Fault”. The e-mail address(es), subject line and message that is emailed after any of the events above shall be programmed such that these inputs can be edited by the user. The control computer shall be connected to the internet by CPSC to send emails.

mailto:AHowie@CPSC.gov

m) [SMALL CYCLIC TESTER] Static Test #1

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

** (Transducer Electronic Data Sheet ~ IEEE1451.4) **

ii. Apply tensile force on the sample at a rate of 5 lbf per minute.

iii. Complete the test when the load exceeds 25 lbf.

iv. The test is successful if the load is accurately applied, measured and recorded with no damage to the [CYCLIC TESTER] test system. No permanent damage or changes should be present.

n) [SMALL CYCLIC TESTER] Static Test #2

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

ii. Apply tensile force on the sample at a rate of 5 lbf per minute.

iii. The test should shut down when the force achieves 38 lbs

o) [SMALL CYCLIC TESTER] Dynamic Test #1

i. Connect a TEDS-compliant load cell to the actuator. Calibrate the load cell using the automated shunt resistor calibration method.

ii. The actuator shall be mounted in a horizontally-level orientation.

iii. Attach the load cell to a clamp on a test structure.

iv. Accelerate the actuator cyclically at a frequency of 0.1 [Hz], such that it applies a cyclic load of no more than ±20 lbf with an amplitude of ± 2 in. on the test structure.

v. Complete the test when the test structure fractures or 20 load cycles have been completed.

vi. The test is successful if the system is capable of nominally achieving (± 5 percent) the specified amplitude, load, frequency within the load cycles specified.

I.) Deliverables and Performance Timeline

a. The contract shall be completed within 1 year of the award date.

Contract shall be extended at no additional cost to CPSC or Eagle, if waiting time is incurred from lack of access to the facility, extended lead times for new equipment, or if Eagle is unable to operate the cyclical testers because of events outside of Eagles control.

b. Deliverables

i. Fully functioning [Cyclic Tester] capable of:

1. Satisfactorily completing all verification testing outlined in Section H.

a. The system shall be fully functional and be capable of meeting the requirements in Section H.

ii. Full performance and documentation of the Verification Tests in section H.

iii. Full report on Commissioning and Calibration.

1. Performance of calibration per Section G above.

2. Full testing per Section H above.

3. Full documentation of commissioning.

iv. A user manual (digital and hardcopy) containing the following information shall be provided:

1. A manual that pertains to the system provided and the overall function of the system.

2. Maintenance information.

3. A complete parts list.

4. Specification / cut sheets for all new parts.

5. All as-built electrical drawings and wiring diagrams created or used.

6. A pinout diagram for all penetrations through the enclosure.

7. A hard copy of all programming performed on controllers, computers, PLCs, etc. shall be provided.

J.) Milestone/ Payment Terms

a. 10% of contract value upon delivery of approved planning documents with timeline for execution

b. 20% Due on completion of Section G

c. 20% Due on completion of Section B, C and D

d. 20% Due on completion of Section H

e. 30% Due on completion of Section I