A01_Hydraulic_Press_Requirements_V7_Attachment_1.pdf

SOLICITATION W911QY-18-R-0017 ATTACHMENT 1

1,000 Ton 4-Post Hydraulic Press Requirements

This press will be used to consolidate ballistic composites in a compression molding process. The press will be used for processing Research and Development in personal protection material applications. This means that force, temperature and mold parameters will be constantly changing. Chilled water, air and steam will be provided on site.

Steam is provided to the press at pressures of 125-175 psi up to 263 lbs/hr. House air is provided up to 115 psi.

Chilled water is supplied at 60 degrees F. The facility is located indoors at ambient temperatures.

PHYSICAL CHARACTERISTICS:

• Stroke – greater than or equal to 29”

• Daylight – greater than or equal to 36”

• Shut Height – less than or equal to 7”

• Bed Height – less than or equal to 45”

• Footprint less than or equal to: 80x70x170” (Must fit through - Bay door height 113” tall)

• Tonnage

- Maximum Tonnage – 1000 Tons or more

- Minimum Tonnage – 50 Tons or less

- Retract - 20 tons or greater

• Die space, clearance– at least 36x36”+ (Front Loading)

- Left to right post clearance – at least 36”

- Front to rear post clearance – at least 26”

• Steam heating/control

- 4 or more zones of steam control, each with its own steam regulator (0-175 psi), controlled by the press

- Quick disconnect steam lines

• Electric heating/control

- 4 or more zones

• Water cooling / air purging

- 4 or more zones

- Provides cooling of tooling with air, water and mist

- Modulating valves for each zone

• Safety

- Vertically sliding polycarbonate guard panels (All four sides/openings of press)

Pneumatic actuation Tied into control system

- OSHA compliant

• Ram speeds (maximum)

- Fast – 40 in/min or faster

- Slow (tonnage) – 4 in/min (at maximum) or faster

- Return – 40 in/min or faster

• Quick Die change system

- Mold/Die weight will be no more than 5,000 lbs in total

- Pneumatically operated roller system for die manipulation (or similar)

- 8 or more hydraulic clamps

- T-slot for mold/die mounting to bolsters

• Maximum deflection less than or equal to 0.002” per linear foot

- Including a loading condition of 12x12” part at maximum tonnage (1000 tons)

• Preferred voltage - 480V

• A mechanism to level the bolsters when new molds are placed into the press, preventing off center loading.

An automated system is preferable.

CONTROL SYSTEM

• Modern touch screen PLC providing the following features/capabilities such as:

Touch interface 18-bit color LCD or better 15" screen or larger 1024 x 768 resolution or better brightness of 300 cd/m^2 or greater 1 GHz or faster processor 512 MB RAM or more 80MB of nonvolatile storage or greater External storage support (SD Cards or similar) Data management through .CSV files Capable of graphing data Capable of network communication including data export

• Ease of use

- Recipe creation and set up should be possible with minimal training, no more than a few minutes

- Recipes should not be limiting

- Controls should be obvious to someone experienced in the use of press equipment

• Feedback control system (position/pressure/temperature)

• Temperature control (heating and cooling)

- direct steam pressure control ramp, soak ramp rate control

• Force control (tonnage)

- ramp, soak

- ramp at specified rate (variable pressing speed)Pressure control accuracy of greater than or equal to +/-5 tons (+/- 0.5% FS)

• Position control/speed control

- ramp, soak

- Positional accuracy of ±0.001 or better

- Variable ram speed control

- Ramp rate control

• Recipe creation and storage

- Multiple set points for pressure, position, temperature

- Ramp, soak, dwell, “bump”

- Recipe naming

- Recipe storage (24 or more recipes)

• Data logging (position, pressing force, temperature, steam pressure and time)

- 12 or more thermocouple connections for logging

Thermocouple naming 4 or more thermocouples to be used for feedback control

- Data Storage Network connectivity / remote data dump Local storage Data storage as “.CSV” Ability to query and analyze cycle data at the press including previous cycles and real time graphical monitoring

• Semi-auto mode

- Control of press settings (temperature, pressure, etc.) through PLC when not using recipes

• Diagnostics

- Alarms

- System diagnostics

Including electrical heating diagnostics

- Remote diagnostics

- Maintenance reminders

TOOLING

• Steam Heated flat platens (single cavity)

- Single cavity steam heated tool for processing flat panels

- Platen size is 24” x 24”

- 1 zone of steam heat per platen

- Surface flatness of 0.001” per foot

- No more than 0.002” defection when 1000 tons is applied to 12x12” area (“point load”)

- Quick connection to T-slots using hydraulic clamps

• Electrical Heated flat platens (single cavity)

- Platen size of 24” x 24”

- 2 or more zones of electrical heating per platen

- Surface flatness of 0.001” per foot or better

- No more than 0.002” deflection when 1000 tons is applied to a 12x12” area (“point load”)

- Quick connections to T-slots using hydraulic clamps

- 5 thermocouples per platen (four corners and center)

- Insulated barrier between bolster and platen

- Heat up to 600 degrees F or higher

- Temperature uniformity of +/-3 degrees F or better

- Heat up speed of 5 degrees F per minute or faster

ANCILLARY

• Shipping and Installation to Natick Soldier Research Development and Engineering Center including the transportation of the press to the final installation location and any rigging necessary to properly move the press in place. Contractor shall provide the necessary employee(s) on site at NSRDEC for supervision of any installation and rigging processes that will be completed by subcontractors. The riggers shall be licensed and the installers & trainers must be certified as qualified by the Contractor.

• Startup & Training on site

- Training for 4 people for two days or more to provide operators with a full comprehension of how to operate the press safely, create recipes and trouble shoot problems.

• Documentation

- Operating manual (Contract Data Requirements List (CDRL) A001)

- Warranty

- Maintenance plan/schedule

- List of wearparts / spare parts

• Shall provide customer service and support by an expert user of this equipment through email and phone communication during normal business hours of 8AM to 4PM for the duration of the warranty period.

• NSRDEC employees will visit manufacturing site prior to delivery of the press for visual inspection and testing of full capacity pressing force, electrical heating, steam heating and control system.

POST AWARD KICK-OFF MEETING: The Government and Contractor shall conduct a post-award kick-off meeting at NSRDEC, Natick, MA to assist the Government and Contractor achieve a clear and mutual understanding of all contract requirements and identify Government representatives responsible for administering the contract. The contractor will visit the NSRDEC facility for this meeting to review the details of the contract and visually inspect the final location of the equipment. This should also give the contractor a chance to discuss their schedule and the equipment in general.

BASE ACCESS PROCEDURES: This contract requires the Contractor to install equipment at the NSRDEC, Natick, MA. The Contractor is required to complete the Contractor Access Request Form, which contains Personal Data (e.g., first and last name, date of birth, driver license number and state of issue, current address and addresses resided in during the past five years) that will be protected from disclosure and submitted In compliance with the Privacy Act of 1974. All Contractor workforce shall comply with applicable installation, facility, and area commander installation/facility access and local security policies and procedures. The Contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshall Office, Director of Emergency Services, or Security Office. Contractor workforce shall comply with all personal identity verification requirements as directed by DOD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in Contractor security matters or processes.

WARRANTY: The contractor shall provide a standard commercial warranty of at least one year or longer, including offers of extended warranties, as is customary in the industry for the Press. The Contractor shall be the sole interface with the Government representatives for the repair or replacement of any items delivered during the warranty period. All repair parts and replacement costs, which include delivery to and from the NSRDEC, Natick, MA facility, are covered under this warranty. The Contractor shall provide detailed warranty information, including warranty repair procedures and procedures for obtaining repair and replacement of failed items that are within and those that are outside the scope of the warranty as an addendum to their warranty manual.

CONTRACTING OFFICER’S AUTHORITY: The Contracting Officer (KO) is the only person authorized to approve changes or modify any of the requirements contained in the contract. The said authority remains solely with the KO. In the event the contractor effects any changes at the direction of any other person other than the KO, the change will be considered to have been made without authority and no adjustment will be made to the contract costs to cover any increase incurred as a result thereof. The Contractor shall submit requests for modification of the contract to the KO. Contractual problems of any nature that may arise during the life of the contract must be handled in conformance with very specific public laws and regulations [i.e., the Federal Acquisition Regulation (FAR) and its Supplements]. Only the KO is authorized to formally resolve such problems. Therefore, the Contractor is hereby directed to bring all such contractual problems to the immediate attention of the KO.

EMERGENCY MEDICAL SERVICES: Emergency medical treatment and services for Contractor workforce is the responsibility of the Contractor.