FRCSE_Plasma_Shop_Camera_Project-_Description_of_Supplies-.pdf

DESCRIPTION OF SUPPLIES

Procurement and Installation of the Booth Camera System for the

B794 Plasma Spray Shop 12 April 2019

1.0 DESCRIPTION OF ITEMS TO BE PROCURED:

a. General Description:

Procure, install, and test six (6) video monitoring / thermal imaging cameras, one (1) additional spare camera, six (6) dynamic camera mounts (one for each camera), and six(6) wall mounted touch-screen flat panel PCs (PROVIDED BY FRCSE) for production booths 1, 3, 4, 5, 6 and 7.

Each booth will operate with one of each type of camera. The PCs shall be fully integrated with the booth cameras and serve as the video live feed monitor. The Contractor shall be responsible for the installation, configuration, testing, startup, and commissioning of the booth camera system at all Six (6) Plasma Spray booths.

The cameras will be mounted inside the booth, hardwire connected to the PC through the booth wall, and the PC will stream the video and software feeds on its monitor located outside of the booth.

b. Characteristics and Quantities of These Items:

Equipment, incidentals, supervision and transportation for installation and startup to include ancillary modifications for connection to existing facilities & services are included with the following PCVD life cycle replacement and risk mitigation spare components:

1.0 Background. The six plasma spray booths do not have video feed capability and requires the artisans to be in the booth for spray operations. The video monitoring cameras are for the artisans to watch the spray process from an external screen outside of the booth in order to comply with a recent initiative to remove the artisan from the booth during spray operations. The thermal imaging cameras are for the artisans to monitor the temperature and spray parameters of the parts being sprayed, ensuring production quality. The Plasma Spray Booths utilize a FANUC 200iC robot to improve these efficiency and uniformity of plasma spray operations. Note: The Government will provide technical data on the interface specifications requirements to the FANUC 200iC in Appendix B.

2.0 Requirements. The video/thermal imaging system required by this contract shall be performed in accordance with the detailed tasks outlined below. The contractor shall provide all products, services, and materials as required by this SOW, including special tooling, fork lifts or any other support equipment needed to complete the installation. All equipment specifications are listed in Appendices A.

3.1 Procurement and Integration of Booth Camera System. The contractor is responsible for procurement, installation configuration, and testing of the booth camera systems in booths 1, 3, 4, 5, 6, and 7 per the following requirements:

3.1.1 Video monitoring / thermal imaging cameras shall be installed in a dynamic position, angled to allow full observation of the application of the plasma spray on the item being treated.

3.1.2 Cameras shall be mounted in an adjustable configuration in each booth in a location that does not interfere with production, but can capture the part being sprayed. Robotically controlled 6 axis rail system ceiling-mount required for full movement and control of cameras. Comparable to ARCAM - XDMotion system mount.

3.1.3 A live feed shall be configured that broadcasts each camera’s image to a flat panel PC mounted outside of the booth. One PC, for each booth, configured to stream the live feed.

Software provided by camera manufacturer can stream simultaneous live feed and thermal imaging feeds.

3.1.4 All required cables, software, and transmitting hardware shall be purchased and installed for full use by FRCSE personnel. Required services include installing and activating the live feed to stream video on the monitors. Software must be FRCSE acceptable meeting Department of Defense software requirements.

3.1.5 The Contractor shall provide all supporting hardware required including the following items: six adjustable mounts, six camera cases for protection during use, all cables and cords required to configure and stream to the software on the PC, software for the thermal imaging program, and integration with the six flat panel PC’s capable of running software.

3.1.6 The thermal imaging software shall be installed on a PC for each booth. The software must be capable of providing thermal imaging display of live feed. Software must be FRCSE acceptable meeting Department of Defense software requirements.

3.1.7 An external FANUC controller will be required for booths 1, 4, and 5. Booths 3, 6, and 7 have control rooms connected to FANUC Controller, while booths 1, 4, and 5 do not. The external controller is used to control the Fanuc-30IA controller cabinet during the spray process.

The current model of controllers used is the FANUC I Pendant Controller.

3.1.8 The Contractor shall procure and install an external FANUC controller for booths 1,4, 5 and shall integrate all three (3) controllers with the booth cabinet to be compatible with the Fanuc robot. The camera systems shall be able to START, PAUSE, and STOP the spray process externally from outside the booth. The contractor shall ensure all holes drilled through the walls shall be air tight sealed for soundproofing when the cable is through the wall.

3.2 Testing Procedures. The following test procedures will be conducted and witnessed by the

FRCSE TPOC:

a. Running a test HVOF (High Velocity Oxygen Fuel) production part with the thermal imaging camera activated in booth 7.

b. Running a test HVOF production part with the live video feed camera activated in booth 7.

c. Running a test plasma spray production part with the thermal imaging camera activated in booth 5.

d. Running a test plasma spray production part with the live video feed camera activated in booth 5.

e. Running a test flame spray production part with the thermal imaging camera activated in booth 3.

f. Running a test flame spray production part with the live video feed camera activated in booth 3.

3.3 Training Requirements

3.3.1 The Contractor shall provide onsite familiarization training for at least three (3) and up to eight (8) FRCSE employees after installation and testing has been completed. The training shall include overview, loading programs, operation of SW and mounted hardware. The Contractor shall provide all training material to include an operation, maintenance, and troubleshooting manuals for the Video/Thermal Cameras and PCs in digital format.

4.0 Delivery Information:

a. Delivery Date or Dates:

Delivery and Installation is needed on or about XXXXX.

b. Ship to address:

Fleet Readiness Command South East Building 794, NAS Jacksonville, Florida

c. Receiving Point of Contact (POC):

1. Name and title: Tyler Hallenbeck, Process Engineer, FRCSE

2. Email address: tyler.hallenbeck@navy.mil

3. Work phone: 904-790-7028

4. Fax Number: 904-790-7028

d. Receiving location work hours:

Work shall be accomplished during regular work hours, 6:00 AM to 5:00 PM seven days per week. POC: Tyler Hallenbeck

Appendix A

Note: All equipment shall have been designed or improved to be ruggedized and suitable for operating in an industrial environment.

1. Video Monitoring Cameras specifications:

a. Provide live feed streaming capability to a PC monitor located directly outside of the booth. Can be wireless or direct cable connection to the PC.

b. Must be movable on the mount inside the booth, but can be placed in a fixed position during the spray process.

c. Must be compatible for use inside a thermal spray booth. High temperature industrial environment rated. Case for protection required.

d. Requires dedicated power source and hookups, shared simultaneously between the thermal imaging camera and the video monitoring camera for each booth.

e. Recommended brand: ThermoView TV46L-TV-0. Software to include one-year software maintenance agreement.

2. Thermal Imaging Camera Specifications:

a. The thermal imaging camera and software shall be comparable with Windows 10 and be commercially available with customized software development.

b. Must configure software on the PC to monitor the temperature recorded by the thermal imaging camera. Thermal imaging process must be connected with a cable running from the camera inside the booth to a PC outside of the booth.

c. Must be movable on the mount inside the booth, but can be placed in a fixed position during the spray process.

d. Must be compatible for use inside a thermal spray booth. Case for protection required.

e. Requires dedicated power source and hookups, shared simultaneously between the thermal imaging camera and the video monitoring camera for each booth.

f. Recommended brand: ThermoView TV46L-TV-0 camera and compatible software.

Latest version. Software to include one-year software maintenance agreement.

Note: The recommended product ThermoView TV46L-TV-0 is a dual purpose camera that simultaneously streams a video live feed and a thermal imaging temperature feed. This is the preferred route, having one camera per booth rather than two different cameras for video and thermal.

3. Touchscreen Flat Panel PC Specifications (Provided by FRCSE – no procurement required)

a. Each PC must be equipped with thermal imaging software and the capability to display the video monitoring camera’s live feed stream. Software must be approved and tested by FRCSE IT department.

b. Each PC must run the thermal imaging software and the live feed from the video monitoring camera simultaneously. Software must be approved and tested by FRCSE IT department.

c. No wireless capability required, but will likely require a cable connection to each camera running from inside of the booth to outside of the booth. This will likely mean that at least two Ethernet ports are required on the PC.

d. A durable PC is required with a protective case since it will be used inside a production area.

e. A power source will be required for the PC.

4. PC Specifications (Provided by FRCSE)

a. Fujitsu – Stylistic Q736 model tablet. (Provided)

b. Dock required for tablet with HDMI video output and minimum of two Ethernet ports.

5. PC Mount

a. A mount to hold the PC and dock will be required for booths 1, 3, 4, 5, 6, and 7 (6 total).

b. The mount must be heavy duty and stable, with a swivel that moves up and down

(vertically). Multiple axis movement capability.

c. The PC shall be able to operate while mounted in a secure and protected manner.

d. The mount will be fixed to the wall above the door on the left of the booth. It should be movable to store the monitor above the door when needing to open the door. It must also pull down on a swivel to use at approximately eye level during production.

6. External Controller

a. An external controller for booths 1, 4, and 5. The controller must be compatible with the Fanuc robot inside the booth. The three current make/models in use are: FANUC I Pendant which control the FANUC R-30iA Cabinet.

b. The external controller must provide at a minimum the following operations: start, pause, and stop. The current controllers do not have a start button, the only start button is located directly on the robot inside the booth, but a new one can be configured

c. A cable must run through the wall that can connect to the external controller. A soundproof seal must be designed for the cable hole in the wall when the cable is through the wall. The cable must be able to disconnect from the cabinet inside, which is standard to the current cable configuration.

Summary of Procurement Items:

- Six (6) Video Monitoring / Thermal Imaging Cameras. (Buy 6)

- One (1) Spare Video Monitoring / Thermal Imaging Camera. (Buy 1, for 7 total).

Cases, mounts, software, and cables required for all 7.

- Six (6) Touchscreen Flat Panel PC. (PROVIDED BY FRCSE)

- Six (6) PC Mounts (Buy 6) – compatible with provided Fujitsu – Stylistic Q736 model tablet.

- Three (3) Fanuc External Controllers for the FANUC R-30iA Cabinet.

Example of Booth Configuration:

- One (1) Video Monitor / Thermal Camera ceiling mounted to robotically control 6 axis mount.

-Camera connected to power source.

-Camera able to be controlled and positioned through use of the mount controller.

-Camera hardwire connected to tablet located outside of the booth.

- One (1) Tablet located outside of the booth (PROVIDED BY FRCSE) -Tablet connected to power source.

-Tablet runs video monitor camera software and thermal imaging camera software.

-Tablet connected to camera through Ethernet cable.

-Tablet connected to FRCSE network – managed by local IT.

- One (1) Tablet externally mounted on the wall above the booth.

4. Electrical Requirements

4.1.1 Each camera and PC will require a power source.

4.1.2 The shop is limited on power availability and capability. Contractor must ensure there is sufficient power and connections to run the system for each booth.

4.1.3 Contractor is responsible for all installation of any power supply infrastructure or electrical configurations required to run and operate the system without impacting the production equipment.

Tech POC: FRCSE Process Engineer: Tyler Hallenbeck / 904-790-7028 / tyler.hallenbeck@navy.mil, NAS Jacksonville / Thermal Spray Shop / B794 / Shop Code 62724 mailto:tyler.hallenbeck@navy.mil