Attachment_0001_-_RIPD.pdf

ROCK ISLAND ARSENAL RIPD: J9000-16-9-14

PURCHASE DESCRIPTION DATE: 22 December 2015

MODULAR ROBOTIC WELD CELL

1. GENERAL SYSTEM DESCRIPTION

The Rock Island Arsenal Joint Manufacturing and Technology Center (RIA-JMTC) owns a modular robotic well cell with 2 robots, and two stations (RIA Number 34539, Serial Number/Work Order J7770). The contractor shall provide and install a new weld cell whose operation, programming, and controls are identical to JMTC’s existing cell (with some minor exceptions). The proposed Modular Robotic Weld Cell shall be installed in Building 208. The intent is to share welding part programs between the two cells with only minor modifications, to manufacture identical parts through either cell. The system will be a modular design allowing maximum flexibility to adjust to incoming work-load. The system will consist of one single common expandable modular floor track (capable of accessing both stations), (2) 6-axis robots mounted on separate carriages riding on the floor track, (2) modular headstocks with a 30,000-lb minimum payload capacity (per station), (2) tailstocks with each station having a tool length of 20-ft, (2) weld power supplies, a torch cleaning station, a modular fence enclosure with light curtains, pedestal mounted controls and all other equipment necessary to make the system fully functional and safe and efficient. The system shall be capable of Gas Metal Arc Welding (GMAW) with control features for touch sensing of joints and seam tracking capability. The system controls shall be designed to allow for the extension of the track up to 72-foot total length along with other future capabilities. The system shall also be expandable to allow addition of a boom mount for at least one robot to increase reach and access if necessary at a future time.

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

Any ambiguities, questions, requests for clarification or discrepancies between sections of this purchase description, drawings, national or industry standards discovered by the contractor in reviewing this purchase description shall be reported by the bidder in writing to the contracting officer BEFORE THE DATE SCHEDULED FOR CLOSE OF BIDDING/receipt of proposal.

Submission of a proposal or bid shall be construed as evidence that such examination has been made. Therefore, later claims for labor, material, or equipment required, or for difficulties encountered, which could have been foreseen had such reasonable examination been made, may be denied.

2.2 National Standards and Specifications

The following specifications in effect on the Date of Invitation for Bid/Request for Proposal form a part of this purchase description. In the case of conflicting requirements, the more stringent shall apply.

2.2.1 Robot Industry Association ANSI/RIA R15 (All)

2.2.1.1 Safety Standard ANSI/RIA R15.06 (R2009).

2.2.1.2 Performance Characteristics Evaluation ANSI/RIA R15.05 (R1999).

2.2.1.3 Criteria for Hand Held Robot Control Pendants ANSI/RIA R15.02.

2.2.2 American National Standards Institute (ANSI).

2.2.3 American Welding Society (AWS).

2.2.4 Occupational Safety and Health Act of 1970 (OSHA).

2.2.5 American Society of Testing and Materials (ASTM).

2.2.6 American Society of Mechanical Engineers (ASME).

2.2.7 National Electrical Manufacturers Association Standards (NEMA).

2.2.8 Electronic Industries Association (EIA).

2.2.9 Institute of Electrical and Electronics Engineers (IEEE).

2.2.10 American Code for Information Exchange (ASCII).

2.2.11 American Gear Manufacturers Association (AGMA).

2.2.12 National Fire Protection Association (NFPA).

2.2.12.1 NFPA-70 National Electrical Code

2.2.12.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.13 Military Standard 130N, Identification Marking of US Military Property

3. DESIGN

3.1 Ownership

This equipment is a standard product of the manufacturer and shall require either no change or minor design changes to meet requirements of these specifications. Therefore, ownership of the design will remain with the manufacturer.

3.2 General Design Standards

3.2.1 DEVIATION FROM PRODUCT: Modifications to the manufacturer’s standard design to achieve requirements as specified in this document are only permissible as dictated by good design practice. For example, mounting a 20-hp motor in a power train designed and normally using a 10-hp motor would not be acceptable.

3.2.2 UNITS OF MEASURE: Dimensions and capacities in this purchase description are given in the English-US (in-lb) system. All dials, gauges, and drawings shall be in the English- US system or both the English-US and the metric systems, unless otherwise specified in this document.

3.2.3 ID DATA PLATE: The equipment shall include a main data plate which will include the following data as a minimum requirement (additional information is acceptable): Manufacturer Name, Manufacturer’s Dunns and Bradstreet Number, Manufacturer’s Model Number, Manufacturer’s Serial Number, Year of Manufacture, Contract Number, Machine Weight. This information is necessary for compliance with the governments Unique Identification Program (UID). The data plate shall also contain a 2D Data Matrix Symbol representing a Unique Item Identifier (UII) assigned by the contractor for the equipment provided in accordance with MIL- STD-130N. The data matrix shall contain data elements in accordance with Construct #2. UII registration and 2D data matrix creation is available in Wide Area Workflow. Additional direction on creating UII, and 2D data matrix is available at 703-848-7314, or by emailing info@uniqueid.ord.

3.2.4 DATA PLATES: All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering.

Lettering shall be permanent and have a contrasting background.

3.2.5 UTILITY CONNECTION: Equipment supplied to the Rock Island Arsenal will have single point shut-off for each utility supplied to a system. This means that equipment constituting a single system shall be wired to a single main electrical disconnect point, plumbed to a single pneumatic shut-off valve, etc. This will be referred to as the “point of first connection”. Each type of power source may have only one point of first connection. E.g. (1) pneumatic shut-off valve, (1) water supply shut-off valve, (1) electrical disconnect, etc. Each point of first connection shall be clearly labeled on the system and shown in the safety lockout portion of the documentation package. These points must be located on a stationary component and positioned such that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.2.6 UTILITY CONNECTION LABOR: Rock Island Arsenal shall provide only such labor and materials as will be needed to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.2.7 UTILITIES AVAILABLE: Rock Island Arsenal shall be responsible for providing the following:

3.2.7.1 Connection of 460-V, 60-Hz, 3-Ph AC electrical power to the fused or breaker type disconnect switch required in the ELECTRICAL DISCONNECT paragraph of this purchase description. Connection does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

3.2.7.2 Connection of approximately 90-psi compressed air to a single point for each system, if needed. Connection does not include filters, dryers, or any peripheral equipment necessary to make the equipment functional.

3.2.7.3 If, due to contractor caused problems, the equipment or components of the equipment must be moved or removed and replaced, by RIA after initial placement, the contractor shall be billed for such work at current RIA labor and overhead rates.

3.2.8 ELECTRICAL DISCONNECT: The equipment shall be equipped with a manual, fused or breaker type disconnect switch, readily accessible to the operator, which will deactivate the entire equipment. It shall be located no more than 6-ft 7-in from the floor to the highest point the control device. It shall be capable of being locked in the de-energized state (OFF) only.

3.2.9 CONDUIT: Flexible conduit is not permitted in exposed areas. All wires, cables, and hoses will be enclosed by rigid, oil-proof protection, except where flexibility is necessary for operation of the equipment. Flexible wires, cables and hoses shall be arranged to prevent draping or tripping hazards.

3.2.10 SERVICE ACCESS: Components subject to periodic adjustment, replacement, or servicing shall be readily accessible. Meaning that experienced personnel can access the part after no more than 30-min of labor. If any special tools or equipment are necessary to access these components, said equipment will be supplied as part of the system and provided with a proper storage location within the system.

3.2.11 DEFLECTION: The system shall recover from distortion and deflection at no load. The machine and its components shall be sufficiently rigid that work piece finish and tolerances are not impaired by machine vibration.

3.2.12 NEW EQUIPMENT: The equipment furnished under this purchase description shall be new and unused.

3.2.13 COMPONENT ENVIRONMENT: Under no circumstances shall a component be used in an application not recommended by the component manufacturer. Components shall not be subjected to conditions of operation beyond the recommendations of the manufacturer, such as excessive heat, lack of lubrication, over-loading.

3.2.14 REPLACEMENT COMPONENTS: All replaceable components shall be manufactured to definite standards for tolerance, clearance, and finish, enabling components to be field installed without further machining.

3.2.15 CASTINGS AND FORGINGS: All castings and forgings shall be free of defects, scale, and mismatching. No process such as welding, peening, plugging, or filling shall be used for reclaiming any defective part for use in this equipment without the prior written consent of the contracting officer.

3.2.16 SURFACE BUILDING AND COATINGS: Welding, brazing, soldering, coating or plating shall be employed only where specified in the original design. These operations may not be employed as a means of reclaiming a defective part.

3.2.17 FASTENING DEVICES: All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change in tightness. Those devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed. They shall not be installed using permanent bonding adhesives.

3.2.18 CLEANING AND DEBURRING: All surfaces of castings, forgings, molded parts, stampings, and welded components shall be cleaned and free from sand, dirt, fins, flash, scale, flux, and other harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s commercial practice.

3.2.19 PAINTING: All unfinished surfaces of the equipment shall be painted with a lead free and chromium free commercial grade of metal primer and a minimum of one finish coat. The color shall be in accordance with the manufacturer’s standard commercial practice, or as necessary to maintain compliance with OSHA regulations, as applicable.

3.2.20 LUBRICATION: Components specified as requiring lubrication by the original manufacturer shall have an appropriate means of providing said lubrication included in the design of the machine. The lubrication points will be labeled on the lubrication drawing provided as part of the maintenance documentation and will also be labeled on the machine at the lubrication point and on any access panel covering the lubrication point. These labels will include as a minimum standard, the specific type of lubricant, the quantity to be used, the frequency for change, and the maintenance manual reference for detailed instructions. The lettering shall be English and the units shall be English standard (i.e. pints, quarts, and gallons)

3.2.21 FILTRATION/REGULATION: Equipment requiring filtered or regulated energy sources shall be supplied with the components necessary to perform this function. E.g. the equipment shall be supplied with a Filter, Regulator, Lubricator (FRL) device, if filtered, lubricated, regulated pressurized air is required for the efficient, proper operation of the equipment. These devices shall be located on the equipment side of the lockout devices at the points of first connections. Equipment which requires a high quality constant power source shall have proper isolation and/or power conditioning equipment for the power service designated in this description. All electrical equipment shall have a power factor (ratio of real power to apparent power) of no less than 80%, as read at the equipment main disconnect. Equipment with a power factor of less than 80% shall be fitted with suitable power factor correction capacitance, sized on the basis of the equipment inductive AC load.

3.2.22 HYDRAULICS: The machine will be equipped with a hydraulic system and the system shall be complete with, but not limited to, pump, valves, piping, cylinders, pressure controls, filter, and reservoir. All components necessary to make the system completely functional shall be provided.

3.2.22.1 If the duty cycle of the system under maximum usage will cause the hydraulic fluid to exceed 120°F in temperature, a suitable air-cooled heat exchanger shall be provided to maintain fluid temperature at or below that temperature. The exchanger shall be equipped with changeable fiberglass filter(s), unless permanent type filters are supplied.

3.2.22.2 The system shall have adequate capacity to provide sufficient pressure and flow to perform all hydraulic operations under all normal machine operating conditions.

3.2.22.3 Protection shall be provided to prevent damage to components.

3.2.22.4 Safeguards shall be provided to alert the operator of temperatures and pressures above/below design limits. If safe limits (within design limits) are exceeded, the system shall automatically shut down.

3.2.22.5 Anti-surge devices or circuits shall be incorporated to ensure uniformity of motion under varying loads.

3.2.22.6 The hydraulic reservoir shall be provided with means for draining and cleaning.

3.2.22.7 Means shall be provided to enable the operator to determine fluid level.

3.2.22.8 Each hydraulic system shall include a filter, which shall be either cleanable or replaceable.

3.2.22.9 All pumps shall be self-priming.

3.2.23 FOUNDATION: The requirement for a separate foundation or floor alteration is not permissible. The system shall be capable of being installed on an existing concrete floor without modification to the system or the floor, except for installation of anchor bolts. The existing floor is 18-in thick reinforced concrete.

3.3 Safety and Environmental

3.3.1 INDUSTRY AND REGULATIONS: The equipment shall comply with the most current of all local, state, and federal laws and regulations listed in Standards and Publications.

3.3.2 MATERIAL EXCLUSIONS: The equipment shall not contain polychlorinated biphenyl (PCB), ozone depleting substances (Class I or Class II), or asbestos materials.

3.3.3 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA standard and RIA-JMTC-R-385-01 safety program requirements, including conforming to confined space work requirements when applicable.

3.3.4 SAFETY LOCKOUTS: Each point of first connection shall be designed and constructed to allow the utility to be completely isolated from the equipment. This isolation shall be insured by application of a standard key locking padlock. The device(s) shall only be lockable in the de-energized (OFF) condition.

3.3.5 LOSS OF PRESSURE: Hydraulic and pneumatic circuits shall be designed such that loss of pressure, or pressure surges, shall not cause a hazard. Means shall be provided to prevent operation of the equipment with insufficient pressure, if such operation could cause a hazard.

3.3.6 TRAPPED ENERGY: Means shall be provided for the controlled release of stored energy. This energy may be in the form of, but not limited to, air and hydraulic pressure accumulators, capacitors, springs, counter balances and flywheels. When appropriate, a label shall be affixed to the stored energy source to identify the hazard.

3.3.7 WORKING RANGE: Hydraulic and pneumatic components shall be selected, which cannot be adjusted outside the safe working range of the circuit and/or equipment.

3.3.8 BRAKES: Braking systems shall be designed to “fail-on”. This means, energy supplied to the brake shall be used to disengage the brake. Loss of energy shall therefore cause the brake to activate.

3.3.9 EMERGENCY STOP: The system will incorporate a clearly identified, red, mushroomed, control button with a yellow backing plate at every operator work station. Upon momentary operation, any emergency stop button shall de-energize all machine motions and override all other controls without creating additional hazards. All motion stopped shall be restarted by the deliberate action of the operator (requiring manual reset). No other red mushroomed buttons shall be allowed on the equipment. It is preferred that there is no other red buttons of any type.

3.3.10 CONTROL GUARDS: Controls shall be guarded against accidental operation.

3.3.11 OPERATOR REACH: Controls shall be within reach and located such that the operator, when in the normal operating position, is not required to reach past moving parts, which may cause injury.

4. COMPONENT SPECIFICATION

The system shall be a modular design with two modular work stations; each work station consisting of one-headstock and one-tailstock, one-single continuous floor-mounted track with 2 carriages, modular fencing and cable trays, control pallet, 2 robots, 2 robot controllers, 2 wire delivery systems, 2 weld power supplies, chiller, torches and nozzles, and accessories. Under Contract W9898S-11-P-

0590 (and the subsequent contract options) a Modular Robotic Welding Cell was previously provided and installed at RIA-JMTC. The Robotic Welding System described in this Purchase Description shall be identical to the previously provided system, except this system shall not include Automatic Torch Changers, Cold Metal Transfer Welding, or Plasma Cutting Capability. It shall be designed to allow specific features (listed below) to be added at a future date without the need to replace hardware or controls. The supplier shall furnish all equipment normally considered the contractor to be standard for his machine unless identified in this requirement to be of specific manufacture. The following equipment shall be provided in addition to the equipment specified in other sections of this purchase description, which may not be standard. The inclusion of standard equipment in this paragraph is inadvertent and should not be construed to allow duplication. The system shall at least include:

Quantity 2 Modular Work Stations. Each Work Station shall include:

o 30,000-lb weight capacity per Work Station o 20-foot Tool Length o 94-inches Tool Swing Diameter

Headstock Adapter Plates (provide the same fixture mounting as existing system) Servo Motor Adapter Plates Tailstock Shafts (provide the same fixture mountings as existing system) Pillow Block Bearings Quantity 2 RG-140 Rotogrounds (one for each robot) Approximately 54-feet of MT-50 Modular Floor Track – with 2 servo driven carriages and cable carriers (same design as existing track to allow for interchangeability) Frommelt side-to-side safety curtains with stand-alone mountings Genesis Controls Packages (must be identical to existing system) HMI PanelView 1000+ touch screen with Ethernet connectivity Genesis Detach Jog (identical to existing system) Quantity 2 LED Status Light Poles Control/Weld Equipment Pallets Safety Barriers using components interchangeable with the existing system (color Gray with

Red accent Stripe) Searchable Documentation Package Warranty – Single Source – 1-yr parts and labor Installation and support – at least 2-weeks at RIA-JMTC Quantity 2 Robots Fanuc Arc Mate M710iC/20L (identical to existing system robots). Each

Robot includes o High-Flex Extension Cables for robot and aux axis motor(s) o Fanuc Collision Guard o Fanuc Constant Path o Fanuc Ethernet IP Adapter o Fanuc Expanded Memory 64-MB DRAM/64-MB FROM/3MB CMOS o Fanuc Coordinated Motion o Fanuc DeviceNet o Fanuc Multi-Group Motion o Fanuc PCMCIA Memory Card o Fanuc Thick Plate Welding Package

Seam Track and Touch Sense with wire brake and wire snip unit o Fanuc Auto TCP (Torchmate III includes Block) o Fanuc DeviceNet Card – Single Channel o 20-meter Teach Pendant o Fanuc Single Alpha-8 auxiliary axis package o Fanuc Single Alpha-22 auxiliary axis package

Quantity 2 Miller AutoAxcess 450 DI Power Supplies with weld interface (identical to existing system)

Quantity 2 Wire Drives and drive roll kits Quantity 2 Binzel WH652 water cooled torches (identical to existing system) o Water cooled torches includes water chiller and separate flow switch) Genesis Torch Alignment Stations (one for each robot,identical to existing system) Torch Wire Brakes (includes air intensifier) Quantity 2 AP Torch Reamers with misters and wire snip unit (one for each robot, identical to existing system)

4.1 Dimensions:

4.1.1 DOOR ACCESS: The equipment shall be shipped either assembled or disassembled to pass through a door 12-ft wide by 12-ft high, and shall not exceed 25-ft in length.

4.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 25,000-lbs.

4.1.3 INSTALLED FLOORSPACE: The Robotic Welding System shall be installed in Building 208 of JMTC. When installed complete, the equipment shall be contained in an area 75-feet long and 25-feet wide, including the operator’s area. Maximum height shall not exceed 18-ft. Width is defined as front to back from the operator’s normal operating position.

4.2 Payload/Work Envelope per Work Station:

4.2.1 Payload Capacity (with Tailstock Support): 30,000-lbs

4.2.2 Payload Capacity (without Tailstock Support): 12,000-lbs

4.2.3 Tool Length (distance between mounting faces): 20-ft ±0.5-in

4.2.4 Tool Swing Diameter (cylinder centered on Headstock axis) 94-in

4.3 Modular Work Station Components (Headstocks and Tailstocks): There shall be two modular work stations for the Robotic Weld Cell. The work stations shall be aligned “end to end”/linearly and at the same height to allow one floor track to travel between both work stations.

Each modular work station shall include:

4.3.1 HEADSTOCKS: The (quantity 2) headstocks shall contain servo driven mechanisms for positioning the fixture/tool.

4.3.1.1 Drive Type: The motor and controls shall be of the same manufacture as the robot servo motors and controls. (e.g. since the robot is a Fanuc brand, the servo motors for all axis shall be Fanuc) The acceleration/deceleration rate of the auxiliary axis servo motors shall be controllable. Hard adjustment is acceptable. It does not need to be programmable.

4.3.1.2 Torque: The maximum output of each headstock drive shall be at least 4,000-ft-lbs.

4.3.1.3 Bending Moment: Each headstock and drive system shall be designed to allow up to 50,000-ft-lb of bending moment (caused by mounting a tool without tailstock support or by flexing of a long tool).

4.3.1.4 Speed: The maximum speed of the headstock drive shall be at least 2-rpm.

4.3.1.5 Centerline Height: The centerline height of the fixture mounting axis shall be at least 48-in above the floor but no more than 52-in above the floor. It shall be designed to safely swing maximum tool swing diameter listed above.

4.3.1.6 Backlash: The system shall be designed to minimize backlash. This means that the rotational repeatability at 20-in is 0.004-in or smaller and at 47-in is 0.010 or smaller.

4.3.1.7 Fixture Mounting: Each headstock shall include a flange with a male locating pilot and mounting holes to allow for mounting of the fixture.

4.3.2 TAILSTOCKS:

4.3.2.1 Fixture Mounting: Each tailstock shall include a flange with a male locating pilot and mounting holes to allow for mounting of the fixture. This mounting configuration shall be identical to the headstock fixture mounting. This will allow the fixture to be reversed with respect to the robot.

4.3.2.2 Adjustability: Each tailstock mounting flange shall move to account for variation in the length of the fixture to be mounted. It will also allow the mounting pilots to engage the fixture. This adjustability shall include at least 2-in of travel.

4.3.3 HYDRAULIC FIXTURES: Each system shall include couplings and hardware to allow the use of hydraulic fixture clamping. Transmission from the positioner to the fixture shall allow for continuous rotation (no wind-up/unwind).

4.3.4 HYDRUALIC POWER SUPPLY: The system shall include a hydraulic power supply to actuate fixture clamps. The system shall be designed to provide pressure up to 1000-psi with a minimum flow rate of 5-gpm.

4.3.5 FIXTURE WIRING: The system shall be capable of connecting control wires to fixtures for proximity sensors. This can be accomplished through the use of slip rings. This shall be capable of monitoring of at least 20 proximity sensors. These sensors will be used to determine part present and clamp positions on fixtures.

4.3.6 GROUNDING: The system shall include a rotary ground coupling(s) sized to properly ground (2) weld power supplies in simultaneous operation (with a capacity to ground at least 800-amps). The coupling shall allow for continuous rotation (no wind-up/unwind).

4.3.7 ROTATION: The headstock/tailstock work stations shall be designed to allow the fixture(s) to rotate continuously in either direction without the need to unwind for wiring and connections.

4.4 Floor Track

4.4.1 FLOOR TRACK BASE: The floor track shall have a total length of approximately 54-ft.

It shall be modular in construction. This means that it will be constructed of standardized sections of specific lengths that are arranged to achieve the required length. No section shall be less than 8-ft in length and no more than 18-ft in length. (Shorter sections would create more joints allowing for wear and maintenance issues while longer sections become difficult to position and reduce the flexibility of the system.)

4.4.2 WALK-WAYS: The system shall be designed to allow a programmer to walk on top of each welder’s base frame.

4.4.3 CARRIAGES: The track shall include two carriages. Each carriage shall demonstrate the following performance requirements:

4.4.3.1 Payload Capacity: The carriage shall be designed to carry at least the robot, wire delivery system (including a 1000# wire spool), torch, a torch cleaning system, and a boom style robot mount. The boom mount is not part of the base system requirement, but may be added later for future projects and the carriage must be designed to support this potential load. This will allow a boom mount to be added without the need to replace the carriage and drive.

4.4.3.2 Travel: The base system shall include (quantity 2) carriages mounted on the track to allow for positioning of the robots. Each robot shall be dedicated to one work station.

4.4.3.3 Location Repeatability: The repeatability of the carriage shall be ±0.005-in or better.

4.4.3.4 Speed: The carriage shall have a maximum speed capability of at least 50-fpm (faster is acceptable). The speed shall be programmable from 0-fpm to the maximum speed.

4.4.3.5 Drive Type: The motor and controls shall be of the same manufacture as the robot servo motors and controls. (e.g. since the robot is a Fanuc brand, the servo motors for all axis shall be Fanuc).

4.4.3.6 Life Expectancy: The system shall include a drive system designed for minimal wear (meaning at least a 3-yr life expectancy without scheduled part replacement).

4.4.3.7 Integrated Control: The servo motor shall be integrated with the robot controller as a true robot axis. This will allow the robot to position the carriage with simultaneously synchronizing motion of the other 6-axis and while welding. A separate controller will not be acceptable.

4.4.4 CABLE CARRIERS: Hoses, wires, cables, etc. shall be connected from the track frame to each carriage using an IGUS brand cable carrier system. This will allow for hinged opening of the carrier anywhere along the length of the carrier (which is important for serviceability of the system).

4.5 Robot and Controller: The Robotic Well Cell shall contain 2 Welding Robots, and 2 Controllers:

4.5.1 ROBOTS: The robots provided and installed shall be 6-axis systems designed specifically for welding applications (Fanuc M-710iC20Ls) as identified by the robot manufacturer. The robot will not be integral to the track and carriage (This will allow removal and replacement of the robot without the need to replace portions of the track). The robot control shall be of the same manufacture as the robot.

4.5.2 HORIZONTAL REACH: The maximum horizontal reach of each robot is defined as the maximum horizontal distance from the centerline of the waist axis (Axis-1) to the wrist joint centerline (Axis-5) when the arm is fully extended. This distance shall be at least 2500-mm.

4.5.3 VERTICAL REACH: The maximum vertical reach of the robot is defined as the maximum vertical distance (with the base of the robot flat – not at an angle) from the lowest point that the wrist joint centerline (Axis-5) can achieve to the highest point of the wrist joint centerline when the arm is fully extended. This distance shall be at least 4400-mm.

4.5.4 PAYLOAD: The maximum payload of the robot arm is the maximum allowable weight of an end-effecter applied at the face plate. The payload capacity of the robot shall be determined by the vendor to support the weld equipment to be provided and the rest of the application requirements. The payload shall be the vendor calculated capacity or 40-lbs whichever is greater.

4.5.5 REPEATABILITY: The repeatability of the robot positioning (as measured at the wrist axis) shall be ±0.006-in or less.

4.5.6 TEACH PENDANT: The teach pendant shall include a cable of at least 20-m length to allow control from the length of the base system. The pendant shall have a home position hook somewhere on the system. This hook shall include a sensor that will indicate that the pendant is safely on the hook before executing a program. This will prevent damage to the pendant.

4.5.6.1 Capability: The teach pendant shall be capable of setting all parameters and motions necessary to shop floor program the system. The pendant will be able to create programs to set weld parameters/schedules, weave schedules, weld paths, weld gun angles, axes and wire speeds and feeds, etc. including approach and depart positions. It will automatically optimize the weld path for linear and circular motions. It will allow the operator to set the weld gun angle for each seam.

4.5.6.2 Detach Jog: The operator/programmer shall have the ability using the pendant to manually move (no program necessary) each of the auxiliary axes.

4.5.6.3 Program Editing: The pendant shall be capable of editing programs created on the shop floor and those created using the off-line programming software.

4.5.6.4 The pendant shall include all features necessary to meet ANSI/RIA R15.06.

4.5.7 CABLES: Cables external to the robot castings shall be bundled together to control whipping.

4.5.8 AUXILIARY AXIS CONTROL: The robot control shall include the ability to control at least 4-auxiliary axes as robot axes in addition to the 6-axes of the robot itself. One of these auxiliary axes will be used to control the carriage of the track. A second auxiliary axis will be used to control the Headstock of the work station. The third and fourth will be utilized at a later date to add capabilities (see paragraph titled “Future Capabilities”).

4.6 Controls

4.6.1 CONTROL PALLET: The system shall include a separate modular control pallet. All electrical and peripheral equipment shall be located on this pallet. All equipment shall be completely accessible. No equipment other than the positioner (headstock and tailstock), the floor track, the control pallet, and the fencing shall be allowed to be located on the floor. The control pallet shall be located outside of the modular fencing or incorporated as part of the fence barrier.

4.6.2 CONTROL CABINET: The system control cabinet shall be no less than NEMA 12 rated. The electrical design shall allow for no less than 20% open space inside the control cabinet. This is to allow for possible future modifications to the system controls.

4.6.3 OPERATOR CONTROL STATION: The station shall include at least the following features:

4.6.3.1 The operator control shall be a pedestal mounted station connected to the system by a flexible cable to allow the station to be moved (by the operator) to a convenient location.

4.6.3.2 Emergency Stop: Safety device to de-energize the system.

4.6.3.3 Control Power On:

4.6.3.4 Light Curtain Reset: The operator will be required to actively reset the safety system before the station ready function can be set.

4.6.3.5 Program Pause: This will allow the operator to pause a program without executing a full emergency stop.

4.6.3.6 Station Ready: The operator will use this to let the system control/robot know that the fixture is loaded and the area is clear and ready to execute the welding program.

4.6.3.7 Enable Clamps: Turns on Power to the Clamps without actuating them. If this is off, the clamps cannot be actuated.

4.6.3.8 Clamps Open/Closed: Allows the operator to actuate the clamps to open or closed.

4.6.4 TOUCH SENSE: This is a control feature allowing the operator to choose to have the robot determine the location of the parts to be welded and automatically adjust to properly weld the selected joint. This shall be capable of locating the part in (quantity 3) dimensions. This feature shall be capable of being turned on/off as determined appropriate by the RIA-JMTC operator/programmer.

4.6.5 SEAM TRACKING: This is a control feature allowing the robot to automatically adjust vertical and lateral trajectory to compensate for part warping or misplacement based upon feedback monitoring of variations in the welding current and use of a robotic weaving search pattern. The system shall store the new path data to allow for increased speed when performing multi-pass welds (e.g. root pass memorization and multi pass offset features from Fanuc or equivalent). The feature shall include a “fill” function to maintain a constant fill for groove weld joints with a varying volume. This feature shall be capable of being turned on/off as determined appropriate by the RIA-JMTC operator/programmer.

4.6.6 COORDINATED MOTION: The system shall be able to operate with all robot and auxiliary axes having full coordinated simultaneous motion. Therefore the programmer shall be able to have any or all axes in motion at the same time.

4.6.7 ANTI-COLLISION PROTECTION: The controls shall include a feature to automatically avoid collisions. This feature will include prevention of collisions with a second robot if/when added in the future.

4.6.8 SERVO MOTORS: All servo motors and drives must be the same manufacture as the robot motors.

4.6.9 CONTROL TYPE: The system control may be a PLC (Programmable Logic Controller), a Robot Controller (e.g. Fanuc “i” type controller, etc.), or a combination of the two. The system may NOT include any type of PC (Personal Computer).

4.7 Accessories

4.7.1 TORCHES: The system shall include a water cooled torch for each weld power supply including a quick change mounting system. Each torch shall include a straight nozzle and either a 30° or a 22° nozzle. The torches shall have a minimum capacity of 400-amps or sufficient to accept the maximum capacity of the weld power supply (whichever is higher).

4.7.2 TORCH STRAIGHTENING STATION: The system shall include a straightening clamp/system that will correct bent torches after crashes.

4.7.3 TORCH CALIBRATION SYSTEM: The system shall include feature allowing the system to automatically determine the Tool Center Point. It shall automatically adjust for variance. It shall also automatically adjust the torch angle as necessary to compensate for variations in the tool center point. It shall be capable of operating with the selected weld power supplies. It compensates for bent torch barrels and worn contact tips. This will increase up-time of the system and reduce the amount of touch-up necessary.

4.7.4 TORCH CLEANING STATION: The system shall include a station for cleaning the torch. This shall be a program controlled feature through the robot controller. The program will periodically request torch cleaning. The robot will then move the weld torch to a designated location where the device will clamp the nozzle, then ream the weld slag from the torch/nozzle and contact tip and apply a spray of anti-spatter compound. This will reduce the amount of slag attaching to the torch and improve the life expectancy of the equipment and reduce maintenance time. The height of the reamer function shall be adjustable.

4.7.5 WIRE CUTTING STATION: The system shall include a cutting device for the weld wire. This shall be a station where the robot will move the torch and extend the weld wire. The cutting device will then cut the wire to allow the robot control to have an exact location for the end of the wire and remove the ball end of the wire. This is critical to the accuracy of the touch sense feature.

4.7.6 WIRE BRAKE: The system shall include a braking device to maintain the location of the weld wire. This device shall be located at the end of the robot arm (end of the 6th axis). The purpose of this device is to maintain the location of the snipped end of the weld wire. The robot uses this information as part of the touch sense feature. This is critical to the accuracy of the touch sense feature.

4.7.7 COOLING: Water cooling shall be provided by an appropriately sized Bernard water cooler (e.g. Coolmate-4). It shall be the responsibility of the vendor to determine the appropriate size equipment necessary to support up to (quantity 2) welding robots operating simultaneously.

This will include a water flow switch to ensure that water is being provided to the torch when needed.

4.8 Welder

WELD POWER SUPPLIES: The system shall be supplied with (quantity 2) weld power supplies. The weld power supplies shall be a Miller Auto-Axcess 450s. This will be used for MIG welding of mild steel components.

4.9 Wire Delivery System

4.9.1 WIRE DELIVERY/SUPPORT: The wire delivery system (except for the torch) shall not be supported or mounted to the robot. It shall be independently supported using a mechanical support and appropriately sized tool balancers.

4.9.2 BULK WIRE SUPPLY: While the track and carriage must be designed to carry a 1000-lb Spool with Dereeler, the initial system shall be supplied with (quantity 2) 500-lb drums (one on the carriage at a time, not both together). The vendor shall supply (quantity 1) 500-lb drum of 0.035-in diameter ER70S copper coated wire and (quantity 1) 500-lb drum of 0.045-in diameter ER70S copper coated wire.

4.10 Fencing

4.10.1 FENCING: The system shall be guarded using modular fencing panels meeting the ANSI/RIA safety standards. The front of the system (operator load/unload position) shall be utilize light curtains for physical protection and a Fromelt Roll Shield (or equivalent) to provide a vision barrier. The vision barrier may be manually or automatically extended or retracted, but must be included in the system safety circuit to prevent welding without the vision barrier in place. The panels shall be in standard length increments to allow mix/match construction of the perimeter fencing. This will accommodate potential future expansions or modifications to the base system. The fencing shall be tall enough to prevent direct line of sight from personnel outside the system to an active weld torch during the welding process. There shall be at least two gates with switches giving access to the area behind the work station. As a minimum, each gate shall include a viewing window (protected with weld rated vision protection).

4.10.2 CABLE TRAYS: The system shall include floor cable trays to contain all wires and hoses. The tray will include a cover and shall be built to withstand the weight of an operator/programmer walking on top without creating a hazardous working/walking surface.

4.11 Fixture: The vendor shall design, build, provide and program one fixture for Part #12564030 (Revision X5, or current Revision). The fixture provided shall be very similar to the fixture provided to RIA under Contract W9098S-11-P-0590 (very minor alterations, if any). The current part drawing is available from the Contracting Officer. The fixture shall include hydraulic clamping and sensors to determine that the clamps are in the correct position prior to executing the welding program. Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues. Examples would include, but are not limited to, significant changes in the size of the part or increases in complexity caused by addition of more components in the weldment. While these are not anticipated, they may occur and cannot be determined until the final component design is completed. The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to torch access to weld joints, clamp sequencing to allow continuous weld seams, proper material selection to prevent weld spatter build-up, hydraulic line locations, protection of sensor lines, etc.

4.11.1 Fixture Support: In addition to providing the fixture, the contractor shall provide fixture support as outlined below:

4.11.1.1 Fixture Design Support: The vendor shall provide up to 40-hrs of engineering support to assist RIA-JMTC to design a fixture for welding. See attached part concept drawing. The vendor shall provide an engineer on-site at RIA-JMTC for 24-hours (3 consecutive work days) to assist in development of the fixture concept. RIA-JMTC will then develop detailed plans for the fixture. The vendor will provide the remaining 16-hrs of support to review the detailed plans and make suggestions for improvements (this time may be on-site or by telephone and internet).

4.11.1.2 Application Engineering: The vendor shall provide 120-hours of on-site application engineering time to develop and prove-out a program to weld the part (same part as fixture design support). This will be in increments of at least 40-hours each (maximum of three trips).

4.12 Future Capabilities

While it is not possible for all of the future capabilities to exist on the same system at the same time, any of these capabilities may be required for future projects. Therefore the base system must include the ability to add any of the following features with minimal modification:

4.12.1 Added Track Sections: The system must include the ability to add modular track sections to extend the length of the base system up to at least 72-ft. The connection cables, wires, and cable carriers would need to be replaced, but the existing track, carriage(s), and drives must be utilized (not replaced but added to).

4.12.2 L-Seat or Skyhook Positioner: The system shall include the ability to add a positioner that would mount only to the headstock and not be supported by the tailstock. This would be an “L” shaped positioner with a rotating fixture mounting at the bottom of the “L” (90° to the headstock mounting). This type of fixture would allow for additional access to welded frames. The positioner would utilize one of the auxiliary axis drives required as part of the base system and would therefore act as an additional robot axis.

4.12.3 Drop Center Positioner: The system shall include the ability to add a positioner that would mount to the headstock and be supported by the tailstock with a rotating fixture mounting in the center (90° to the headstock mounting). This type of fixture would allow for additional access to welded frames. The positioner would utilize one of the auxiliary axis drives required as part of the base system and would therefore act as an additional robot axis.

4.12.4 Boom Mount for Robot: The system shall include the ability to add a boom mount to the carriage of the track. This would then mount the robot upside-down and swing the robot over the work station. Modifications to the system fencing and guarding would be necessary to add this feature. The centerline of the robot (when boom mounted) would need to be at least 6-ft from the centerline of the track.

4.12.5 Y-Axis: The system shall be designed to allow for the addition of a Y-Axis positioner.

This positioner would mount to the carriage and replace the initial robot riser. It would be a servo controlled axis allowing the robot to move at horizontally at 90° to the floor track travel. It would utilize one of the auxiliary axis drives required as part of the base system and would therefore act as an additional robot axis.

4.12.6 Z-Axis: The system shall be designed to allow for the addition of a Z-Axis positioner.

This positioner would mount to the carriage and replace the initial robot riser. It would be a servo controlled axis allowing the robot to move at vertically at 90° to the floor track travel. It would utilize one of the auxiliary axis drives required as part of the base system and would therefore act as an additional robot axis.

5. APPROVAL/SHIPPING

5.1 Shipping

5.1.1 RESPONSIBILITY: The contractor is responsible for delivery of the equipment to the Rock Island Arsenal. Adequate preserving of equipment surfaces, packing, marking, and skidding of materials for shipment shall be the responsibility of the contractor. If special lifting devices, such as hooks or eyes, are required for ease of handling, they shall be supplied with the equipment. Any special devices shall be returned to the contractor upon request only if they will not be required for future movement of the equipment, and at the contractor’s expense.

5.1.2 SHIPPING SCHEDULE: Be aware, the Rock Island Arsenal will only off-load equipment arriving between 7:00 am and 12:00 am (noon), local time on Mondays through Fridays except holidays. For information concerning holidays, the contractor should consult the contracting officer. There is no place to stage transporting vehicles awaiting the arrival of contractors. All equipment shall be delivered at the same time, meaning the same day (multiple trucks are acceptable) unless pre-authorized to deliver on multiple days by the RIA-JMTC contracting officer. The vendor will contact the designated COR to obtain an electronic key for their representative (i.e. delivery driver) in order to have access to the facility. Deliveries and service calls outside the normal hours stated above must be coordinated with the COR to address any emergency situations.

5.1.3 RECEIVER: All shipments to Rock Island Arsenal including installation tools and/or replacement parts, as well as the original shipment of the equipment, shall be marked “ATTN:

Mr. Joe Carpentier, TARA-PTP”. Items not correctly marked are subject to being returned at the vendor’s expense.

5.1.4 ARRIVAL INSPECTION: Upon receipt of equipment at Rock Island Arsenal, a preliminary inspection shall be performed to determine condition and/or count. This inspection shall be performed by Rock Island Arsenal personnel.

5.2 Installation

5.2.1 PREPARATION EXECUTION SUPPORT: Rock Island Arsenal will support the preparation portion of the installation by providing utilities to the points of first connection.

5.2.2 LABOR AND MATERIAL: The supplier is solely responsible for providing all labor, materials, hardware, tools, and equipment necessary for complete installation of this system except as specifically listed in this document as being provided by the Rock Island Arsenal.

5.2.3 SUPERVISION: Supervision of the installation process will be the responsibility of the contractor. Rock Island Arsenal shall retain the right to periodic inspection and evaluation of the process, as it deems necessary.

5.2.4 OFF-LOADING/PLACEMENT: Off-loading of the equipment from the delivery vehicle, and placement of the equipment in position for the installation is the responsibility of the contractor. The contractor shall not be allowed to use government equipment to accomplish this work.

5.2.5 OFF-LOADING/PLACEMENT OPTION: At the request of the contractor, Rock Island Arsenal will perform the off-loading and placement of the equipment.

5.2.5.1 Any special requirements or precautions to be observed shall be the responsibility of the contractor to provide.

5.2.5.2 The contractor or his representative may be present during this process; however, such person will be responsible for being present upon arrival of the equipment at Rock Island Arsenal. Off-loading and placement shall not be delayed to allow arrival of the contractor or his representative.

5.2.5.3 If, due to contractor caused difficulties, the equipment or components of the equipment must be moved, removed or replaced by Rock Island Arsenal after initial placement, the contractor shall be billed for such work at current Rock Island Arsenal labor and overhead rates.

5.2.6 LIABILITY: In any case, the equipment remains the property of the contractor, and the contractor shall assume all responsibility and liability for the equipment and the work performed upon it. The government shall be held harmless for any damage done to the equipment at any time up until final acceptance of the equipment by Rock Island Arsenal, except in the case of intentional damage and/or…