60-81-120mm Horizontal Rigid Stage Mortar Cannon Laser Bore Mapping Inspection System

1.0 SCOPEThis specification describes the requirement for a 60-81-120 mm mortar laser bore inspection system (LBIS) with a rigid delivery stage to US Army Yuma Proving Grounds (USYPG). The LBIS shall be capable of use for:? Precision laser-based bore erosion mapping of tubes with typical accuracy +/- 0.001 inch or better.? High resolution laser-generated video imaging, quantitative measurement of material loss, flaw detection and reporting, and 3D feature imaging? Capable of precision profiling of 120mm bore using LVDT technology, with typical accuracy +/-0.0005 inch (+/- 0.0127mm) or better.1.1 GENERAL DOCUMENTATIONThe following documents shall be supplied with the system:? One complete set of Operator?s Manuals? Certification of calibration ring accuracy? Certification of calibration laser sensors1.2 ENVIRONMENTThe system shall operate in a shop with:? Ambient temperatures ranging from 10 to 45 degrees C? Relative humidity between 10 and 95% (non-condensing)? Available power 120-240 VAC (+/- 10%) at 50-60 Hz2.0 GENERAL REQUIREMENTThe system deliverables shall include the following major components:? 1 each 3-axis channel Data Acquisition and Control Instrument? 1 each Rigid Horizontal Delivery Stage with 8 feet of travel? 1 each Laser Profile Sensor Scanning Assembly for 120mm bores? 1 each Laser Profile Sensor Scanning Assembly for 60 and 81mm bores? 1 each 120mm Calibration Ring? 1 each 60mm Calibration Ring? 1 each 81mm Calibration Ring? 1 each Guide Tube Adaptor for M298 Mortar? 1 each Guide Tube Adaptor for 60mm Mortar? 1 each Guide Tube Adaptor for 81mm Mortar? 4 each Shipping Cases? 1 each Calibration Workspace2.1 Component System Identification hardcode shall be installed in the following components:All major components of the LBIS shall be include electronic component identification circuitry that allows components to be interchanged without requiring manual interfacing. As a minimum, each major system component shall store and be capable of downloading the following: 2.1.1 Data Acquisition and Control (DAC) Instrument? Component serial number and date manufacture2.1.2 Laser Bore Scanners (LBS)? Rotary motor parameters? Rotary encoder parameters? Calibration parameters? Calibration date record? Component serial number2.1.3 Sensor Delivery Unit (SDU)? Linear motor parameters? Linear encoder parameters? Component serial number2.2 Data Acquisition and Control (DAC) Instrument The DAC Instrument shall include an internal motor control unit, laser control circuitry and data acquisition software pre-installed.2.2.1 DAC shall meet or exceed the following specifications:? Maximum Dimensions: 19? W x 9.5? H x 11? L? Maximum Weight: 29 lbs. max.? Operating System: Windows 11 or better? Minimum Processor: Intel Core i5-1360P, 3.7 GHz clock speed or better? Minimum RAM: 16GB DDR4 RAM; 2666 MHz? Minimum Display: 15.6? Dia. 1920x1080 pixels 16:9 aspect ratio? Motor Fuse 2.5A? Military Grade Linear Motor and Sensor Cable connections? External HDMI port? Cat5e Ethernet port? USB 3.0 ports (4 ea.) ? USB-C Port? Display: 15.6? 1920 x 1080 pixels 16:9 Aspect? USB keyboard and mouse? Software Registration: Soft Key type? Hard Sided Shipping Case? High outdoor brightness screen display at minimum 1000 nits2.2.2 DAC Control SoftwareDAC control software shall be a commercially available, standard product employing based on Microsoft Windows-10 operating system platform or better. It shall provide the following functions/capabilities:2.2.2.1 Motion Control? Shall enable operator-controlled Forward, Reverse, Go-To, Return-to-Home routines? Enable/Disable Forward/Reverse motion control? Encoder position display for each axis? Encoder Set-to and Zero functions2.2.2.2 Semi-Automatic Sensor Calibration:? Control software is capable of conducting a fully automatic calibrationroutine? Software shall provide a Pass/Fail display of calibration test results? If the calibration fails, the software shall automatically calculate the corrected calibration parameters and allow the operator to implement the adjusted calibration parameters? Calibration software shall allow the operator to manually adjust offset and slope of the calibration algorithm? If the calibration is substantially out of range, the software will notify the operator to facilitate trouble-shooting, including re-installation of default calibration parameters2.2.3 Data Acquisition SoftwareLBIS shall include two modes of operation Engineer Mode and Operator Mode2.2.3.1 Engineer Mode:? Shall be password protected and intended to allow access to all advanced control, calibration and data acquisition functions ? Operator-configurable scan routines for helical, step/increment? Variable scan control with axial scan resolution to as low as 0.1 mm (0.004 inch) per increment? Variable scan control with rotary scan resolution to as low as 0.1 mm (0.004 inch) per increment? Shall include operator-configurable data acquisition workspaces which may be customized and saved as unique workspaces? Scan Parameter dialog window provides estimated file size, data rate and scan time2.2.3.2 Operator Mode:? Is intended for routine operation of the system.? Allows the Operator to access pre-defined workspaces? Shall not allow the Operator to modify or change any aspect of a pre-defined Scan Setup2.2.4 Data Display shall include, as a minimum:? Multiple, operator-adjustable color palette, including rainbow, thermal greyscale, and solid color palettes? Laser-generated video image of data for visual display of features such as fine scratches, chips, tool-marks, etc.? Zoom and pan display functions.? Cross-sectional and axial display of surface profile data2.3 Scanner Assembly ? 120mm BoresThe Scanner Assembly shall be self-centering and provided with rollers or equivalent that will not damage the launch tube surface. The 120mm Scanner Assembly shall be designed to operate in 120mm nominal tubes, and shall meet or exceed the following specifications:? Single Sensor (0.150 inch) radial range? For Scanning Tubes 120mm in Diameter? Sensor Measurement Resolution: 0.0001 inch? Sensor Linearity: 0.00015 inch or better? Sensor accuracy: +/- 0.0005 inch typical? Measuring Range (diameter): 4.632 to 4.932 inch? Average Laser Spot Size (max): 0.0025 inch ? Laser Power: less than 5 mW @ 650 nm? Laser Power Classification: Class 3R ? Angular Sampling Resolution: Variable ? up to 0.025 degrees per sample (4,800 samples per revolution)2.4 Scanner Assembly ? 60/81mm BoresThe Scanner Assembly shall be self-centering and provided with rollers or equivalent that will not damage the launch tube surface. The 60/81mm Scanner Assembly shall be designed to operate in 60mm and 81mm nominal tubes, and shall meet or exceed the following specifications:? Single Sensor (0.150 inch) radial range? For Scanning Tubes 60mm or 81mm in Diameter? Sensor Measurement Resolution: 0.0001 inch? Sensor Linearity: 0.00015 inch or better? Sensor accuracy: +/- 0.0005 inch typical? Measuring Range (diameter): 60mm: 2.252 to 2.552 inch; 81mm: 3.078 to 3.378 inch? Average Laser Spot Size (max): 0.0025 inch ? Laser Power: less than 5 mW @ 650 nm? Laser Power Classification: Class 3R ? Angular Sampling Resolution: Variable ? up to 0.025 degrees per sample (4,800 samples per revolution)2.5 Sensor Delivery Unit (SDU)The Sensor Delivery Unit shall include the following features:? Combined Sensor Delivery and Barrel Support Stand? Precision, belt-driven delivery stage.? High precision magnetic encoder.? Length of travel 8 feet ? Axial positional resolution: - 0.001 inch? Axial positional accuracy: - 0.010 inch? Provision for shock-resistant and solid mounting to shop floor2.6 Guide Tube Assemblies (GTAs)The system shall be provided with 1 each M298 muzzle guide tube adapter, 60mm muzzle guide tube adapter, and 81mm muzzle guide tube adapter that is capable of being mounted to customer-owned tubes. Each GTA shall be capable of holding the Calibration ring and interchangeable spacer (pass-thru) ring. 2.7 Calibration HardwareThe system shall be provided with 1 each precision three (3) step 120mm calibration ring, 60mm calibration ring, and 81mm calibration ring. The calibration rings shall have:? Roundness of +/- 0.001?? Surface finish of 16RMS or better? No visible machining marks or honing ?cross-hatch? marks? Provided with NIST-traceable certification 2.8 System AccessoriesThe LBIS shall include the following accessories:? Calibration Software/Workspace (installed on DAC)? Shielded Cables for the Laser Profiling Sensor and Rigid Delivery Stage? Hard Sided Shipping Cases for the Laser Profiling Sensor Scanning Assemblies, DAC, Guide Tube Adapters and Calibration hardware? Operating Manual and Addendums2.9 Factory Acceptance Test ? Upon completion, the factory acceptance test shall be conducted at manufacture prior shipping to Yuma Proving Ground.3.0 Delivery, Setup, and Training3.1 Manufacturer shall provide no less than 4 days of on-site assistance for system set-up and functional testing3.2 Training shall be on-site and including:? System set-up? Calibration verification? Basic operation? Data acquisition? Data storage? Data analysis and reporting? Periodic and preventive maintenance? Trouble-shooting4.0 Quality Assurance and Warranty Provisions? Preservation, packaging and packing shall be in accordance with the manufacturer?s commercial practice? Manufacturer shall warrant all components for one year from data of acceptance.? Shipping and handling shall be included.