15-50-2071_5-Axis_HBM_Retrofit.docx

VIBB 15-50-2071

November 8, 2016

STATEMENT OF WORK (SOW) FOR A CNC CONTROLLER & COMPONENTS

FOR A 5 AXIS HORIZONTAL BORING MILL (HBM) RETROFIT

1.0 SCOPE.

1.1 Scope. The following SOW describes the minimum requirements for the purchase of a FANUC 32i MB Controller, Servo Motors, Digital Spindle System, Operator Pendant, Remote Pendant and new Electrical Enclosure for the upgrade of a conventional 5-Axis Horizontal Boring Mill (Mfg. Lucas Model # 42B60) to a Computer Numerically Controlled (CNC) controlled HBM. The controller shall be designed to support all features of the existing Lucas HBM. The vendor shall be responsible for sending all new equipment to a Government rebuild facility where the machine is currently being rebuilt to OEM standards. Once the machine has been rebuilt, including the CNC upgrade and tested for quality assurance, it will be disassembled and shipped to the end users facility. The machine will then be re-assembled by the Government and have a final inspection and acceptance test to insure all new components of the upgrade perform as required. The vendor shall be required to verify at the Government rebuild facility and the customers facility that all upgraded components supplied in this specification for the conversion to CNC control are in good working order.

2.0 APPLICABLE DOCUMENTS.

2.1 General. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2.1 Specifications, Standards, and Handbooks.

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 Volts Maximum) (2014 Ed.)

NEMA MG 1: Motors and Generators (2016 Rev.)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

TECHAMERICA

TIA-232-F: Interface between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange (1997 Ed., 2012 Rev.)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania Ave., NW, North Building Suite 600 Washington D.C. 20004-2650)

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

3.1 Design. The items offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The new CNC Controller shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the controller shall be graduated in the inch/pound and metric system.

3.1.2 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

3.2 Construction. The items required for the upgrade shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.3 Components.

3.3.1 CNC Controller. The machine controller shall consist of a Fanuc 32i MB CNC Control incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be independent and have independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of X, Y, Z, V (Tailstock) and W-Axis, linear interpolation, circular interpolation, programmable interface, part program edit, buffer edit capability, part program storage, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits. The Fanuc 32i MB shall include the following features:

3.3.1.1 CNC Software. The new CNC software shall be fully documented. The PMC ladder logic shall support lubrication cycles, faults and alarms, and display pages. The following Fanuc options shall be enabled on the CNC control:

a. AI contour control I (AICCI)

b. Automatic corner override

c. Bell shaped acceleration/deceleration after interpolation

d. Dual position feedback

e. Tool retract and recover

f. Handle interruption

g. Stored limit check before move

h. Optional block slip

i. Program restart

j. Coordinate system rotation

k. Fixture offsets, minimum 48 registers for X,Y, W/Z axes

l. Workpiece coordinate system

m. Workpiece coordinate system preset

n. Tool offset memory C, including a minimum of 200 sets of X, Y,W and Z offsets

o. Tool geometry/wear compensation

p. Canned cycles for drilling, tapping, and boring

q. Custom macro B, including a minimum of 100macro variables

r. Control axis detach

s. External data input

t. Inch/Metric conversion

u. Stored pitch error compensation

v. Part program storage, minimum 1 MB

w. Optional chamfering and corner radius

x. Inverse time feed rate

y. CNC screen display function

3.3.1.2 W/Z Zero Tracking. This feature shall electronically track each axis of the collinear set W and Z to calculate the part reference coordinate of the collinear set. This part reference coordinate shall represent the relationship between the reference point of the W-axis and the reference point of the Z-Axis. The reference point of the Z-Axis is typically the gage line of the spindle and the reference point of the W-Axis is typically a surface on the work piece. Therefore the part coordinate of the collinear set W/Z is typically the distance from the workpiece part zero to the gage line of the spindle. Once the relationship is established through the part reference procedure, the CNC control shall track all the Z and W-axis moves and display their relationship as the W/Z axis actual position. While the part coordinate is displayed in the W/Z axis register, the W and Z registers shall display the absolute coordinates of their respective axes in the machines coordinate system. At a minimum, the W/Z tracking shall:

a. Always be in tracking mode

b. Have no special screen just for W/Z tracking

c. Position/Program check screen shall show position displays for W/Z, Z, W, X, and Y-Axes

d. Work offset screen shall show only X, Y, and Z-Axes

e. Common offset of work coordinate offsets shall only be used by operator, and shall not be used by system logic

f. Allow both the W and Z-Axes to be commanded individually to an absolute position relative to the machines coordinate system via a G-code such as G98.

3.3.1.3 Program Input.

a. Least input increment of 0.001 mm/0.0001” for X, Y, W, and Z-Axis, and 0.001° for B-Axis

b. Interpolation increment of 0.0005 mm/0.00002” for X, Y, W, and Z-Axis, and 0.0005° for B-Axis

c. Maximum programmable dimension of ± 9999.9999

d. Decimal point programming

e. Inch and metric codes

f. Interpolation functions shall include rapid traverse positioning, linear interpolation, multi-quadrant circular interpolation, helical interpolation, and cylindrical interpolation

g. Feed modes shall include feed per minute, feed per revolution, inverse time, and rapid traverse

h. Program input shall be feasible via keyboard input from the operator panel, USB port, RS-232 port, and PCMCIA port and conform to TIA-232-F.

3.3.1.4 Post Processor and Machine Definition. A post processor for use with Mastercam version 13 shall be provided, including a machine definition file. The post processor shall include all files necessary to provide the capability to generate tool paths and output ASCII format NC files for all available functionality of the CNC Horizontal Boring Mill including, but not limited to, simultaneous 2 and 3 axis machining. The files shall include documentation and be delivered on compact disc.

3.3.1.5 Maintenance Diagnostic System. Maintenance diagnostics software shall be furnished either in the control as nonvolatile memory or as a separate program that is compatible with the input media specified herein. The diagnostic software shall test and display failures. The system shall monitor operating conditions and have automatic means of rapidly stopping operations to prevent damage when potentially harmful malfunctions are detected.

3.3.1.6 Other Functionality. The following functionality shall be provided by the new CNC software and PMC ladder logic:

a. Allow bidirectional jog while in “HOME” mode

b. Axis selection buttons shall illuminate when respective axis is at home position while in “HOME” mode.

c. Allow feed hold while in “HOME” mode

d. Rapid override selector, versus the federate override, shall control axis velocity while referencing the axis in the “HOME” mode.

e. Allow feed hold during M06 tool changes

3.3.1.7 Pitch Error Compensation. All axes shall have their respective pitch error compensation table populated with values to achieve the accuracy and precision requirements listed in 3.3.6 TABLE I.

3.3.1.8 Emergency Stop Devices. The equipment specified herein shall be provided with emergency stop buttons at the equipment control panel, and on the remote pendant. These stop buttons shall be the mushroom type, be colored red, and be labeled as such. When activated, the emergency stop devices shall cause all operations or functions to cease immediately.

3.3.2 Motors. All motors shall be continuous duty rated and shall have ball or roller bearings of the sealed and permanently lubricated type with the exception of motors above 25 HP. Motors above 25 HP may use externally lubricated type ball or roller ball bearings. All motors, except axis motors, shall conform to the requirements of NEMA MG-1 and be of the AC type.

3.3.2.1 Servo System. A new X, Y, Z, W, and V axis servo system consisting of Fanuc AC digital velocity units, Fanuc AC servomotors with high-resolution absolute encoders shall be provided. All axes motors shall be sized with torque, inertia, and speed characteristics required to meet or exceed the existing system on the machine. All vertical axis shall have a holding brake. The vendor shall provide all new power and feedback cables. The V-axis shall be capable of being detached. When attached, the Y and V-axis shall home, and the V-axis will then follow the Y-axis for positioning mode.

3.3.2.2 Spindle Motor and Drive System. A new spindle motor and drive system consisting of a Fanuc spindle motor and drive shall be provided. The spindle drive shall be sized with torque, inertia, and speed characteristics required to meet or exceed the existing system on the machine. The vendor shall provide all new power and feedback cables. The drive system shall interface to the machine tool as required.

3.3.3 Operator Pendant Station. A new operator's pendant station that shall consist of a 10.4" display, discrete key operator's panel and miscellaneous control devices that are needed to meet or exceed the existing pendant station. The new station shall be mounted on the existing pendant assembly and be made to swivel. The current pendant is located off the top of the column with a tubing type style to the pendant.

3.3.3 Pendant. A new pendant shall be provided to house the new video monitor and North American Fanuc operator panel and Fanuc MDI style (not QWERTY) keyboard. The new pendant cabinet shall have a means to prevent damage to the wiring from door swing when the cabinet is open.

3.3.3.1 Video Monitor. A new industrial video monitor with at least a 10.4” diagonal shall be provided. Cathode ray tube type monitors are not acceptable.

3.3.3.1 Remote Pendant Station. A remote pendant shall be provided with enough cabling to allow the operator full operation anywhere in the machining envelope. The remote pendant shall have axis jog controls for each axis in both incremental and hold to jog, similar to joystick functionality and a manual pulse generator (MPG) for moving in 0.01”, 0.001”, and 0.0001” increments. The remote pendant shall have an emergency stop button.

3.3.4 Electrial Enclosure. A complete new electrical enclosure and back panels shall be designed and provided for installation. The new back panels shall house the main breaker, CNC control, servo drives, new wheel drive, model A I/O, all magnetics, and all new electrical/electronic components, etc. needed to complete the upgrade. Provisions shall be made for power cable entrance. The enclosure shall be of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA 250 Type 12.

3.3.5 Additional Miscellaneous Equipment. The contractor shall supply all pre-made cables, cables, wiring, and sealtight needed for these interconnections. The contractor shall also supply all fully assembled control enclosures, pendant stations, operator stations, pushbutton stations, motors, and feedback devices needed to complete the upgrade.

3.3.6 Accuracies and Precision. The machine is being rebuilt to the following accuracies and tolerances listed in TABLE I.

TABLE I

ACCURACY AND TOLERANCES

3.4 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.4.1 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's Name Manufacturer's Model Designation Manufacturer's Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contract Number Date of Manufacture

3.5 Installation. The vendor shall be responsible for installing the CNC controller, servo motors, spindle drive system, operator pendant, remote pendant and the electrical enclosure. The vendor shall also be responsible for initial start-up at the rebuild facility and final start-up at the customer’s facility. DLA electrical personnel will install the new motor mountings, all field devices (limit switches, pressure switches, solenoids, cable and hose carriers, and interconnections between control enclosures, pendant stations, operator stations, pushbutton stations, j-boxes, motors, and feedback devices).

3.5.1 Installation Overview. The initial start-up and integration of the machine shall be performed at Defense Logistics Agency- Aviation, Industrial Plant Equipment Services Div. 5450 Carlisle Pike Mechanicsburg, Pa. 17050-2411. During the start-up at DLA Mechanicsburg, the machine shall be put through functional testing, operational testing, perform cut testing of final test piece with assistance of DLA, and any linear compensation of the system needed to meet ball bar and laser tests. The machine will then be disassembled and shipped by DLA to Trident Refit Facility 990 USF Thomas Jefferson Drive, Kings Bay, GA. 31547. At that point the machine will be reassembled by DLA. The contractor shall be required to perform start-up of the machine consisting of all operational functions, feeds, speeds, and cut testing at Trident Refit Facility 990 USF Thomas Jefferson Drive, Kings Bay, GA. 31547. See section 4 for testing requirements at final destination.

3.6 Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is an American citizen of good standing and repute and proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with familiarization of the control, navigation of the control, download and uploading of part programs, functions of the control, operation, and all functions of the machine control system. The training time shall be between 07:30 hours and 16:00 hours excluding any federal holidays. The courses shall utilize as-built drawings and manuals provided under this contract, and shall include both classroom and hands-on portions. All printed training aids shall be supplied at no additional cost to the government, and be in the English language. The following personnel shall be trained:

3.6.1 Operational/Programming Training. Operational/Programming training shall be performed at final installation location for no less than five (5) operator/programmer personnel for a minimum of three (3) consecutive, eight (8) hour workdays.

3.6.2 Maintenance Training. Maintenance training shall be performed at final installation location for no less than five (5) maintenance personnel for a minimum of two (2) consecutive, eight (8) hour workdays.

3.7 Technical Data. Two (2) hard copies and one (1) electronic copy of technical data shall be provided with the machine. Technical data shall contain CNC documentation, Fanuc operator and control maintenance manual, electrical schematics, P.L.C.

schematics, parameter list, Fanuc appropriate manuals, and CNC engineering operator addendum. All copies of technical data shall be legible and written in the English language.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.2 Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.3 Classification of Inspection. The inspection requirements specified herein are classified as follows:

a. Contract Quality Assurance Inspection (Mechanicsburg)

b. Final Inspection and Acceptance Destination

4.4 Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at Mechanicsburg’s facility prior to being offered for acceptance under the contract. The machine and all peripheral equipment added to the machine shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and the tests in 4.7 through 4.7.3 (excluding 4.7.4).

4.5 Final Inspection and Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the machine to ensure conformance with this SOW. The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.6 and all tests in 4.7. The machine shall pass the examination and all tests to be accepted.

4.6 Examination. The system shall be examined to determine compliance with all requirements of this SOW.

4.7 Tests. The contractor shall be present for all the below tests at Mechanicsburg and at the customers facility for final inspection and acceptance. The contractor is responsible for the control and all ancillary equipment that is listed in this SOW. Any failure of the controller or ancillary equipment to perform as specified herein shall be cause for rejection.

4.7.1 Operational Test. The machine shall be operated at no load for at least 30 minutes for an initial warm-up period. Proper operation of all manual controls, motors, adjusting mechanisms and accessories shall be verified during the warm-up period. Upon completion of the initial check procedure, the system shall be cycled continually for three (3) hours under computer numerical control to demonstrate operability of the equipment and permit the machine to reach a steady operating temperature. The contractor supplied program shall include rapid travel of the slides and ram, independently and simultaneously, tool changes and spindle rotation of varying speeds and gear ranges. The contractor supplied program shall also demonstrate the W/Z zero tracking, cutter radius and length compensation, canned cycles (G80 series. If a malfunction occurs during the cycling period, the program shall be restarted each time until a full three (3) hour programmed cycle is completed without a malfunction.

4.7.2 Axis Accuracy and Repeatability Tests. The machine and its components shall be tested for conformance with the accuracies and repeatability specified herein. Unless otherwise specified, the tolerances in 3.3.6, TABLE I. shall apply. The instruments and methods used in performing the tests shall be at the option of the supplier.

4.7.3 Cutting Performance Tests. The machine shall produce two parts that conform to Aerospace Industries Association of America (AIA/NAS) NAS 979 standards 4.3.3.5.1 circle, diamond, square test, Type I.

4.7.4 Post Processor Test. The post processor shall be demonstrated to generate valid tool paths for up to 3-Axis machining. A part program shall be generated via the post processor. Program(s) generated by the post processor shall be demonstrated to upload properly and dry run without error. The Mastercam software and computer will be supplied by Kings Bay TRF.