Commander, Naval Air Systems Command (Code 2.5.3), Building 441, UNIT 7, Naval Air Station, Patuxent River, MD 20670-1127

49 -- RESISTANCE SPOT WELDING MACHINE SOL N00019-99-R-1541 DUE 050999 POC Christine M. Cullison, Contract Specialist at (301)757-8977, Contracting Officer is John C. Ulmer at (301)757-9062 E-MAIL: ERROR --, Cullisoncm@navair.navy.mil. Naval Air Systems Command is seeking sources for a commercial off-the-shelf three-phase, press-type, microprocessor controlled electric resistance spot welding machine. The machine shall be capable of welding as a minimum the following material thickness: Aluminum, 0.012+ 0.012 in minimum and 0.064+ 0.064 in. maximum; stainless steel (300 series) 0.012+ 0.012 in minimum and 0.070+ 0.070 in. maximum; and mild steel 0.012+ 0.012 in minimum and 0.125+ 0.125 in. maximum. The contractor shall provide a "turnkey" system and be responsible for the operation of the systems components. The system must comply with MIL-W-6858: Spot and Seam Resistance Welding, Rev D (30 July 1987); MIL-W-7973: Three Phase, Press Type, Spot Electric Resistance Welding Machines, Rev F (8 May 1991); OSHA 2206: General Industry, OSHA Health and Safety Standards (29 CFR 1910) July 1995; and NFPA 79: Electrical Standards for Industrial Machinery (1994). All parts in the machine that are subject to wear, breakage, or distortion shall beaccessible for adjustment, replacement and repair. All electrical and mechanical controls shall be located near the operator's workstation. All parts, components, mechanisms and assemblies furnished on the machine, whether or not specifically required herein, shall conform to all requirements of OSHA 29 CFR 1910. These include but are not limited to: electrode air pressure failure no-weld interlock, two-stage guarded foot pedal, and cabinet door locks with interlocks. All parts of the end item shall be manufactured to definite standards and tolerances that will provide for the interchangeability of respective replacement parts between end items of the same model without modification of the part or the machine. All replacement parts shall be available domestically and within 48 hours. The equipment shall be Three-Phase, Press Type Microprocessor Controlled, Electric Resistance Spot Welding Machine with the following specifications: Deep Throat, forty-eight (48) inches from the centerline of the electrodes to the first obstruction on the machine frame. The machine shall be equipped with a dual diaphragm low inertia pneumatic head of the frictionless diaphragm design, with a pressure control system to permit use of either constant or variable electrode force. The dual diaphragm system shall be adjustable up to a maximum of 2,550 pounds at 80-psi air line pressure. The upper diaphragm shall be adjustable to 540 pounds-force. The lower diaphragm shall be adjustable to 2,010 pounds force. The minimum shall be 125 pounds at 1 psi (low setting). Both diaphragms operating in tandem shall be adjustable to 2,550 pounds of force. Air pressure supplied to the dual diaphragm head shall be controlled by air mounted regulators that are mounted convenient to the operator. With this system, the electrode force shall be adjustable up to a maximum of 2,550 pounds at an air line pressure of 80 psi. Pressure gauges shall be calibrated from 0-100 psi. Selection of low force, constant high force, and variable force shall be obtained byselecting the desired function on the process control. Transformer Rating: 75 KVA at 50% duty cycle, capable of producing a maximum of 60,000 peak short circuit secondary amperes for a duration of 5 cycles without saturation.: This machine shall weld materials and thicknesses in accordance with the requirements of Military Specification MIL-W-6858D (for Class A quality). This machine shall include an inlet water manifold and strainer and a closed water drain circuit, including sight flow indicators and drain manifold with a single outlet. Alpha-numeric display shall provide operator/control communication and diagnostic messages. The control shall be provided with Automatic Voltage Compensation, which shall maintain the welding current within plus or minus 2% in spite of a plus or minus 10% variation in the power line voltage. System shall provide feedback, which insures the air pressure in the top and bottom cylinders is exactly as programmed. System shall allow air pressure settings to be stored in a control memory file with other parameters of the weld schedule. The system shall automatically adjust the air pressure along with other weld parameters when a new schedule is selected from the memory file. The breaker shall provide an under-voltage trip which when connected to the door interlocks of the machine will shut off all power. Water cooling to the power SCR's shall be connected directly to the supply. Over temperature switches shall be provided to prevent the machine from passing current should the SCR's become overheated. Solenoid valves shall be supplied for controlling water cooling to the electrodes. A thermostat operated solenoid valve to prevent condensation shall control cooling of the welding transformer. An inlet water manifold with strainer shall be included. A closed water drain circuit including sight flow indicators and drain manifold with single outlet shall be provided. Welding Transformer: The welding transformer shall be of the three phase design with balanced primary loading on a three phase power system at a power factor of 85%. Secondary current shall consist of pulses of D.C. current with a slow-rising wave front. Each pulse may be controlled in a magnitude from a minimum of approximately 3,000 amperes to a maximum of 60,000 amperes (short circuit), and in duration from a minimum of one cycle to a maximum of 5 cycles without saturation (based on 60 cycles per second). The welding transformer shall be mounted on the welder frame and connected to the copper alloy faceplate and secondary lug. A series parallel tap switch shall provide two ranges of secondary current. The machine shall be rated for 460 volts, 3 phase 60 Hz. The chiller shall be a minimum 3 ton capacity, 36,000 BTU's per hour with 45 gallon capacity. The electrical requirements shall be 460 volts, 3 phase, 60 Hz. The fluid circulating rate shall be NLT 30 gallons per minute at 38 psi. The chiller shall be able to maintain a temperature of 70 degrees F plus or minus 3 degrees within a temperature range of 50-88 degrees F. The noise level shall not exceed 84 decibels. Control: The controller shall be a three phase synchronous VME/PC based unit. The control shall function as an on-line quality control network with data acquisition capability. The controller shall display menus for machine setup, calibration, maintenance schedules, and instructions. The control shall monitor various process parameters including primary voltage, secondary current, load cells and tip pressures. The memory shall be a minimum 128K with battery backup. The system shall display features to monitor and indicate changes in load cell, linear encoder and secondary pick-up coil. The control shall insure each operation cycle or pulse of secondary current shall be uniform in amplitude and time duration, as programmed. The firing of the SCR's shall be in precise relation with the supply voltage to guarantee that no transient currents are produced on either the primary or secondary circuit. The control shall display as a minimum: transformer over temperature, rectifier over temperature, water not flowing, transformer saturation factor exceeded, over current, storage full, average line voltage, nugget expansion and contraction. The control shall have anti-arcing circuitry which will prevent arcing of the electrode tips if very short hold times are used. The Automatic Voltage Control circuit shall minimize effects of line voltage variation. The control shall maintain the welding current within plus or minus 2% for a variation of the line voltage of plus or minus 10%. This compensation shall be within 1/3 cycle. The contractor shall provide drawings, manuals and off-the-shelf documentation as follows: Installation Drawings, Operating Manuals, Maintenance Manuals (including Preventive Maintenance schedules), Parts Listings and Weld Schedule Settings. Equipment warranty shall be a standard commercial warranty for a minimum of one year and shall commence upon acceptance by the government. The transformer shall maintain a warranty for a minimum of three years. Interested parties should send a brief letter expressing their interest, ability to provide such a commercial product, two copies of any literature on the product; and their company type and size business to Department of the Navy, Assistant Commander for Contracts, Naval Air Systems Command, AIR-2.4.3.2.5 Building 441, Unit 7, Naval Air Station, Patuxent River, MD 20670-1127, not later than 30 days from the date of this notice. This action is being classified under the Standard Industrial Classification (SIC) Code 3548 (Electric and Gas Welding and Soldering Equipment), indication a concern including its affiliates, that is independently owned and operated, not dominant in the field of operation in which it is bidding on Government contracts and having less than 500 employees as a small business. This synopsis does not constitute a sealed bid, nor a request for proposals. This synopsis is not be construed as a commitment by the Government. Posted 04/09/99 (W-SN318088). (0099)

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