SPMYM2-22-Q-2341 (SOW) MATTISON GRINDER REBUILD.pdf

STATEMENT OF WORK

MATTISON SURFACE GRINDER REBUILD

1.0 Reciprocating lateral bed axis (X axis) analysis.

• Hydro-mechanical diagnostic to establish the baseline performance capabilities of the internal, hydraulic drive cylinder.

• Electro-mechanical diagnostic to establish the maximum and minimum electric disturbance fields generated by the electro-magnetic work holding device.

• EMF, EMI, RFI

• Ca coupling

• propagated inductance.

• Documentation and label generation for hydraulic, pneumatic, electric and electronic services supply and return passageways.

• Mechanical survey of the bed, bed way pocket, vee, vee way pocket surfaces, retainers and hold downs.

• Metrological survey of the axis travel alignment.

• Lube system diagnostics to establish lubrication distribution performance.

2.0 Longitudinal spindle axis (Y axis) analysis.

• Electro-mechanical diagnostic to establish axis travel performance.

• Mechanical survey of way surfaces, gibs and retainers / hold downs.

• Metrological survey of the axis travel alignment.

• Lube system diagnostics to establish lubrication distribution performance.

3.0 Vertical axis (Z axis) analysis

• Electro-mechanical diagnostic to establish axis travel performance.

• Mechanical survey of way surfaces, gibs and retainers / hold downs.

• Metrological survey of the axis travel alignment.

• Lube system diagnostics to establish lubrication distribution performance.

4.0 Hydraulic group analysis.

• Document all supply and return hose locations and routes.

• Pressure test all pump stages at “dead-head” full load performance.

• Electrical diagnostic to establish volt amp performance utilizing sustained digital signal logging and monitoring device/s.

• Cooling system diagnostic to establish thermal performance baseline.

• Oil filtration diagnostic to establish flow versus filtration data matrix.

5.0 Swarf / process debris handling system analysis.

• Mechanical diagnostic to establish operational performance.

6.0 Project review

• Compile all diagnostic reports and formulate overview of machine mechanical and electrical condition as found.

• Document all operational functions as currently configured and generate software build sheet.

• Define location and mounting configuration of all new equipment.

• Catalog all system documentation.

7.0 Repair – recondition lateral axis table way surfaces.

• Replace internal bed lubrication supply and return conduits.

• Repair – recondition machine bed mating surfaces.

• Repair – replace hydraulic reciprocating main cylinder seals, glands and packings.

• Replace hydraulic supply and return hoses to main reciprocating cylinder.

8.0 Repair – recondition longitudinal axis column way surfaces.

• Purge lubrication ports, lines, troughs and weeps.

9.0 Repair – recondition vertical axis way surfaces.

• Purge lubrication ports, lines, troughs and weeps.

• Repair – recondition spindle head mating surfaces.

• Resurface – repair gibs, hold downs and retainers as required to achieve calculated parasitic drag coefficient for precise vertical operation.

10.0 Machine control upgrade

• Remove existing manual control hardware as required to facilitate the new control (Fanuc 0i CNC) installation.

• Remove hand operated mechanical linkage to hydraulic, flow controlled, speed regulation valve.

• Cover remaining passageway with metal closure utilizing butyl sealing material.

• Remove operator knee station hydraulic interface and cap all hydraulic lines in place as to control leakage during further manipulation.

• Cover hydraulic direction control operator openings with metal closure utilizing butyl sealing material.

• Remove operator knee station electrical interface and terminate all electrical wiring with NEC insulated wire terminations.

• Cover electrical control operator openings with metal closure utilizing butyl sealing material.

• Remove operator knee station electro-mechanical time scale control device.

• Cover remaining opening with metal closure utilizing butyl sealing material.

• Remove operator knee station mechanical interlock control operators.

• Remove electrical interface to hydraulic group valve array.

• Documentation and label generation for electrical interface to hydraulic group valve array.

• Remove hydraulic flow regulated speed control valve stack and sub manifold.

• Remove electromechanical and magnetic power equipment.

• Clean and prep the existing electrical control cabinet.

• Replace control cabinet intrusions.

• Install new hydraulic valve stack sub manifold.

• Install new hydraulic servo proportioning valve adaptor plate.

• Install new hydraulic servo proportioning valve.

• Install hydraulic servo proportioning valve filter unit.

• Install new hydraulic plumbing.

• Install new hydraulic main supply line filter unit.

11.0 Install new CNC control package and OS Walker Chuck Control

• Install new CNC controller operator station cabinet adjacent to operator knee station at the NMTBA recommended height.

• Install operator station safety device to ensure operator station will not intrude into the work envelope.

• Install the servo amplifier power supply and servo amplifier rack in the existing control cabinet.

• Install the spindle amplifier in the existing control cabinet.

• Replace and repurpose existing interconnect cabling as required to facilitate the CNC control retrofit.

• Install fiber optic cables.

• Install new fiber optic cables for remote I/O located at the power magnetics control cabinet.

• Any operationally pertinent user interface hardware will be used in the as found condition based on operational disposition.

• Install new FANUC operator panels.

• Install new FANUC operator display.

• Perform preparation for power checks.

• Perform ground fault test on all interconnecting devices.

• Install all safety devices, protective covering, arc suppression and power safety management indicators.

• Install all remote I/O modules.

• Install motion control management hardware.

• Apply system power while maintaining emergency stop conditions.

• Perform power on checks.

• Check all system voltage levels.

• Check all energized device temperature measurements.

• Check all device status indicators and displays.

• Check CNC control boot-up status.

• Generate power on status report.

• Initialize the CNC controller and perform all commissioning routines.

• Generate CNC control initialization and commissioning report.

• Install system software.

• Perform system software initialization diagnostics.

• Perform machine specific software commissioning routines.

• Generate system software initialization and commissioning report.

• Install system safety software.

• Initialize error trapping software routines.

• Initialize error reporting software routines.

• Initialize system safety redundancy routines.

• Generate system safety software initialization and commissioning report.

• Install machine specific PLC software.

• Perform PLC specific system parametric initialization routines.

• Perform PLC configuration routines.

• Generate machine specific PLC software initialization and commissioning report.

• Machine start up and commissioning.

• Perform all site safety checks.

• Generate site survey and site safety report with all mitigation activities relating to the machine tool start-up operation.

• Energize CNC control system.

• Generate preliminary power on report.

• Energize all systems.

• Perform machine tool start up routines.

• Generate machine start up report.

• Perform machine tool commissioning routines.

• Confirm operation of all monitoring systems.

• Configure all machine specific parameters for the axes of motion.

• Configure all machine specific parameters for the spindle drive system.

• Configure all machine specific parameters for the lubrication systems.

• Configure all machine specific parameters for the communications systems.

• USB port program transfer configuration.

• DNC port program transfer configuration.

• ETHERNET port program transfer configuration.

• Perform operational checks on all axes of motion.

• Perform operation checks on all application specific conversational programming.

• Perform operational checks on lubrication system.

• Perform operational checks on communication systems.

• Generate machine start up and commissioning report.

12.0 Install feedback system.

• Install bed axis linear scale.

• Ensure bed axis linear scale reader head cable is mounted / routed for serviceability.

• Install vertical axis linear scale.

• Install longitudinal axis linear scale.

13.0 Metrology.

• Machine tool level and alignment.

• Check machine level and alignment utilizing a laser tracker in conjunction with high precision spirit levels.

• Generate level and alignment report.

• Perform mechanical adjustments to the machine tool as required to satisfy the OEM specifications for level and alignment.

• Check machine level and alignment utilizing a laser tracker in conjunction with high precision spirit levels.

• Generate level and alignment report.

• Machine tool calibration.

• Check machine tool calibration utilizing a calibration laser.

• Generate "as found" machine tool calibration report.

• Install parametric calibration data in CNC control.

• Check machine tool calibration utilizing a calibration laser.

• Generate "as calibrated" machine tool calibration report.

• Repeat 12.2 in order to satisfy 3 run repeatability criteria.

• Machine tool retrofit job acceptance.

• Perform operational test via customer defined test criteria TBD.

14.0 Final tasks.

• Generate machine tool retrofit job acceptance report.

• Conduct operator training.

• Conduct maintenance training.

• Provide all manuals, warranties, instructions, documents and certificates pertaining to the machine tool retrofit at a quantity of two each be provided in a format TBD and as specified by the job site data handling requirements.. All prints and parts lists to be drawn with CAD system.

• Any and all modifications to any aspect of the machine will meet or exceed original specifications

• Provide all wire, tags, conduit, flex and other miscellaneous equipment required to complete the installation per NFPA codes

• All electrical, mechanical, hydraulic, pneumatic and safety systems will be installed in accordance with all applicable customer specifications, and ISO, IEEE, ANSI, DIN, NFPA and any other standards listed within this contract, machine will have NRTL inspection when rebuild is complete.

• Any shipping costs that would be incurred during rebuild to be included in price.

Repeat 12.2 in order to satisfy 3 run repeatability criteria.