Attachment_0001_-_DVP_-_SLA_Battery_Pack_for_M-ATV_DAS_-_PCO_Concur.xlsx
XLSX spreadsheet 31 KB Posted
- Attached to
- M-ATV Battery Procurement
- Solicitation number
- W56HZV18Q0007
About this file
Design Validation Plan for Batteries for the Mine Resistant Ambush Protected(MRAP) All-Terrain Vehicle (ATV)(M-ATV) Door Assist System (DAS)
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Other files
| File | Type | Posted |
|---|---|---|
| W56HZV-18-Q-0007_Solicitation.pdf | ||
| Attachment_0001_-_DVP_-_SLA_Battery_Pack_for_M-ATV_DAS_-_PCO_Concur.xlsx | XLSX spreadsheet | |
| W56HZV-18-Q-0007_Solicitation_13_JUN_2018.pdf |
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Test Unit Matrix
| Test | Time to complete Test (calendar days) | Specification(s) | TR # | Unit #1 | Unit #2 | Unit #3 | Unit #4 | Unit #5 | Unit #6 | Unit #7 | Unit #8 | Unit #9 | Unit #10 | ||
| 1 | Approval drawing received | 0 | |||||||||||||
| 2 | Test Units Ordered | 56 (8 weeks) | All | All | All | All | All | All | All | All | All | All | |||
| 3 | Analyses | 14 (2 weeks) | All | All | All | All | All | All | All | All | All | All | |||
| 3a | Battery Capacity | 2.3 | TR #TBD | ||||||||||||
| 3b | Battery State of Charge | 2.4 | TR #TBD | ||||||||||||
| 3c | Altitude Capability | 3.3 | TR #TBD | ||||||||||||
| 3d | Power Source Interface | 5.1 | TR #TBD | ||||||||||||
| 3e | Hazardous Materials | 6.1 | TR #TBD | ||||||||||||
| 4 | Inspections | 7 (1 week) | All | All | All | All | All | All | All | All | All | All | |||
| 4a | Dimensional Inspection | 2.1 | TR #TBD | ||||||||||||
| 4b | Weight | 2.2 | TR #TBD | ||||||||||||
| 4c | Connector Configuration | 5.6 | TR #TBD | ||||||||||||
| 4d | Wire Lead Configuration | 5.7 | TR #TBD | ||||||||||||
| 5 | Tests | ||||||||||||||
| 5a | Low Temp Operational Test | 2 | 3.1.1, 4.2 | TR #TBD | 2ND | 2ND | 2ND | Section 5 describes the different tests that will be conducted on the batteries. Under each unit, there is a box for each possible test. For each unit, if a box is left blank, it indicates that the test is not required for that unit. If there is a number notated in the test box, this indicates that the test is required, and it also indicates the order in which the test shall be completed, in relation to other tests. | |||||||
| 5b | High Temp Operational Test | 2 | 3.1.2 | TR #TBD | 3RD | 3RD | 3RD | ||||||||
| 5c | Storage Temperature Exposure | 4 | 3.2 | TR #TBD | 4TH | 4TH | 4TH | ||||||||
| 5d | Vibration Testing | 2 | 3.4 | TR #TBD | 1ST | 1ST | 1ST | 1ST | 1ST | 1ST | 1ST | ||||
| 5e | Room Temperature Testing | 2 | 4.1 | TR #TBD | 1ST | 1ST | 1ST | ||||||||
| 5f | Single Charge Cycling | 1 | 4.3 | TR #TBD | 2ND | 2ND | 2ND | 2ND | |||||||
| 5g | Endurance Cycling | 59 (consecutive days) | 4.4 | TR #TBD | 2ND | 2ND | 2ND | ||||||||
| 5h | Maximum Charge Current | 1 | 5.2 | TR #TBD | 3RD | 3RD | 3RD | 3RD | |||||||
| 5i | Charging Pull-in Voltage | 1 | 5.3 | TR #TBD | 5TH | 5TH | 5TH | 5TH | |||||||
| 5j | Charging Drop-out Voltage | 1 | 5.4 | TR #TBD | 6TH | 6TH | 6TH | 6TH | |||||||
| 5k | Float Mode Charging | 1 | 5.5 | TR #TBD | 4TH | 4TH | 4TH | 4TH |
| Required Shipments | Battery Group One | X | X | X | X | X | X | X | |||
| Battery Group Two | X | X | X |
Design Validation Plan
| Design Validation Plan (DVP) | |||||||
| Project Number: I15-12-02 | Project Name: Sealed Lead Acid (SLA) Battery Pack for M-ATV Door Assist System (DAS) | Specification Document: M-ATV Battery Pack Product Specification PS-0083 - Rev. 3 | Last Updated: 07/15/2017 | ||||
| Specification | |||||||
| Number | Description | Acceptance Criteria | Evaluation | ||||
| Method | Validation Artifact | Owner | Status | Notes | |||
| 2.1 | The battery pack shall fit within the envelope defined in Parker HPS drawing number 418136. | The battery pack shall be inspected to verify it meets the dimensional requirements defined in Parker HPS drawing number 418136 | Inspection | IR #TBD | Vendor | Incomplete | |
| 2.2 | The battery pack shall have a maximum weight of 5.5 lb | The battery pack shall be inspected to verify it does not weigh more than 5.5 lb. | Inspection | IR #TBD | Vendor | Incomplete | |
| 2.3 | The battery pack shall have a nominal capacity of 2.5 Ah | An analysis shall validate the cells specified have a nominal capacity of 2.5 Ah. | Analysis | EA #TBD | Parker HPS | Incomplete | |
| 2.4 | An approximate correlation between battery pack State of Charge (SOC) and Open Circuit Voltage (OCV) is shown in Table 1 | An analysis of the cell manufacturer's literature shall validate the battery pack OCV correlates to a SOC as defined in Table 1 of the document "M-ATV Battery Pack Product Specification PS-0083". | Analysis | EA #TBD | Parker HPS | Incomplete | |
| 3.1.1 | The battery pack shall be capable of operating in temperatures down to -25°F | A test shall validate that a fully charged battery pack is capable of outputting a minimum of 700 Watts for a minimum of 14 seconds immediately after soaking at -25°F for a minimum of 18 hours. | Test | TR #TBD | Vendor | Incomplete | |
| 3.1.2 | The battery pack shall be capable of operating in temperatures up to 130°F | A test shall validate that a fully charged battery pack is capable of the performance requirements specified in Sections 4.1, 4.2 and 4.3 immediately after soaking at 130°F for a minimum of 18 hours. | Test | TR #TBD | Vendor | Incomplete | |
| 3.2 | The battery pack shall be capable of storage in temperatures between -60°F and 160°F | A test shall validate that the battery pack is capable of the performance requirements specified in Sections 4.1 and 4.3 after being brought back to room temperature after a soak at the following temperatures for a minimum of 18 hours: |
1) -60°F
| 2) 160°F | Test | TR #TBD | Vendor | Incomplete | |||
| 3.3 | The battery pack shall be capable of operating at altitudes between 0 – 12,000 feet above sea level. The battery pack performance shall not be degraded after exposure to altitudes between 0 – 50,000 feet above sea level | An analysis shall validate that the battery pack solution is capable of operating in altitudes up to 12,000 feet above sea level, and will not degrade when exposed to elevations up to 50,000 feet above sea level. | Analysis | EA #TBD | Parker HPS | Incomplete | |
| 3.4 | The battery pack shall capable of exposure to vibration testing per MIL-STD-810G, Method 514.7, Annex E, Minimum Integrity Test, 1 hour per axis. | A test shall validate that the battery pack is capable of the performance requirements specified in Sections 4.2 and 4.3 following exposure to vibration testing per MIL-STD-810G, Method 514.7, Annex E, Minimum Integrity Test, 1 hour per axis. |
| During vibration exposure, battery pack shall be installed into M-ATV Door Assist System Control Box (Parker HPS PN: 776149 or 776151) using production-intent mounting provisions. | Test | TR #TBD | Vendor | Incomplete | |||
| 4.1 | For SOC between 50% and 100%, the battery pack shall be capable of outputting a minimum of 50 amps for a minimum of 7 seconds at 70°F | A test shall validate that a battery pack with a steady state OCV equal to or greater than 24.4 VDC is capable of outputting 50 Amps for a minimum of 7 seconds at 70°F. | Test | TR #TBD | Vendor | Incomplete | |
| 4.2 | From the fully charged state (100% SOC), the battery pack shall be capable of outputting a minimum of 700 Watts for a minimum of 14 seconds at the minimum operating temperature | A test shall validate that a fully charged battery pack is capable of outputting 700 Watts for a minimum of 14 seconds after soaking at -25°F for a minimum of 18 hours. | Test | TR #TBD | Vendor | Incomplete | |
| 4.3 | The battery pack shall be capable of performing 75 cycles on a single battery charge at 70°F. |
One cycle shall be defined by the following:
Output 15 amps for 7 seconds
| Dwell for 2 seconds | A test shall validate that the battery pack is capable of performing 75 discharge cycles at 70°F after being charged to 100% SOC. | Test | TR #TBD | Vendor | Incomplete |
| 4.4 | The battery pack shall be capable of completing 40,000 endurance cycles at 70°F and meet performance requirements specified in Sections 4.1 and 4.2. |
During endurance test, one cycle shall be defined by the following:
Output 15 amps for 7 seconds Dwell for 120 seconds A test shall validate that the battery pack is capable of performing 40,000 endurance cycles and still meet the performance requirements specified in Section 4.1, 4.2 and 4.3.
| During endurance cycle test, the battery pack shall be continously provided a source voltage of 28 VDC to allow for recharging during dwell periods. | Test | TR #TBD | Vendor | Incomplete | |||
| 5.1 | The battery pack power source shall be MIL-STD-1275D compliant, with a nominal supply voltage of 28 VDC. | An analysis shall validate that the battery pack is capable of interfacing to a power supply that is compliant with MIL-STD-1275D. | Analysis | EA #TBD | Parker HPS | Incomplete | |
| 5.2 | The battery pack shall draw a trickle charge from the vehicle supply voltage, with a maximum steady state charge current of 1.0 amps | A test shall validate that, when provided with a source voltage of 28 VDC, the inegral battery charger draws a maximum steady state current of 1.0 Amps for battery SOC between 0%-100% and tempertures between -25°F and 130°F. | Test | TR #TBD | Vendor | Incomplete | |
| 5.3 | The charger shall charge the battery to a fully charged condition if the vehicle supply voltage is 23.0 VDC or greater | A test shall validate that the integral battery charger intiates charging of the battery pack when the vehicle power supply voltage is 23.0 VDC or greater, and continues to charge until the battery pack reaches 100% SOC. | Test | TR #TBD | Vendor | Incomplete | |
| 5.4 | The charger shall discontinue charging when the vehicle power supply voltage is less than 23.0 VDC. | A test shall validate that the integral battery charger does not charge the battery pack when the vehicle power supply voltage is less than 23.0 VDC. | Test | TR #TBD | Vendor | Incomplete | |
| 5.5 | Once the battery is fully charged, the charger shall stop charging and maintain the battery in float mode to compensate for self-discharging and preserve its full-charge voltage. Float mode shall only be active if the vehicle supply voltage is greater than 23.0 VDC | A test shall validate that the integral battery charger transitions to float mode when the battery pack reaches 100% SOC and the vehicle supply voltage is greater than 23.0 VDC. | Test | TR #TBD | Vendor | Incomplete | |
| 5.6.1 | The battery pack shall have the following connector: |
Housing:
Deutsch PN: DTP04-4P
Terminals:
Qty. 2 Deutsch PN: 1060-12-0222 (Discharge) Qty. 2 Deutsch PN: 0460-204-12141 (Charge)
Wedgelock:
Deutsch PN: WP-4P
| The battery pack shall be inspected to verify that the correct connector housing, terminals and wedgelock are utilized. | Inspection | IR #TBD | Vendor | Incomplete | ||
| 5.7 | The battery pack shall contain Qty. 2 10 AWG leads for battery discharge and Qty. 2 14 AWG leads for battery charge | The battery pack shall be inspected to verify that 10 AWG wire is used for the two discharge leads and 14 AWG wire is used for the two charge leads. | Inspection | IR #TBD | Vendor | Incomplete |
| 6.1 | Hazardous Materials such as asbestos, beryllium, radioactive materials, hexavalent chromium (electroplating and coatings), cadmium (electroplating), mercury, or other highly toxic or carcinogenic materials, as defined in 29 CFR 1910.1200, shall be prohibited in the manufacture, assembly, maintenance or sustainment of the system without prior approval from the customer. The system shall be designed in such a way that the use of benzene, N-butyl alcohol, toluene, dichloromethane, and xylene are not required during maintenance or sustainment of the vehicle. |
Trace amounts of identified prohibited materials contained in base materials or alloys are to be reported but do not require a waiver. Trace amounts are defined as <0.1% for carcinogens and <1% for all other materials.
Supplier shall conduct an analysis and submit a certificate of conformance to validate the battery solution complies with the hazaradous materials requirements. Analysis EA #TBD Vendor Incomplete
Schedule
| Schedule | ||||||||||||||||||||||||||||||||||||||||
| WEEKS | ||||||||||||||||||||||||||||||||||||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 | 31 | 32 | 33 | 34 | 35 | 36 | 37 | 38 | 39 | ||
| 1. Approval Drawing Received (0 days after contract award) | ||||||||||||||||||||||||||||||||||||||||
| 2. Units Ordered/Fab (56 days after contract award) | ||||||||||||||||||||||||||||||||||||||||
| 3. Analysis (70 days after contract award) | ||||||||||||||||||||||||||||||||||||||||
| 4. Inspections (77 days after contract award) | ||||||||||||||||||||||||||||||||||||||||
| 5. Tests | Battery Group One (Units 1-4 and 8-10) | Testing Completed | Validtn Report Submit | Govt/Contractor Review | Shipping | |||||||||||||||||||||||||||||||||||
| Battery Group Two (Units 5-7) | Testing Completed | Validtn Report Submit | Govt/Contractor Review | Shipping | ||||||||||||||||||||||||||||||||||||
| 6. Option - 200 units (190-554 days after contract award) | Option - Up to 1 year (365 days, 52 weeks)after pre-production acceptance |
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