Starrag BPA SoW rev 5 (final) - Statement of Work_Redacted.pdf

Table of Contents

1. OVERVIEW

1.1. Scope

2. APPLICABLE DOCUMENTS

2.1. General Information

2.2. Government Documents

2.3. Non-Government Publications, Specifications, Standards, and Handbooks

2.4. Order of Precedence

3. GENERAL REQUIREMENTS

3.1. Prototype Equipment

3.2. Measuring and Indicating Device Graduations

3.3. Safety, Environmental, Hazardous Materials

3.4. Lubrication Data

3.5. Instrument, Control Panel, and Plate Marking

3.6. General Equipment Requirements

3.7. Machine Operating Controls

3.8. Replacement Parts

3.9. Special Tooling and Equipment

3.10. Third Party Software License

3.11. General CNC Machine Requirements

3.12. Network Communication and Sensing

3.13. Network Security Requirements

3.14. CAD/CAM Software (Option)

4. STC MODEL REQUIREMENTS

4.1. Machine Configuration

4.2. Axes

4.3. Longitudinal Bed and Rotary Axis

4.4. Standard Mill Table

4.5. Mill Turn Table (Option)

4.6. Transverse Bed

4.7. Column

4.8. Tilting Spindle Head Housing and Saddle

4.9. Spindle Head

4.10. Spindle

4.11. 6th Axis Spindle Head (Option)

4.12. Power Failure Protection

4.13. Machine Pallet

4.14. Automatic Pallet Changer

4.15. Automatic Tool Changers

4.16. Machine Coolant System

4.17. Coolant Wash Down Hose

4.18. Through Spindle Air Supply

4.19. Flexible Nozzle Air Supply

4.20. Chip Conveyor

4.21. Chip Briquette System (Option)

4.22. Miscellaneous Requirements

4.24. STC Model Size and Capacity

4.25. STC Model Alignment and Accuracy Tolerances

4.26. Machine Controller/PLC Operating Systems and Interfaces

4.27. Machine Controller Functions

4.28. GE P11TF12 Compliance

4.29. Spindle Crash Detection

4.30. Post Processor (Option)

4.31. Basic Workpiece Probing

4.32. Tool Length Offset/Breakage Detection System

4.33. Handheld Operator Pendant

5. ECOSPEED MODEL REQUIREMENTS

5.1. Machine Configuration

5.2. Axes

5.3. Longitudinal Bed

5.4. Column

5.5. Spindle Head

5.6. C-Axis

5.7. Automatic Pallet Changer

5.8. Automatic Tool Changers

5.9. Automatic Right Angle Head Changer

5.10. Machine Coolant System

5.11. Tool Taper Air Purge

5.12. Chip Conveyor

5.13. Miscellaneous Requirements

5.14. Ecospeed Size and Capacity

5.15. Ecospeed Alignment and Accuracy Tolerances

5.16. Machine Controller/PLC Operating Systems and Interfaces

5.17. Machine Controller Functions

5.18. Spindle Crash Detection

5.19. Post Processor (Option)

5.20. Basic Workpiece Probing

5.21. Tool Length Offset/Breakage Detection System

5.22. Handheld Operator Pendant

6. RVU MODEL REQUIREMENTS

6.1. General Description

6.2. Machine Configuration

6.3. Axes

6.4. Crossrail

6.5. Saddle

6.6. Turret Assembly

6.7. Spindle

6.8. Grinding Wheel Hub

6.9. Rotary Table

6.10. Pallet Receiver

6.11. Pallet Transfer Station (Option)

6.12. Machine Pallet

6.13. Turning Capability

6.14. Automatic Tool Changers

6.15. Machine Coolant System

6.16. Wheel Dressing Capability

6.17. Chip Conveyor

6.18. Miscellaneous Requirements

6.19. RVU Model Size and Capacity

6.21. Machine Controller/PLC Operating Systems and Interfaces

6.22. Machine Controller Functions

6.23. Time Display and Part Count

6.24. Spindle Crash Detection

6.25. Power Failure Protection

6.26. Tool Management

6.27. Tool Dimension Control/Gap Elimination System

6.28. Tool Length Offset/Breakage Detection System

6.29. Post Processor (Option)

6.30. Basic Workpiece Probing

6.31. Handheld Operator Pendant

7. TVU MODEL REQUIREMENTS

7.1. General Description

7.2. Machine Configuration

7.3. Axes

7.4. Column

7.5. Crossrail

7.6. Carriage

7.7. Ram

7.8. Ram Accessories

7.9. Spindle

7.10. Rotary Table

7.11. Pallet Receiver

7.12. Pallet Transfer Station (Option)

7.13. Machine Pallet

7.14. Automatic Tool Changers

7.15. Coolant System

7.16. Chip Conveyor

7.17. Tool Air Supply

7.18. Miscellaneous Requirements

7.19. TVU Model Size and Capacity

7.20. TVU Model Alignment and Accuracy Tolerances

7.21. Machine Controller/PLC Operating Systems and Interfaces

7.22. Machine Controller Functions

7.23. Spindle Crash Detection

7.24. Post Processor (Option)

7.25. Basic Workpiece Probing

7.26. Temperature Probe System

7.27. Tool Length Offset/Breakage Detection System

7.28. Handheld Operator Pendant

8. FLEXIBLE MANUFACTURING SYSTEM REQUIREMENTS (OPTION)

8.1. FMS System Description

8.2. FMS Hardware Components

8.3. FMS Cell Control System

8.4. FMS Control Hardwar/Software Components

8.5. Database Management

8.6. System Communications and Connectivity

8.7. System Status Reporting & Logging

8.8. Restore/Recovery Function

8.9. Control Application Functionality

8.10. Pallet Scheduling

8.11. Pallet/Fixture Offset Baseline Evaluation

8.12. NC Program Management

8.13. Work Management

8.14. Tool Data and Control Management

8.15. System Status Monitoring

8.16. Artifact and Part Probing Measured Data

8.17. Maintenance Notifications & Monitoring

9. TRANSPORTATION, RIGGING, FOUNDATIONS, AND INSTALLATION

9.1. Transportation

9.2. Rigging

9.3. Installation

9.4. Leveling

9.5. Utility Hook-Up

9.6. System Charging

9.7. Installation and Foundation Drawings

9.8. Foundation

9.9. Foundation Work Area

10. TRAINING REQUIREMENTS

10.1. Training Overview

10.2. Initial Training

10.3. Follow-Up Training

10.4. Advanced Training

11. TOOLING, ACCESSORIES, & TECHNICAL DATA

11.1. Tooling

11.2. Accessories

11.3. Technical Data

12. EXTENDED MACHINE WARRANTY PACKAGE (OPTION)

12.1. General Description

13. QUALITY ASSURANCE

13.1. Responsibility for Inspection

13.2. Responsibility for Compliance

13.3. Classification of Inspections

13.4. Inspection Conditions

13.5. Origin Inspection

13.6. Final (Destination) Inspection/Acceptance Test

13.7. Examination

13.8. Tests

13.9. Post Order Delivery Award Meeting

13.10. Plan of Action and Milestones

13.11. Design Review Meeting

14. OTHER REQUIREMENTS: TINKER AFB

14.1. Safety and Quality Control

14.2. FOD and DOP

14.3. Housekeeping

14.4. Standard Operating Procedures

15. INSTALLATION RESPONSIBILITIES

16. APPENDICIES

Appendix A – STC1800MT Tool List

Appendix B – STC1250 Tool List

Appendix C – STC1000 Tool List

Appendix D – STC1250X and Ecospeed 1540 Tool List

Appendix E – RVU and TVU Model Tool List

Appendix F – STC 1000 / 1250 / 1800 / 1800MT Model Accessory List

Appendix G – STC 1250X / Ecospeed F1540 Accessory List

Appendix H – RVU and TVU Non-Warranty Spindle Accessory List

Appendix I – RFID Tool Data Format

Appendix J – RFID Tool Management Flow Logic

Appendix K – MTConnect Adapter Data Tag Output

17. TABLES

Table I: Simulation Software Program

Table II: Maximum Layout Dimensions by Machine Model

Table III: Mill Turning Option Minimum Requirements

Table IV: 6th Axis Spindle Head Minimum Requirements

Table V: STC Model Minimum Requirements

Table VI: STC Model Accuracy and Repeatability

Table VII: Ecospeed F1540 Minimum Requirements

Table VIII: Ecospeed F1540 Accuracy and Repeatability

Table IX: Grinding Wheel Hub Requirements

Table X: RVU Model Minimum Requirements

Table XI: RVU Model Accuracy and Repeatability

Table XII: TVU Model Minimum Requirements

Table XIII: TVU Model Accuracy and Repeatability

Table XIV: Minimum Quantity of Extension Modules Required by Model

1. OVERVIEW

1.1. Scope. The content of this specification describes the minimum requirements for the name brand procurement of Starrag and Starrag subsidiary, Berthiez, 5/6-axis machining centers, vertical cylindrical grinders, vertical turning lathes and Flexible Manufacturing System (FMS).

Models included in this specification are STC1250, 1250MT, 1250/170, 1250MT/170, STC1250X, STC1000, 1000/MT, STC1800, 1800MT, 1800/170, 1800MT/170, Ecospeed F1540, Berthiez RVU 1100/100, Berthiez RVU 1350/125, Berthiez RVU 2800/250, Berthiez TVU

1400/100F. Except for Ecospeed Model F1540, all models shall be offered as a standalone standard build or custom build for integration into an FMS. Equipment, materials, labor, and services shall be provided as a turn-key solution and completed in accordance with the specification(s) defined within this document as needed to deliver and install the machine(s) at

Tinker Air Force Base.

2. APPLICABLE DOCUMENTS.

2.1. General Information. The Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation, and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.” While every effort has been made to ensure the completeness of this section, document users are cautioned that they must meet all specified requirements of documents cited throughout this SOW whether they are listed.

2.2. Government Documents. The following Government documents form a part of this document to the extent specified herein.

2.2.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

2.2.2. U.S. Department of Labor

29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

(Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.2.3. Environmental Protection Agency

40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

(Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.2.4. Federal Standards

FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition

FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

(Application for copies should be addressed to Superintendent of Documents, Government

Printing Office, Washington, D.C. 20402-001).

2.2.5. Military Standards

MIL-STD-130N w/Change 1: Identification Markings of U.S. Military Property (2012 Ed.)

Item Unique Identification Marking (IUID) or most recent edition

(Application for copies should be addressed to Air Force Product Data Systems

Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

2.2.6. National Institute of Standards and Technology (NIST)

FIPS 140-3: Security Requirement for Cryptographic Modules

(Request for information should be addressed to Information Technology Laboratory, National Institute of Standards and Technology, Gaithersburg, MD 20899-8900. This document is available free of charge at https://doi.org/10.6028/NIST.FIPS.140-3)

2.2.7. Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein.

Local Facility Documents

2.3. Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein.

2.3.1. National Fire Protection Association (NFPA)

NFPA 1 – Fire Code, 2010 edition or most recent edition

NFPA 70 – National Electrical Code, 2014 edition or most recent edition

NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition.

NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

(Application for copies should be addressed to National Fire Protection Association, Battermarch Park, Quincy, MA 02269)

2.3.2. Telecommunications Industry Association (TIA) Standard

EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data Circuit- Terminating

Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition.

(Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3.3. National Electrical Manufacturers Association (NEMA)

NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

NEMA ICS 1 – Industrial Control and Systems General Requirements (2015 Ed.) or most

NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

(Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.3.4. Underwriter Laboratories, Inc.

UL 508A – Industrial Control Panels

(Application for copies should be addressed to Underwriter Laboratories, Inc. 333 Pfingsten

Road, Northbrook, IL 60062)

2.3.5. American Society for Testing and Materials.

ASTM SI 10 – American National Standard for use of the International System of Units (SI):

The Modern Metric System, 2010 or most recent edition.

(Application for copies should be addressed to ASTM Headquarters, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959)

2.3.6. American National Standards Institute

ANSI/(NFPA) T2.25.1 – Pneumatic Fluid Power – System Standard For Industrial Machinery

– Supplement to ISO 4414:1998 – Pneumatic Fluid Power – General Rules Relating To

Systems (2005) or most recent edition.

ANSI/ASME B5.1M – T-Slots, Their Bolts, Nuts, and Tongues (1985) or most recent edition.

ANSI B11.20 – Safety Requirements for the Integration of Machinery into a System (2017) or most recent edition.

ANSI B11.23 – Safety Requirements for Machining Centers and Automatic, Numerically

Controlled Milling, Drilling, and Boring Machines (2012 Rev.) or most recent edition.

ANSI B11.25 – Safety Requirements for Large Machines (2022) or most recent edition.

ANSI B11.19 – Performance Requirements for Risk Reduction Measures: Safeguarding and

Other Means of Reducing Risk (2019) or most recent edition.

(Application for copies should be addressed to American National Standards Institute, Attn:

Sales Department, 1430 Broadway, New York, NY 10018-3363)

2.3.7. American Welding Society INC (AWS)

AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most

(Applications for copies should be addressed to the American Welding Society Inc., 550

North LeJeune Road, Miami, FL 33126)

2.3.8. International Organization for Standardization (ISO)

ISO 2047:1997/Amd 1:2016 – Test condition for internal cylindrical grinding machines with horizontal spindle; Testing of accuracy – Amendment 1 (3rd edition, May 2016) or most recent edition.

ISO 2433:1999 – Machine tools: Test condition for external cylindrical and universal grinding machines with a movable table; Testing of accuracy (3rd edition, Dec 1999) or most recent edition.

ISO 4413 – Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition.

ISO 4414 – Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.) or most recent edition.

ISO 8573-1 – Compressed air: Contaminants and purity classes; Part 1 (3rd edition, Apr 2010) or most recent edition.

ISO 13041-6 – Test conditions for numerically controlled turning machines and turning centres: Accuracy of finished test piece (2nd edition, June 2009) or most recent edition.

ISO 10791-7 – Test conditions for machining centres: Accuracy of finished test pieces (3rd edition, January 2020) or most recent edition.

(Application for copies should be addressed to the International Organization for

Standardization (ISO) 1 rue de Varembé, Casepostalea56, CH211Geneva 20, Switzerland)

2.3.9. Society of Automotive Engineers (SAE)

SAE EIA-267-C – Axis and Motion Nomenclature for Numerically Controlled Machines

(2015 Ed.) or most recent edition

(Application for copies should be addressed to: Society of Automotive Engineers 400

Commonwealth Drive; Warrendale, PA 15096)

2.4. 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. GENERAL REQUIREMENTS. Unless otherwise indicated, the following requirements in

Section 3 apply to all equipment and subcomponents as applicable.

3.1. Prototype Equipment. The items offered shall be new, current, and commercially available models. 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 machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. Parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.2. Measuring and Indicating Device Graduations. Measuring and indicating devices on the equipment shall be graduated in both US customary units and International System of Units (SI).

3.3. Safety, Environmental, Hazardous Materials.

3.3.1. Safety and Health Requirements. Machine parts, components, mechanisms, and assemblies furnished on the machine, whether specifically required herein, shall comply with requirements of OSHA 29 CFR 1910.

3.3.2. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI

B11.19, B11.20, B11.22, B11.23, and B11.25 as applicable. The safety devices shall prevent operator contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts. Guarding shall be constructed and attached in a manner as to not create safety hazards. Incorporated safety devices shall not limit the OEM intended operation of the machine.

3.3.3. Emergency Stop Devices. Equipment design shall incorporate a single emergency stop function. The emergency stop function may be accomplished by one or more emergency stop devices. Emergency stop devices shall conform to NFPA 79 requirements. Other than locations specifically identified in elsewhere in this SoW, emergency stop devices shall be made readily accessible and placed at all normal operating locations.

3.3.3.1. Safety Device Layout Analysis (FMS Only). NLT 90 days post delivery award, the

Contractor shall provide the Government a detailed safety device layout analysis illustrating the recommended type, location, and intended span of control for all safety-related control devices.

The analysis shall encompass both FMS and all integrated equipment. The Contractor may use

ANSI B11.20-2007 as a reference for the analysis. The Contractor shall be responsible for providing the Government an updated layout analysis for each subsequent delivery order award.

3.3.4. Slip Hazards. Non-slip stepping surfaces shall be provided in locations where it is necessary for operator/maintenance personnel to step or walk on part of a machine that presents a potential slip hazard due to wet/slick conditions from coolant, chip, swarf, or lubricants.

3.3.5. Unintended Projectile Protection. Machine(s) shall be equipped with means to protect personnel from the unintended ejection of workpiece, tooling, and fluids. The means of protection shall not deteriorate over time due to contamination by lubricants, metal removal fluids, solvents, etc. The protection shall be of sufficient strength that it can absorb the energy and momentum associated with the speed and mass of potential projectiles derived in the use of the equipment.

3.3.6. Work Envelope Monitoring. Machine(s) shall comply with ANSI B11.25 regarding viewing of the work envelope with fully enclosed equipment.

3.3.6.1. Workpiece Monitoring System. The Contractor shall provide each machine a workpiece video monitoring system. The system shall be of a design that is properly protected for a flood coolant machining environment. The installation location of the viewing system shall not interfere with the operation of the machine or machine accessories. Video camera(s) within the machine enclosure shall be installed at a locations that permit direct visual access to the components and the cutting process. The system shall be provisioned with a separate, minimum

21 inch, display located at the machine’s main control panel that permits the concurrent observation of the video output and machine control display. The display shall be mounted in a manner that allows for its future maintenance or replacement without requiring modification(s) to machine enclosure. The system shall permit, at a minimum, operator control of the camera tilt, pan, and zoom functions via motor drive. The system shall be provisioned for concurrent transmission of video feed across the Government industrial network.

3.3.7. Spindle Function Limit. Machines shall be configured to reduce rapid operations to 25 of normal and spindle rotation to no greater than 50 rpm when the work envelope access door is left in the open position.

3.3.8. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels

(dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator’s work position or any point three (3) feet away from the equipment. Noise generated by the work piece and ambient workplace shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.3.9. Mercury Restriction. The machines shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.3.10. Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machines/equipment.

3.3.11. Lead. Lead and materials containing lead shall not be used on or in the machines with the exception to radiation cladding and lead solder in circuits.

3.3.12. Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited. The machine shall be considered PCB free providing certification to be verified containing less than 5 parts per million (<5ppm) in accordance with 40 CFR part 761.

3.3.13. Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.3.14. Electrical Enclosures. Construction of electrical enclosure(s) shall conform to NEMA

ICS 6 standards. Electrical enclosure(s) shall be a NEMA type 12 intended for indoor, non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. Machine electrical cabinet shall meet requirements of NFPA70 and NFPA 79.

Electrical enclosure(s) shall provide means for ventilation. Each machine shall be equipped with a maintenance mode for electrical troubleshooting and repair. A lighting device shall be incorporated inside each enclosure. Each lighting device shall provide adequate lighting for troubleshooting and maintenance purposes.

3.3.15. Arc Flash Protection. Each machine’s electrical enclosure and enclosures of disconnecting devices shall be marked for arc flash hazard warning in accordance with NFPA

79.

3.4. Lubrication Data. The Contractor shall provide the following information and the US equivalent on all liquid or grease lubricants contained within equipment/system or in bulk (5 gallons or more) supplied under this procurement.

3.4.1.1. Liquid Lubricants

• Viscosity grade in ISO units

• Viscosity Index

• AGMA and/or SAE classification as applicable

• Mil Spec and/or NATO Code as applicable

• Cincinnati Milacron Specification Number as applicable

• Viscosity in Centistokes (cst) @ 40° C and 100° C

• Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

• Neutralization, the TBN (alkalinity) and/or TAN (acidity).

• Flash point

• Pour point

3.4.1.2. Grease Lubricants

• National Lubrication and Grease Institute (NLGI) Number

• Type and percent of thickener

• Dropping point

• Maximum Service Temperature

• Base oil viscosity range in SUS or centipoise

3.5. Instrument, Control Panel, and Plate Marking.

3.5.1. Plate Requirements. 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.

3.5.2. Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

• Points of Lubrication Application

• Servicing Interval

• Type of Lubricant

• Viscosity

• Military or Federal Specification for Each Lubricant (If available)

• Size and Type of Each Lubricant Filter

3.5.3. Machine Nameplate. A nameplate shall be securely attached to each machine. The nameplate data shall meet the requirements of NFPA 79 and contain, at a minimum, the following 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.

• Manufacturer’s Name

• Manufacturer’s Model Designation

• Manufacturer’s Serial Number

• Rated voltage, number of phases, and frequency

• Full-load current for each supply

• Ampere rating of the largest motor or load

• Short-circuit current rating of the industrial control panel

• Maximum ampere rating of the short-circuit and ground fault protective device, where provided.

• Electrical diagram number(s) or number of the index to the electrical drawings

3.5.4. Identification Marking of Military Property. An Item Unique Identification Marking

(IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) and item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in Paragraph 3.5.3 “Nameplate”.

• Nomenclature

• Cage Code

• Manufacturer

• Model Number

• Serial Number

• Date of Manufacture

• Contract Number

3.5.5. Warranty Data Plate. At machine acceptance, Contractor shall securely attach a warranty data plate to the machine enclosure. In accordance with MIL-STD-130N, the data plate shall include the statement “WARRANTED ITEM” and the warranty expiration date.

3.6. General Equipment Requirements. Unless otherwise noted, the following requirements shall apply all equipment components.

3.6.1. General Construction. All Equipment and sub-components 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.

3.6.2. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder, or filling with paste shall be used for reclaiming any defective part.

3.6.3. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.6.4. Threads. All threaded parts used on the machines and their related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein.

3.6.5. Gears. All gears of axis drive trains shall conform to or exceed all provisions of

ANSI/AGMA ISO 1328-1-B14 (PESO). All gears shall be of proper width and size to transmit full-rated torque and power throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

3.6.6. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

The condition and finish of all surfaces shall be in accordance with the manufacturer’s commercial practice.

3.6.7. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.6.8. Painting. The machines shall be painted in accordance with the manufacturer’s commercial practice. Paint shall not contain lead.

3.6.9. Workmanship. Workmanship of the machines shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.6.10. Bearing Information. The Contractor shall provide bearing manufacturer and part number for all bearings used in all rotating equipment supplied under this contract. The information shall be included on the sectional drawings for each bearing location. The Contractor shall provide the operating speed for constant speed units and the normal operating speed range for variable speed equipment.

3.6.11. Fans and Blowers. The Contractor shall provide the following information on fans and blowers supplied with the proposed equipment:

• Fan and blower type(s)

• Number of rotating fan blades/vanes

• Number of stationary fan blades/vanes

• Rotating speed(s)

3.6.12. Belts. The Contractor shall provide the following information for belt driven fans:

• Number of belts

• Belt lengths

• Belt Part Number

• Diameter of the drive sheave at the drive pitch line

• Diameter of the driven sheave at the drive pitch line

3.6.13. The Contractor shall ensure sufficient access is permitted to all fans for the purpose of performing maintenance without the need for significant disassembly of the machine.

3.7. Machine Operating Controls. Electrical, mechanical, hydraulic, and pneumatic operating controls shall be installed in a location convenient location for their intended use.

3.7.1. Control Panel Display Language. All control panels shall display information in the

English language.

3.8. 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. All replacement parts shall have a guaranteed availability for a minimum of ten years.

3.9. Special Tooling and Equipment. All special tooling and equipment required for proper operation of each machine e.g., special tools needed for the regular maintenance, shall be furnished. The Contractor shall provide the Government a list of all special tools and equipment for each piece of equipment at time of proposal.

3.10. Third Party Software License. The Contractor shall provide all necessary license(s) for third party applications used to meet the requirements outline in this statement of work. The

Contractor shall transfer ownership of all licenses to the Government for sustainment over the lifecycle of the system. All license(s) provided to Government shall:

• Not be subscription based.

• Not require a connection to the internet for its activation, use, or updating.

3.11. General CNC Machine Requirements. Unless otherwise noted, the following requirements shall apply to all CNC machines and sub-components.

3.11.1. Machine Bases. The machine bases shall be a stress relieved and heavy-duty ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects.

The bases shall be of strength and size to provide support for all loads within the machines rated capacity without distortion to the bases, machine, or other machine components.

3.11.2. Machine Ways. The ways shall be of a type suitable for high grade precision numerically controlled machines covered by this document. Machine ways shall be constructed of hardened, precision ground steel. The Ways shall be hand scraped to its final condition. Movement of the slides on the way surfaces shall be through adjustable, preloaded, re-circulating roller bearing cartridges or nonmetallic way liners having a low coefficient of friction with slip-stick and damping properties including hydrostatics. Protection of the machine ways shall be either telescoping or curtain type way covers equipped with way wipers.

3.11.3. Axis Measuring Systems. The axes for each machine shall be provisioned with linear glass scales for axes traversing distance calculations. The rotary axis shall also have a measuring system designed for the specified performance. All measurement systems shall be fully encapsulated by housings or sealed machine structure to prevent coolant, debris, and swarf from interfering with the system or causing damage.

3.11.4. Machine Enclosures. Each machine shall be housed within a self-contained enclosure.

The enclosure shall provide containment for coolant/chips and for operator safety in the event of a broken tool. The enclosure shall be equipped with interlocking sliding doors. Interlocking doors shall provide unhindered access to the work envelop for unloading/loading of tools, raw material, and parts. The enclosure shall be constructed with safety windows for operator visibility of the workpiece and machine spindle. Enclosure doors shall contain a reinforced safety glass for all workpiece viewing windows IAW Paragraph 3.5.5.

3.11.5. Mist/Emission Extractors. Each machine shall come provisioned with a mist and fume extractor system. The extractor shall remove dust, mist, and fumes generated during turning, cutting, and grinding operations. The extractor shall automatically activate and operate concurrently during machining operations without the need for operator input. Access to the system filter shall be made readily available for maintenance and replacement. Air filtration quality shall meet EU13/H13 (DIN24183/EN1822).

3.11.6. Workpiece Area Light. A built-in LED work light shall be provided to the area of the workpiece fixture. The light shall comply with NFPA 79 requirements, have a protective shield, and supply a minimum of 400 lux or greater. Replacements shall be available in North America.

3.11.7. Hydraulic System. Each machine’s hydraulic system shall conform to ISO 4413. The system shall be complete including all pumps, valves, piping, cylinders, and pressure controls. A means shall be provided for controlling fluid temperature, so that it does not exceed 120℉ during normal operation. Each Machine shall alarm and report IAW Paragraph 3.12.4 when temperature thresholds are reached or exceeded.

3.11.8. Pneumatic System. Pneumatic system(s) and components provided with the machine(s), as applicable, shall conform to both ANSI/NFPA T2.25.1-2005 and ISO 4414:1998 or more recent publication. Pneumatic system(s) shall come complete including all pumps, valves, plumbing, cylinders, and pressure controls necessary to operate the machine and its ancillary equipment. Each machine provided shall integrate with the facility source compressed pneumatic air. The existing source pneumatic air available at the facility ranges from 80 to 120 psi. Source air integration shall maintain air quality class IAW ISO 8573-1 as applicable for machine make and model listed in the delivery award. Each machine shall alarm and report IAW Paragraph

3.12.4 when pressure thresholds are reached or exceeded.

3.11.9. Operator Compressed Air. Each machine shall come equipped with a compressed air quick disconnect located with 10 feet of the operator workstation. The compressed air quick disconnect shall be configured to supply filtered compressed air at a minimum of 70 psi. An airline “Y” fitting will be considered acceptable.

3.11.10. Electrical System. Each machine shall conform to NFPA 79. The existing source power available by the Government is 480 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of +/- 10 percent. The electrical system shall be complete including electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with a means of lockout in the off position only. Wiring inside electrical enclosures shall be individually labeled.

3.11.11. Enclosure Outlets. All internal and external enclosure electrical outlets shall conform to the requirements of NFPA 79. Each machine shall be equipped with one (1) 120V (15A) duplex outlet located externally on the enclosure within 10 feet of the machine controls. Access to the outlet shall be unobstructed and easy to access

3.11.12. Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall handle the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.11.13. Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.11.14. Electrical Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-

1. Each motor shall have an identification plate with the following information below. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer’s design and construction drawing(s).

• Manufacturer

• Model number

• Voltage

• Amperage

• Horsepower

• Phase

• Frequency

• Frame number

3.11.15. Lubrication. Each Machines shall be equipped with a system that provides lubrication

(oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements.

Recirculating lubrication systems shall include a filter that is cleanable or replaceable. The lubricant reservoir shall have at least a 24-hour capacity. Each machine shall be provisioned via electronic means to indicate that a low-level lubrication condition exists. The lubrication status shall be available for data collection IAW Paragraph 3.12.4. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.11.16. Initial Lubrication Fill. The Contractor shall be responsible for the initial filling of all lubricants, grease, and milling coolant required to operate a machine or piece of equipment. The current milling coolant used by the Government is TRIM MicroSol 585XT semisynthetic, microemulsion coolant.

3.11.17. Analog Hour Meter. Each machine shall be equipped with a non-resetting type, digital or analog hour meter to display accumulated operating time of the system. The hour meter(s) shall be mounted on the main electrical panel, visible from the outside. The hour meter(s) shall be sealed to prevent the entrance of dust, moisture, and capable of withstands shock/vibration generated by the machine. The hour meter(s) shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one (1) hour.

3.11.18. Machine Warm Up Program. Each machine shall come equipped with a warmup program. The program shall be capable of cycling automatically when electrical power is applied to the machine control. The program shall include spindle warm up with incremental RPM increases with a programmed dwell at each level. The program shall warm up axes drives through full traverse of each axis.

3.11.19. Shutdown Program. Each machine shall come equipped with a shutdown program. The program shall be capable of a controlled, automatic shutdown of the NC-control without fault upon completion of a NC part program. The program shall maintain warm condition for spindle, controls, and circulating coolant system.

3.11.20. Preventative Maintenance. The Contractor shall provision each machine control for the automatic tracking, scheduling, notifying, and reset of OEM recommended preventative maintenance actions. Each recommended maintenance action shall contain, at a minimum, a description of what service is needed to be completed and a specific value indicating when the action should be completed.

3.11.20.1. Preventative Maintenance Action Notification. The Contractor shall provision each machine control to automatically report “due” and “overdue” preventative maintenance actions to the Government’s maintenance of record database in accordance with Paragraph 3.12. A preventative maintenance action shall be considered “due” when the current action of interest for which the notification is issued falls within a ±10% window of the target completion value defined in Paragraph 3.11.20. Preventative maintenance notifications that indicate a maintenance action is “due” shall not prevent the operation of a machine.

3.11.20.2. Overdue Maintenance Action Notifications. A preventative maintenance action that exceeds the recommended “due” threshold of +10% shall automatically report to the

Government’s maintenance of record database that the subject maintenance action is “overdue”.

An overdue maintenance action shall prohibit activation of the machine’s “cycle start” function.

An “overdue” maintenance action shall not prevent the application of power to the affected equipment.

3.11.20.3. Notification Display. The contractor shall configure the operator HMI to display all due or overdue preventative actions in a clearable pop-up or equivalent format. At a minimum, due or overdue preventative action shall be displayed upon start-up of the machine.

3.11.20.4. Preventative Maintenance Action Reset. Each machine shall be configured to require

“maintenance” level of administrative control access to reset the timing function for a preventative maintenance action.

3.11.21. Remote Diagnostics. Each CNC machine shall include OEM remote diagnostics hardware, software, and software license(s). Access and use of the Remote diagnostic software shall require administrator account privileges with two-way authentication. The diagnostics hardware installed on machine(s) shall be capable of being physically disconnected or rendered inoperable by non-permanent means. Contractor shall provide, as an appendix to the technical data, detailed easy to read instructions in English for disabling remote diagnostic hardware.

3.11.22. RFID Tool Management. Each equipment offered in this SoW shall be provisioned for

RFID read/write capability. The RFID system shall be licensed enabled to perform read and write functions to Balluff BIS C RFID chip(s) imbedded within tool holder(s), workpiece(s), and pallet(s). Components of the RFID system shall adhere to network security requirements listed elsewhere in this document. RFID data mapping shall follow the Siemens standard format as defined in Appendix I. At a minimum, the RFID system shall perform the following key automatic functions:

• Transfer (reading/writing) of tool data from the RFID chip to the respective machine registry during loading of the tool into the machines tool holding system.

• Update (reading/writing) of RFID chip tool data during transfer of tools from tool magazine/storage area to spindle.

• Update (reading/writing) of RFID chip data during transfer of tool from the spindle to the tool magazine/storage area.

• Update (reading/writing) of RFID chip data during unload of tools from the tool magazine/storage area via the tool loading door.

• Tool identity check before tool change.

3.11.22.1. Incorrect/Dirty Tool Rejection (CNC Only). Each machine’s RFID system shall be configured to accept or reject loading of tooling in accordance with the Tool Management Logic

Flow as outlined in Appendix J.

3.11.23. Machine Digital Twin. NLT thirty (30) calendar days prior to commencement of programmer training, the Contractor shall provide the Government all necessary hardware, software, software license(s) to commission a Siemens Run MyVirtual Machine “digital twin” representing the identical machine controls, parameters, and kinematics for each Make and

Model indicated in the delivery order. The Contractor shall be responsible for the full installation, commissioning, and testing of each digital twin. All software licenses shall come in a floating license server configuration. Each machine digital twin shall include the following Run

Myvirtual Machine applications.

• Run MyVirtualMachine/Operate

• Run MyVirtualMachine/Open

• Run MyVirtualMachine/3D

3.11.24. Machine/Control Simulation Model. The Contractor shall deliver one (1) functional simulation model representative of machine features and purchased options for the Make and

Model listed in the delivery award. The simulation model shall be provided in the file format for the software listed in Table I. No later than the initial post award meeting, the Government may, at its discretion, provide the Contractor with an existing Government owned simulation model for Contractor modifications and updates. The final version of the simulation model shall be delivered NLT seven (7) calendar days prior to initial programmer training.

Table I: Simulation Software Program

Location Organization Software

Tinker Air Force Base PMXG NCSIMUL

Tinker Air Force Base PMXG/CMXG Vericut

3.11.25. Max Layout Footprint. Equipment layout shall not exceed the dimensions indicated in

Table II for the respective machine(s) listed in the delivery order award. Layouts dimensions take into consideration the base machine footprint, placement of its auxiliary equipment, and requisite foundation size.

Table II: Maximum Layout Dimensions by Machine Model

Model Length Width Height

Feet + Inches Feet + Inches Feet + Inches

RVU 1100/100 37 + 6 17 + 6 12 + 4

TVU 1400/100 F 37 + 4 21 + 8 18 + 9

RVU 2800/250 39 + 2 29 + 1 16 + 12

STC1000 31 + 6 25 + 6 18 + 1

STC1250 37 + 10 32 + 9 18 + 1

STC1800 52 + 4 39 + 4 18 + 1

3.11.26. Machine Health Monitoring System. For each CNC Machine listed in the delivery order, the Contractor shall provide an equipment monitoring system/methodology that aids in the early detection of machine component failure(s) and collision. The Contractor shall provide all applicable hardware, software, licenses, measuring cycles, calibration devices necessary to perform the requirements listed below.

• Establishment of machine baseline measurements for frequency response, circularity, and power/current intake for systematic condition monitoring of all axes.

• Automatic and continuous monitoring of peripheral components including but not limited to pumps, mist extraction unit, tool clamping cycle, and accumulator charge.

• Collision protection.

• Automatic monitoring of the machine zero point and kinematic accuracy.

3.11.26.1. Machine Operational Baseline. The Contractor shall record and provide to the

Government, all machine baseline measurements that are necessary to meet the requirement of

Paragraph 3.11.26. All Measurements shall be performed during machine assembly and commissioning at destination.

3.12. Network Communication and Sensing.

3.12.1. Data Communication Protocols. Controller(s) shall come licensed enabled and able to communicate using industry standard protocols including, at a minimum, OPC UA and

MTConnect. Controller(s) shall come equipped with a minimum of one RJ45 Ethernet Interface port configured and available for the connection to the Customer’s Industrial network. The

Industrial network port shall be placed in an accessible location on the equipment in a manner that does not require the need for major disassembly of the equipment.

3.12.2. MTConnect Adapter. The Contractor shall provide an MTConnect adapter for each machine indicated in delivery order award. The MTConnect adapter shall be version 1.4 or newer.

3.12.3. OPC-UA Server. Each machine controller shall be provided with a fully provisioned, licensed enabled OPC UA server. The OPC-UA server software shall be the latest version available at the time of machine delivery at destination.

3.12.4. Data Tags. The minimum tag information for collection through OPC-UA and

MTConnect shall conform to the requirements listed in Appendix K. Changes to appendix K requirements shall be provided by Government no later than 90 calendar days prior to destination acceptance inspection.

3.12.5. Machine Sensing Requirements. In addition to standard OEM sensor configuration, each machine shall include sufficient hardware, software, and software license(s) to perform the requirements outlined in Paragraph 3.11.26. All sensors and sensor components shall be integrated into the machine’s control system. Discrete outputs for data collection purposes shall be conditioned to display meaningful values. Sensor data shall be made available as a discrete output for data collection purposes IAW Paragraph 3.12.4

3.12.6. Hour Meter Data. Machine(s) and equipment shall be provisioned to collect, display, and report cumulative operational “run-time” data via digital output. Hour meter data shall be made available as an output for data collection purposes IAW Paragraph 3.12.4. Operational run-time use data shall include at a minimum, the machine’s operating, working, and CNC spindle runtime hours as defined by the following:

• Operating hours: Time the control voltage is applied to the system and the system is not in emergency stop.

• Working hours: Time the machine spindle or FMS lift mechanism is cycling.

• Spindle Runtime (CNC Machines Only): Time the machine spindle is running regardless of axis movement.

3.13. Network Security Requirements.

3.13.1. Universal Serial Bus (USB) Communications. All internal and external USB communications shall be clearly documented and described within the contractor provided technical data.