Salient_Characteristics_Rev_1.doc

SUBJECT: Salient Characteristics DATE: 8 March 2017

Revision: 1

PURCHASE DESCRIPTION

For

ABRASIVE WATERJET CUTTING CENTER

1.0 SCOPE

1.1 Scope: The following establishes the minimum requirements for the purchase of an abrasive waterjet machine with equipment and accessories specified herein.

2.0 APPLICABLE DOCUMENTS

U. S. DEPARTMENT OF LABOR

29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 1998 or most recent edition.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA-79 – Electrical Standards for Industrial Machinery, 2013 or most recent edition.

ELECTRONIC INDUSTRIES ALLIANCE (EIA) STANDARD

EIA TIA/EIA-232-F – Interface between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 or most recent edition.

AMERICAN NATIONAL STANDARD INSTITUTE

ANSI/NEMA MG-1 - National Standards for Motors and Generators, 1998 or most recent edition

ANSI/NFPA/JIC T2.24.1 - Hydraulic Fluid Power-Systems Standard for Stationary Industrial Machinery, 1991 or most recent edition.

2.2 Order of Precedence: In the event of a conflict between the text of this specification and the reference cited herein, the text of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

3.0 REQUIREMENTS

3.1 General: The waterjet abrasive cutting machine shall be new (not a prototype) and one of the manufacturer’s standard current production models capable of operations in accordance with the requirements herein. The machine shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. Designs with separate catcher tank (independent of cutting unit) will not be allowed.

3.1.1 Measuring/Indicating Devices: All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine shall be graduated in dual, inch-pound units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator’s normal workstation.

3.1.2 Safety and Health: Covers, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance, and repair of the parts. All machine parts, components, mechanisms, and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.

3.1.3 Caution-Warning Plates: Corrosion resistant “Caution” or “Warning” plates shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

3.1.4 Audible Noise: Audible noise emitted by the equipment under no load shall not exceed 81 dBA at the operator’s workstation or at any other point at a distance of three (3) feet from the equipment as measured on the “A” weighted scale of a standard Type II sound level meter.

3.1.5 Prohibited Materials: Asbestos, mercury, lithium or polychlorinated biphenyl (PCB) shall not be used in any part or component of the system. Lithium batteries used in the computer system are exempt from this requirement.

3.1.6 Environmental Protection: The machine shall be so designed and constructed that under the operating, service, transportation and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prescribed by federal, state, or local statutes in effect at location of installation.

3.1.7 Nameplate: A corrosion resistant metal nameplate identifying the machine shall be securely attached to the machine. The nameplate shall contain the following information:

Nomenclature

Contractor’s Name Contractor’s Model Designation

Contractor’s Serial Number

3.2 Construction: The abrasive waterjet cutting machine shall be constructed of parts which are new, without defects, and free of repairs. The cutting axes and tank shall be one unit to guarantee the cutting accuracy listed herein. The machine structure shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion. Processes such as welding, plugging, or filling with solder or paste shall not be used for reclaiming any defective part(s). All screws, pins, bolts, and other fasteners shall be installed in a manner as to prevent change of tightness. The machine table, pump, and controller will all be designed and built in the USA. The machine shall be manufactured, tested and shipped as a complete unit from the manufacturer’s location within the USA.

3.2.1 Castings/Forgings: All castings/forgings shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solders or paste shall not be used on casting or forgings for reclaiming any parts of the machine.

3.2.2 Welding, Brazing or Soldering: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

3.2.3 Surfaces: All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt, fins, sprues, flux, and other harmful or extraneous materials. External surfaces shall be smooth, and all edges shall be either rounded or beveled unless sharpness is required to perform a function.

3.2.4 Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

3.2.5 Painting: The machine shall be painted in accordance with the manufacturer’s commercial practice. Yellow or orange safety color-coding shall be used for designating physical hazards.

3.2.6 Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28.

3.2.7 Interchangeability: All replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that any such parts of a particular type or model can be replaced or adjusted without modification of the equipment.

3.2.8 Maintainability: The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, and repair of parts.

3.3 Components: The abrasive waterjet cutting machine shall consist of, but not limited to, the following described principle components, attachments, and accessories necessary to meet the operational and performance requirements specified herein.

3.3.1 Table: The machine footprint shall be 22’1” x 12’8” and provide a working envelope capable of housing a 15’0” x 7’5” piece of material. The bed shall have 4” x 14 gage galvanized steel support slats. The bed shall have means for leveling the machine on a flat mounting surface. The system must be of unitized design to eliminate misalignment due to an operator bumping either the cutting head or table during material loading. The base shall have access doors or removable plates as necessary for servicing components housed within. The table must be capable of supporting 400 pounds per square foot of load. The contractor shall provide the necessary anchor bolts, leveling screws and related hardware to secure machine components to the floor, if design requires.

3.3.1.1 Table X-Axis: The X-axis shall be controlled by closed loop, digital drives with brushless servo motors that require no periodic tuning. The resolution shall be 1 micron with linear scale. The X-axis shall have full X-axis travel. The linear motion system shall use digital linear encoders to provide instant micron-level cutting head position feedback to the Windows® 8 controller to assure accurate part production.

3.3.2 Bridge: The bridge shall be controlled by closed loop, digital drives with brushless servo motors that requires no periodic tuning. The resolution shall be 1 micron with linear scale. The bridge shall have full Y-axis travel and a motor controlled, precision Z-axis. A cantilever style cutting head is not allowed. Bridge design is defined as a structure that is supported and driven on both ends of the bridge that caries the cutting head.

3.3.2.1 Second Bridge: The second bridge will operate independently from the first bridge. The two bridges shall operate at the same time on different parts. It shall be required to have both bridges work together on the same part. Each bridge control shall operate independently and be able to start/stop on a separate schedule.

3.3.2.2 Remote operational control on the cutting bridge: The bridge must include a remote keypad to allow operation of the machine from the cutting bridge location.

3.3.3 Computer Control System (CCS): The waterjet abrasive cutting system shall be provided with a fully automatic, solid-state, integrated circuit, 32-bit, multiple microprocessor based-type personal computer integrated with CAD/CAM software and LCD flat panel display. The unit shall provide for 3-axis simultaneous contouring capabilities and automatic control for all machine functions.

3.3.4 Software: Software shall run on Windows® 8 and be compatible with Windows® 10 and be specifically designed for all abrasive jet and waterjet machining functions. Functions of the software must include automatic and manual lead in/out tools, parametric shape generator, automatic collision prediction and correction, support tool path fonts and Windows® true type fonts, specialize in automatic raster to vector format conversions, advanced corner and piercing optimizations are automatically applied, advanced taper reduction methods, calculate cutting in software before sending to machine, comprehensive and highly accurate part time estimates and job quoting, generate custom reports, optimal stack height calculator, special cutting quality for minimum taper, easily resize, rotate, or flip part for prototyping or to align with existing features, open over 70 file formats (CATIA, SolidWorks, 3d dxfs, etc), easily create 3D tool paths from solid models, comprehensive alert system of machine status including email/SMS notifications, customizable pause and alert triggers, comprehensive interactive waterjet reference including articles, videos, and tutorials.

3.3.4.1 Software Seats: Software must include 25 seats. Upgrades to software must be provided when available for all 25 seats.

3.3.5 Pump System: Each pump shall be a direct drive crankshaft type pump with variable frequency drive controller, capable of obtaining and maintaining the designed operating pressure, 60,000 psi, without the use of hydraulic assistance. Pressure attenuators are not allowed to maintain operating pressure. Pump must drive 0.016” orifice at 60,000 psi. Each head will operate with a 0.016” orifice.

SAFETY ITEM: When unit is shut down, must release high pressure water from the entire system including all waterlines and head unit.

3.3.5.1 Dual Pump System: High pressure pumps must be able to drive a 0.022” orifice at 60,000 psi by combining both pumps to drive a single head.

3.3.6 Electrical System: The machine shall be designed to operate from a 460 volt (±3%), 3 phase, 60-hertz (Hz) (±1 hertz) power source. The machine shall consist of independent electric servo drives. All electrical equipment shall comply with NFPA-79 standards.

3.3.7 Cutting Head: One piece nozzle body with integrated diamond orifice warranted to last 500 hours. This one-piece integrated nozzle eliminates the need for rebuilding the nozzle assembly; simply replace the whole assembly when needed.

3.4 Capacities: The sizes and capacities of the machining center shall meet the minimum requirements of Table I below:

TABLE 1

TRAVELS

TABLE

NOZZLE

SPEED

3.5 Accuracy/Repeatability: The machining center shall conform to the following accuracies/alignments of Table 2:

TABLE 2

AXIS REPEATABILITY

3.6 Optional Equipment: The following optional equipment shall be separately priced items:

3.6.1 High Pressure Tubing: The high pressure tubing that supplies pressurized water to the cutting head via the X and Y axis must be made of 3/8” stainless steel tubing, ¼” tubing supply lines will not be allowed.

3.6.2 Pump and Nozzle Spares: Spares for the nozzle and pump are required. Include any special tooling for maintenance. Include first two sets of filter changes, nozzle muffs, and abrasive tubing along with two minor pump rebuild kits and nozzle spares including two diamond orifice nozzle bodies. A compartmented box for storage of spares must be included. Multiple mixing tubes for each head must be supplied.

3.6.3 5-axis cutting head: 5 axis cutting head is a complete software-controlled, multi-axis accessory that features the flexibility to automatically compensate for taper, as well as cut severe angles up to 60° off vertical. The 5 axis head cuts countersunk holes and precision shapes with beveled edges at angles specified by the user. The accessory supplies additional axes of motion, allowing the operator to fabricate and shape metal edges for weld preparation.

3.6.3 Tilting Head for Taper Elimination: Method for eliminating taper must be provided. A nozzle that automatically rotates up to 9 degrees controlled by the software is required. The software can easily enable this mode with a single click. The software calculates the taper requirements continuously, not by average.

3.6.4 Variable Speed Solids Removal System: The garnet removal system must utilize a programmable variable frequency drive providing precise control over garnet evacuation rate, direction, and duration to efficiently remove garnet from the waterjet Catcher Tank. Garnet removal rate as high as 5.6 #/min. Components will utilizes 21 sqft of floor space for equipment. Must be CE and UL approved.

3.6.5 Settling System: The settling tank must efficiently clean overflow water from the Catcher Tank for environmental disposal to a public drain. The tank shall be rust resistant and the baffles shall be easily removable. The tank shall have an inlet of 1-1/2” NPT and an outlet of 1” NPT with a clean-out of 1” NPT. A submersible sediment pump with ground fault circuit interrupter (GFCI) that moves sediment laden water to a Dump Hopper or Catcher Tank must be part of the settling system.

3.6.6 Water Recycling System: The system must be self-contained and recycle the water from the catcher tank back to the high pressure pump. The system must contain a settling tank, chiller, and filtering system. The settling tank must efficiently clean overflow water from the Catcher Tank for environmental disposal to a public drain. The tank shall be rust resistant and the baffles shall be easily removable. The tank shall have an inlet of 1-1/2” NPT and an outlet of 1” NPT with a clean-out of 1” NPT. A submersible sediment pump with ground fault circuit interrupter (GFCI) that moves sediment laden water to a Dump Hopper or Catcher Tank must be part of the settling system. Chiller must be at least 90,000 BTU/hour capacity to maintain a maximum water temperature of 65 F. Acceptable refrigerant types are R-410a, R-134a and R-407c. The filtering system must contain mechanical filtration to remove particles, nano filtration to remove dissolved solids, and a bacteria elimination system. The necessary pumps and monitoring equipment must be included in the filtration system.

3.6.7 Chiller: The machine shall be provided with a water chiller system for cooling process water prior to entering the high pressure pump. The system shall be complete with all necessary pumps, motors, filters, reservoirs, valves, piping, and flow controls. The reservoir system shall be protected from contamination. The chiller must be sized to cool the incoming water to 65F. The chiller shall utilize refrigerant R-410a.

3.6.8 Collision Sensor/Terrain Follower: The Collision Sensing Terrain Follower allows the waterjet to automatically and accurately cut parts from materials with irregular or warped surfaces without the need for special programming. The device is a ring that fits around the nozzle body and automatically sets the appropriate stand-off height to achieve accurate cutting.

3.6.9 Precision Optical Locator: The device allows for accurate location of parts on the machining table or feature on exiting parts. USB camera with microscope lens is provided to zoom in on features, locate, and select with software integrated into the cutting program. Camera resolution must be 1280 x 1024 pixels. The Precision Optical Locator (POL) facilitates precision reverse engineering of existing components and parts. The part is placed on the table and can be accurately measured to within 0.001” using the POL. This information can be automatically used to create the part in OMAX Intelli-MAX Layout software. All features can be accurately identified and programmed without requiring offline software. This allows fabrication of a part without an existing drawing quickly and easily.

3.6.10 600 pound abrasive delivery: Pressurized abrasive tank for holding 600 pounds of garnet must be supplied. One hopper for each bridge must be supplied. This tank must automatically keep the z-axis abrasive hopper full. The tank must include the appropriate air valves and pressure regulators to provide pressure sufficient to move garnet from the tank to the z-axis.

3.6.11 Water and Air Conditioning: The machine shall be supplied with water conditioning equipment. Dual Water wall filters for removal of entrained solids must be included. An air dryer to conditioning incoming air is also required.

3.6.12 Transformer: A transformer to convert existing 240V power to 460V power must be included. The transformer must be sized to handle the loads from the waterjet and all accessories listed.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection: The contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The contractor may utilize his own or any other facility suitable for the performance of the inspection requirements specified herein. Purchaser reserves the right to perform any of the inspections set forth in the specification when such action is deemed necessary to assure supplies and services conform to prescribed requirements. The contractor shall provide all tooling, fixturing, measurement indicating devices, material and programs required of the compliance, accuracy alignment and machining acceptance tests.

4.2 Responsibility for Compliance: The machine shall meet all requirements of Section 3. The inspections set forth in this specification shall become a part of the contractors overall inspection system or quality program.

4.3 Quality Conformance Inspection: Quality conformance inspection shall be conducted on machine prior to being offered for acceptance under the contract. Quality conformance inspection shall be conducted at origin and could be monitored by purchasing personnel. Testing of the complete machine (Table, controller, and pump) must be completed at the factory prior to shipment. The inspection shall be in accordance with par. 4.5, 4.6, and 4.7.

4.4.1 Origin Acceptance Test: All components (pump, table, controller) must be tested together as a complete system prior to shipment. Cut a sample part using the complete system to ensure adherence to specifications before shipment.

4.4.2 Destination Acceptance Test: Final inspection, testing and acceptance shall occur at destination. The acceptance test shall be in accordance with par. 4.5 through 4.6.

4.5 Test Conditions: All tests shall be performed in an indoor facility with ambient conditions of 41°F to 104°F and 20% to 95% relative humidity.

4.6 Examination: The machine shall be visually examined to determine compliance with all requirements within Section 3. Buyer may select part for cutting to specification during installation.

4.7 Training: On-site training must be provided during machine installation. On-site training must consist of no less than 3 days which will include operation, programming and routine maintenance of the machine. Additional training at factory location must be offered to unlimited individuals for the life of the machine at no additional cost other than all travel expenses.

4.8 Warranty: The machine shall have a two year parts and labor limited warranty.

5.0 TECHNICAL DATA

5.1 Manuals/Drawings: The contractor shall furnish one (1) hard copies of all technical manuals/drawings containing all information necessary for the programming, operation and maintenance (parts lists, electrical schematics, ladder logic and I/O diagrams) of the waterjet abrasive cutting system. One (1) complete set of manuals/drawings shall be sent to the receiving activity concurrent with machine delivery.

5.2 Installation Drawings: The contractor shall provide to the receiving facility, installation drawings showing the necessary compressed air, water, and electrical utilities of the waterjet abrasive cutting system.

5.3 Documentation: All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct.