SPECIFICATIONS - VEA CT System 4-30-25.pdf

Source Selection Information -- See FAR 2.101 and 3.104 1

Defense Logistics Agency

DLA Installation Operations

DM-FRIF

SPECIFICATIONS

DLA Aviation Richmond, Sourcing and Reliability Program Branch (VEA) Bldg. 47, Purchase and Install One (1) New Computed Tomography System

Source Selection Information -- See FAR 2.101 and 3.104 2

Technical Requirements:

This procurement is for a turn-key, state-of-the-art, 7-axis, digital radiography computed tomography system. The system must be able to scan parts up to a 32” diameter and 48” in length. The system must be fully shielded and interlocked cabinet-style unit. It must comply with all applicable industry regulations. The system must include a flat panel detector, 225Kv Microfocus Tube,450 HP Tube, DR Image processing acquisition workstation and software, and a separate CT reconstruction workstation including software and meet Technical Requirements listed below.

Technical Requirements

System Capabilities

· Advanced 2D X-ray inspection

· 2D CT Slice reconstruction

· CT volume reconstruction for 3D inspection

· 3D internal and external surface scanning

· Measurement and Analysis tools

System Specifics

X-ray tube: The x-ray tube shall have the following characteristics:

Microfocus 225kV Directional

· Tube Voltage …25 - 225kV

· mA Range …0 -3 mA

· Power …320 W max

· Focal Spot Size < 6 microns

· Detail Recognition …< 2 microns

· 10 Meter High Tension Cable

· Closed Loop Water Cooler X-ray Control Software

· Windows based

· Automatic tube warm-up

· Automatic filament current adjustment

· Automatic focusing

· Automatic target loading control

· Intensity control

· Spare parts and service kit

225 Microfocus Automated/Motorized Filter Wheel:

• Integration with DR motion programs

Source Selection Information -- See FAR 2.101 and 3.104 3

• Selection of several different thicknesses of copper

• Tungsten beam blocker

• Open slot for use without filter

• Fast technique optimization

450Kv Mesofocus Xray Source

• 450/11 metal ceramic tube head

• EN 12543 Spec 0.4mm and 1.0mm dual focal spots

• Continuous rating: 700 watts/1.5mA; 1500 watts/3.3mA

• 5mm Be window

• Target angle: 11 degrees

• Radiation coverage: 30 degrees x 40 degrees

• CF-450 high stability generators, 1800 watt

• Digital controller with enclosure features

• 6 operating modes, which are Warm Up, Radiographic, Fluoroscopic, Auto Watt, and Remote Control via RS232. Up 600 stored techniques.

• I/O power distribution panel

• 2-10 meter high-tension cable

• Oil to air cooler with flow and temperature interlocks

• All associated cables, cooling lines and documentation

450HP X-ray Tube Shutter

• Four leaf, two axis tube shutter shielded for 450kV

• Independent axis control

• Laser alignment system

Spare Pack of 225kV Filaments Spare Pack of 225kV Filaments

Spare 225kV Target Spare 225kV Target

X- ray detector: The x-ray detector shall have the following characteristics:

4343N DRZ +

• 17” x 17” (432mm x 432mm) active area

• DRZ+ (Gadox) Scintillator

• 150 micron pixel pitch

Source Selection Information -- See FAR 2.101 and 3.104 4

• 2880x2880 pixel matrix

• 16 bit A/D Conversion

• 15 fps (1x1); 30fps (2x2 pixel binning)

• Premium CT Grade

• Tungsten shielded to 450kV (increased lifetime)

• Power & Ethernet cables

Manipulator: The manipulator shall have the following characteristics:

Movement of the inspection object is limited to x, z, tilt and rotation, along with detector and tube vertical movement.

· All drives are motorized with variable speed joystick operation.

· Tethered desktop control console

· Detector Manipulator:

o Focal Distance: 0” to 48” (0cm to 122cm) o Detector and Tube Vertical Axis – 48” (122cm)

· Part Manipulator:

o X Axis / front to back translation: 33” (84cm) o Z Axis / focal distance tube to detector translation: 48” (122cm) o Tilt: +20 /- 20 Degrees CT precision nickel plated 9” (22cm) rotational stage - 360 Degrees Continuous. Resolution

0.001 degree

· 500lb (227kg) static capacity (not including tilt)

· Integrated electronics.

· Heavy duty welded and precision machined frame construction

· Precision linear bearing rail

*Exact measurements may vary slightly at time or order based on x-ray source, detector, optional component selection, or revision.

Cabinet – Radiation Enclosure 450kV

· Radiation shielding to energies of 450kV constant potential.

· Approximate dimensions: 80" deep, 98” tall, 115" wide (2032mm deep, 2489mm tall, 2921mm wide)

· Steel/lead/steel construction.

· Cable access port with cover.

· Large motorized sliding access door.

· Primary and secondary X-ray safety interlocks.

· Interior lighting.

· X-ray on warning light.

Source Selection Information -- See FAR 2.101 and 3.104 5

· Designed to meet all state and federal X-ray safety regulations.

Motion Control Module The Motion Control Module provides an operator friendly teach and learn interface to create complex motion control programs easily and quickly. Includes additional 31" (787mm) 4k monitor.

4 Camera Color Surveillance System Internal Camera surveillance system w/split screen monitor and 4 cameras.

Computer hardware and Software:

The system shall include a computer(s) workstation to operate the system. The workstations shall include:

DR Workstation (Minimum Requirements)

• Windows® 11 Operating System

• Ten-Core Intel® Xeon® Processor

• 48 GB RAM

• 512 GB Operating System Drive

• 4TB of Data Storage in RAID 0 Configuration

• DVD+/-RW Drive

• 10/100/1000 Network Interface

• NVidia High Performance Display Adaptor

• 31.5” (800mm) 4K Color Display

• Wired Keyboard and Mouse

• SSD Data Drive

DR software High performance image analysis system with a comprehensive set of image analysis tools.

Windows® based (Compatible with Windows 7 or higher)

• Non-proprietary image storage format

• DICONDE compliant

• Tools to help ensure ASTM compliance

• High performance image processing and measurement functions utilizing GPU technology

• Automatic parallelization for systems with multiple CPU’s and GPU’s

• Live Imaging up to 30 frames per second

• Live Averaging, Live Histogram, Live line Profile, Live Rotation between portrait and landscape modes

Source Selection Information -- See FAR 2.101 and 3.104 6

• Live Measurements with up to 1-pixel resolution

• Live image gain/offset calibration and defective pixel correction

• Automatic creation of Technique sheet

• Capture video into AVI files

• Supports digital flat panel detectors, LDA’s and digital/analog cameras at 8, 10, 12 and 16 bits

• Read and store images in TIFF 32 bit / 16 bit / 8 bit, BMP, JPEG, RAW, DCM

• Acquisition of images on supported systems

• Cropping support for reduced file size and versatility

• Seamless integration with CT software

DR CT Acquisition Module The CT acquisition module provides automated CT acquisition capabilities for:

• Capable of CT acquisition up to 10,000 angle steps

• Automatic creation of Technique sheet

• Monitors x-ray performance and will pause the CT scan if x-ray interruption is detected

• Acquisition of Spiral CT scans

• Ring Reduction acquisition capabilities

Fast CT Acquisition Module Module allows continuous fast CT acquisition of projections for fast CT scans from 5 seconds to minutes for thousands of projections.

Reconstruction Workstation (Minimum)

• Windows® Operating System

• Dual 12-Core Processors (Total 24 Cores)

• 1 TB RAM

• 1 TB SSD Operating System Drive

• 24 TB Hard Drive with high speed Raid 5 capabilities

• 4 NVidia High Performance Display Adapters for Display and Reconstruction

• 15,360 total processing cores

• 96 GB of GPU Memory

• 3D Rendering capabilities

• 31.5” 4K Color Display

• Wired Keyboard and Mouse

CT Computed Tomography Software CT software shall include:

Source Selection Information -- See FAR 2.101 and 3.104 7

⋅ CT calibration, Cone-Beam reconstruction, 3D real time visualization and analysis tools in the same interface.

⋅ The software shall not limit the size of the reconstruction ⋅ The software shall be capable of the following:

o Combining 2 or more datasets taken at different current settings o Significantly improving CT quality of widely varying densities.

o Increasing the dynamic range of the CT dataset.

o Reducing noise and photon starvation in the CT reconstruction o The software shall be able to perform local CT reconstructions of a small area of interest inside a larger object.

Simplified processing - The software shall include a simplified, user-friendly mode that lets the user quickly navigate through the full CT scanning process, from the creation of the project to the final results. The simplified interface shall include features to guide the user through the calibration and reconstruction process.

Automatic Calibration - This tool has been developed to optimize cone-beam CT reconstruction process and to simplify CT and μCT equipment.

· Cone Beam Reconstruction –Reconstruction performed on GPU hardware.

· 3D Volume Rendering –

• Real time volume rendering

• Export slices at any angle

• Create movie animations

• Perform localized reconstruction.

• Ring Reduction - Uses a combination of hardware and software to virtually eliminate ring artifacts caused by nonuniform pixel responses. *

· 3D Surface Rendering - Surface extraction to CAD compatible format:

• Export to STL (Stereolithography), cloud points, OBJ, DXF, WRL, PLY.

Visualization in wireframe mode. Map textures with reflection.

• Export an executable viewer module with a dataset to allow others to view, slice, rotate, window and manipulate the dataset on a traditional laptop or desktop computer. Ideally, the viewer module is a fully capable and equivalent to the post-processing capabilities of the CT Workstation.

High Accuracy Geometry Tools High accuracy geometry tools for use with metrology applications

· Serialized small, medium & large tools

· Certificate of Conformance

· High accuracy CMM inspection

Source Selection Information -- See FAR 2.101 and 3.104 8

· Precision engineered mounting fixtures

· Heavy duty carrying case

⋅ Spiral Acquisition ⋅ The system shall be capable of performing automated spiral acquisition with a digital flat- panel detector for the scanning of elongated objects that traditionally cannot fit into a single exposure. The scan does not require volume stitching and the object length is only limited by the system scanning area. This reduces or eliminates the cone angle artifacts caused by flat, planar features common in non-spiral CT techniques.

⋅ Image stitching ⋅ Larger parts may require multiple scans to completely scan the part when it is larger than the detector panel. The software shall be able to stitch multiple images into one seamless image of the part or assembly.

⋅ Sub-pixel resolution The designed motion of the manipulator and the software shall be capable of displaying and analyzing scan data utilizing sub-pixel analysis routines that is typically double of what the detector alone is capable of achieving.

⋅ Time and motion analysis (4D Computed Tomography Module) The system shall be capable of creating and analyzing moving or changing parts as dynamic, time-based data sets. The system shall be able to acquire time-based data in either a continuous or stepped mode. Continuous scan mode refers to repeatedly scanning the part while motion or change is occurring at a speed that is slow relative to the time it takes to complete a full scan. Stepped scanning refers to re-scanning the part multiple times after the part is removed from the CT unit, subjected to some condition that will cause motion or change in the part. The system shall be able to generate time-sequenced images (videos) showing the motion or change in the part resulting from the continuous or stepped scans.

Focal Spot Measurement & Correction for Microfocus X-Ray Source:

• Hardware (Microfocus Automated/Motorized Filter Wheel): and Software for providing an automated method of measuring the focal spot of MicroFocusX-ray tubes in compliance with ASTM E2903 and EN12543-5. The Digital Radiography Acquisition Software must include the following capabilities.

• A method for Automatically measuring focal spot size in a minimum of two directions in Realtime.

Source Selection Information -- See FAR 2.101 and 3.104 9

• A method for automatically calculating and displaying the geometric unsharpness and number of pixels of unsharpness based on the newly measured focal spot, the system identified geometry, and the pixel pitch for a given setup.

• A method of providing suggestive, and adjustable unsharpness thresholds based on the measured focal spot to assure image quality and speed requirements are both optimized for a given application.

• A method of measuring and recording focal spot size into ongoing Electronic Process Control Records.

• A method of automatically updating and storing the measured focal spot to an electronically stored technique sheet.

• A method of using the measured focal spot and calculated geometric unsharpness (Ug) to calculate the maximum unsharpness (Uim) of a given setup per ASTM E2698 and provide indication of whether the focal spot size is sufficient to meet the maximum unsharpness requirements of a given technique

X- ray System CT Simulation and Offline Programming SIMULATION Software Simulation Software 1. Windows based software that simulates the operation of the CT system which shall include the following items:

• Some of the key features include:

• Windows® based (Compatible with Windows 10 or higher)

• Offline Technique Development o Import/Export configurations directly from an NSI system o Optimize system settings & positions offline o Import CAD models of parts/fixtures/etc o Configure part alloy with alloy mixing o Simulated machine environment o Visualize system crash protection o Ability to define custom materials based on a pre-populated repository and the ability to generate custom materials based on custom inputs g.

Ability to export CAD model files of optimized part orientation for use in creation of support structure o Software shall have operation and functions that can be adjusted in the simulation software to mirror those on actual system to take the parameters used and match them on the actual system to provide a scan as consistent as possible with the model outputs

Source Selection Information -- See FAR 2.101 and 3.104 10 o Ability to define custom materials based on a pre-populated repository and the ability to generate custom materials based on custom inputs g.

Ability to export CAD model files of optimized part orientation for use in creation of support structure

• Offline Motion Programming o Program motion routines without tying up a system o Controls look/feel/act the same as the real system

• Imaging Simulation o Simulate different results based on changing settings o Change beam hardening parameters o Realistic polychromatic beam results

• Training o Remotely learn system operation o Train new employees o Reduce system damage by training in a virtual environment

⋅ Programmable CNC Motion Control ⋅ The system shall utilize programmable CNC motion control.

⋅ Detector Lateral Shift o Detector Lateral Shift of at least 60”

⋅ Continuous CT scan mode included for faster CT scans in seconds or minutes.

⋅ Local CT reconstruction capabilities (reconstruct just a small area of interest inside a larger object).

⋅ No limitation of reconstruction size – Successful tests have been made with 10000x10000x10000 voxels reconstruction

Detector Qualification Package The Process Control Software is an interface that allows the user to routinely monitor digital detectors.

Specifically, this module allows for the qualification of pixel mapping and the verification of the detector quality, spatial resolution, and contrast sensitivity. Also included in this module is an SMPTE test pattern used for checking the quality of the display monitor.

To include the following:

· Pixel Mapping Qualification

· Detector Quality Check

· Spatial Resolution

Source Selection Information -- See FAR 2.101 and 3.104 11

· Contrast Sensitivity Check

· SMPTE Display Test Pattern

Also includes:

· EN-462 D13 Duplex Wire Gauge

· Photo Light Meter

Secondary Hard Drive Set - DR & CT Hot swappable hard drives in both the DR and CT workstations to quickly and easily separate sensitive and non-sensitive scan data. A protective storage/carrying case.

Powered MicroPositioner

• 2 Axis

• 85mm travel (each axis)

• Jog movements controlled through DR

• Precision centering of samples

225Kv Power Microfocus Filter Wheel Some features of the MicroFocus Filter Wheel:

• Integration with DR motion programs

• Selection of several different thicknesses of copper

• Tungsten beam blocker

• Open slot for use without filter

• Fast technique optimization

Additional Components

Copper Filter Kit Set of copper filters for use with microfocus tubes

· Selection of 0.005", 0.010", 0.020", 0.040", 0.060", 0.080" thick filters

High Energy Copper Filter Kit Set of copper filters for use with minifocus tubes

· Selection of 0.093", 0.250", 0.375" thick filters

Turn Table Riser

Maintenance 12 Month Hardware Warranty and one preventative maintenance visits

Local support time zone support by main manufacturing facility located in the USA

Source Selection Information -- See FAR 2.101 and 3.104 12

All forementioned Software must be developed and Sold by the Mfg. of the Provided X- Ray System.

First year DR & CT Software Maintenance/Updates

Technical Manual: The system shall include a user’s guide technical manual that covers system operation, routine maintenance and basic troubleshooting information. The standard commercial user/technical manual(s) for the hardware and software should meet this requirement.

Demonstration of Salient Characteristics: Failure to provide the following samples and successful demonstrations will prevent one from becoming technically acceptable.

Provide a sample part that is up to 25” in length and under 6” in width, that the seller must demonstrate the ability to use one continuous helical motion in which the sample is CT scanned using a single automated spiral acquisition. This shall not be separate CT scans stitched together. This will demonstrate the spiral acquisition capabilities.

Provide a sample part that is up to 20” in length and under 20” in width, which will demonstrate the ability to seamlessly stitch together the 2D images from multiple projection angles and reconstruct a single CT volume of the entire part. This will demonstrate the image stitching capabilities.

Provide a sample which demonstrates the ability to automatically move the detector a sub pixel distance both horizontally and vertically, capturing 4 images within each pixel for each CT projection. The system shall be capable of performing sub-pixel resolutions scans in both step- scan and continuous-scan modes. The result shall produce a CT voxel size equal to half that of a standard cone beam CT scan. This will demonstrate the sub-pixel resolution capabilities.

X-Ray Simulation Software:

Provide x ray simulation software that is representative of the actual system configuration including the Manipulator, x ray tube, detector, and scan envelope geometry. The simulation software must provide a polychromatic x ray beam representing the kV and current range of the actual system. It shall also provide for controls of the detector and motion system and complete image acquisition parameters for both 2D DR imaging a CT scanning. The software shall be capable of inserting a representative part file into the simulator for imaging and providing acquisition of full motion programs. The software shall provide for material alloy selection of the product sample as well as allow for inserting assemblies and fixtures of

Source Selection Information -- See FAR 2.101 and 3.104 13 varying materials and x ray beam filters.

The simulation software controls shall be representative of the actual system software controls. The sample must demonstrate within the simulation software, the creation of a CT data acquisition and a reconstruction data set of a representative part as well as a multi position DR motion control program which records all imaging technique and geometry parameters to a file. This simulation generation demonstration shall be performed on a different system than the actual system. This sample must also demonstrate the placement of the simulation file onto the actual x ray system along with the insertion of the actual part into the actual system to generate DR images from the simulation recorded motion control program and a CT Data set of the actual part. This will demonstrate the x ray system CT simulation and offline programming capabilities.

Delivery, Installation, and Training

System Delivery Delivery location will be Building 47, 6090 Strathmore Road, Richmond, VA 23237 with proper truck and material handling equipment to offload and transport system to staging area.

Shipping/Freight/Crating included, no touch freight for customer during delivery.

System Installation Pre-Install Site Visit will be conducted and coordinated with PM/COR/Installation Management Richmond Representatives to coordinate installation, delivery dates, delivery methods, and identify any issues with install, delivery or any changes.

Installation will be performed with factory trained personnel.

Installation will be in Room 150 (Metrology Lab) and to be placed in the corner of the room (which corner TBD). 12” to 18” will need to be between the cabinet and walls to allow for radiation checks.

Disposal of all materials once system is assembled and clean-up of entire area. Customer will provide dumpsters for disposal.

DR / CT System Training:

7 Days On-Site DR/CT system operation training. The offeror shall provide 7 Days On-Site training for system operators covering: digital radiography, computed tomography, and operation/maintenance/safety of the delivered CT system operation. This training shall be provided as part of the system delivery and acceptance.

2 Seats to Digital Radiography & Intro to CT Training (40 hour course) 40-hour ASTM/ASNT Certified DR/CT training course, held at vendors site.

This course follows the recommended curriculum of FWG-IDR, MAI, ASTM and ASME in a format for compliance with NAS 410 Qualification/Certification program.

Source Selection Information -- See FAR 2.101 and 3.104 14

1 Seat to Advanced CT Training The Advanced CT Training is a 40-hour class at vendors’ site that dives into the advanced capabilities of the Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction, The class shall focus on the advanced capabilities of the delivered system and Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction

Combatting Trafficking in Persons (CTIP) The Contracting Officer Representative (COR) will monitor the vendor compliance with Combatting Trafficking in Persons (CTIP) clause in accordance with DFARS PGI 222.1703(4), such that noncompliance with 52.222-50 is documented to the Contracting Officer, utilizing and annually completing the CTIP checklist at: http://ctip.defense.gov/.

http://ctip.defense.gov/