PWS.pdf

Performance Work Statement

Mobile Field Dynamometer M19/M18 Control System Upgrade

C.1 GENERAL:

C.1.1 SCOPE. This is non-personal services contract to design, build, and integrate a speed and force control systems for the U.S. Army Yuma Test Center (YTC), Yuma Proving Ground (YPG), AZ and Aberdeen Test Center (ATC), Aberdeen Proving Ground (APG), MD. The contract shall be Base: the control system will be integrated on the government owned heavy mobile field dynamometer, designated M19, and companion Absorption Trailer, designated T19, for the Automotive Instrumentation Division of YTC. Option: the control system will be integrated on the government owned heavy mobile field dynamometer, designated M18, and companion Heavy Absorption Trailer, designated HAT02, for the Automotive Instrumentation Division of ATC. The Government shall not exercise any supervision or control over the contract service provider performing services herein however the contract service provider will coordinate scheduled engineering and installation efforts with the COR, COTRs, or other government technical points of contact and provide all documentation for all engineering and manufacturing/installation functions. The Contractor shall provide all required certified factory trained labor, documentation, schematics, integration supplies, tools, test equipment, transportation and integrate control system.

C.1.2 BACKGROUND. The Automotive Instrumentation Division of ATC has an agreement with the Automotive Instrumentation Division of YTC forming a partnership to retain the working similarities within the Mobile Dynamometer Fleet. ATC and YTC’s partnership secured funding to purchase the new commercial control system for both YTC’s and ATC’s dynamometers. The test centers have sister dynamometers manufactured by Barnes and Reinecke Inc. (BRI) within a year of each other. These dynamometers have a control systems that was identical in design and function. ATC’s M16 recently finished a control system upgrade and was accepted in partnership with YTC in January of 2019.

YTC and ATC use the heavy mobile field dynamometers and trailers, designated M19 and T19 (YTC), and M18 and HAT02 (ATC), to conduct automotive performance tests of tracked and wheeled combat and tactical vehicles. The mobile field dynamometer is used to closely control the speed of a test item while measurements of drawbar force and other pertinent powertrain characteristics are obtained using independent on-board data acquisition. Typical performance tests conducted with the dynamometer include drawbar pull, tractive effort, full-load cooling, full-load fuel consumption, resistance to towing and recovery winch performance. The dynamometer is also used to conduct quasi-static line pulls that provide gradual force application and measurement through the front load cell. Force application is required for proof test loading of lifting and tiedown provisions and for testing the capacity of braking systems.

Tight control and regulation of the test vehicle speed and drawbar force is critical to successful automotive field-testing. Even small fluctuations in sustained speed can have a detrimental impact on the force measurements, subsequent power calculations and stabilized performance parameters. The speed control requirements are + 0.1 km/hr of the speed set point for road speeds between 0.5 to 20 km/hr, and within + 0.3 km/hr of the speed set point for road speeds above 20 km/hr. Tests are typically conducted on level (within 1.0 %) paved test courses. The BRI designed speed control system provides the interface to the General Electric locomotive controls to give the required resolution of speed control needed for performance testing. Force control is a requirement for tests where tractive force or cable loads are specified and for gradeability simulations.

The dynamometers are 30+ years old and the BRI designed speed control system is constantly prone to reliability issues. Major electrical components are no longer commercially available and replacement parts on hand at YTC or ATC for repairs have been depleted to a critical level. The original manufacturer and technical personnel are no longer in business to provide maintenance support or recommended product improvements like a force control feature. While breakdowns occur in both the mechanical and electrical realm, electrical breakdowns are more frequent and their complexity to diagnose and repair exceed the mean time to repair (MTTR) thresholds desired by instrumentation engineers. Taking into account the age and current state of the dynamometers, coupled with the advancements in control system technology, there is an urgent need to upgrade the speed control system to include speed and force control capabilities.

C.1.3 PERIOD OF PERFORMANCE. The period of performance shall be specified by the contractor’s proposal, from contract award start date not to exceed one year per option year. The option years will run consecutive. The upgraded control system will be integrated into the existing dynamometer chassis and be ready for acceptance testing one hundred eighty (180) days after the government accepts the preliminary design proposal. Acceptance testing will be completed within thirty (30) days after the integration of the new speed control system. YTC/ATC will provide the dynamometer crew (driver, dynamometer operator and engineer) to execute the acceptance tests described. YTC/ATC will also provide the test vehicles.

C.1.4 PLACE OF PERFORMANCE. Base: A fully functional integrated control system shall be delivered to YTC on or before the contractual commencement of the acceptance testing period; however a contractor may elect to ship the dynamometer or components thereof to their facility and back to YTC at the contractor’s expense. The contractor must provide onsite demonstration and acceptance testing services at the above installation. The cost estimate shall provide the line item(s) for any projected shipping costs.

Option: The contractor shall provide onsite demonstration and acceptance testing services at ATC. The installation services shall be completed at the above location, but a contractor may elect to ship the dynamometer or components thereof to their facility and back to ATC at the contractor’s expense. The cost estimate shall provide the line item for the cost.

C.1.5 HOURS OF NORMAL OPERATIONS.

C.1.5.1 Base: Principal Period of Maintenance (PPM): YTC is currently operating under an alternative work schedule. The contractor shall perform the maintenance within the government alternative work schedule and that work schedule will be known as the PPM for this contract. The PPM will be 8 workdays of 10 hours each, and every Friday off as shown below. All workdays commence at 0600.

M T W T F

Week 1 10hrs 10hrs 10hrs 10hrs 0hrs

Week 2 10hrs 10hrs 10hrs 10hrs 0hrs

Option: Principal Period of Maintenance (PPM): ATC is currently operating under an alternative work schedule. The contractor shall perform the maintenance within the government alternative work schedule and that work schedule will be known as the PPM for this contract. The PPM will be 8 workdays of 9 hours each, 1 workday of 8 hours, and every other Friday known as the Regular-Day-Off (RDO) as shown below. All workdays commence at 0700.

M T W T F

Week 1 9hrs 9hrs 9hrs 9hrs 8hrs

Week 2 9hrs 9hrs 9hrs 9hrs 0hrs

C.1.5.2 Integration and demonstration work shall not be scheduled during the following Federal Holidays:

New Years Day, M.L. King Birthday, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Day, Thanksgiving Day, and Christmas Day.

C.1.5.3 The Government reserves the right to postpone services based on sensitive work activities occurring at the facility. The COR will provide 24 hour notification of the requirement and advise the duration, up to 5 business days.

C.1.5.4 The Government has the option to permanently change the hours and days of operation if the contractor is provided two weeks’ notice.

C.1.6 PERSONNEL. All services under this contract shall be performed by competent personnel, experienced and highly qualified to provide the required services in accordance with the equipment manufacturer’s maintenance and repair procedures, without unnecessary delays or interference with government mission.

C.1.6.1 The contractor shall provide certified personnel with a minimum of 4 years of experience and demonstrated knowledge in the fields of hardware and software engineering applicable to design and implementation of industrial control processing unit (CPU) based control systems. Additional personnel shall have a minimum of 2 years’ experience and demonstrated knowledge in maintenance, troubleshooting and repair of electrical/electronic apparatuses and large mechanical equipment.

C.1.6.2 Program Management and Key Personnel. N/A

C.1.6.3 Identification of Contractor Personnel. The contractor shall ensure all personnel possess a form of identification (nametag) that contains the following information: personnel name, company name and the word “Contractor”. Such identification shall be prominently displayed at all times while in at work. In addition to that, the contractor shall ensure all personnel identify themselves as a contractor employee (with the name of their company) when answering the telephone, using the email system, and when attending meetings.

C.1.6.4 Personal Protective Equipment (PPE). All contractor personnel shall wear the appropriate PPE when in the following work areas: range areas where entrance is controlled by the Range Operations Team, industrial buildings, at construction sites, test sites and test facilities. Other areas may be reviewed to determine if hazards are present which necessitate the use of PPE. Failure to wear/use PPE may cause removal from the job site and/or seizure of non-compliant equipment/items.

C.1.7 SAFETY. Base: The Contractor's employees shall observe and comply with all local policies and procedures concerning fire, safety, environmental protection, sanitation, security, and possession of firearms or other lethal or illegal weapons or substance. Prior to commencing work, the Contractor shall provide their company's Accident Prevention Plan to the Government. The Contractor shall comply with all OSHA, U.S. Army, YTC, State, and other applicable industry safety standards. The Contractor shall report all accidents and occupational illnesses immediately to the Safety Office through the Contracting Officer's Representative (COR). The Contractor agrees to abide by all YTC Safety Policies at no additional cost to the government.

Option: The Contractor's employees shall observe and comply with all local policies and procedures concerning fire, safety, environmental protection, sanitation, security, and possession of firearms or other lethal or illegal weapons or substance. Prior to commencing work, the Contractor shall provide their company's Accident Prevention Plan to the Government. The Contractor shall comply with all OSHA, U.S. Army, ATC, State, and other applicable industry safety standards. The Contractor shall report all accidents and occupational illnesses immediately to the Safety Office through the Contracting Officer's Representative (COR). The Contractor agrees to abide by all ATC Safety Policies at no additional cost to the government.

C.1.7.1 Hazardous Conditions. Contractor personnel may be exposed to the following conditions during performance of work:

C.1.7.2 High noise levels (impulse and steady state);

C.1.7.3 Proximity to electric power sources of high voltage and/or amperage;

C.1.8 SECURITY. The Contractor will abide by all Base: YTC and Option: ATC security policies at no additional cost to the government.

Base: YPG

C.1.8.1 1 Installation Access. All employees working on this contract will be U.S. citizens; non U.S.

persons are not authorized to work on this contract. Contractor and all associated sub-contractors employees shall provide all information to meet installation access requirements. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) 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.

Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05/AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures.

C.1.8.2 Escort required access into Restricted Areas: The Contractor is responsible for hiring personnel eligible for escorted access to service equipment in the YPG Restricted Areas (RA). YPG Security Office will be issue an organizational credential to be used while in the RA. This credential identifies that the employee has an official need to be in the RA. Contractor personnel shall wear their security credential above the waist at all times when in the restricted areas of YPG with the following exceptions: (a) when photography is ongoing and the employee is likely to be in the photograph, and (b) when the employee is actually working with a piece of equipment that could catch the security credential and endanger the safety of the employee.

C.1.8.3 Reports of Adverse Information. The contractor shall report to the YPG Security Manager all adverse information on contractor personnel such as security violations, arrests, bankruptcy, wage garnishments and denial, suspension, or revocation of security clearances. The YPG Security Manager may deny employees’ access into YPG restricted areas based upon the adverse information.

C.1.8.4 Safeguarding Government Information and Property. The contractor shall be responsible for safeguarding all Government information and property provided for contractor use.

C.1.8.5 Usage of Privately Owned Personal Electronic Devices (PEDs) within the RA. A privately owned personal electronic device (PED) is defined as a civilian multifunction cell phone, iPhone, personal digital assistant, tablet, blackberry, digital inventory devices and electronic recording/storage devices. Contractor personnel shall not use the PED’s photographic/recording capability within the YTC RA. The contractor shall not install or connect a privately owned PED to any government-owned computer or network system. Also, a PED that has the capability to store data cannot be connected to a government computer for purposes of charging the device’s battery. Contractor employees must use the appropriate wall adapter to charge a privately owned PED. PEDs are authorized for private, non-work related matters. Under no circumstances will a privately owned PED be used to photograph or record images while in the YPG RA.

Option: APG

C.1.8.6 Unescorted access into Restricted Areas: The Contractor is responsible for hiring personnel eligible for unescorted access to service equipment in the APG RA. Unescorted access shall be granted to contractor personnel who possess a current SECRET security clearance, or higher issued by the Defense Security Clearance Office (DISCO) or who were the subject of a favorably completed National Agency Check, National Agency Check with Law and Credit Check (NACLC) or Special Agreement Check (SAC). The Contractor shall advise employees that the SAC will be used to review criminal history records and that adverse information may result in an employee being denied access into the RA.

Unescorted access shall be authorized provided no more than 24 months have lapsed since the date of the termination of the security investigation or break in service and there is no known adverse information.

All employees working on this contract will be U.S. citizens, non U.S. persons are not authorized to work on this contract.

C.1.8.7 Special Agreement Check (SAC). The contractor shall complete an IMAP Form 1199 (Application for Security Badge) and Fingerprint Applicant Worksheet, for each employee requiring unescorted access who does not meet one of the requirements above. Upon contract award, the

Contractor shall obtain required forms from the COR and return the completed forms to the COR within 10 working days. Until a favorable SAC is completed, contractor personnel shall be continually escorted into and out of the RA by other contractor or government personnel who possess a RA Security Identification Credential.

C.1.8.8 Restricted Area (RA) Security Identification Credential. Contractor personnel will be granted unescorted access provided the security investigation requirement stated above has been met. Once a written request from the COR has been received and the investigation or security clearance has been verified by a visit authorization letter being sent directly to the ATC Visitor Control Desk from the contracting company, the contractor employee will be issued an organizational credential to be used while in the RA. This credential identifies that the employee has an official need to be in the RA.

Contractor personnel shall wear their security credential above the waist at all times when in the restricted areas of ATC with the following exceptions: (a) when photography is ongoing and the employee is likely to be in the photograph, and (b) when the employee is actually working with a piece of equipment that could catch the security credential and endanger the safety of the employee.

C.1.8.9 Reports of Adverse Information. The contractor shall report to the ATC Security Manager all adverse information on contractor personnel such as security violations, arrests, bankruptcy, wage garnishments and denial, suspension, or revocation of security clearances. The ATC Security Manager may deny employees’ access into ATC restricted areas based upon the adverse information.

C.1.8.10 Installation Access. All contractor personnel will comply with the requirements of APG Regulation 190-4, Movement Control within the Installation, for entry, exit, and internal control of personnel, material and vehicles on APG. To gain access to APG, DA Form 1602, Civilian Identification Card, shall be issued to contractors who do not require computer access or do not travel on official Government business upon written approval from the COR. All vehicles and personnel are subject to search and seizure of contraband and/or unauthorized Government property in accordance with Army Regulation 190-13, The Army Physical Security Program.

C.1.8.11 Safeguarding Government Information and Property. The contractor shall be responsible for safeguarding all Government information and property provided for contractor use. Government-furnished property will be secured in accordance with AR 190-51, Security of Unclassified Army Property (Sensitive and Non-sensitive).

C.1.8.12 Usage of Privately Owned Personal Electronic Devices (PEDs) within the RA. A privately owned personal electronic device (PED) is defined as a civilian multifunction cell phone, iPhone, personal digital assistant, tablet, blackberry, digital inventory devices and electronic recording/storage devices. Contractor personnel shall not use the PED’s photographic/recording capability within the ATC RA. The contractor shall not install or connect a privately owned PED to any government-owned computer or network system. Also, a PED that has the capability to store data cannot be connected to a government computer for purposes of charging the device’s battery. Contractor employees must use the appropriate wall adapter to charge a privately owned PED. PEDs are authorized for private, non-work related matters. Under no circumstances will a privately owned PED be used to photograph or record images while in the ATC RA.

C.2 APPLICABLE DOCUMENTS AND AVAILABILITY.

C.2.1 Documentation which includes the following will be made available to the contractor to aid in their proposal development:

a. Electronic (scanned) copies of original drawings and schematics

b. Test Operating Procedures (TOP) used for acceptance testing

c. Physical Dimensions and Pertinent Component Document

d. SAE White Paper on Mobile Dynamometer and Absorption trailer for Military Vehicles

C.3 REQUIREMENTS. The primary requirement is to design, build, integrate and demonstrate a modern reliable speed and force control system for the existing M19 and M18 mobile field dynamometer chassis and to reuse the cab, diesel engine, generator, direct current traction motor, auxiliary generator, auxiliary power unit and dynamic braking grids, where practical. Any existing vehicle components that are retained as part of the speed control upgrade project should be evaluated by the Original Equipment Manufacturer (OEM) or a certified repair facility to determine their functional condition and whether any repair, rebuild, or upgrades are needed. The speed and force control system shall have the user interface identical to ATC’s M16 modern control system.

A subsequent requirement is to design, build, integrate and demonstrate a modern reliable control system for the existing T19 and HAT02 Absorption Trailers, when coupled to the M19 and M18/M16 mobile field dynamometers, respectively, and to reuse the diesel engine generator, direct current traction motor, and dynamic braking grids, where practical. Any existing vehicle components that are retained as part of the control upgrade project should be evaluated by the Original Equipment Manufacturer (OEM) or a certified repair facility to determine their functional condition and whether any repair, rebuild, or upgrades are needed. The control system shall have the user interface and interface protocol identical to ATC’s HAT01 modern control system.

The compatibility of the M16, M18, and M19 dynamometers to control any one of the absorption trailers (T19, HAT01, and HAT02) shall be maintained. Currently ATC’s M16 or M18 and YTC’s M19 can control each of the three trailers. This interconnect ability shall be maintained with the new control system installed into the M19 and M18 dynamometers. The HAT02 shall maintain interconnect ability to the ATC’s M16 upon completion of its new control system upgrade.

C.3.1 Speed Control. The dynamometer, when equipped with the new speed control system, shall control the test vehicle speed to + 0.1 km/hr of the speed set point for true ground speeds between 0.5 to 20 km/hr, and within + 0.3 km/hr of the speed set point for speeds above 20 km/hr for all load conditions.

Control of the test vehicle speeds will be demonstrated on paved level (within 1.0 %) test courses at YTC.

Speed control will be required for all modes of dynamometer truck operation. The road speed shall be electronically controlled via a modern graphical user interface (GUI); a physical turn dial shall be installed as a secondary speed input device. For safety operation compliance, the driver shall be able to override the speed setting using the service brakes.

C.3.2 Force Control. The force control feature shall control the dynamometer to +1.5% of the force set point for speeds between 0.5 km/hr and 72 km/hr. Force control shall be an option when operating the mobile field dynamometer in the dynamometer and winch modes. Force selection will be controlled by the dynamometer operator and will have a maximum resolution of the force set point of 1 kN (~250 lbf).

The force control feature for the dynamometer mode will be demonstrated on paved level (within 1.0 %) test courses at the respective test center. The force control feature will be operable with the M19 and the T19, and the M18 and HAT02. To provide for safe operation the driver can override the force set point using the service brake pedal. The current load cells included on the dynamometer are a 100k lbf and a 50k lbf capacity load cell mounted at the front and rear, respectively. The load cell readout is a Himmelstein 700 series strain gauge conditioner.

C.3.3 Operating Conditions. The M19 and M18 mobile field dynamometer coupled with the T19 and HAT02 are specialized equipment developed for controlling and measuring full power drawbar pull of military and commercial tracked and wheeled vehicles. They are also used to control and measure the resistance to towing characteristics of the same types of vehicles. They are expected to perform heavy-duty service primarily on dry, smooth, hard surfaced roads. The M19/T19 and M18/HAT02 combinations shall be capable of continuous power absorption of up to 65,000 lbf for a minimum of 2 hours in ambient temperatures up to 120oF without overheating or damage.

C.3.4 Drive Modes. The M19 and M18 will be required to operate in five driver selectable modes. The modes of operation are truck, prime mover, dynamometer, winch, and inch.

C.3.4.1 Truck Mode. Truck mode is used for general movement of the dynamometer truck when not engaged in testing. The M19 and M18 are required to be driven at posted speeds over primary roads up to 88 km/hr (M19) and 90 km/hr (M18) and in/around shop maintenance and garage storage areas at slow controllable speeds. The driver controls the dynamometer using the foot operated accelerator and service brake pedals. The service brake pedal shall smoothly blend the dynamic braking (electric motor braking) and the air operated s-cam service brakes.

C.3.4.2 Prime Mover Mode. Prime mover mode is used when towing a test vehicle for the purpose of measuring the resistance to towing (power loss) characteristics with the rear pintle mounted load cell at incremental road speeds up to 88 km/hr (M19) and 90 km/hr (M18).

C.3.4.3 Dynamometer Mode. In the dynamometer mode the M19 and M18 are coupled to and towed by a test vehicle through the height adjustable front pintle/load cell. The test vehicle is operated at a constant throttle setting (typically full throttle) while the dynamometer is used to control the road speed of the combination over its operating speed range. The dynamometer absorbs and measures (through the front mounted load cell) the drawbar pull developed at each stabilized speed condition. Loading changes to the test vehicle are required to be applied smoothly and without the need of stopping to change gearing for various load/speed combinations. On the new control system, the road speed or force shall be electronically controlled via a modern GUI or using a physical turn dial located on the dash. To provide for safe operation the driver can override the speed setting using the service brakes.

C.3.4.3.1 Dynamometer Extended Capacity. When testing vehicles with drawbar pull exceeding the capability of the M19, the dynamometer can be coupled with T19. When using M18/M16, the dynamometer can be coupled to with HAT01 or HAT02. When using T19 or HAT02 the dynamometer operator can control it from the cab of the M19 or M18/M16. The new control system shall control both items with one control input. The controller shall have the capability to auto balance the load amongst both units but also have a user enabled/disabled function for manual load set points. The control system shall sense the presence of trailer and enable controls for the absorption load on T19 and HAT02. The load shall be visible to the dynamometer operator so all systems can be monitored.

C.3.4.4 Winch Mode. Winch mode is used for quasi-static line pulls that provide gradual force application and measurement through the front load cell. This force application is required for applying fixed horizontal loads to lift and tiedown provisions, for applying simulated cable loads to recovery winches and to determine braking forces of service and parking brake systems on various surfaces. The force control option will be used in the winch mode. During operations the system shall have the ability to have a set point change and time to change. This is needed for winch testing. As a winch wraps in cable generally the pull force lowers with each layer on the winch drum. The dynamometer control shall have the ability to be preset and with a smooth ramp down rate that can be initiated so the winch does not stall at the transition from one layer to another.

C.3.4.5 Inch Mode. Inching mode is also selected for coupling operations when “close quarter” maneuvering is needed when connecting the dynamometer to a test vehicle or to the absorption trailers.

C.3.5 Engineering Design Documentation. The speed and force control upgrade will require the development and YTC/ATC review of a technical design package. The proposed control system design is required to be fully documented to include wiring diagrams, schematics, theory of operation, parts lists, source code and sources of supply for all major components. Any special tools or processes will be identified. A theory of operation document will be provided to assist YTC/ATC engineers in the understanding of the updated system operation. Troubleshooting and recommended maintenance intervals/procedures will also be provided.

C.3.6 Electrical Upgrade. The existing electrical control panel will either be replaced in its entirety or fitted with a new subpanel. The upgraded electrical cabinet will contain new and modern discrete components along with new power and control system wiring.

Any associated electrical control components located outside of the electrical control cabinet will be replaced and rewired with new power and control wiring. This includes the control and power electronic components located in the main generator housing.

The dash mounted controls and indicators will be replaced. Redundant, unused and obsolete panel indicators will be discarded. A new dashboard will be fabricated as part of the project. Units for all panel readouts and displays should be in U.S. customary units.

C.4 PROPOSAL DEVELOPMENT/EVALUATION:

C. 4.1 Each technical proposal is required to have sufficient detail to enable a comprehensive evaluation of the proposed control system modifications and its impact on acceptable dynamometer operation to determine whether the design will meet the essential requirements of the government. Proposals should be specific, complete and demonstrate a thorough understanding of the requirements.

C.4.2 Acceptability of proposals will be based on meeting all of the requirements of the government specification. Failure to address each requirement will result in the proposal being rated unacceptable.

Contractors submitting unacceptable technical proposals will be notified upon completion of the government’s technical review process. If a proposal is not clear in its response to a requirement, that proposal will be rated susceptible of being made acceptable and at the government’s sole discretion may or may not request further clarification.

C.4.3 In order to facilitate the evaluation process each proposal should contain sufficient detail with respect to the following:

a. Basic design approach

b. Adherence to the requirements of the government specification

c. Inter compatibility among dynamometers and trailers

d. Use of state-of-the-art technologies

e. Component selection and commercial availability

f. Overall dynamometer performance

g. Adequacy of software

h. Familiarization and training plans for government personnel (end user)

i. Documentation, troubleshooting, and schematics in an electronic format

C.5 CONTROL SYSTEM IMPLEMENTATION

Base: YTC

C.5.1 The final modifications to the mobile field dynamometer to complete the control system upgrade will be performed on-site at YTC. Prior to final modifications, the dynamometer or individual dynamometer components may be shipped at the contractor’s discretion for inspection, rebuild or modification as required to support the control system upgrade. All shipments requested by the contractor will be completed at the contractor’s expense. The cost estimate shall provide the line item for the cost.

C.5.2 Dedicated shop space will be provided by YTC to facilitate the control system modifications. A trained dynamometer operator will be provided by YTC if the dynamometer needs to be started, moved or operated as part of the upgrade.

Option: ATC

C.5.3 The final modifications to the mobile field dynamometer to complete the control system upgrade will be performed on-site at ATC. Prior to final modifications, the dynamometer or individual dynamometer components may be shipped at the contractor’s discretion for inspection, rebuild or modification as required to support the control system upgrade. All shipments requested by the contractor will be completed at the contractor’s expense. The cost estimate shall provide the line item for the cost.

C.5.4 Dedicated shop space will be provided by ATC to facilitate the control system modifications. A trained dynamometer operator will be provided by ATC if the dynamometer needs to be started, moved or operated as part of the upgrade.

C.6 ACCEPTANCE TESTING

Base: YTC

C.6.1 After completion of the control system upgrade, component overhaul and wiring improvements, the M19 will be subjected to a series of acceptance tests to insure the dynamometer operation meets the government specifications. Contractor personnel are expected to be on-site during the acceptance tests to make any adjustments, modifications or repairs that may be needed during the course of the acceptance test.

C.6.2 The acceptance of the mobile field dynamometer control system upgrade will be based on its ability to meet the speed and force control requirements for each intended mode of operation. Government personnel at YTC will execute the acceptance tests after completion of the control system integration.

Evaluation of the speed and force controls will be conducted on YTC’s paved test courses. The test course gradient for all tests will not exceed 1.0 percent. Tests will be conducted on YTC’s Dynamometer Test Course. Descriptions of the test courses are provided in reference [2].

C.6.3 Truck mode: The M19 will be driven at posted road speeds up to 88 km/hr. The vehicle will be maneuvered in and out of simulated shop and maintenance areas marked with traffic pylons. The slow speed maneuvers will simulate moving in and out of the garage storage areas, hooking up to test vehicles and connecting to the absorption trailer. YPG’s experienced operators will evaluate the handling, maneuverability; throttle response and braking control of the dynamometer. The analysis will be subjective in nature and will be based off YPG’s long-term experience with the truck.

C.6.4 Prime mover mode: The dynamometer will tow test vehicles using the rear mounted load cell. A wheeled vehicle (e.g. FMTV or HMMWV) and a tracked vehicle (e.g. M2 Bradley Fighting Vehicle) will be towed over their respective speed operating ranges or up to 88 km/hr. Sustained stabilized speed runs will be conducted for a minimum time interval of two minutes each. The selected speed intervals will not exceed 2 km/hr and the minimum test speed will be 0.5 km/hr. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) speed data will be compared to the speed control requirements. The speed control requirement on a level paved surface is + 0.1 km/hr of the speed set point for speeds between 0.5 to 20 km/hr, and within + 0.3 km/hr of the speed set point for speeds above 20 km/hr for all load conditions. The U.S. Army Test and Evaluation Command (ATEC) Test Operating Procedure (TOP) 2-2- 605, Wheeled Vehicle Towing Resistance, reference [3] will be used as the guide for the prime mover tests.

C.6.5 Dynamometer mode: Full load, tractive effort tests using M19/T19 in single and coupled configurations will be conducted using ATEC TOP 2-2-604, Drawbar Pull, reference [4] as a guide.

Specifically, “Drawbar Pull on Hard Surface”, paragraph 4.2 will be followed during the acceptance tests.

Several test vehicles will be used so that the speed and load range of the dynamometer and trailer will be adequately covered. Tracked and wheeled vehicles (e.g. FMTV, HMMWV, and M2 Bradley Fighting Vehicle) will be used. Sustained stabilized speed runs will be conducted for a minimum time interval of two minutes each. The speed intervals selected will not exceed 2 km/hr and the minimum test speed will be 0.5 km/hr. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20

Hz) speed data will be compared to the speed control requirements. The speed control requirement on a level paved surface is + 0.1 km/hr of the speed set point for speeds between 0.5 to 20 km/hr, and within +

0.3 km/hr of the speed set point for speeds above 20 km/hr for all load conditions.

C.6.5.1 Sustained stabilized force runs will be conducted for a minimum time interval of two minutes each. Force values will be selected based on typical gradeability and tractive effort requirements. Force values that simulate ascending 2-, 5- and 10-percent grades will be determined for a light wheeled vehicle (e.g. HMMWV) and a heavy tracked vehicle (e.g. M2 Bradley Fighting Vehicle). Tractive force values that represent 30- and 60-percent of the vehicle test weight will also be used for validation. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) force data will be compared to the force control requirement. The force control feature shall control the dynamometer to +1.5% of the force set point for speeds between 0.5 km/hr and 72 km/hr

C6.6 Winch mode: Winch line pulls will be conducted at constant forces typical of self-recovery or material handling winch systems. Changes (a decrease) in cable loading to compensate for increasing cable layers will be demonstrated. Static cable loads to check the safety relief settings and winch brakes will also be demonstrated. This test will also be used to demonstrate the static loads required to proof test lift and tiedown provisions. The U.S. Army Test and Evaluation Command (ATEC) Test Operating Procedure (TOP) 2-2-712, Automotive Winches, reference [5] will be used to evaluate the line speed control and winch capacity characteristics. Test vehicles and winch load capacities will be selected to cover as much of the load range as practical. The force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) force data will be compared to the force control requirement. The force control feature shall control the dynamometer to +1.5% of the force set point. Continuous line pulls should be possible without stopping between cable layers.

C.6.7 Inch Mode: Proper inch mode performance will be validated when connecting the appropriate towbar between the dynamometer and test vehicles. Smooth predictable vehicle operation and low speeds are essential for safe operation. The analysis will be subjective in nature and will be based off YTC’s long-term experience with the truck.

C.6.8 The contractor will have personnel on-site to witness all acceptance tests and should be ready to make any required adjustments, modifications or repairs needed to the new speed control system to insure conformance to the government specifications. The contractor will be responsible for the data collection and data presentation; government oversight to include additional instrumentation could be used for data validation. Acceptance tests will be documented in a formal written report and supplied to the government fifteen (15) days after completion of the acceptance test phase.

Option: ATC

C.6.9 After completion of the control system upgrade, component overhaul and wiring improvements, the M18 will be subjected to a series of acceptance tests to insure the dynamometer operation meets the government specifications. Contractor personnel are expected to be on-site during the acceptance tests to make any adjustments, modifications or repairs that may be needed during the course of the acceptance test.

C.6.10 The acceptance of the mobile field dynamometer control system upgrade will be based on its ability to meet the speed and force control requirements for each intended mode of operation.

Government personnel at ATC will execute the acceptance tests after completion of the control system integration. Evaluation of the speed and force controls will be conducted on ATC’s paved test courses.

The test course gradient for all tests will not exceed 1.0 percent. Tests will be conducted on ATC’s Dynamometer Test Course and/or Automotive Test Evaluation Facility (ATEF). Descriptions of the test courses are provided in reference [2].

C.6.11 Truck mode: The M18 will be driven at posted road speeds up to 90 km/hr. The vehicle will be maneuvered in and out of simulated shop and maintenance areas marked with traffic pylons. The slow speed maneuvers will simulate moving in and out of the garage storage areas, hooking up to test vehicles and connecting to the absorption trailers. ATC’s experienced operators will evaluate the handling, maneuverability; throttle response and braking control of the dynamometer. The analysis will be subjective in nature and will be based off ATC’s long-term experience with the truck.

C.6.12 Prime mover mode: The dynamometer will tow test vehicles using the rear mounted load cell. A wheeled vehicle (e.g. FMTV or HMMWV) and a tracked vehicle (e.g. M1A2 Abrams) will be towed over their respective speed operating ranges or up to 72 km/hr. Sustained stabilized speed runs will be conducted for a minimum time interval of one minute each. The selected speed intervals will not exceed 2 km/hr and the minimum test speed will be 0.5 km/hr. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) speed data will be compared to the speed control requirements. The speed control requirement on a level paved surface is + 0.1 km/hr of the speed set point for speeds between 0.5 to 20 km/hr, and within + 0.3 km/hr of the speed set point for speeds above 20 km/hr for all load conditions. The U.S. Army Test and Evaluation Command (ATEC) Test Operating Procedure (TOP) 2-2- 605, Wheeled Vehicle Towing Resistance, reference [3] will be used as the guide for the prime mover tests.

C.6.13 Dynamometer mode: Full load, tractive effort tests will be conducted using ATEC TOP 2-2-604, Drawbar Pull, reference [4] as a guide. Specifically, “Drawbar Pull on Hard Surface”, paragraph 4.2 will be followed during the acceptance tests. Several test vehicles will be used so that the speed and load range of the dynamometer will be adequately covered. Tracked and wheeled vehicles (e.g. FMTV, HMMWV, M2 Bradley Fighting Vehicle) will be used. Sustained stabilized speed runs will be conducted for a minimum time interval of one minute each. The speed intervals selected will not exceed 2 km/hr and the minimum test speed will be 0.5 km/hr. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) speed data will be compared to the speed control requirements. The speed control requirement on a level paved surface is + 0.1 km/hr of the speed set point for speeds between 0.5 to 20 km/hr, and within + 0.3 km/hr of the speed set point for speeds above 20 km/hr for all load conditions.

C.6.13.1 Sustained stabilized force runs will be conducted for a minimum time interval of one minute each. Force values will be selected based on typical gradeability and tractive effort requirements. Force values that simulate ascending 2-, 5- and 10-percent grades will be determined for a light wheeled vehicle (e.g. HMMWV) and a heavy tracked vehicle (e.g. M2 Bradley Fighting Vehicle). Tractive force values that represent 30- and 60-percent of the vehicle test weight will also be used for validation. Speed and force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) force data will be compared to the force control requirement. The force control feature shall control the dynamometer to +1.5% of the force set point for speeds between 0.5 km/hr and 72 km/hr

C6.14 Winch mode: Winch line pulls will be conducted at constant forces typical of self-recovery or material handling winch systems. Changes (a decrease) in cable loading to compensate for increasing cable layers will be demonstrated. Static cable loads to check the safety relief settings and winch brakes will also be demonstrated. This test will also be used to demonstrate the static loads required to proof test lift and tiedown provisions. ATEC TOP 2-2-712, Automotive Winches, reference [5] will be used to evaluate the line speed control and winch capacity characteristics. Test vehicles and winch load capacities will be selected to cover as much of the load range as practical. The force data will be recorded at a minimum sample rate of 100 Hz. The filtered (20 Hz) force data will be compared to the force control requirement. The force control feature shall control the dynamometer to +1.5% of the force set point.

Continuous line pulls should be possible without stopping between cable layers.

C.6.15 Inch Mode: Proper inch mode performance will be validated when connecting the appropriate towbar between the dynamometer and test vehicles. Smooth predictable vehicle operation and low speeds are essential for safe operation. The analysis will be subjective in nature and will be based off ATC’s long-term experience with the truck.

C.6.16 Proper operation of ATC’s existing heavy absorption trailers will also be verified. Each absorption trailer will be towed by the M18 mobile field dynamometer while the trailer loading is applied using the dynamometer controls for the trailer. The trailers will be towed as single units with the dynamometer.

Force and speed control will be measured and compared to the government requirements. The M16 will be connected to HAT01 and HAT02 to confirm Dynamometer Extended Capacity is maintained.

C.6.17 The contractor will have personnel on-site to witness all acceptance tests and should be ready to make any required adjustments, modifications or repairs needed to the new speed control system to insure conformance to the government specifications. The contractor will be responsible for the data collection and data presentation. Acceptance tests will be documented in a formal written report and supplied to the government fifteen (15) days after completion of the acceptance test phase.

C.7 References

1) ATC M16 Mobile Dynamometer Theory of operation and Major Component Evaluation, Dyne Systems Inc. Midwest & Dynamatic Dynamometers, April 2015.

2) ATEC TOP 1-1-011A, Vehicle Test Facilities at Aberdeen Test Center and Yuma Test Center, February 2012.

3) ATEC TOP 2-2-605, Wheeled Vehicle Towing Resistance, July 1993.

4) ATEC TOP 2-2-604, Drawbar Pull, September 2007.

5) ATEC TOP 2-2-712, Automotive Winches, January 1987.

C.8 Submission Procedures:

Please submit proposals in the following format:

Address all elements of the performance work statement in the proposal. On a separate document submit the firm fixed pricing information. The firm fixed pricing shall be broken out into these payment categories: Base: Engineering, Installation, Commissioning, Training and Testing, Materials, Travel, and Other Direct Costs and Option: Engineering, Installation, Commissioning, Training and Testing, Materials, Travel, and Other Direct Costs. These categories shall be listed as Base: Clins 0001-0007 and Option Clins 0008-0014 in the contract to be paid upon completion. Do not submit pricing and technical proposals in the same document.

C.9 NON-PERSONAL SERVICE STATEMENT

Contractor employees performing services under this order will be controlled, directed, and supervised at all times by management personnel of the contractor. Contractor management will ensure that employees properly comply with the performance work standards outlined in the performance work statement (PWS). Contractor employees will perform their duties independent of, and without the supervision of, any Government official. The tasks, duties, and responsibilities set forth in the task order may not be interpreted or implemented in any manner that results in any contractor employee creating or modifying Federal policy, obligating the appropriated funds of the United States Government, overseeing the work of Federal employees, providing direct personal services to any Federal employee, or otherwise violating the prohibitions set forth in Parts 7.5 and 37.1 of the Federal Acquisition Regulation (FAR).

C.10 CONTRACTOR MANPOWER REPORTING (CMR).

The Office of the Assistant Secretary of the Army (Manpower & Reserve Affairs) has established a secure data collection site, entitled Contractor Manpower Reporting System, for the purpose of capturing contractor (and subcontractor) manpower utilized during the performance of this contract. As a result, the contractor shall report all the information required by the Contractor Manpower Reporting System. The information requiring completion by the contractor includes, but may not be limited to the following:

Contracting Office, Contracting Officer, Contracting Officer's Technical Representative, Contract number, Requiring activity identification code (UIC), Command, Obligated Dollars, Fund cite information, Contractor name, address, phone number, e-mail address, Direct labor hours, Direct labor dollars, Federal Service Code (FSC) and Locations of service. The contractor shall submit all required information before final invoice. The contractor shall access the Contractor Manpower Reporting System database on the internet and fill-in the required data entry fields. The system can be accessed at the following internet address: https://cmra.army.mil.

C.11 The contractor shall utilize the Wide Area Work Flow (WAWF) system for requesting payment for all CLIN from the Government.