Attachment 0001 - RIPD E4000-18-1-16 (Rev4).pdf

ROCK ISLAND ARSENAL RIPD: E4000-18-1-16

PURCHASE DESCRIPTION DATE: 7-April-20

LASER CUTTER, TUBE

1. GENERAL SYSTEM DESCRIPTION

2. STANDARDS AND PUBLICATIONS

2.1 Clarification

2.2 National Standards and Specifications

3. DESIGN

3.1 Ownership

3.2 General Design Standards

3.3 Safety, Security and Environmental

3.4 Responsibilities

4. COMPONENT SPECIFICATION

4.1 Dimensions:

4.2 Machine Configuration and Motion System:

4.3 Machine Control:

4.4 Chiller Unit:

4.5 Automated Load and Unload System:

4.6 Touch Probe Sensor:

4.7 Other Equipment Options Required:

4.8 Options Excluded From This Purchase:

4.9 Other Performance Specifications:

4.10 Equipment:

5. APPROVAL/SHIPPING

5.1 Pre-shipment

5.2 Shipping

5.3 Installation

5.4 Completion

5.5 Point of Origin:

6. TRAINING

6.1 Schedule

6.2 Location

6.3 Type

7. SERVICE

7.1 Service/Support Requirements

8. NOTES:

1. GENERAL SYSTEM DESCRIPTION

This purchase description represents a Tube Laser Cutter. The contractor shall provide and install the Tube Laser Cutter described in this document as a “turnkey” operation, where all actions are the contractor’s responsibility, unless specifically stated otherwise in this purchase description. The Tube Laser shall be designed and fabricated to enable automatic 3-D laser cutting of long pipe, tubing, square and round steel and aluminum stock. The 3-D laser cutting capability allows contour cutting and precise beveling for weld operation. The required machine is comprised of a load section, cutting head module, and unload section, offering a minimum of 8 controlled axis of part or tool movement.

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. The contractor shall be responsible for complying with all standards listed or not that apply to this type of equipment.

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

2.2.2 American Society of Testing and Materials (ASTM).

2.2.3 American Society of Mechanical Engineers (ASME).

2.2.4 American National Standards Institute (ANSI).

2.2.5 National Electrical Manufacturers Association Standards (NEMA).

2.2.6 Electronic Industries Association (EIA).

2.2.7 Institute of Electrical and Electronics Engineers (IEEE).

2.2.8 American Code for Information Exchange (ASCII).

2.2.9 American Welding Society (AWS).

2.2.10 American Gear Manufacturers Association (AGMA).

2.2.11 National Fire Protection Association (NFPA).

2.2.11.1 NFPA-70 National Electrical Code

2.2.11.2 NFPA-79 Electrical Standard for Industrial Machinery.

2.2.12 International Standards Organization (ISO).

3. DESIGN

3.1 Ownership

3.1.1 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).

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 ITEM UNIQUE IDENTIFICATION (IUID) REGISTRATION: The contractor shall register the equipment in the IUID Registry (as one single system). IUID registration requires the contractor to input Cage Code, Model Number, and Serial Number into a Government Database to allow for asset and inventory tracking. IUID Registry of the equipment shall be performed at http://dodprocurementtoolbox.com/site/uidregistry/. Training for IUID is available in https://wawftraining.eb.mil. IUID registration of this equipment is required prior to final payment in the Wide Area Work Flow (WAWF). The contractor shall also affix a machine readable 2-dimensional (2-D) matrix representing the IUID registry to the machine. The IUID 2-D matrix may be included on the ID Data Plate outlined in paragraph 3.2.4.

3.2.6 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.

3.2.7 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.

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

3.2.8.1 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.

3.2.8.2 Connection of approximately 80-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.

3.2.8.3 Connection of approximately 65-psi water to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional. If water is required, the contractor shall be responsible for installing a back-flow limiting device sufficient to prevent possible contamination of the water system. This is necessary to maintain IEPA compliance.

3.2.8.4 Connection of 1.5-in diameter natural gas pipe to a single point for each system, if needed. Connection does not include filters or any peripheral equipment necessary to make the equipment functional.

3.2.8.5 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.

3.2.9 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.

3.2.10 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.

3.2.11 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.

3.2.12 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.

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

3.2.14 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.

3.2.15 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.

3.2.16 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.

3.2.17 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.

3.2.18 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.

3.2.19 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.

3.2.20 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.

3.2.21 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.

3.2.21.1 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)

3.2.21.2 If an automatic circulation system is used, it shall be complete, including, but not limited to the following: reservoir, valves, nozzles, filters, pumps, sight gages, and other components as necessary to make the system completely functional.

3.2.21.2.1 A system allowing blockages or inadequacies to go undetected is unacceptable. The system shall be interlocked to the machine control, providing an alarm that lubrication failure has occurred. The system shall not initiate immediate shutdown of the affected function during a cutting cycle. It shall allow completion of the cycle and shutdown in an orderly sequence.

3.2.21.2.2 The reservoir shall be sized to allow no less than 80-hrs of machine run time before requiring refill. It shall also have a means provided for draining and cleaning. A means shall be provided to enable the operator to determine the fluid level.

3.2.21.2.3 All filters shall be either cleanable or replaceable.

3.2.21.2.4 All pumps shall be self-priming.

3.2.22 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.

3.2.22.1 Equipment which requires compressed air shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35°F pressure dew point, minimum, from air entering the equipment at 110°F, and capable of supplying air to the rated standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of the latter, the refrigerant used shall not be a Class I or Class II, ozone depleting substance. The air dryer shall be connected and/or piped to the equipment by the contractor.

3.2.22.2 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.

3.2.23 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.

3.2.23.1 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.

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

3.2.23.3 Protection shall be provided to prevent damage to components.

3.2.23.4 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.

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

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

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

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

3.2.23.9 All pumps shall be self-priming.

3.2.24 WORK LIGHT: If work light(s) are required herein, the work light(s) shall be equipped with an individual switch mounted at the control station; or the work light shall come on automatically when master start is depressed. In the latter case, means shall be provided to change the bulb without deactivating the machine. The light shall be pre-wired and fused. The light(s) shall be capable of illuminating the entire machine work area, and shall be constructed to meet environmental conditions inherent to machining operations. Operation voltage shall be nominal 115 VAC.

3.2.25 CHIP REMOVAL: There must be means of chip removal from the system. If trays are used, they shall be designed in a manner that the trays can be removed with ease by the operator. Ease is described as the ability to do so in under 5 minutes and without requiring help from another operator.

3.2.26 MOTORS:

3.2.26.1 All motors shall be rated for continuous duty.

3.2.26.2 Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with overload protection.

3.2.26.3 Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.2.26.4 Motor starters and controls shall operate at no greater than 120-VAC. It is preferred that they operate at 24-VDC.

3.2.26.5 Motor starters shall provide drop-out protection. This means that, in the event of a loss of power, the equipment shall be re-energized only by the deliberate action of the operator. Manual or mechanical motor starters shall not be deemed acceptable.

3.2.27 DIALS AND GAUGES: All scales, dials, and gauges shall be manufactured of corrosion and oil resistant material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.2.28 HANDWHEELS: Hand-wheels turned in a clockwise rotation shall produce a linear motion, of the controlled component, to the right, away, or upwards. If rotary motion is produced by the hand-wheel, clockwise rotation of the hand-wheel shall produce clockwise movement of the controlled component.

3.2.29 CONTROL LEVERS: Control levers shall move in the same direction as the motion of the controlled component.

3.2.30 CONTROL NOISE: Electronic controls shall be designed and constructed such that they shall not be affected by radio frequency signals generated by communication equipment used at Rock Island Arsenal. Such equipment includes:

3.2.30.1 Portable, two-way radio – 139.05 MHz

3.2.30.2 Portable, two-way radio – 164.9875 MHz

3.2.30.3 Portable, two-way radio – 165.0875 MHz

3.2.30.4 Fork truck radios – 165.1875 MHz

3.2.30.5 Pager system – 412.875 MHz

3.2.30.6 Crane remote controls – 406 MHz through 420 MHz

3.2.30.7 Controls shall not be affected by radio frequency interference generated by machinery. Controls shall not be affected by radio signals transmitted by any and all legal radio stations.

3.2.30.8 The equipment supplied under this description shall not generate radio frequencies which will interfere with the electronic controls existing equipment located at Rock Island Arsenal. Emission of such electromagnetic noise shall be grounds for rejection of the equipment supplied. Relocation of the equipment to avoid interference shall not be considered an acceptable means of correction.

3.2.30.9 Testing for conformance to FCC regulation relating to maximum permissible radio frequency radiation shall be accomplished after installation. It shall be the responsibility of the contractor to supervise installation and testing before acceptance and certification as required by FCC rules and regulations.

3.2.31 FOUNDATION: The requirement for a separate foundation is permissible, if necessary to meet the specified alignment tolerances, to provide isolation, or to conform to a standard system configuration. The contractor shall describe the foundation requirements at the time of bid. RIA-JMTC shall be responsible for installation of the foundation based upon the drawings provided by the vendor.

3.3 Safety, Security and Environmental

3.3.1 SECURITY: The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

3.3.1.1 Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

3.3.1.1.1 Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the Access Control Records Check request Form though the Rock Island Arsenal Directorate of Emergency Services.

3.3.1.1.2 Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti- Terrorism Training.

3.3.1.1.3 During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

3.3.1.1.4 Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR, or paced in a drop box at a RIA-JMTC access point.

3.3.1.2 Security Training: The contractor shall complete the following training:

3.3.1.2.1 Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete.

The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys, or access pass being authorized.

3.3.1.2.2 iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

3.3.1.3 For Contractors requiring Common Access Card (CAC): Before CAC issuance, the contractor employee requires a favorably adjudicated National Agency Check with Inquiries (NACI) or an equivalent or higher investigation in accordance with Army Directive 2014-05.

The contractor employee will be issued a CAC only if duties involve one of the following:

(1) Both physical access to a DoD facility and access, via logon, to DoD networks onsite, or remotely or (2) Remote access via logon, to a DoD network using DoD-approved remote access procedures, or (3) Physical access to multiple DoD facilities or multiple Non-DoD Federally controlled facilities on behalf of the DoD on a recurring basis for a period of 6-months, or more. At the discretion of the sponsoring activity, an initial CAC may be issued based on a favorable review of the FBI fingerprint check and a successfully scheduled NACI at the Office of Personnel Management. Contractors needing a NACI or equivalent investigation or higher investigation will coordinate this investigation through their COR.

Contractor personnel shall turn in CAC cards upon completion of their contractual obligations, or at the request by the COR, or at the request of the Contracting Officer.

3.3.2 FIRE PREVENTION AND PROTECTION: The contractor shall comply with all fire prevention measures prescribed in the installation Fire Regulations, a copy of which is on file in the office of the Contracting Officer. A written fire permit shall be obtained from the installation Fire Marshall for use of open flame devices, such as torches, portable furnaces, tar kettles, or gas and electric welding and cutting equipment, in, on, or within 15-ft of the building. The contractor shall be liable for any fire loss to the Government properly attributable to negligence on the part of the contractor, including failure to comp1y with fire prevention measure described by the terms of this purchase description.

3.3.3 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.

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

3.3.5 SAFETY REGULATION COMPLIANCE: The contractor shall comply with standard OSHA and RIA safety standards, including conforming to confined space work requirements when applicable.

3.3.6 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.

3.3.7 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.

3.3.8 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.

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

3.3.10 ACCUMULATORS: Gas charged accumulators operating above 200-psi charging pressure shall be charged with inert gas.

3.3.11 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.

3.3.12 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.

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

3.3.14 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.

3.3.15 AUDIBLE NOISE: The equipment noise level during normal operation shall not exceed 85-dbs, “A” scale. Tests shall be conducted around the entire equipment 60-in to 65-in above the floor within 3-ft of any major sound source. Metal removal equipment shall comply with the standard noise requirement while making a midrange horsepower cut on rigidly clamped mild steel. The contractor shall furnish shields, baffles, enclosures, or other devices necessary to bring the equipment into conformance. Any such device shall not interfere with the proper operation of the equipment and shall be designed to preserve the visibility necessary for safe operation of the system.

3.4 Responsibilities

3.4.1 SITE INSPECTION: Any site inspections and/or measurements, which must be taken in order to determine the suitability of the proposed location or to perform the design of the system, are the sole responsibility of the contractor. This may begin prior to completing the bidding process. Rock Island Arsenal will support this function through the POC (point of contact) by guiding personnel, facilitating security registration, and providing general assistance. The contractor will be responsible for providing any and all equipment necessary for any onsite measurements.

3.4.1.1 In the event that a preliminary site inspection is not offered/allowed, it is the responsibility of the contractor to ask questions pertaining to measurements required to determine the suitability of the proposed location or to perform design of the system. RIA personnel will provide information about the facility to answer such questions.

3.4.2 SITE CONDITIONS: Rock Island Arsenal will be responsible for additional costs incurred by unforeseen, but controllable manmade issues with the location of the system.

Examples would include, but are not limited to, buried sewer lines, standing water, and so forth.

The contractor will be responsible for all costs associated with correcting foreseeable conditions, including but not limited to inclement weather, interference with established machines or structures by components not shown on the footprint drawing, etc.

4. COMPONENT SPECIFICATION

The contractor shall provide and install a Tube Laser Cutting System as described in this Purchase Description. The laser cutting system shall be a minimum 8-axis computer numerically controlled (CNC) laser cutting machine, capable of cutting precise clean cuts of an infinite number of geometries, on a plane or three-dimensional contour (profile), in a range of material, during continuous operation, as specified herein. It shall require only simple positioning/work holding devices, maximize material usage and not impede any secondary operations.

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 35-ft in length.

4.1.2 COMPONENT WEIGHT: The maximum weight of any one piece shall not exceed 35,000-lbs.

4.1.3 INSTALLED FLOORSPACE: When installed complete, the equipment shall be contained in an area 20-ft wide and 80-ft long, excluding the operator’s area. Maximum height shall not exceed 15-ft. Width is defined as front to back from the operator’s normal operating position. The RIA can accommodate up to a 30 foot width specifically in the vicinity of the operator’s console. The nominal width shall be less than 20 feet in the remainder of the machine.

4.2 Machine Configuration and Motion System:

4.2.1 CUTTING PARAMETERS: The laser cutter shall be capable of processing round, square, rectangle “C”, “H”, “I” channel and angle. The following cutting parameter are minimum requirements:

4.2.1.1 Mild steel up to at least .875-inch wall thickness.

4.2.1.2 Stainless steel up to at least .375-inch wall thickness.

4.2.1.3 Aluminum 0 & T6 conditions (6061, 5086), up to at least .375-inch thickness.

4.2.1.4 Titanium up to at least .250-inch thickness.

4.2.1.5 Square channel size up to 6.0-inch X 6.0-inch.

4.2.1.6 Round Pipe up to 8.5-inch diameter or larger

4.2.1.7 “C”, “L”, “H”, “I” All up to at least 6.0-inch X 6.0-inch.

4.2.1.8 System shall be able to accommodate 25-foot long runs of stock.

4.2.1.9 Cutting Speeds: The following cutting speeds are for reference and do not represent total workload of material ran at RIA-JMTC on the tube lasers.

4.2.1.9.1 Mild Steel (.25-inch wall): 100ipm with Nitrogen assist

4.2.1.9.2 Stainless steel (.060-inch wall): 1350ipm with Nitrogen assist

4.2.1.9.3 Aluminum (.25-inch wall): 125ipm with Nitrogen assist

4.2.1.9.4 Aluminum (.080-inch wall): 1100ipm with Nitrogen assist

4.2.2 MACHINE AXIS DEFINITION:

4.2.2.1 X-axis shall be defined as the longitudinal movement of the chuck/part, moving right and left (along the centerline of the part) from the operator’s perspective.

4.2.2.2 Y-axis shall be defined as the movement of the machine torch head saddle fore and aft (to and away) from the operator’s perspective.

4.2.2.3 Z-axis shall be defined as the vertical movement and adjustment of the laser torch head over the cutting area and its work piece. (Torch head movement up and down from the operator’s perspective.

4.2.2.4 C-axis shall be defined as the chuck/part rotation around the X-axis

4.2.2.5 U and V-axis shall be defined as the part travel via the automated load and unload systems fore and aft from the operator’s perspective.

4.2.3 MACHINE BASE AND WAYS: The machine base, cutting head bridge, and cutting head saddle shall be provided with hardened ground replaceable ways. The ways shall be mounted to scraped surfaces, held against locating stops, and securely fastened to supporting components. The replaceable way design shall facilitate replacement at the using facility. Ways welded to the machine are not acceptable.

4.2.3.1 The load bearing surfaces of all ways shall be hardened to a minimum of 51 Rockwell C and ground to a finish of not less than 32 micro-inches

4.2.3.2 All slides shall be equipped with way covers or wipers to prevent extraneous material from gaining entry between sliding components. If way covers are used, they shall be of the collapsing or telescoping steel type. The use of bellows is not acceptable.

4.2.3.3 All axis shall be provided with adjustable, preloaded, recirculating ball and/or roller bearings to support and guide the sliding elements. The use of gibs is unacceptable.

4.2.3.4 The machine shall be of heavy construction throughout, and all parts shall be of such size and strength to properly sustain the maximum allowable loads imposed upon them, with minimal wear and no permanent deflection.

4.2.3.5 All major machine components such as, but not limited to, saddle, table, and laser cutting head shall be iron or steel alloy castings or welded fabrications, heavily ribbed and braced, and stress relieved to minimize distortion and deflection caused by forces which may be imposed during maximum duty cutting cycles.

4.2.3.6 All components subject to corrosion shall be fabricated of stainless steel.

4.2.3.7 All gearing throughout the machine shall be of sufficient hardness and durability to ensure long life.

4.2.4 DRIVE SYSTEM: The laser shall have an AC digital servo drive system. The Y and Z axis shall have ball screws and the X, U, and V axis shall be Rack and Pinion.

4.2.5 LASER CONFIGURATION: The laser system shall be a solid state laser with laser efficiency of at least 30%. It shall be designed for both continuous wave (CW) and pulse operation. It shall incorporate a high-speed power sensor to monitor the laser quality beam output to assure high output stability of plus or minus 2%.

4.2.5.1 The laser system shall deliver its energy in the lowest order (TEM00) mode to assure consistent and superior process quality and shall be programmable over a wide power range from 800W up to the full wattage capabilities using CW, as well as over a wide enhanced pulsing range up to peak power during continuous operation. These power ranges shall be infinitely variable within a part program. Whole integer power adjustment over the entire range are acceptable.

4.2.5.2 The laser shall have a high-pressure option to enhance laser cutting of thicker material.

4.2.5.3 Due to the advancements in technology and danger associated with solid state lasers, the laser enclosure shall be a Class I enclosure and fully enclose the system.

4.2.5.4 The laser controller shall automatically bring the laser to a ready status when all interlock conditions are satisfied. Activation of panel switches or control signals from external devices shall coordinate the operation of the power supply and shutter to deliver CW or pulsed laser energy at the pre-selected power level or pulse rate.

4.2.5.5 The laser controller shall continuously monitor and display laser operating conditions on the panel.

4.2.5.6 By means of the panel keyboard, access to the laser controller shall be obtained for setting power, current, and similar parameters.

4.2.5.7 The program controller shall be accessed through the same multifunction keyboard to set pulse rate, pulse width, power ramping, and pulsed power ramping programs, and shall display the program information on the panel CRT.

4.2.5.8 The following features shall be provided:

4.2.5.8.1 High peak square wave pulse.

4.2.5.8.2 High-speed power sensor.

4.2.5.8.3 Digital or analog control

4.2.5.8.4 Minimal warm-up time.

4.2.5.9 Position feedback shall provide resolution of 0.0001-inch, or less.

4.2.5.10 The system shall include a constant beam length delivery system.

4.2.6 3D HEAD: To accommodate complex parts as well as stock size and shape constraints, the laser system shall include a 3D Tilt or Rotational Head that can tilt +/- 45 degrees or greater.

4.2.7 AUTO FOCUS: The system shall have a positioning feature that automatically focuses the torch head to help reduce pierce times in different materials without the operator intervening.

4.2.8 HORIZONTAL SUPPORTS: The system shall include a feature to support thin wall material. This is to compensate for sag and bow in the material. They shall follow the material shape by positioning up and down.

4.2.8.1 The supports shall have an adjustable clamping force.

4.2.9 SMALL DIAMETER SUPPORTS: To combat deflection in material under the machining torch, specifically angle and small diameter materials, the contractor shall provide supports.

4.3 Machine Control:

4.3.1 The control shall be a Fanuc solid state, soft-wired, computer numerical control (CNC) system utilizing large-scale integrated circuits for data processing and control. It shall be a multi-blocked, buffered, contouring system. The controller shall include at minimum, a 15-inch LCD Color display.

4.3.2 The controller shall have a 64 bit CPU.

4.3.3 The control shall comply with NEMA Standard 12 and shall be sealed against dust and shop environmental conditions that might adversely affect performance of the system. No outside air shall be blown through the control for cooling purposes. The control shall be equipped with an industrial type air conditioner, allowing it to operate optimally in ambient temperatures of 32 through 140 degree Fahrenheit (F) and relative humidity of 5 through 95 percent.

4.3.4 Static logic circuits shall be on modular, plug-in, printed circuit boards. The back plane shall consist of printed conductors arranged in a bussing structure so that any slot can accept any board type, or the board and back plane shall be marked and/or keyed to assure insertion in the correct socket.

4.3.5 The control shall display on the screen such data as, but not limited to, mode of operation (auto, single block, MDI, and manual); machine position; programmed position;

offsets; subroutine index; active program name; indicator of a program edit; list the active block and the next two blocks; sequence number; “distance to go screen”; operator messages, including diagnostics; and stored NC programs.

4.3.6 The control station shall be provided with a keyboard or membrane covered touch panel.

In either case, the switches shall be functionally grouped. The keyboard shall be provided with tactile and/or audio acknowledgement for entry verification, unless individual key responses are immediately displayed on the screen.

4.3.7 The control shall be provided with a EIA Standard RS 232C, serial interface port and plug for data input and output devices. The control shall be able to execute a part program downloaded from a remote location utilizing the RS232C port.

4.3.8 The control shall accept program data and translate this data into positioning and feed motion command signals for all axes drives. Path of X, Y, and Z axes movements, and sequence and timing of all operations shall be directed by the control. Axes and motion nomenclature shall conform to EIA RS-267, emulating a gantry profiler (laser equipment is not included as an example).

4.3.9 The system shall be designed to operate from memory, loaded from an USB Connection, and/or loaded from Manual Data Input (MDI) using the keyboard. It shall also have the ability to concurrently download from a host computer or upload to the host computer, while machining a part.

4.3.10 The system shall be capable of shop floor programming by the operator.

4.3.11 Provision shall be made to allow operation in automatic, single block, and manual modes.

4.3.12 The control shall ensure that the machine functions occur in the proper order and shall initiate protective action should a faulty condition develop. Axis travel limits shall be stored in the control as software limit switches.

4.3.13 The control shall be capable of accepting manual entries and external program data in both inch and metric, with programmed switch by G code.

4.3.14 The control shall accept programs in absolute mode (dimensioned from a reference point) and in incremental mode (dimensioned from point to point).

4.3.15 The control shall allow for circular interpolation in the X/Y plane.

4.3.16 The control shall be capable of producing mirror image movements.

4.3.17 The control shall be capable of pattern repeat and program nesting.

4.3.18 The control shall be capable of conditional and unconditional jumps.

4.3.19 The control shall be capable of controlling acceleration and deceleration of axis feed rate and traverse moves, maximizing axis movement speeds, while reducing stress to the machine.

4.3.20 The control shall be capable of being programmed to generate a continuous cutter path, then continuing on to the next programmed command.

4.3.21 Feed rates shall be programmed in both inch and metric.

4.3.22 A feed rate potentiometer shall be provided to override the programmed feed rate from 1 to 120 percent of the programmed rate, as minimum.

4.3.23 Single block programming of up to four quadrants, 360-degree moves by defining a radius and end point shall be possible.

4.3.24 It shall be possible to program and edit a decimal point on work values with fractional values, eliminating the need for trailing zeros.

4.3.25 Control resolution shall be no greater than 0.0001 inch.

4.3.26 The control shall be provided with a minimum of the equivalent of 2MB of usable parts program memory storage, in addition to necessary memory for other requirements listed in this purchase description. Control memory shall be non-volatile or battery backup shall be provided to prevent loss of program memory for at least 72 hours.

4.3.27 The controller shall have program storage for up to 1000 programs.

4.3.28 A search feature shall be included in the control whereby the operator can search forward and reverse to a selected sequence number in the parts program. It shall be possible to edit the program at that block and restart at that block with modal commands carried forward.

4.3.29 The control shall include diagnostic system for monitoring the control during operation and for locating malfunctions when troubleshooting.

4.3.29.1 The system shall give fault data in understandable code or message form on the display, which will identify a problem in the control and identify program errors.

4.3.29.2 Diagnostics shall include the following, as a minimum:

4.3.29.2.1 Diagnostics page for digital I/O status.

4.3.29.2.2 Power up diagnostics.

4.3.29.2.3 Full time watchdog diagnostics

4.3.29.2.4 Full time excessive lag diagnostics

4.3.30 A programmed stop feature shall be provided which shall bring the machine to an automatic controlled stop within the part program cycle to allow a manual function by the operator.

4.3.31 An optional stop feature shall be provided which will allow the machine to be brought to an automatically controlled stop within the part program cycle. It shall be possible for the operator to enable or disable the optional stop.

4.3.32 The operator shall have the capability of jogging linear aces incrementally. Jog speed shall be variable with movement in increments of 0.1, 0.01, and 0.001 inches and continuous:

and in increments of 1.0, 0.1, and 0.01 mm and continuous

4.3.33 A cutter compensation function shall be provided for compensating for radial differences in kerf width. It shall be possible to use cutter compensation in linear and circular interpolation, absolute and incremental mode, and positioning mode. The control shall be capable of storing offset dimensions of at least +/-999 inches in the offset memory.

4.3.34 The control shall be provided with key lock or password program edit protection.

4.3.35 The control shall be provided with test/dry run modes to minimize time needed for program prove out and for running diagnostic program checks on the control.

4.3.36 A hand-held laser head positioning control feature shall be provided to allow the operator to access the entire operator area of the machine for setup purposes and allow X, Y, and Z axis jog function.

4.3.37 The control shall reduce the risk of internal cutting of tubes as well as eliminate excessive burning on the outside of the materials.

4.4 Software:

RIA currently utilizes SigmaTUBE, SigmaNest provided by SigmaTek as a software program for the tube lasers. The equipment must be compatible with this software program.

4.5 Chiller Unit:

The contractor shall provide a sealed, pressurized air-cooled system that shall have a cooling capacity and gpm flow sized appropriately for the equipment. The chiller shall have a reservoir of at least 45 gallons.

4.6 Automated Load and Unload System:

4.6.1 The unit shall be provided with an automated Load and Unload part/material handling systems.

4.6.2 Loading system: The automatic loading system shall be capable of loading bar and round-stock from at least 87-inches through 314-inches in length. The system shall have at least 5 load locations. Load System part weight carrying capacity of at least 1,000 pounds.

4.6.3 Unload System: The automatic unloading system shall be capable of unloading finished parts from at least 28-inches through 314-inches in length.

4.7 Touch Probe Sensor:

The contractor shall provide and install a Touch Probe Sensor with the Tube Laser. The Touch Probe Sensor shall measure the external diameter of the workpiece, and shall be installed at the side of the machining head. Measurements of the work-piece exterior dimensions, coupled with the required automatic offset feature in the Y-Axis ensures close tolerance machine performance accuracies are maintained.

The contractor shall provide means of measuring center alignment of material within the system.

This is due to the bow and sag that may be apparent in some of the material being ran through the machine.

4.8 Other Equipment Options Required:

4.8.1 The contractor shall furnish all equipment and services normally considered by the contractor to be standard for his/her machine, whether specifically called for in this purchase description or not. 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.

4.8.2 The contractor shall provide an assist gas kit, complete.

4.8.3 The contractor shall provide and install the Auto…