Temp Data Logger SOW-DRAFT.pdf

STATEMENT OF WORK

For

Flare Data Logger

1.0 Introduction / Background

The Air Force currently has a need for a sensor system embedded in a countermeasure flare. Current flare standards require that expendable countermeasure flares be designed to survive and operate at temperatures of -65ºF to 165ºF, some modern platforms requiring up to 171oF. This temperature range limits the type of powder and other materials that can be used in the flare assembly and increases the anticipated variability in performance. Because the flares are housed inside the aircraft during flight, it is anticipated that the actual temperature the flares experience is above the ambient airstream temperature (-65ºF). This anticipated gradient is difficult or impossible to theorize or model due to multiple variables, ultimately the presence of a temperature gradient means that some components are significantly above the ambient airstream temperature of -65ºF. Furthermore, aircraft vibration profiles are not well understood for the exact area where expendable countermeasures are housed. The Air Force requires a data acquisition system embedded in an inert countermeasure flare housing in order to gather test data on different aircraft and flight conditions, which can then be used to refine the temperature requirements of the countermeasure flare system. The data acquisition system will provide temperature measurements at multiple locations (impulse cartridge and end cap) within the flare case in order to demonstrate a thermal gradient while measuring 3-axis vibration.

2.0 Scope / Initiative Objective

The contractor shall manufacture and deliver 20 functional flare based data logger items. The assets will be self-contained (not interfacing with the aircraft) data logger COTS systems. The proposed data logger system will have a method of extracting and storing the data such as a USB interface and/or SD card, battery power, and configurable measurement parameters. The system shall have a readable exportable format interface compatible with excel. The system shall not be GPS, Wi-Fi, or Bluetooth enabled.

3.0 Applicable Documents

The following documents are incorporated as part of this Agreement.

NOTE: MIL-STD documents will not be provided to the contractor.

Document Number / Title Document Date

3.1 3976AS118 “MJU-61 End Cap Drawing” 180130

3.2 3976AS120 “MJU-61 Square Seal Drawing” 180130

3.3 3763AS127 “MJU-61 O-Ring, I. C. Cup Drawing” 180130

3.4 3763AS101 “MJU-61 Case Drawing” 180130

3.5 3830AS101 “MJU-53 Case Drawing” 041102

3.6 3976AS100 “Flare, Infrared, Countermeasure, MJU- 61A/B” 180130

3.7 3976AS113 ”MJU 61 Grain Drawing” 180130

3.8 MIL-STD-810H Vibration Section or most current revision

190131

3.9

MIL-STD-331D Fuses, Ignition Safety Devices and Other Related Components, Environmental and Performance Tests or most current revision

170531

3.10 MIL-STD-129R Military Marking For Shipment and Storage or most current revision 190927

4.0 Requirements

The contractor shall perform the following requirements to fulfill this initiative. Execution of these tasks in the sequence listed is not required.

4.1 Task 1: Flare Data Logger (FDL)

4.1.1 Sensor Identification

4.1.1.1 The contractor shall evaluate and verify the most suitable temperature sensors for performance, power consumption, survivability, and compatibility with the existing data logger electronics.

4.1.1.2 The contractor shall identify a compatible pressure sensor for down to 10kPa (up to 45k ft MSL) suitable for the required altitude of the test.

4.1.1.3 The contractor shall provide certification traceable to NIST standards sensors. (DEL: Sensor Certifications)

4.1.2 Board Redesign and Heater Selection

4.1.2.1 The contractor will redesign the COTS microprocessor board to be suitable for this application. Additionally, power management electronics may be modified based on the results of 4.1.4. Battery Requirements.

4.1.2.2 If the contractor requires the integration of a thermal management system to maintain the system at a functional temperature (-40℉), there will be no measurable effect greater than 1℉ to the thermal measurements.

4.1.3 Mechanical Design and Packaging

4.1.3.1 The contractor shall package everything into a nominal flare case (DWG

3763AS101), including the inert grain (DWG 3976AS113), end cap (DWG 3976AS118), and applicable seals (DWG 3976AS120 and 3763AS127), with a 1” x 1” x 8” (DWG 3763AS101), as well as a 1” x 2” x 8” (DWG 3830AS101), configuration. The inert grain is able to be cut and modified to accommodate the data logger. DWG 3976AS100

4.1.3.2 The contractor shall package the inert flare in such a way that it is sealed to the external environment. The seal must be removable as to allow access to the data logger and power supply; to export data/ remove memory chip as well as change batteries.

4.1.3.2.1 The government will provide 30 piece parts for integration, aluminum cases, end caps, and inert grains.

4.1.3.2.2 The contractor shall modify the provided aluminum cases to be an appropriate color with appropriate test markings described in MIL-STD-129.

4.1.3.2.3 The contractor shall mark each case with a unique serial number for traceability.

4.1.3.3 The contractor shall provide a recessed power button centered on the end cap along with an indicator light.

4.1.3.3.1 The power button shall, when held for a minimum of 2 seconds, power on the Data Logger board into low power mode, see 4.1.7, and the indicator light shall flash green for 5 ± 0.5 seconds.

4.1.4 Battery Requirements

4.1.4.1 The contractor shall evaluate and test a battery source that meets the proposed temperature, lifetime, and thermal management requirements.

(DEL: Battery Performance at Low Temperatures Trade Study)

4.1.4.1.1 The contractor shall select a battery that will operate properly within the required temperature range (-65℉ to 171℉) during in-flight testing.

4.1.4.1.2 The contractor shall select a battery that will operate for the full duration required during in-flight testing (12 hours)

4.1.4.1.3 The contractor shall select a non-rechargeable battery that will operate without any thermal interference with the temperature sensors during in-flight testing.

4.1.4.1.3.1 Compliance with 4.1.4.1.3 shall be determined

through low temperature chamber conditioning showing battery self-heating of the sensors will not raise the temperature sensor readings more than 1°F in the lower range of testing (-40°F to -65°F). (DEL:

Self-heating effect study)

4.1.5 Temperature Gradient

4.1.5.1 The temperature data logger shall be capable of measuring and recording the temperature at multiple points along the length of the expendable countermeasure case. The threshold requirement is three separate locations with an objective requirement of six locations. (DEL:

Temperature Gradient Performance Study)

4.1.5.1.1 The contractor shall place a minimum of one temperature sensor in close proximity to the following locations; internal face of the end cap, internal face located at the center of the case (length-wise), and internal face of the squib cup in close proximity to the impulse cart,

4.1.5.1.2 The contractor shall verify the temperature data is both accurate and precise, measuring in absolutes (-65℉ to 171℉ ±2℉) at 1 Hz over the duration of the vibration data recording.

4.1.6 Vibration (3-Axis)

4.1.6.1 The FDL shall measure and record 3-axis vibration.

4.1.6.1.1 The contractor shall utilize accelerometers that will have the capacity to record data for:

A threshold of a 2 ± 0.1 second duration with a sample rate of at least 2500hz occurring every 600 ± 2 seconds when in active operation for a minimum length of 12 hours. Measure up to 8 G with a resolution of 0.01 G

An objective of a 3 ± 0.1 second duration with a sample rate of at least 5000hz occurring every 120 ± 2 seconds when in active operation for a minimum length of 12 hours. Measure up to 80 G with a resolution of 0.001G

4.1.6.1.1 The FDL shall be subjected to a total of 9 hours (3 axes, 3 temperatures) of random vibration in accordance with the requirements described in MIL-STD-810H, Test Method 514.6, Test Procedure I, Category 12 (Jet Aircraft). The test levels are shown in Figure 12 in Appendix B. The FDLs shall be loaded into a MJU-34/A magazine or equivalent test fixture as approved by the Government procuring activity and secured to the vibration fixture depicted in Figure 1 in Appendix A. The following backer plate shall be used; PN:

9732390-10, NSN: 5340-01-468-9784 or equivalent test fixture secure method as approved by the Government procuring activity. The vibration shall be conducted in three axes (vertical, 1st transverse, and 2nd transverse). The average of two accelerometers, as shown in Figures 2 through 5 in Appendix A, shall be used to control the vibration table inputs.

Vibration time at each axis shall be one hour at ambient, one hour at +160°F±10°F, and one hour at -65°F±10°F.

Preconditioning at each temperature shall be a minimum of two hours. (DEL: Vibrational Performance Study)

4.1.6.1.2 The contractor shall verify the vibration data is accurate.

4.1.7 Pressure

4.1.7.1 The contractor shall evaluate and record pressure at the same sample rate as the thermal recordings.

4.1.7.2 The data logger shall, upon power up, be in a low power mode (only measuring pressure) to then initiate recording upon reaching an altitude of 6000 ft above Mean Sea Level (MSL). The data logger shall also deactivate recording upon reaching 6000ft MSL on descent.

4.1.8 The contractor shall hold a Preliminary design review (PDR) once verification of sensor performance is complete per Task 2. The contractor shall not move onto Task 2 until the contractor has completed PDR (DEL: PDR Design Package)

4.2 Task 2: Preliminary Manufacturing, Assembly and Testing

4.2.1 The contractor shall procure all preliminary materials and hardware necessary for

First Article test manufacture.

4.2.2 The contractor shall complete an iterative build, design, and test process to refine the design, up to four iterations. (DEL: System Level Design and Test Result package)

4.2.2.1 The contactor shall manufacture a small quantity (3) of complete FDL systems for testing/design and process evaluation.

4.2.2.2 The contractor shall complete testing on the small quantity. The results shall be evaluated against performance requirements.

4.2.3 Software and Firmware Updates

4.2.3.1 The contractor shall modify any existing firmware and software of COTS board to accommodate any additional new sensors and power system.

4.2.4 The flare based data logger shall be subjected to one 14-day temperature and humidity cycle as prescribed in Test C1 of MIL-STD-331 Rev D. The data loggers shall be tested bare on the shelf, e.g. not inside a magazine. The data logger shall be completely functional after the 14 day T&H cycling. In the event of cycle interruption, continuation of the 14 day process is allowed from last known completed ambient step.

4.2.5 The flare based data logger shall be subjected to a total of 9 hours (3 axes, multiple temperatures) of random vibration in accordance with the requirements described in MIL-STD-810H, Test Method 514.8, Test Procedure I, Category 12 (Jet Aircraft) in accordance with the vibration spectra shown in Figure 1 in Appendix B.

4.2.6 The flare based data logger shall be able to operate reliably in a minimum of 20 in-flight tests. Consumables such as batteries, and piece parts may be replaced as needed.

4.2.7 The contractor shall conduct a Critical Design Review (CDR) at the contractor’s location at the conclusion of Task 3; customer approval of the CDR package shall be required prior to initiating Task 4, production and deliverables.

4.2.7.1 The contractor shall hold a Developmental Data Logger CDR once the design of the developmental data logger is 90% finalized. (DEL: CDR Design Package)

4.3 Task 3: production and Deliverables

4.3.1 The contractor shall procure all materials and hardware necessary for contract deliverable manufacture, per Task 3.

4.3.2 In conjunction with the customer, the contractor shall develop an acceptance test criteria for the final 20 assemblies.

4.3.3 The contractor shall conduct testing per government approved requirement verification plan and conduct necessary acceptance test to ensure all design requirements are met. (DEL: Acceptance Test and VP Testing Results)

4.3.4 The contractor shall deliver 20 final assemblies to customer for government testing. (DEL: Government Testing)

4.3.4.1 The contractor shall provide all necessary instructions for usage, data processing, and typical troubleshooting. (DEL: Operating Instructions)

4.3.4.2 The contractor shall provide all of the necessary components for operation

(sensor system, USB cable and/or SD Card for data output, documentation, battery etc.). Documentation and modifiable software will be provided on the units and available as a pdf file along with an accompanying CD.

5.0 Deliverables

Deliverable Reference Data Rights

5.1 WBS 6.0 Unlimited

5.2 Sensor Certifications 4.1.1.4 Unlimited

5.3 Battery Performance at Low Temperatures Trade Study 4.1.4.1 Unlimited

5.4 Self-heating effect study 4.1.4.1.3.1 Unlimited

5.5 Temperature Gradient Performance Study 4.1.5.1 Unlimited

5.6 Vibrational Performance Study 4.1.6.1 Unlimited

5.7 PDR Design Package 4.1.8 Unlimited

5.8 System Level Design and Test Result Package 4.2.2 Unlimited

5.9 CDR Design Package 4.2.7.1 Unlimited

5.10 Acceptance Test and VP Testing Results 4.3.3 Unlimited

5.11 Government Testing -20 4.3.4 Unlimited

5.12 Operating Instructions 4.3.4.1 Unlimited

5.13 Quarterly Technical and Business Status Reports 8.1 Unlimited

5.14 Final Technical and Business Status Report 8.2, 8.3 Unlimited

5.15 Patent Report 8.4

6.0 Milestone Payment Schedule

Milestone / Deliverable Due Date Cost

6.1 Expected Award Date mm/dd/yyyy

6.2 Requirements Document $XX,XXX

6.3 SRR Presentation

6.4 Battery Performance at Low Temperatures Trade Study

6.5 Temperature Gradient Performance Study

6.6 Vibrational Performance Study

6.7 Self-heating effect study

6.8 PDR Presentation

6.9 System Level Design and Test Result Package

6.10 CDR Presentation

6.11 IHC

6.12 LAT and VP Testing Results

6.13 Government Testing -20

6.14 Quarterly Technical and Business Status Reports

6.15 Final Technical and Business Status Report/Patent Report

6.16 End of PoP

Total Cost $XXX,XXX Total Period of Performance 9 Months

Contract Type FFP

7.0 Shipping Provisions

Deliverables shall be sent to the following POCs:

7.1 Non-Explosive Shipments:

Name: Steve Kas

Organization: Air Force

AFLCMC/EBHCC

Mailing Address: 6033 Elm Lane, Bldg 1247 Hill AFB, Utah 84056 Phone: (801)775-4733 Email: steven.kas.2@us.af.mil

8.0 Data and Reporting

8.1 Quarterly Reports: The contractor shall prepare a Quarterly Report which will include a Technical

Status Report and a Business Status Report in accordance with Attachment B, Report Requirements.

8.2 Final Technical Report: At the completion of the initiative, the contractor shall submit a Final Technical Report, which will provide a comprehensive, cumulative, and substantive summary of the progress and significant accomplishments achieved during the total period of performance, in accordance with Attachment B, Report Requirements.

8.3 Final Business Status Report: At the completion of the initiative, the contractor shall submit a Final Business Status Report, which will provide summarized details of the resource status of the initiative, in accordance with Attachment B, Report Requirements

8.4 Patent Report: The contractor is required to submit an Annual Invention (Patent) Report in accordance with Attachment B, Report Requirements, as well as with the Final Technical Report.

9.0 Safety

The contractor shall adhere to all local, state, and federal rules and regulations required in order to maintain a safe and non-hazardous occupational environment throughout the duration of this Agreement. At a minimum, the contractor shall provide the following reports and material on an as needed basis:

9.1 Accident / Incident Report: The contractor shall report immediately any major accident/incident (including fire) resulting in any one or more of the following: causing one or more fatalities or one or more disabling injuries; damage of Government property exceeding $10,000; affecting program planning or production schedules; degrading the safety of equipment under contract, such as personnel injury or property damage may be involved; and identifying a potential hazard requiring corrective action. The contractor shall prepare the report IAW the attached CDRL DI-SAFT-81563 for each incident.

10.0 Environmental Requirements

10.1 Environmental Compliance: All activities must be in compliance with Federal, State, and local environmental laws and regulations, Executive orders, treaties and agreements. The recipient shall evaluate the environmental consequences and identify the specific types and amounts of hazardous waste being generated during the conduct of efforts undertaken under this Agreement.

10.2 Pollution Prevention Plan: The contractor shall give consideration to alternative materials and processes in order to eliminate, reduce or minimize hazardous waste being generated.

This is to be accomplished while minimizing item cost and risk to item performance. If it is determined by the contractor that pollution will be generated under this Agreement, the contractor shall prepare, one time, a Pollution Prevention Plan, in accordance with the CDRL requirements for DI-MISC-80508B.

10.3 Hazardous Waste Report: The contractor shall evaluate the environmental consequences and identify the specific types and amounts of hazardous waste being generated under this Agreement. If it is determined by the contractor that hazardous waste will be generated under this Agreement, the contractor shall prepare a Hazardous Waste Report.

10.4 Hazardous Materials Management Program Plan (HMMP): If it is determined by the contractor that hazardous materials will be used under this Agreement, the contractor shall prepare, one time, a Hazardous Materials Management Program Plan (HMMP), in accordance with the CDRL requirements for DI-MGMT-81398C.

10.4.1 Hazardous Materials Management Program Plan Report (HMMPR): If it is determined by the contractor that hazardous material will be used under this Agreement, the contractor shall prepare, annually, a Hazardous Materials Management Program Plan Report (HMMPR), in accordance with the CDRL requirements for DI-MISC-81397C.

10.5 Disposal Instructions for Residual/Scrap Materials: The contractor shall dispose of residual and scrap materials generated from this Agreement, including high explosives. The contractor shall specify the anticipated quantities, methods, and disposal costs.

10.6 Ozone Depleting Chemical (ODC): Class 1 Ozone Depleting Chemicals (Class 1 ODCs) shall not be used under this Agreement

11.0 Security

11.1 The security classification level for this effort is UNCLASSIFIED.

12.0 Government Furnished Property

12.1 The government will provide inert flare components required for development, testing, and manufacturing. DWG 3976AS100

13.0 POC

13.1 POC Info:

Name: Heather Schaefer Organization: Air Force

AFLCMC/EBHCC

Mailing Address: 6033 Elm Lane, Bldg 1247

Hill AFB, Utah 84056 Email: heather.schaefer.1@us.af.mil Phone: (801)777-6086

13.2 Alternate POC Info:

Name: Steven Kas

Organization: Air Force

AFLCMC/EBHCC

Mailing Address: 6033 Elm Lane, Bldg 1247 Hill AFB, Utah 84056

Email: steven.kas.2@us.af.mil Phone: (801) 775-4733 mailto:steven.kas.2@us.af.mil

Appendix A

Figure 1. Aircraft Vibration Test Level

Figure 2. Vibration Fixture 12255-11J00004

TOP, FIXTURE

11J00004-5

BLOCK, FIXTURE

11J00004-1

MJU-34/A

MAGAZINE

BASE PLATE, FIXTURE

11J00004-2

PN: 9732390-10

Figure 3. Aircraft Vibration Test Setup (Vertical Orientation)

Control Accelerometers

Figure 4. Aircraft Vibration Test Setup (1st Transverse)

Control Accelerometers

Figure 5. Aircraft Vibration Test Setup (2nd Transverse)

Control Accelerometers

Attachment B Report Requirements

This page intentionally left blank. See separate document for Attachment B