Combo_W56HZV-16-R-L703.pdf

I. INTRODUCTION

A. This is a Combined Synopsis/Solicitation for commercial items prepared in accordance with the format in FAR Parts 12.6 as supplemented with additional information in this notice. This announcement constitutes the only solicitation; quotations are being requested and a written solicitation will not be issued.

B. The combined synopsis and Request for Proposal (RFP) number is:

W56HZV-16-R-L703.

C. This solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular 2005-77.

D. Small Business Set-Aside: N/A

E. Posting Date: March 03, 2016

F. Response Date: March 21, 2016, 1200pm (Eastern Standard Time)

G. Contracting Office: Army Contracting Command - Warren (ACC-WRN) 6501

E. Eleven Mile, Warren, MI 48397. Contract Specialist Pam Mazure pamela.j.mazure.civ@mail.mil

H. The NAICS code applicable to this acquisition is 335999. Offeror must be certified in the System for Award Management (SAM) under this NAICS code prior to receiving an award.

I. This Combined Synopsis Solicitation contains clauses and provisions requiring a fill-in or representation. Offeror shall submit a copy of this Combined Synopsis Solicitation with their bid and respond to these clauses and provisions accordingly. A failure to complete these fill-ins may cause your offer to be determined ineligible for award.

J. Multiple awards are being considered for this solicitation. The Government may award two separate contracts: one for the 75kW Inverters requirement and its corresponding option (CLIN 0001 & CLIN 1001), and one for the 20kW Inverters requirement and its corresponding option (CLIN 0002 and CLIN 1002). Offerors are encouraged to propose for one or both of the requirements. Since multiple awards are being considered the Scope of Work is broken out into two parts, one for each requirement. The Contract Data Requirements List (CLIN 0003) is identical and applies to both requirements.

K. Basis for award - See 52.212-1 Instruction to Offerors and 52.212-2 for evaluation criteria.

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30

1. REQUISITION NUMBER

SEE SCHEDULE

2. CONTRACT NO. 3. AWARD/EFFECTIVE DATE 4. ORDER NUMBER 5. SOLICITATION NUMBER 6. SOLICITATION ISSUE DATE

W56HZV-16-R-L703

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME b. TELEPHONE NUMBER (No Collect Calls) 8. OFFER DUE DATE/LOCAL TIME

9. ISSUED BY

CODE

W56HZV

10. THIS ACQUISITION IS

X UNRESTRICTED OR

SET ASIDE: % FOR:

U.S. ARMY CONTRACTING COMMAND

6501 E. 11 MILE ROAD

WARREN MI 48397-5000

SMALL BUSINESS

HUBZONE SMALL

WOMEN-OWNED SMALL BUSINESS (WOSB)

ELIGIBLE UNDER THE WOMEN-OWNED

SMALL BUSINESS PROGRAM

NAICS:

BUSINESS

TEL: SERVICE-DISABLED

VETERAN-OWNED

EDWOSB

8(A)

335999

SIZE STANDARD:

FAX:

11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

12. DISCOUNT TERMS

SMALL BUSINESS

13a. THIS CONTRACT IS A

RATED ORDER UNDER

13b. RATING

SEE SCHEDULE

DPAS (15 CFR 700) 14. METHOD OF SOLICITATION

RFQ IFB

X RFP

15. DELIVER TO CODE 16. ADMINISTERED BY

CODE

17a.CONTRACTOR/ CODE FACILITY

OFFEROR CODE

18a. PAY MENT WILL BE MADE BY CODE

TELEPHONE NO.

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

SUCH ADDRESS IN OFFER BELOW IS CHECKED SEE ADDENDUM

19. 20. 21. 22. 23. 24.

ITEM NO. SCHEDULE OF SUPPLIES/ SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

25. ACCOUNTING AND APPROPRIATION DATA 26. TOTAL AWARD AMOUNT (For Gov t. Use Only )

27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1. 52.212-4. FAR 52.212-3. 52.212-5 ARE ATTACHED.

ADDENDA ARE

ARE NOT ATTACHED

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA ARE ARE NOT ATTACHED

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN 1 29. AWARD OF CONTRACT: REF.

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND OFFER DATED . Y OUR OFFER ON SOLICITATION

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED.

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a.UNITED STATES OF AMERICA (SIGNATURE OF CONTRACTING OFFICER)

30b. NAME AND TITLE OF SIGNER 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER

(TYPE OR PRINT)

(TYPE OR PRINT) 31c. DATE SIGNED

TEL:

EMAIL:

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA – FAR (48 CFR) 53.212

X

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

(CONTINUED)

19.

ITEM NO.

20.

SCHEDULE OF SUPPLIES/ SERVICES

21.

QUANTITY

22.

UNIT

23.

UNIT PRICE

24.

AMOUNT

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED

ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED:

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE 32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f . TELEPHONE NUMBER OF AUTHORIZED GOVERNMENT REPRESENTATIVE

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

33. SHIP NUMBER 34. VOUCHER NUMBER 35. AMOUNT VERIFIED

CORRECT FOR

36. PAYMENT

COMPLETE PARTIAL FINAL

37. CHECK NUMBER

PARTIAL FINAL

38. S/R ACCOUNT NUMBER 39. S/R VOUCHER NUMBER 40. PAID BY

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT 42a. RECEIVED BY (Print)

41b. SIGNATURE AND TITLE OF CERTIFY ING OFFICER 41c. DATE

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012) BACK

Prescribed by GSA – FAR (48 CFR) 53.212

Section SF 1449 - CONTINUATION SHEET

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 2 Each

75kW Inverter Controller

FFP

FOB: Destination

PURCHASE REQUEST NUMBER: 0010772927-0001

NET AMT

0002 2 Each

20kW Inverter Controller

FFP

PURCHASE REQUEST NUMBER: 0010772925

UNCLASSIFIED – Distribution Statement A. Approved for public release.

CDRLS Not Separately Priced

CONTRACT DATA REQUIREMENTS LIST.

THE CONTRACTOR WILL PREPARE AND DELIVER THE DATA IN

ACCORDANCE WITH THE REQUIREMENTS. QUANTITIES AND

SCHEDULES SET FORTH IN THE CONTRACT DATA REQUIREMENTS

LIST (DD FORM 1423), EXHIBIT A, AS REQUIRED.

A DD 250 OR WAWF FORM IS NOT REQUIRED.

See Exhibit A

1001 10 Each OPTION 75kW Inverter Controller

FFP

OPTION

20kW Inverter Controller

Each

FFP

STATEMENT OF WORK (SOW) 75KW

STATEMENT OF WORK

75 kW Generator Controller

C.1 OBJECTIVES:

C.1.1 Overview

C.1.1.1 Objective of the overarching program - The goal of the Improving Fuel Economy for the Current Tactical Ground Vehicle Fleet (IFECGTF) effort is to develop and demonstrate an affordable truck auxiliary system electrification kit on one or more existing Tactical Wheeled Vehicle (TWV) platforms to significantly improve vehicle operational energy, range, and system growth. The program vision is to demonstrate an electrification kit that creates a 15% to 25% reduction in fuel usage, improved vehicle mobility performance, enhanced silent watch capability, a shore power connection for export power capability, and possess the future electrical capability to support large electrical loads.

To accomplish this program vision, the following components will be investigated for inclusion in the electrification kit: an integrated starter generator (ISG), ISG controller, LI-Ion 6T batteries, electrified steering, electrified HVAC, electrified engine cooling, electrified pumps, and a shore power connection. The intent of the program is to develop an affordable electrification kit for the TWV platform application. The electrification kit must be lightweight, robust, compact, and affordable.

C.1.1.2 Objective of this statement of work - This effort will develop two 75 kW generator controllers to support the IFECGTF program. The intent is to modify a commercially available unit to operate without degradation with an 85C liquid cooling input. The controllers will be ruggedized to withstand numerous operational and environmental requirements. The controllers will be first tested at the contractor’ facility, then delivered to TARDEC for testing in the Government’ facility. There are also options to buy additional quantities of the controllers, for vehicle integration testing. It is envisioned that the IFECGTF electrification kit will be applicable to a wide range of tactical vehicles, and be transitioned as part of a TWV kit.

C.1.2 The contractor, acting as an independent contractor and not an agent of the government, shall provide the necessary personnel, facilities, materials and services to complete the effort described herein.

C.1.3 The requirements listed are for continuous operation unless otherwise specified. The generator controller shall be capable of meeting all requirements as stated within this statement of work continuously without reducing the capability of one requirement in order to meet another requirement.

C.1.4 In the event of conflict between the text of this specification and the references cited herein, the text of this specification takes precedence.

C.1.5 Unless otherwise specified, all requirements must be met without the assistance of external devices such as capacitors, inductors, or other electronic devices.

C.2 SCOPE OF WORK:

C.2.1 Specifications: Unless specifically attached hereto, all MIL-STDs referenced herein may be downloaded from https://assist.daps.dla.mil/quicksearch/. Standards from the International Organization for Standardization (ISO) are available from http://www.iso.org/iso/home.html. The generator controller shall meet the following specifications:

C.2.1.1 The generator controller shall output 600 volts direct current (VDC) in accordance with (IAW) and meet the design characteristics of MIL-PRF-GCS600A Characteristics of 600 Volt DC Electrical Systems for Military Ground Vehicles (Attachment 0002). The High Voltage interlocks listed in MIL-PRF-GCS600A are optional. A step load of 40kW with a cable length between the controller and the generator of five (5) me t e r s , shall be used for the step load test of MIL-PRF-GCS600A. The generator controller has multiple modes of operation and must meet the MIL-PRF-GCS600A requirements as a Power source, Power Distribution Equipment, and as Power Utilization equipment.

C.2.1.2 The generator controllers shall be designed to meet its operational performance requirements described in this statement of work during and after being subjected to the following emission and susceptibility requirements of MIL-STD-461G:

a. Conducted Emissions, Power Leads, 10 kHz to 10 MHz (CE102),

b. Conducted Susceptibility, Power Leads, 30 Hz to 150 kHz (CS101),

c. Conducted Susceptibility, Bulk Cable Injection, 10 kHz to 200 MHz (CS114),

d. Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation (CS115),

e. Conducted Susceptibility, Damped Sinusoidal Transients, Cables and Power Leads, 10 kHz to 100 MHz

(CS116),

f. Radiated Emissions, Electric Field, 2 MHz to 12 GHz (RE102),

g. Radiated Susceptibility, Electric Field, 2 MHz to 40 GHz (RS103).

C.2.1.3 The generator controller shall be designed to meet its operational performance requirements described in this statement of work immediately after being subjected to the Radiated Susceptibility, Transient Electromagnetic Field (RS105) requirement of MIL-STD-461F.

C.2.1.4 Reserved

C.2.1.5 The generator controller during generating mode, shall utilize a pre-charge circuit for safe initial activation for all high voltage power feeds as described in MIL-PRF-GCS600A.

C.2.1.6 The generator controller during motoring mode, shall incorporate protection circuitry to protect against inrush currents and transient voltages during initial activation (pre-charge) of the high voltage power supply feed. The generator controller shall be commanded to a low power state until the pre-charge is successful.

C.2.1.7 The generator controller must use readily available commercial materials to meet the requirements of this statement of work.

C.2.2 Performance Requirements: The generator controller shall meet the following performance requirements:

C.2.2.1 Electric Machine Compatibility C.2.2.1.1 The generator controller shall control a 75 kW, 3 phase permanent magnet (PM) machine with a position feedback device in both motoring and generating modes.

C.2.2.1.2 The generator controller shall have inputs and function with all of the following position feedback devices: Resolver, Encoder, Hall Effect sensor, with a power supply capable of supplying 150 milliamps of current to power the feedback device.

C.2.2.2 Power and Torque C.2.2.2.1 The generator controller shall provide 75 kilowatts (kW) of continuous power output on the 600 volts direct current (VDC) side, for the whole motor operating range of 1200 RPM (Revolutions per minute) to 7000RPM.

C.2.2.2.2 The generator controller shall operate an electric machine in torque mode and speed mode to allow for vehicle engine starting and burst acceleration.

C.2.2.2.3 The generator controller shall motor the ISG to perform the engine cranking function pursuant to the following steps:

a. Before the cranking event, the bulk coolant will be flowing with a temperature of 85 degrees Celsius (C).

b. The controller shall also be capable of operating with a bulk coolant temperature of -46C before the cranking event.

c. Minimum peak (five (5) second transient) cranking shall be at least 240 Amps Root-Mean-Square (RMS) output.

d. After the peak, the minimum sustained cranking (steady-state) speed shall be 300 revolutions per minute (RPM), with a capability of at least 130 Amps RMS output.

C.2.2.2.4 The generator controller shall have an output direct current (DC) link capacitance no less than 100 micro-Farads (uF) for DC bus stability. The generator controller shall minimize the effects of source harmonics from the effects of dead time, unbalance of alternating current (AC) input, and torque ripple.

The generator controller shall absorb up to three percent harmonics Root Mean Square (RMS) values relative to the DC magnitude in current from the other DC bus loads.

C.2.2.2.5 The generator controller shall provide 75 kW of continuous power output to the motor.

C.2.2.3 Environmental C.2.2.3.1 The generator controller shall at a minimum meet IP67 and IP66K ratings as defined by the International Electrotechnical Commission (IEC) IP Code, and not be damaged by exposure to engine oil, Diesel fuel, transmission fluid, or engine coolant.

C.2.2.3.2 The generator controller shall operate without performance degradation during basic shock conditions. Basic shock conditions consist of imposing shock half sine impulses of 50 g (1 g=acceleration due to earth’s gravity) with an effective duration of 6 millisecond (ms), in all six spatial directions at the interface between the subsystem and the location of the vehicle where it is mounted per ISO 16750-3, Test

4.2.2.2. This includes mounting brackets, weld joints, shock isolators, or any other mounting device as applicable.

C.2.2.3.3 The generator controller shall operate with no physical damage that affects the performance or functionality at the conditions described in this statement of work.

C.2.2.3.4 The generator controller shall operate without performance degradation during and after exposure to relative humidity up to 100%.

C.2.2.3.5 The generator controller shall meet its full performance requirements without performance or physical degradation while operating to an ambient air and coolant temperature of -46 degrees C.

C.2.2.3.6 The generator controller shall have a Mean Time Between Failure (MTBF) of no less than 25,000 hours.

C.2.2.3.7 The generator controller shall meet the full performance requirements without performance or physical degradation during and after vibrational stresses when tested ISO 16750-3, 4.1.2.4 Test IV

C.2.2.4 Safety

C.2.2.4.1 The generator controller shall have protection from short circuit conditions at the high voltage AC and DC outputs.

C.2.2.4.2 Reserved.

C.2.2.4.3 The generator controller high voltage (HV) power (600 VDC) and return shall have 2500 Volt galvanic isolation or greater from the generator controller control power (28 VDC).

C.2.2.4.4 The generator controller HV power (600 VDC) and return shall be electrically isolated from the equipment chassis by a resistance of 10 Mega-ohms or greater.

C.2.3 Control Interface

C.2.3.1 The generator controller communications (control, monitoring, programming, and GUI) shall be via J1939 CAN protocol (CAN). The generator controller shall provide no network termination.

C.2.3.2 The generator controller shall make available on the CAN all monitored data; this may include phase voltages, DC bus voltage, currents, calculated torque, temperatures, fault status, feedback [bus voltage, current quadrature (Iq) component, and current direct (Id) component {higher update rates for Iq and Id}, rotor position, speed, available temperatures and all other data that the controller monitors.

C.2.3.3 The generator controller shall make available on the CAN the following functions: Enable/disable, Torque command, speed command, voltage command, mode selection (torque, speed, voltage), and individual fault reset.

C.2.3.4 The generator controller shall be configurable via reprogramming through the CAN interface.

C.2.3.5 The generator controller CAN messages shall use the messaging format in the CAN message interface control document (ICD) template (Attachment 0001).

C.2.3.6 The generator controller shall record faults and report them over the CAN for system diagnosis.

C.2.3.7 The generator controller software shall alert via CAN when regulation pursuant to MIL-PRF- GCS600A (ARMY) (Attachment 0002) is not possible due to ISG and generator controller limitations.

C.2.3.8 The generator controller shall be configurable without modifying source code. Configuration Options shall at a minimum include the following:

a. Machine Type (Interior Permanent Magnet (IPM), Surface-mount Permanent Magnet (SPM))

b. Number of pole pairs

c. Resolver, encoder, hall feedback

d. Resolver configuration (excitation frequency, number of resolver poles, alignment)

e. Encoder configuration (number of lines, alignment (index))

f. Hall configuration (alignment)

g. Tuning parameters (Proportional Integral Derivative gains for current/speed/voltage loops)

h. Calibration (offset and gain on current/voltage sensors)

i. Limits (current, voltage, slew rates, temperature, speed)

j. Switching frequency

k. Dead time

l. Temperature foldback and shutdown current settings

m. Digital to analog (D/A) output settings real-time update rate (e.g. Id, Iq, Volts Direct Current (Vdc), Phase Currents (Ia, Ib, Ic) Voltage quadrature (Vq) component, Voltage direct (Vd) component, position, speed)

n. Field weakening parameters (e.g. Iq and Id profiles with respect to torque and speed)

o. Save serial configuration options to non-volatile memory

p. Calibration for operation with a position sensor.

q. Save and restore all parameters to disk (on the programming computer)

C.2.3.9 The generator controller shall be designed to be programmable by the end user with minimal training to allow for integration with PM machines of varying designs.

C.2.3.10 The generator controller shall utilize a 28VDC input for low voltage control power. The 28 VDC bus shall be compatible with MIL-STD-1275E.

C.2.3.11 The generator controller application software shall provide access to:

a. Input / Output (I/O) signals

b. Status

c. Drive faults

d. Torque (current)

e. Feedback signals (rotor position and rotor speed, current, bus voltage, and power delivered to the HV DC Link (HV Bus).)

C.2.3.12 The generator controller shall cease bus regulation and cease energizing the bus within 100 millisecond after receipt of an external command via messaging from the CAN bus.

C.2.3.13 The generator controller firmware and embedded operating system software shall be upgradable with the provided software from the contractor.

C.2.3.14 The generator controller shall have a minimum of four Digital to Analog (D/A) programmable outputs, and four Analog to Digital inputs, and two Resistance Temperature Detector (RTD) inputs. The inputs and outputs shall be user programmable through the provided software.

C.2.4 Cooling C.2.4.1 The generator controller shall operate at full power with 85 degrees Celsius input coolant and a 105 degrees Celsius ambient temperature. The flow rate shall not exceed 12 liters/minute, at 9 psig (Pounds per Square Inch Gauge) inlet pressure. The maximum outlet temperature shall not exceed 120 degrees Celsius.

C.2.4.2 The generator controller components shall be designed to withstand a non-operational peak soak back temperature of 105 degrees Celsius.

C.2.4.3 The generator controller shall be compatible with a Water Ethylene Glycol (WEG) 50/50 mixture as well as a 60/40 mixture, and be capable of operating at a pressure of 50 PSIG.

C.2.4.4 The generator controller shall monitor critical cooling performance data, including at a minimum, inlet and outlet coolant temperatures, and critical heat rejection component temperatures (e.g. power conversion devices). Examples of Critical components include the components that will be first to suffer failure due to excessive heat rejection while under load conditions.

C.2.4.5 The generator controller shall have average operational efficiency of at least 95%.

C.2.5 Space Claim C.2.5.1 The generator controller volume shall not exceed 18 liters. The power used to compute the volume and weight shall be the continuous electrical power of the generator controller. Continuous operation is defined as operation for 120 minutes at constant output power and stabilized conditions with coolant inlet temperatures of greater than or equal to 85 degrees Celsius inlet and a 105 degrees Celsius ambient temperature, while operating from 600 VDC Bus. The volume and weight used for the power density and specific power (power/weight) calculation is calculated with a rectangular box that includes the total generator controller enclosure and all components that are mechanically and permanently attached, including all generator controller hardware such as the power stage, gate drive/power supply, inductors, sensors, filters, and interfaces.

C.2.5.2 The generator controller weight shall not exceed 25 kg.

C.2.5.3 The generator controller shall be designed to be mounted in any physical orientation and operate without degradation. The contractor shall deliver PRO-E compatible models of the exterior envelope of the generator controller IAW C.5.5.

C.2.5.4 The generator controller shall have a 600VDC bi-directional circuit with a 125 amp current rating.

The 600VDC circuit shall utilize solid state circuit breakers that are configured electrically as normally off (the device will not pass current without a gate signal). The circuit shall have a user adjustable current setting that allows for adjustments from 20% to 100% of its maximum current rating. The circuit shall have the ability to be disabled via a message from the CAN bus. The circuit shall provide bi-directional pre-charge protection as described in MIL-PRF-GCS600A section 3.5.1.4.

C.2.6 Graphical User Interface (GUI):

C.2.6.1 The contractor shall deliver a GUI (C.5.6) for the generator controller that functions over a CAN communication interface, and that provides data acquisition capability for testing.

C.2.6.2 The GUI shall allow for the tuning of the ISG parameters, including hardware controlled and monitored current and voltage limits, control(s) system gain parameters, bus voltage control gains and limits, and any other parameters essential for HV Power production and HV Bus voltage regulation. The GUI shall have data logging and debugging functionality.

C.2.6.3 The contractor shall deliver a user manual for the GUI IAW CDRL A007 and C.5.7. The contractor shall also deliver the final version of firmware required for operation of the generator controller IAW CDRL A009 and C.5.2.

C.2.7 Cost

C.2.7.1 The Contractor shall provide a report describing the cost of the generator controller at a production quantity of 1000/year. The report will detail any special equipment, tooling, modifications necessary to get below a cost of $2250 at a production quantity of 1000/year. The Contractor shall provide supporting information regarding volume cost roll-up of the inverter. This information shall be included in the Final Report.

C.3 Testing, Integration and Training:

C.3.1 Reserved.

C.3.2 A test of the controller will be conducted at the contractor facility prior to delivery. This test will be referred to hereafter as the Contractor Facility Test. The COR or COR alternate will be present for this test.

Acceptance will be completed following the methodology identified in Attachment 0003 (Generator Controller Performance Testing Inspection and Acceptance Criteria). After COR concurrence of a successful test the contractor shall ship the controller to the TARDEC Systems Integration Lab (SIL) in Warren, MI. The contractor shall document test results and provide them to the COR no less than 10 calendar days after the completion of the test and test results shall be included in the Final Report (CDRL A002)

C.3.3 The contractor shall provide one day of training for up to 15 TARDEC personnel at TARDEC on the use and optimization of the ISG operation no later than 270 days after contract award. The contractor shall develop a Training Plan IAW CDRL A010. The Training Plan shall be delivered IAW C.5.13. An existing government owned ISG will be utilized for the training. The contractor shall coordinate the specific dates for the integration of the generator controller unit and training with COR no less than ten (10) calendar days in advance.

C.3.4 The contractor shall provide remote technical assistance in support of government testing for the delivered controllers. The support shall be provided for 1240 days after contract award.

C.4 Meetings C.4.1 Start of Work Meeting: The contractor shall plan and conduct a one (1) day start of work meeting via teleconference within fourteen (14) calendar days after contract award. The date and time of the start of work meeting shall be mutually agreed to between the COR and contractor. The contractor shall coordinate this meeting with the COR and at a minimum invite the COR, the Contract Specialist shown on page one of the contract and the Administrative Contracting Officer shown in Section G of the contract. The contractor shall prepare presentation materials IAW CDRL A003. The presentation materials shall at a minimum include a project schedule, and detailed line by line description how this statement of work will be met. The presentation materials shall be delivered to the COR no later than one (1) calendar day prior to the scheduled meeting. The contractor shall prepare minutes from the Start of Work meeting IAW CDRL A004. The minutes shall be delivered IAW C.5.11.

C.4.2 Reserved.

C.5 Deliverables C.5.1 Bi-Monthly Reports: The contractor shall submit bi-monthly (every two months) progress reports for the duration of this contract IAW CDRL A001. The first report shall be due 60 days after contract award.

Subsequent reports are due every 60 days thereafter.

C.5.2 Generator Controller Unit: The Contractor shall deliver two (2) functioning generator controllers that meet the requirements specified above, no later than 270 days after contract award. The controllers shall be delivered to the US Army TARDEC in Warren, MI. The contractor shall also deliver the final version of firmware required for operation of the generator controller IAW CDRL A009 in conjunction with the generator controller hardware deliverables to the US Army TARDEC in Warren, MI. Performance acceptance will be completed following the methodology identified in Attachment 0003 (Generator Controller Performance Testing Inspection and Acceptance Criteria).

C.5.3 Performance Specification and Interface Control Document: The Contractor shall develop and deliver a non-proprietary, public releasable Performance Specification and Interface Control Document (ICD) that will enable integration of the controller into an electrical power system. The generator controller CAN messages shall use the messaging format in the CAN message interface control document (ICD) template (Attachment 0001).The contractor shall deliver the Performance Specification and ICD to the COR IAW CDRL A005 within 270 days of contract award. The contractor shall provide a draft of the Performance Specification and ICD to the COR no later than 240 days after award. The COR will concur or comment within 15 calendar days of each design review. Any revisions required to obtain COR approval shall be made and resubmitted to the COR for approval within 15 calendar days of receipt of COR comments.

C.5.4 Functional Diagrams and Schematics: The Contractor shall deliver functional diagrams and schematics IAW CDRL A006 to describe the operation of the controller for the generator controller hardware and software developed and delivered under this contract. The contractor shall deliver As-Built functional diagrams and schematics IAW CDRL A006. The As-Built Finals shall be delivered no later than 270 days after award. The COR will concur or comment within 15 calendar days. Any revisions required to obtain COR approval shall be made and resubmitted to the COR for approval within 15 calendar days of receipt of COR comments.

C.5.5 RO-E Compatible Models of Exterior Envelope: The Contractor shall deliver the electronic version of the PRO-E compatible models of the exterior envelope, with connections and mounting points, for the generator controller IAW CDRL A006. The contractor shall deliver As-Built PRO-E compatible models of the exterior envelope IAW CDRL A006. The As-Built shall be delivered no later than 270 days after award.

The COR will concur or comment within 15 calendar days. Any revisions required to obtain COR approval shall be made and resubmitted to the COR for approval within 15 calendar days of receipt of COR comments.

C.5.6 GUI Software: The Contractor shall deliver the GUI software, CAN communication interface, and any necessary programming interfaces to upgrade the embedded firmware, to the COR IAW CDRL A007 within 270 days of contract award.

C.5.7 GUI Software User Manual: The contractor shall deliver the user manual for the GUI software IAW CDRL A007 within 270 days of contract award. A draft of the GUI software user manual shall be delivered to the COR no later than 240 days after award. The COR will review and approve or comment on the user manual within 15 calendar days of receipt. The contractor shall revise and resubmit the Final GUI software manual within 15 calendar days of receipt of COR comments.

C.5.8 Final Report: The contractor shall deliver a Final Report IAW CDRL A002 no later than 1240 days after award. This report shall include all data collected during tests and the test results, source code developed under this effort, recommendations for future improvements, lessons learned, and a detailed cost breakdown to support 1000 unit costing to be used for development of cost/payback for the inverter integrated with the balance of the system (see C.2.7.1). A draft of the final report shall be delivered to the COR no later than 17 months after award. The COR will review and provide comments within 15 calendar days after receipt. The contractor shall incorporate COR comments and submit the Final Report within 15 calendar days after receipt of COR comments.

C.5.9 Reserved.

C.5.10 Presentation Materials: The contractor shall deliver presentation materials IAW CDRL A003. All presentation materials shall include an agenda and program plan. Presentation materials shall be provided to the COR no later than seven (7) calendar days prior to the applicable meeting or review unless otherwise s t a t e d in the statement of work. The contractor shall obtain COR approval of the program plan and any subsequent update thereto prior to proceeding with the effort. The COR will concur or comment on the program plan within 15 calendar days after each meeting and review. Any revisions required to obtain COR approval shall be made and resubmitted to the COR for approval within 15 calendar days of receipt of COR comments.

C.5.11 Meeting Minutes: The contractor shall deliver conference minutes (meeting minutes) IAW CDRL A004. All meeting minutes shall be provided to the COR no later seven (7) calendar days after each m e e t i n g .

C.5.12 Reserved.

C.5.13 Training Plan: The contractor shall deliver a training plan IAW CDRL A010 no later than 270 days after award. The contractor shall provide a draft of the training plan to the COR no later than 240 days after award.

The COR will review and approve or comment on the training plan within 15 calendar days of receipt. The contractor shall revise and resubmit within 15 calendar days of receipt of COR comments.

C.6.1 Option 1: Additional generator controllers:

C.6.1.1 If exercised, the Contractor shall build up to ten (10) functioning generator controllers that meet the requirements specified in the base statement of work (C.1 through C.5).

C.6.1.2 The contractor shall test each of the generator controller(s) at its facility in accordance with the approved test plan developed and approved by the COR in paragraphs C.3.2. The contractor shall deliver all test data to the COR in accordance with CDRL A002. After COR concurrence of successful demonstration of the generator controller(s) (at the contractor facility), the contractor shall deliver the functioning generator controller(s) within 240 days of the start date of the option, in accordance with Section F.3.2.1.1 of the contract for government acceptance testing.

C.6.1.3 The contractor shall deliver Bi-Monthly (every two months) Progress reports for the duration of the Generator Controller option effort, in accordance with CDRL A001, aligned and continuing timing listed in C.5.1.

[End of Statement of Work]

STATEMENT OF WORK (SOW) 20KW

STATEMENT OF WORK

20 kW Generator Controller

C.1 OBJECTIVES:

C.1.1 Overview

C.1.1.1 Objective of the overarching program - The goal of the Improving Fuel Economy for the Current Tactical Ground Vehicle Fleet (IFECGTF) effort is to develop and demonstrate an affordable truck auxiliary system electrification kit on one or more existing Tactical Wheeled Vehicle (TWV) platforms to significantly improve vehicle operational energy, range, and system growth. The program vision is to d e m o n s t r a t e an electrification kit that creates a 15% to 25% reduction in fuel usage, improved vehicle mobility performance, enhanced silent watch capability, a shore power connection for export power capability, and possess the future electrical capability to support large electrical loads.

To accomplish this program vision, the following components will be investigated for inclusion in the electrification kit: an integrated starter generator (ISG), ISG controller, LI-Ion 6T batteries, electrified steering, electrified HVAC, electrified engine cooling, electrified pumps, and a shore power connection. The intent of the program is to develop an affordable electrification kit for the TWV platform application. The electrification kit must be lightweight, robust, compact, and affordable.

C.1.1.2 Objective of this statement of work - This effort will develop two 20 kW generator controllers to suppor t the IFECGTF program. The intent is to modify a commercially available unit to operate without degradation with an 85C liquid cooling input. The controllers will be ruggedized to withstand numerous operational and environmental requirements. The controllers will be first tested at the contractor’ facility, then delivered to TARDEC for testing in the Government’ facility. There are also options to buy additional quantities of the controllers, for vehicle integration testing. It is envisioned that the IFECGTF electrification kit will be applicable to a wide range of tactical vehicles, and be transitioned as part of a TWV kit.

C.1.2 The contractor, acting as an independent contractor and not an agent of the government, shall provide the necessary personnel, facilities, materials and services to complete the effort described herein.

C.1.3 The requirements listed are for continuous operation unless otherwise specified. The generator c o n t r o l l e r shall be capable of meeting all requirements as stated within this statement of work continuously without reducing the capability of one requirement in order to meet another requirement.

C.1.4 In the event of conflict between the text of this specification and the references cited herein, the text o f this specification takes precedence.

C.1.5 Unless otherwise specified, all requirements must be met without the assistance of external devices s u c h as capacitors, inductors, or other electronic devices.

C.2 SCOPE OF WORK:

C.2.1 Specifications: Unless specifically attached hereto, all MIL-STDs referenced herein may be downloaded from https://assist.daps.dla.mil/quicksearch/. Standards from the International Organization for Standardization (ISO) are available from http://www.iso.org/iso/home.html. The generator controller shall meet the following specifications:

C.2.1.1 The generator controller shall output 600 volts direct current (VDC) in accordance with (IAW) and m e e t the design characteristics of MIL-PRF-GCS600A Characteristics of 600 Volt DC Electrical Systems for Military Ground Vehicles (Attachment 0002). The High Voltage interlocks listed in MIL-PRF-GCS600A are optional. A step load of 11kW with a cable length between the controller and the generator of five (5) me t e r s , shall be used for the step load test of MIL-PRF-GCS600A. The generator controller has multiple modes of operation and must meet the MIL-PRF-GCS600A requirements as a Power source, Power Distribution Equipment, and as Power Utilization equipment.

C.2.1.2 The generator controllers shall be designed to meet its operational performance requirements described in this statement of work during and after being subjected to the following emission and susceptibility requirements of MIL-STD-461G:

a. Conducted Emissions, Power Leads, 10 kHz to 10 MHz (CE102),

b. Conducted Susceptibility, Power Leads, 30 Hz to 150 kHz (CS101),

c. Conducted Susceptibility, Bulk Cable Injection, 10 kHz to 200 MHz (CS114),

d. Conducted Susceptibility, Bulk Cable Injection, Impulse Excitation (CS115),

e. Conducted Susceptibility, Damped Sinusoidal Transients, Cables and Power Leads, 10 kHz to 100 MHz

(CS116),

f. Radiated Emissions, Electric Field, 2 MHz to 12 GHz (RE102),

g. Radiated Susceptibility, Electric Field, 2 MHz to 40 GHz (RS103).

C.2.1.3 The generator controller shall be designed to meet its operational performance requirements described in this statement of work immediately after being subjected to the Radiated Susceptibility, Transient Electromagnetic Field (RS105) requirement of MIL-STD-461F.

C.2.1.4 Reserved

C.2.1.5 The generator controller during generating mode, shall utilize a pre-charge circuit for safe initial activation for all high voltage power feeds as described in MIL-PRF-GCS600A.

C.2.1.6 The generator controller during motoring mode, shall incorporate protection circuitry to protect against inrush currents and transient voltages during initial activation (pre-charge) of the high voltage power supply feed. The generator controller shall be commanded to a low power state until the pre-charge is successful.

C.2.1.7 The generator controller must use readily available commercial materials to meet the requirements of this statement of work.

C.2.2 Performance Requirements: The generator controller shall meet the following performance requirements:

C.2.2.1 Electric Machine Compatibility C.2.2.1.1 The generator controller shall control a 20 kW, 3 phase permanent magnet (PM) machine with a position feedback device in both motoring and generating modes.

C.2.2.1.2 The generator controller shall have inputs and function with all of the following position feedback devices: Resolver, Encoder, Hall Effect sensor, with a power supply capable of supplying 150 milliamps of current to power the feedback device.

C.2.2.2 Power and Torque C.2.2.2.1 The generator controller shall provide 20 kilowatts (kW) of continuous power output on the 600 volts direct current (VDC) side, for the whole motor operating range of 1200 RPM (Revolutions per minute) to 7000RPM.

C.2.2.2.2 The generator controller shall operate an electric machine in torque mode and speed mode to allow for vehicle engine starting and burst acceleration.

C.2.2.2.3 The generator controller shall motor the ISG to perform the engine cranking function pursuant to the following steps:

a. Before the cranking event, the bulk coolant will be flowing with a temperature of 85 degrees Celsius (C).

b. The controller shall also be capable of operating with a bulk coolant temperature of -46C before the cranking event.

c. Minimum peak (five (5) second transient) cranking shall be at least 65 Amps Root-Mean-Square (RMS) output.

d. After the peak, the minimum sustained cranking (steady-state) speed shall be 300 revolutions per minute (RPM), with a capability of at least 35 Amps RMS output.

C.2.2.2.4 The generator controller shall have an output direct current (DC) link capacitance no less than 100 micro-Farads (uF) for DC bus stability. The generator controller shall minimize the effects of source harmonics from the effects of dead time, unbalance of alternating current (AC) input, and torque ripple.

The generator controller shall absorb up to three percent harmonics Root Mean Square (RMS) values relative to the DC magnitude in current from the other DC bus loads.

C.2.2.2.5 The generator controller shall provide 20 kW of continuous power output to the motor.

C.2.2.3 Environmental C.2.2.3.1 The generator controller shall at a minimum meet IP67 and IP66K ratings as defined by the International Electrotechnical Commission (IEC) IP Code, and not be damaged by exposure to engine oil, Diesel fuel, transmission fluid, or engine coolant.

C.2.2.3.2 The generator controller shall operate without performance degradation during basic shock conditions. Basic shock conditions consist of imposing shock half sine impulses of 50 g (1 g=acceleration due to earth’s gravity) with an effective duration of 6 millisecond (ms), in all six spatial directions at the interface between the subsystem and the location of the vehicle where it is mounted per ISO 16750-3, Test

4.2.2.2. This includes mounting brackets, weld joints, shock isolators, or any other mounting device as applicable.

C.2.2.3.3 The generator controller shall operate with no physical damage that affects the performance or functionality at the conditions described in this statement of work.

C.2.2.3.4 The generator controller shall operate without performance degradation during and after exposure to relative humidity up to 100%.

C.2.2.3.5 The generator controller shall meet its full performance requirements without performance or physical degradation while operating to an ambient air and coolant temperature of -46 degrees C.

C.2.2.3.6 The generator controller shall have a Mean Time Between Failure (MTBF) of no less than 25,000 hours.

C.2.2.3.7 The generator controller shall meet the full performance requirements without performance or physical degradation during and after vibrational stresses when tested ISO 16750-3, 4.1.2.4 Test IV

C.2.2.4 Safety

C.2.2.4.1 The generator controller shall have protection from short circuit conditions at the high voltage AC and DC outputs.

C.2.2.4.2 Reserved.

C.2.2.4.3 The generator controller high voltage (HV) power (600 VDC) and return shall have 2500 Volt galvanic isolation or greater from the generator controller control power (28 VDC).

C.2.2.4.4 The generator controller HV power (600 VDC) and return shall be electrically isolated from the equipment chassis by a resistance of 10 Mega-ohms or greater.

C.2.3 Control Interface

C.2.3.1 The generator controller communications (control, monitoring, programming, and GUI) shall be via J1939 CAN protocol (CAN). The generator controller shall provide no network termination.

C.2.3.2 The generator controller shall make available on the CAN all monitored data; this may include phase voltages, DC bus voltage, currents, calculated torque, temperatures, fault status, feedback [bus voltage, current quadrature (Iq) component, and current direct (Id) component {higher update rates for Iq and Id}, rotor position, speed, available temperatures and all other data that the controller monitors.

C.2.3.3 The generator controller shall make available on the CAN the following functions: Enable/disable, Torque command, speed command, voltage command, mode selection (torque, speed, voltage), and individual fault reset.

C.2.3.4 The generator controller shall be configurable via reprogramming through the CAN interface.

C.2.3.5 The generator controller CAN messages shall use the messaging format in the CAN message interface control document (ICD) template (Attachment 0001).

C.2.3.6 The generator controller shall record faults and report them over the CAN for system diagnosis.

C.2.3.7 The generator controller software shall alert via CAN when regulation pursuant to MIL-PRF- GCS600A (ARMY) (Attachment 0002) is not possible due to ISG and generator controller limitations.

C.2.3.8 The generator controller shall be configurable without modifying source code. Configuration Options shall at a minimum include the following:

a. Machine Type (Interior Permanent Magnet (IPM), Surface-mount Permanent Magnet (SPM))

b. Number of pole pairs

c. Resolver, encoder, hall feedback

d. Resolver configuration (excitation frequency, number of resolver poles, alignment)

e. Encoder configuration (number of lines, alignment (index))

f. Hall configuration (alignment)

g. Tuning parameters (Proportional Integral Derivative gains for current/speed/voltage loops)

h. Calibration (offset and gain on current/voltage sensors)

i. Limits (current, voltage, slew rates, temperature, speed)

j. Switching frequency

k. Dead time

l. Temperature foldback and shutdown current settings

m. Digital to analog (D/A) output settings real-time update rate (e.g. Id, Iq, Volts Direct Current (Vdc), Phase Currents (Ia, Ib, Ic) Voltage quadrature (Vq) component, Voltage direct (Vd) component, position, speed)

n. Field weakening parameters (e.g. Iq and Id profiles with respect to torque and speed)

o. Save serial configuration options to non-volatile memory

p. Calibration for operation with a position sensor.

q. Save and restore all parameters to disk (on the programming computer)

C.2.3.9 The generator controller shall be designed to be programmable by the end user with minimal training to allow for integration with PM machines of varying designs.

C.2.3.10 The generator controller shall utilize a 28VDC input for low voltage control power. The 28 VDC bus shall be compatible with MIL-STD-1275E.

C.2.3.11 The generator controller application software shall provide access to:

a. Input / Output (I/O) signals

b. Status

c. Drive faults

d. Torque (current)

e. Feedback signals (rotor position and rotor speed, current, bus voltage, and power delivered to the HV DC Link (HV Bus).)

C.2.3.12 The generator controller shall cease bus regulation and cease energizing the bus within 100 millisecond after receipt of an external command via messaging from the CAN bus.

C.2.3.13 The generator controller firmware and embedded operating system software shall be upgradable with the provided software from the contractor.

C.2.3.14 The generator controller shall have a minimum of four Digital to Analog (D/A) programmable outputs, and four Analog to Digital inputs, and two Resistance Temperature Detector (RTD) inputs. The inputs and outputs shall be user programmable through the provided software.

C.2.4 Cooling C.2.4.1 The generator controller shall operate at full power with 85 degrees Celsius input coolant and a 105 degrees Celsius ambient temperature. The flow rate shall not exceed 4 liters/minute, at 9 psig (Pounds per Square Inch Gauge) inlet pressure. The maximum outlet temperature shall not exceed 120 degrees Celsius.

C.2.4.2 The generator controller components shall be designed to withstand a non-operational peak soak back temperature of 105 degrees Celsius.

C.2.4.3 The generator controller shall be compatible with a Water Ethylene Glycol (WEG) 50/50 mixture as well as a 60/40 mixture, and be capable of operating at a pressure of 50 PSIG.

C.2.4.4 The generator controller shall monitor critical cooling performance data, including at a minimum, inlet and outlet coolant temperatures, and critical heat rejection component temperatures (e.g. power conversion devices). Examples of Critical components include the components that will be first to suffer failure due to excessive heat rejection while under load conditions.

C.2.4.5 The generator controller shall have average operational efficiency of at least 95%.

C.2.5 Space Claim C.2.5.1 The generator controller volume shall not exceed 5 liters. The power used to compute the volume and weight shall be the continuous electrical power of the generator controller. Continuous operation is defined as operation for 120 minutes at constant output power and stabilized conditions with coolant inlet temperatures of greater than or equal to 85 degrees Celsius inlet and a 105 degrees Celsius ambient temperature, while operating from 600 VDC Bus. The volume and weight used for the power density and specific power (power/weight) calculation is calculated with a rectangular box that includes the total generator controller enclosure and all components that are mechanically and permanently attached, including all generator controller hardware such as the power stage, gate drive/power supply, inductors, sensors, filters, and interfaces.

C.2.5.2 The generator controller weight shall not exceed 10 kg.

C.2.5.3 The generator controller shall be designed to be mounted in any physical orientation and operate without degradation. The contractor shall deliver PRO-E compatible models of the exterior envelope of the generator controller IAW C.5.5.

C.2.5.4 The generator controller shall have a 600VDC…