Sources Sought: Generator Control Unit (GCU)

1.0 Description The Naval Air Systems Command (NAVAIR) in support of the V-22 Joint Program Office (PMA-275) is seeking information from industry on a proposed solution for the redesign of the Generator Control Unit (GCU) currently utilized on the United States Marine Corps and United States Air Force, United States Navy (USMC/USAF/USN) V-22 aircraft. The design should support future generator upgrades in a safe, reliable, cost effective, and sustainable manner. Development concepts should outline an approach that ensures maximum utilization of infrastructure and platform integration elements that already exist. As a result of this RFI, the Government expects to receive responses from interested and capable sources in the form of concept summary paper containing a description of the technical data defining the proposed concepts. The concept summary paper shall be written from a system solution perspective showing how the concept and development methodology could satisfy the requirements addressed herein. Each concept summary paper should include a top level description of the proposed GCU redesign concept, a detailed list of anticipated end product physical and performance characteristics, scope of development effort, reliability and maintainability characteristics, platform and support equipment integration/interface concept, design provisions to support incremental upgrades, technology insertion opportunities, growth potential, an assessment of the Technology Readiness Level (TRL) of proposed product including key subsystems, and a description of the Manufacturing Readiness Level (MRL) for the proposed product. THIS IS A REQUEST FOR INFORMATION (RFI) ONLY. This RFI is issued solely for information and planning purposes - it does not constitute a Request for Proposal (RFP) or a promise to issue an RFP in the future. This request for information does not commit the Government to award a contract as a result of this announcement. Further, the Navy is not at this time seeking proposals and will not accept unsolicited proposals. Respondents are advised that the Government will not pay for any information or administrative costs incurred in response to this RFI. All costs associated with responding to this RFI will be solely at the expense of interested party. Not responding to this RFI does not preclude participation in any future RFP, if issued. If a solicitation is released, it will be synopsized on the Federal Business Opportunities (FBO) website. It is the responsibility of the potential offerors to monitor this website for additional information pertaining to this requirement. - 2.0 Background The Government is soliciting information on industry's ability to provide solution concepts for four (4) current GCUs on the USMC/USAF V-22 aircraft. The Government intends to utilize the responses to determine what is available in the marketplace to complete the performance specification. The V-22 aircraft has two 50/80 kVA Variable Frequency Generators (VFGs) and two 40 kVA Constant Frequency Generators (CFGs). The VFG is a 4-pole generator that operates from 10,800 to 13,700 rpm and provides 360 to 457 Hz 115/200 V ac power. The CFG is a 2-pole Integrated Drive Generator (IDG) that operates from 15,300 to 22,184 rpm and provides 400 Hz 115/200 V ac power. Both generators are synchronous wound rotor machines, with a Permanent Magnet Generator (PMG) that provides power to the GCU. The GCU controls the output voltage by modulating the exciter field. The CFG GCU also controls the speed of the generator rotor by monitoring a magnetic pickup sensor and controlling a servo valve. Both generators have unique GCUs that are directly attached. The current location is exposed to high vibration, temperature extremes, water, salt spray, and aircraft fluids. The Government has determined that the relocation of the GCUs into the more benign environment of the aircraft fuselage is required. The V-22 has experienced electrical load growth since it was designed and is expected to continue over the life of the aircraft. - 3.0 Requested Information NAVAIR expects to receive from each respondent a concept summary, which contains a detailed description of the GCU product and supporting technical data. The GCU concept summary shall be written from a system solution perspective showing how the GCU will satisfy the requirements below. Prospective offerors should be able to work with the Government and the aircraft manufacturer to integrate the proposed solution into the V-22 program. Each concept summary should address how the proposed solution meets the following GCU requirements: - 1. Description of the proposed solution - 2. End product physical and performance technical data - 3. How the proposed solution meets the performance requirements stated below - 4. Reliability and maintainability, and affordability characteristics - 5. Integration/interface methodology - 6. Potential for the GCU concept to support increases in generator and power distribution capacity that are in the realm of possibility and any potential power growth - 7. Technology insertion opportunities - 8. An assessment of the Technology Readiness Level (TRL) of the proposed product to include key subsystems and a description of the Manufacturing Readiness Level (MRL) - 9. Options for life-cycle sustainment support utilizing existing commercial and/or Government (Department of Defense (DOD)) infrastructure. - 10. Rough Order of Magnitude (ROM) Costs for design, development and kit. Performance Requirements: - 1. GCU must be compatible with the existing CFG and VFG. - 2. The location of the proposed solution may be moved in the aircraft, but should not exceed 100 feet away from the current location of the VFG and CFG. The responder would need to address the weight of wiring for this distance and any potential power losses. - 3. Electrical connections made with MIL-38999 Series III connectors. - 5. Non-Volatile Memory will comply with DODI 8500.01 14 March 2014 and DODI 8510.01 12 March 2014. - 6. GCU housing environmentally or hermetically sealed to prevent fluid and dust intrusion. - 7. Detect the type of generator it is controlling and automatically configure itself for that generator. Generator identifying data (e.g. part number, serial number) will be embedded in the generator on a non-volatile memory device that will be read by the GCU. - 8. Provide speed/frequency regulation when controlling an IDG, compliant with MIL-E-85583A. - 9. Provide output voltage regulation, compliant with MIL-E-85583A. - 10. Electromagnetic Compliance (EMC) with MIL-STD-461F. - 11. Environmental (fungus, salt fog, dust, humidity, acceleration, explosive atmosphere, and temperature-altitude) testing per MIL-STD-810G. Maximum operating altitude 27,000 feet. Temperature-altitude limits per MIL-HDBK-5400 class 1A. - 12. Incorporate prognostics and diagnostics (P&D) for generator system (GCU, generator, line contactor, current transformers, control switch, interconnect wiring). Avoid introducing failure modes (e.g., avoid active injection of signals, use high input impedance monitoring, isolate faults in P&D circuitry from control and protection (C&P) circuitry). - 13. Modular design allowing I-level replacement of modules. Failures should not propagate from one module to another. E.g., an electrical short in one module should not damage other modules. Place P&D circuitry in separate module from C&P circuitry. - 14. Incorporate accurate measurement of electrical load, generator temperature and system state and health. - 15. Incorporate a wide bandwidth communications interface (e.g. Gigabit Ethernet) with other GCUs and with the aircraft integrated avionics system (IAS). GCUs shall coordinate contactor control to isolate faulted buses and optimize power distribution. Provide system status to the IAS for implementation of crew cautions, alerts and advisories, updating of Electrical System Status display pages, and updating of the maintenance database downloaded post-flight by maintainers. Transfer prognostics and diagnostics data to the aircraft mass memory unit for download by maintainers. - 16. Control and protection circuits fully operational when powered solely by Permanent Magnet Generator (PMG) output. - 17. Nominal 28 volt direct current (VDC) operating power for P&D circuitry provided through 2 inputs, designated main and battery, that are then diode-ORed together. The battery input is to be disconnected after 7 to 10 seconds of no power on the main input if the generator is off line to prevent drain on the aircraft battery. The GCU shall utilize nominal 28 VDC in accordance with MIL-STD-704F, except that the steady state voltage range for normal operation shall be 16 to 31.5 volts to ensure P&D data is collected during abnormal aircraft electrical system operation. The battery input ensures operation during normal bus transfer interrupts that may occur on the main input. - 18. Provide 4 individually protected 28 VDC outputs rated 1 A steady state. One will drive the line contactor; the other 3 will be available for driving other contactors. Each output will protect the GCU from external shorts and overloads by removing power if the condition persists. - 19. Provide faulted bus isolation logic that determines if a bus fault is on its own or a cross-tied bus and prevents transfer of a faulted bus to another generator. - 20. Capable of supporting generator upgrades, including capacity increases, through firmware updates only. It's expected that some laboratory development testing with the generator upgrade may be required to define and validate the firmware update required to support a specific generator upgrade. 4.0 Responses Data Markings. In order to complete its review, NAVAIR must be able to share a respondent's information both within the Government and with covered Government support contractors as defined in DFARS clause 252.227-7013 Rights in Technical Data - Noncommercial Items (FEB 2014). Any responses marked in a manner that will not permit such review may be returned without being assessed or considered. All submissions must include a statement which clearly allows for the information to be disclosed with covered Government support customers. International Traffic in Arms Regulations (ITAR). If the respondent is a foreign concern or if a US respondent has a team member or partner who is a foreign entity, adherence to all ITAR regulations is required. Submissions to the above requested supporting unclassified data must be received no later than 5:00 PM EDT 09/21/2015 to the following address - NAVAL AIR SYSTEMS COMMAND ATTN: TIMOTHY AYERS (AIR-2.3.3.2.3) 47123 BUSE ROAD, BLDG 2272, SUITE 155 PATUXENT RIVER, MD 20670-1547 Mr. Ayers' phone number is (301) 757-5098 and the email address is timothy.c.ayers@navy.mil. Provide full unclassified response via two hardcopies and two CD ROM with electronic media that is Microsoft Office 2010 compatible. Classified material SHALL NOT be submitted It is requested that the response, have a page limit of 75 pages, and must be in English. All responses should include sources sought reference number, company name, company address, CAGE code, DUNS number, and a point-of-contact who is able to discuss the material submitted. Point-of-contact information should include name, position, phone number, and email address. - 5.0 Questions Any questions regarding this RFI can be directed to Mr. Timothy Ayers (timothy.c.ayers@navy.mil) at (301) 757-5098. - 6.0 Summary THIS IS A REQUEST FOR INFORMATION ONLY to identify sources that can provide alternate GCU concepts for the current GCU on the USMC/USAF/USN V-22 aircraft. The information provided in the RFI is subject to change and is not binding on the Government. The Government has not made a commitment to procure any of the items discussed, and release of this RFI should not be construed as such a commitment or as authorization to incur cost for which reimbursement would be required or sought. All submissions become Government property and will not be returned.