NASA/Lyndon B. Johnson Space Center, Houston, Texas, 77058-3696, Mail Code: BE

16 -- BRUSHLESS DC MOTORS SOL 9-BE13-27-8-21P DUE 041698 POC Wendy L. Boudreaux, Contract Specialist, Phone (281) 483-5338, Fax (281) 244-5331, Email wendy.l.boudreaux1@jsc.nasa.gov -- Lisa Rea-Phillips, Contracting Officer, Phone (281) 483-8395, Fax (281) 244-5337, Email lisa.r.phillips1@jsc.nasa.gov WEB: Click here for the latest information about this notice, http://nais.nasa.gov/EPS/JSC/date.html#9-BE13-27-8-21P. E-MAIL: Wendy L. Boudreaux, wendy.l.boudreaux1@jsc.nasa.gov. This notice is a combined synopsis/solicitation for commercial items prepared in accordance with the format in FAR Subpart 12.6, as supplemented with additional information included in this notice. This announcement constitutes the only solicitation; offers are being requested and a written solicitation will not be issued. This notice is being issued as a Request for Offer (RFO) for brushless DC motors to drive the fans and pumps in the environment control and life systems in the X-38 project. The Government plans to purchase at a minimum 4 motors and at a maximum 11 motors. Offerors should provide the following: 1) Package outline drawings and block diagrams of the circuits 2) Outline of proposed standards for: -- Electrical parts selection; -- Printed circuit boards; -- Soldering; -- Staking and strain relief; -- Crimping; -- Quality control/verification plans. 3) Description of supplier's experience in the field of aerospace motor controllers and electronic equipment 4) Descriptionof proposed qualification/acceptance testing 5) Price breakdown as follows: -- NRE; -- Qual testing; -- Qual unit; -- Production units (qty 7 through 11) including Acceptance; -Testing on each; -- Documentation. Statement of Work: 1.0 INTRODUCTION The X-38 experimental space test vehicle (V201) shall make use of brushless DC motors to drive the fans and pumps in the Environmental Control and Life Support System (ECLS). These motors make use of dedicated Pulse-Width-Modulation (PWM) amplifiers for motor phase commutation and speed control. Although the electrical current for the fan will be much higher than for the pump, to minimize non-recurring engineering and logistics costs, NASA intends to use the same motor controller design for both the fan and pump. 2.0 SCOPE This SOW is intended to clarify expected practices and deliverable items which NASA requires of the contractor in design, manufacturing, and testing of the subject components. It should be used in conjunction with the environment and performance specifications for each component, which are included as appendix A of this document. Note that this document outlines the work required of a supplier after contract award. A subset of information is being requested from all prospective suppliers as part of their proposal packages. 3.0 DESIGN It is the desire of the government that existing designs, or adaptations of existing designs be used as much as possible. For off-the-shelf designs, NASA will be provided with a complete set of as-built drawings for review prior to purchase of the component. For custom components, NASA will be provided with a complete set of design and as-built drawings/schematics. All design drawings/schematics, analyses, and parts lists shall be provided to NASA for approval prior to manufacturing of custom component(s). Each prospective supplier should provide an outline drawing, circuit block diagram, and basic description of operation as part of their proposal package. 4.0 ANALYSIS The contractor shall show by analysis that the design meets the mechanical loads environment as specified. 5.0 MANUFACTURING The contractor shall manufacture the number of production units as negotiated and stated in the contract. In responding to the solicitation, potential suppliers should provide cost estimates for flight unit quantities of 6, 7, 8, 9, 10, and 11, plus one qualification unit. 6.0 QUALITY CONTROL The contractor shall propose and exercise quality control procedures consistent with experimental space flight hardware. An outline of the contractor s quality control plans shall be provided by the contractor with their proposal package for NASA review prior to the contract award. In particular, prospective suppliers are requested to provide in their proposal, an outline of their design/manufacturing standards and quality verification plans for: n Printed circuit boards; n Soldering; n Staking & stress relief; n Crimping. While the SOW outlines the minimum quality verification requirements, the absence of any certification/verification requirement shall not relieve the contractor of the responsibility of ensuring that the hardware delivered to NASA complies with all performance requirements in the contract. 7.0 QUALIFICATION & CERTIFICATION The contractor shall prepare and submit a brief Certification Plan describing the tests, analyses, inspections, etc. to be performed (over and above acceptance testing) to verify that the design meets the requirements outlined in the SOW and specifications. The certification plan shall be a NASA approved document, and shall be provided for review to NASA prior to assembly of the component(s). The contractor shall prepare and submit a Certification Data Package, documenting all test results, analyses, inspections, etc. described in the Certification Plan. The Certification Plan shall address the following issues at a minimum: The contractor shall supply to NASA evidence that the motor controllers are built appropriately to operate in the stated X-38 random vibration environment (see Appendix Asection 1.2). A random vibration qualification test shall be performed by the vendor or by NASA. Final NASA acceptance of the hardware and completion of the contract is contingent on successful completion of qualification and acceptance vibration testing, whether performed by the vendor or by NASA. The contractor shall conduct EMI/EMC qualification testing to verify that the design is compliant. Testing shall be performed with a representative motor. The contractor shall certify compatibility with specified radiation environments (see Appendix A section 1.7) and estimated lifetime by analysis or other appropriate means (subject to NASA approval). The contractor shall provide a complete electrical parts list, with a total dose and single event effect radiation-tolerance assessment provided for each part. 8.0 ACCEPTANCE TESTING The contractor shall develop appropriate acceptance test procedures and conduct associated testing on each unit prior to delivery to NASA. As a minimum, the test procedures shall incorporate the following: n Performance test n Environmental Stress Screening vibration test to following levels: Frequency (HZ) Acceptance 20 .015 g2/Hz; 50 .09 g2/Hz; 800 .09 g2/Hz; 2000 .015 g2/Hz; Overall -- 10.8 grms- 1 min./axis. Note: Contractor may propose that NASA conduct this test, but acceptance of controller is contingent on successful test. 9.0 DELIVERABLES/DOCUMENTATION The following paragraph summarizes the deliverable items (other than the components themselves) which the contractor is responsible for: n Design and as-built drawings/schematics; n Loads/stress analysis; n Quality Control Plan; n Qualification/Certification Plan; n Qualification/Certification data pack; n Acceptance Test Procedures; n Acceptance Test Data for each unit; n Parts list including radiation-tolerance assessment; The contractor shall also deliver one mating electrical plug for each electrical receptacle. 10.0 COMMUNICATIONS There are no formal intermediate reporting requirements. However, the contractor should plan to conduct brief informal exchanges with NASA personnel via telephone or e-mail at monthly intervals. The contractor should plan for at least one visit to the contractor facility by NASA personnel. 11.0 DELIVERY The contractor shall deliver final documentation to NASA prior to delivery of the units. Contractor shall package units to prevent damage during transportation to JSC. APPENDIX A (Specifications) 1.0 GENERAL The following requirements are general, and apply to all components which are covered under this procurement. 1.1 LOADS Each component must be capable of meeting performance specifications and remaining structurally intact when subjected to a dynamic loading environment equivalent to 150% of the following static loading: 40g Any axis 10g Remaining 2 axis 1.2 RANDOM VIBRATION Each component must be able to meet its individual performance specifications while being exposed to a random vibration spectrum as given below, for 3 minutes in each axis. One of the production units will be designated as a qualification unit, and will be subjected to this environment for 3 minutes in each axis as a qualification test. 20 Hz .026 g^2/Hz; 50 Hz .160 g^2/Hz; 800 Hz .160 g^2/Hz; 2000 Hz .026 g^2/Hz. 1.3 EXTERNAL PRESSURE ENVIRONMENT For components located within the pressurized cabin, they must be able to operate continuously at ambient air pressures between 8 psia and 16 psia. 1.4 AMBIENT TEMPERATURE ENVRIONMENT For components located within the cabin, the ambient air temperature can range between 40 degF and 90 degF. The components must be able to operate continuously over this range. 1.5 HEAT DISSIPATION Heat dissipation for the motor controllers shall be provided by baseplate cooling. NASA will provide an appropriate liquid or air-cooled coldplate for this function. The temperature of the coldplate shall not exceed 120 degF. 1.6 EMI/EMC The motor controllers shall be EMI/EMC compliant per SSP 30237C through paragraph 3.2.4. 1.7 RADIATION Immune to single event effects, and tolerant to total dose of 1000 rad Si. 1.8ELECTRICAL PARTS SELECTION It is preferred that electrical parts be selected in accordance with NASA publication GSFC-PPL-21, with use of grade 2 or better parts. This document can be found at http://arioch.gsfc.nasa.gov/ppl/ppl.htm. Vendor can propose use of alternate parts, but use is subject to NASA approval. 1.9 LIFETIME Shelf Life -- 10 years minimum Operating Life -- 3 years minimum (continuous operation) 2.0 SPECIFIC REQUIREMENTS The following paragraphs detail the specific performance and material requirements for each component. Reference the complete Statement of Work for any additional generic requirements. 2.1 Cabin Fan/Water Pump Motor Control Assembly Input Voltage: 24-130 VDC. Return Line: Isolated from chassis ground. Speed Control: Closed-loop (constant RPM) proportional to speed command. Speed Command: Provided by external differential voltage signal (0 to 5 VDC) or internal voltage signal. Both signals will be diode-coupled so that the internal signal will provide a minimum speed command in the event that the external signal is lost. Internal signal level (speed command) adjustable from outside of controller box by adjustment of potentiometer. Enable/Inhibit Signal: 0 VDC (no connection) = Enable, 5 to 32 VDC = Inhibit. Temperature Signal Conditioning: Controller will incorporate resistor-divider circuit to facilitate measurement of motor thermistor resistance (see schematic). Connectors: MS-style circular connectors will be used. Type D38999 is preferred. Vendor to also supply mating plugs. Test Ports: Separate connector providing access to measure voltage for following signals: n Input voltage; n Motor windings (3 phases); n Motor hall voltage supply; n Motor hall sensor outputs; n Return. Compatibility: Controls MPC-manufactured motors for BNP-12 fan or BNP-13 water pump built by Barber-Nichols. Data for each of the motors is given below: Cabin Fan Motor Data: # Hall Sensors 3; Configuration Wye; # of pole pairs 2; resistance (ohms) .035; Inductance (mH) .060; Kv (Volts/KRPM) 1.8; Kt (In-Oz/Amp) 2.4; Max Speed 10KRPM; Max Continuous Current 30 amps. Water Pump Motor Data: # Hall Sensors 3; Configuration Wye; # of pole pairs 2; resistance (ohms) .300; Inductance (mH) .21; Kv (Volts/KRPM) 2.65; Kt (In-Oz/Amp) 3.6; Max Speed 10KRPM; Max Continuous Current 5 amp. Functional Schematic: For a copy of the schematic, fax your request to (281) 483-5338. The provisions and clauses in the RFO are those in effect through FAC 97-3. The SIC code and the small business size standard for this procurement are 3764 and 1000 respectively. The offeror shall state in their offer their size status for this procurement. All qualified responsible business sources may submit an offer which shall be considered by the agency. Delivery to JSC is required within 360 days ARO. Delivery shall be FOB Destination. The DPAS rating for this procurement is DO-C9. Offers for the items(s) described above may be mailed NASA Johnson space Center, 2101 NASA Road 1, Houston, TX 77058, Attn: Wendy Boudreaux, Mail Code BE13 by the date/time specified above and include, solicitation number, FOB destination to this Center, proposed delivery schedule, discount/payment terms, warranty duration (if applicable), taxpayer identification number (TIN), identification of any special commercial terms, and be signed by an authorized company representative. Offerors are encouraged to use the Standard Form 1449, Solicitation/Contract/Order for Commercial Items form found at URL: http://procure.arc.nasa.gov/Acq/Standard_Forms/Index.html to submit a offer. Offerors shall provide the information required by FAR 52.212-1. If the end product(s) offered is other than domestic end product(s) as defined in the clause entitled "Buy American Act -- Supplies," the offeror shall so state and shall list the country of origin. FAR 52.212-4 is applicable. FAR 52.212-5 is applicable and the following identified clauses are incorporated by reference; 52.203-6, Restrictions on Subcontractor Sales to the Government (Jul 1995), with Alternate I (Oct 1995); 52.203-10, Price or Fee Adjustment for Illegal or Improper Activity (Jan 1997); 52.219-8, Utilization of Small Business Concerns and Small Disadvantaged Business Concerns (Jun 1997); 52.219-9, Small, Small Disadvantaged and Women-Owned Small Business Subcontracting Plan (Aug 1996); 52.219-14, Limitation on Subcontracting (Dec 1996); 52.222-26, Equal Opportunity (Apr 1984); 52.222-35, Affirmative Action for Special Disabled and Vietnam Era Veterans (Apr 1984); 52.222-37, Employment Reports on Special Disabled Veterans and Veterans of the Vietnam Era (Jan 1988); 52.225-3, Buy American Act -- Supplies (Jan 1994); 52.225-9, Buy American Act -- Trade Agreements Act -- Balance of Payments Program (Jan 1996). Questions regarding this acquisition must be submitted in writing no later than April 2, 1998. Offers are due by close of business 4:30p.m. April 16, 1998 to the identified office, marked with this RFO number. Selection and award will be in accordance with FAR 52.212-2 with the following value characteristics: 1) Screening level for internal parts -- describe what grade of screening of electrical parts is being included in the proposal. 2) Quality control for soldering and general assembly. 3) Heritage of the design or similar designs -- provide a listing of which vehicles the basic controller design has been used on before. 4) Describe the company's experience in the field of aerospace motor controllers and provide references to demonstrate ability to meet schedules. 5) Ability to delivery sooner than the specified delivery schedule. Technical acceptability will be determined by information submitted by the offeror providing a description in sufficient detail to show that the product offered meets the Government's requirement. Offerors must include completed copies of the provision at 52.212-3, Offeror Representations and Certifications -- Commercial Items with their offer. These may be obtained via the internet at URL: http://nais.nasa.gov/msfc/pub/reps_certs/midrange/. These representations and certifications will be incorporated by reference in any resultant contract. An ombudsman has been appointed -- See Internet Note "B". Prospective offerors shall notify this office of their intent to submit an offer. Potential offerors will be responsible for downloading their own copy of this combination synopsis/solicitation and amendments (if any). Any referenced notes can be viewed at the following URL: http://genesis.gsfc.nasa.gov/nnotes.htm. (0085)

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