KARI PROPRIETARY
Request For Proposal
for
Vibration shakers & Interface equipment
for Large Vibration Test Facility
December 2014
Space Environment Test Team
Korea Aerospace Research Institute
169-84 Gwahangno, Yuseong-gu, Daejeon, 305-806, KOREA
Phone : 82(42)860-2562, Fax : 82(42)860-2234
KARI PROPRIETARY
Request For Proposal
for
Vibration shakers & Interface equipment for
Large Vibration Test Facility
IMPORTANT
1. This RFP should be kept in confidentiality and should neither
be copied nor distributed to the third parties.
2. The questions and opinions on this RFP can be asked or
suggested to Korea Aerospace Research Institute before
submission of the proposal.
3. This RFP should be returned to Korea Aerospace Research
Institute with bidder
’s proposal.
4. This RFP shall be legal bind after the contract is awarded
unless the bidder explicitly expresses the differences from the
RFP in the compliance sheet.
December 2014
Space Environment Test Team
Korea Aerospace Research Institute
169-84 Gwahangno, Yuseong-gu
DAEJEON, 305-806, KOREA
Phone : 82(42)860-2562, FAX : 82(42)860-2234
e-mail :acoust@kari.re.kr
2014. 12
i
Space Environment Test Dept.
Table of Contents
I.
OVERVIEW ............................................................................................................................. 2
1.
OVERVIEW OF THE PROJECT ..................................................................................................... 2
2.
REQUISITES OF PARTICIPANTS .................................................................................................. 3
3.
WORK DESCRIPTION ................................................................................................................ 4
4.
MANAGEMENT REPORTING MEETINGS AND DELIVERABLES .................................................. 13
5.
KARI’S UNDERTAKINGS RELATED TO THE SHAKERS .............................................................. 14
6.
WARRANTY ........................................................................................................................... 15
7.
PRODUCT SUPPLY SCHEDULE ................................................................................................. 16
8.
PAYMENT CONDITION ............................................................................................................ 16
II.
TECHNICAL REQUIREMENTS .................................................................................... 17
1.
TOTAL SYSTEM CONFIGURATION ........................................................................................... 17
2.
TECHNICAL REQUIREMENTS FOR QUAD VIBRATION SYSTEM ................................................ 17
3.
TECHNICAL REQUIREMENTS FOR LARGE VIBRATION SYSTEM ............................................... 30
4.
TECHNICAL REQUIREMENTS FOR INTERFACE EQUIPMENT ..................................................... 41
III.
FORMAT OF PROPOSAL ................................................................................................ 50
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
2
Space Environment Test Dept.
I. OVERVIEW
1.
Overview of the project
1.1
Korea Aerospace Research Institute
(hereinafter referred to as “KARI”) is located
at Daeduk Research Complex, 140 km south of Seoul.
1.2
KARI has a satellite assembly, integration and test center (hereinafter referred to
as “AITC”) for joint use by corporations and research institutes for the purpose of
the effective development of domestic satellites. And basic facilities and
equipment for satellite assembly and test have been supplied, installed and used.
1.3
As a Korean government-funded research institute, Korea Aerospace Research
Institute (KARI) has undertaken the implementation of the GEO-KOMPSAT-2
(Geostationary Earth Orbit - Korea Multi-Purpose Satellite-2).
1.4
To increase the vibration shaker capability and improve the accessibility to satellite
for the safe environmental testing, new guided expander system with quad
shakers will be designed and built. Also lateral vibration system with 3m x 3m slip
table will be designed and built
1.5
For these reasons, KARI would like to procure vibration shakers system and
related interface equipment.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
3
Space Environment Test Dept.
1.6
The purposes of this project are ;
1.6.1
To supply new one shaker for quad vibration system(Multi-shaker
operation)
1.6.2
To upgrade the performance and extend the useful period for existing
three shakers of LDS V984 as those of new one
1.6.3
To supply one shaker(Large vibration system) for single operation
with 3m x 3m slip table
1.6.4
To supply the interface equipment(devices) for shaker
The work covers the procurement and the installation of the shakers, amplifiers,
and interface equipment including:
Shakers & Interface equipment design
Shakers & Interface equipment manufacturing and testing at factory
Shakers & Interface equipment Installation and Acceptance Testing
Assistance to Installation and Commissioning of the Integrated
System
The performance of the individual shakers and of the quad-system shall meet the
requirements as detailed in the II Technical requirement.
The performance of interface equipment shall meet the requirements as detailed
the II Technical requirement.
1.7
The supplier should submit the proposal of the new vibration shaker system in
KARI.
1.8
All the descriptions in this RFP are minimum requirements and the supplier can
suggest a better one to improve the overall performance and cost. But in this case,
the prop
osal should clearly indicate the improvements from KARI’s requirements.
2.
Requisites of participants
2.1
The participants shall supply information about themselves including organization,
financial standing, major business, experience in manufacturing and delivery
performance for five (5) years and technical support.
2.2 The participants shall have experience in manufacturing and delivery of a quad-
shakers system for a hydraulic-guidance head expander (above 3 x 3 m) for the
purpose of vibration test.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
4
Space Environment Test Dept.
3. Work description
3.1 WP S1000 Shakers, Amplifiers and Interface Management
3.1.1
General
An effective and economical management of the Project shall be conducted. A Project Manager shall
be responsible for the management and execution of the work to be performed.
3.1.2
Access
The KARI shall be allowed free access to any plan, procedure, specification or other documentation
relevant to the work. Areas and equipment used during the development/testing activities shall also
be available for inspection and audit.
The KARI shall be notified at least three weeks before the start of any test program, or as mutually
agreed, in order to enable the KARI to select those tests that it wishes to witness. The KARI shall
notify its visit at least three week in advance.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
5
Space Environment Test Dept.
3.2 WP S2000 Shakers, Amplifiers and Interface Design
3.2.1
Design
The design of the shakers, amplifiers, interface shall be carried out. Since the four shakers shall be
integrated in the seismic foundation to be designed and connected to the table under the Upgrading
of the Multishaker Vertical Configuration Contract, a complete mass-spring model of the shaker shall
be provided.
3.2.2
Design Review (DR)
Upon successful completion of the Design Review (DR) meeting the KARI shall authorise
manufacturing and assembling of the relevant equipment. From that time on, a configuration control
system for the documentation and drawings shall be established. All changes to the design shall be
processed via Contract Change Notice (CCN) to be approved by KARI.
3.2.3
Deliverables: Design Review Data Package
The following documents shall be handed over to the KARI 2 weeks prior to the DR:
Exhaustive list of equipment to be delivered
Technical justification for the selected components
Functional description of the main and auxiliary equipment
Individual shaker performance specifications
Quad Vibration System performance specifications
Detailed internal and external interfaces document
Mass-spring model of one shaker used in quad-shaker
Measurements supporting the equipment performance specifications
Certificates supporting the compliance with EMC requirements
Electrical load list for equipment and auxiliary equipment
Calculation of reactive power and mains filters (if applicable)
Detailed description of the safety devices and interlocks
Design Specifications and FMECA report for the Interlock Supervisory Kit
Cable list with cable number, type, size, length and destination (cable length
to be verified at KARI site)
Factory Acceptance Plan
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
6
Space Environment Test Dept.
3.3 WP S3000: Shakers, Amplifiers and interface Manufacturing
During this work package the following tasks shall be performed:
3.3.1
Manufacturing
The system hardware shall be manufactured according to the design accepted under WP S3000.
All manufacturing operations shall be planned in co-ordination with inspections and tests. This
planning shall be documented in a concise Manufacturing and Inspection Plan.
3.3.2
Factory acceptance
The Factory Acceptance objective is to verify that the requirements detailed in technical requirements
are fulfilled.
The factory acceptance tests and inspections shall be performed according to a Factory Acceptance
Plan, which shall identify all the activities to be performed and the requirements intended to be
verified.
The Factory Acceptance Review meeting in order to review the results of the implementation of the
Factory Acceptance plan shall be organised.
A board composed of members to be agreed with the KARI’s representatives shall attend the Factory
Acceptance Review meeting and confirm that:
All the equipment to be delivered is ready to be shipped.
The functional requirements are fulfilled.
The shakers perform individually as specified
The Quad vibration system perform as specified
This task shall be completed upon a successful Factory Acceptance Review.
3.3.3
Deliverables:
Exhaustive list of the equipment to be shipped
Factory Acceptance test reports
Factory Acceptance Review minutes of meeting
KARI on site Acceptance Plan
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
7
Space Environment Test Dept.
3.4 WP S4000 Shakers, Amplifiers and Interface Installation and Testing
During this work package the following tasks shall be performed:
3.4.1
Mechanical installation.
The mechanical installation comprises the:
Connection of the cooling units to the interfaces with KARI supplies.
3.4.2
Amplifiers:
The amplifiers and cooling units shall be installed in KARI basement Room. The amplifier related
equipment shall be brought in the basement room through a loading bay by means of a cargo crane.
3.4.3
Shakers:
The shakers shall be installed in the seismic foundation procured under Part 2.
The shakers shall be transported at the ground floor level and lowered inside the seismic foundation
using a 20,000 Kg [10,000kg x 2EA] crane supplied by KARI.
3.4.4
Electrical installation
The electrical installation comprises the:
Routing, installation and termination of input and output power cables and
control cables.
Connection of power cables (feeder) of the amplifiers to KARI RFI filters.
Continuity and insulation testing according to the Contractor specifications.
Labeling and marking of installed cables and wires.
Connection of earthing cables to the existing KARI dedicated network
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
8
Space Environment Test Dept.
3.5 WP S5000: Shakers, Amplifiers and Interface Acceptance testing
Upon completion of the installation of the shakers and auxiliary equipment, the provisional
acceptance of the shakers, not connected to the table, shall take place according to the Acceptance
Plan.
The acceptance tests shall be performed in accordance with formal test procedures and documented
in test reports.
The draft operation manual will be used during the acceptance test to confirm its suitability to support
the operation of the system. KARI staffs and other authorized persons will be trained on the operation
of the system during the acceptance test.
The Acceptance Plan shall cover all tests and verifications, which were already performed during
Factory Acceptance but are invalidated by the installation at KARI.
During this work package the following tasks shall be performed:
3.5.1
Interlock/ External trip acceptance
The proper functioning of the internal and external interlocks shall be verified
individually; external trips may be checked by simulation.
The individual shaker amplifiers behavior shall be recorded during a soft and
hard shut down and checked against specifications. To this end armature and
vibrator body acceleration responses during soft and hard shutdown of a
typical sine vibration test run shall be measured.
The Multishaker amplifiers behavior, not connected to the table, shall be
recorded during a soft and hard shut down and checked against specifications.
To this end each armature and vibrator body acceleration responses during
soft and hard shutdown of a typical sine vibration test run shall be measured.
3.5.2
Vibration acceptance test sequence
The vibration acceptance tests shall verify the capability of the amplifiers to drive the vibrators in
compliance with KARI specification. The following vibration tests have to be performed:
Individual shaker full performance tests
Quad Multishaker bare armatures, performance tests
Quad Multishaker loaded by interconnecting the four shaker armature with a
KARI furnished plate, performance tests
Abort sequence verification
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
9
Space Environment Test Dept.
During the test runs the following measurements shall be recorded:
Amplifier AC input voltage and current
Amplifier signal output voltage and current (amplitude and phase)
Matching transformer output voltage and current (if applicable)
Acceleration, amplitude and phase, for each armature
3.5.3
Cooling units acceptance test
The adequacy of the amplifier forced air-cooling as well as water and oil cooling has to be proven.
Therefore temperatures at essential locations shall be measured and recorded while performing a
vibration test run at maximum shaker performance (Multishaker configuration) over a period of time,
relevant to the test duration.
3.5.4
Acceptance review and acceptance data package
An Acceptance Review (AR) shall be performed to review the results of the implementation of the
Acceptance Plan. A Board composed of KARI representatives, including PA Representatives and
other member to be agreed shall perform the Acceptance Review.
3.5.5
Deliverable
The AR shall be supported by an Acceptance Data Package (ADP). The ADP shall be provided two
weeks prior to the review in 2 paper copies and 5 electronic copies. The ADP shall comprise the
following documents:
3.5.6
System Description Document
A system description document containing the Quad Multishaker and Lateral single shaker
performance specifications, the general functional description including block diagrams, layouts and
principal schematics as necessary.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
10
Space Environment Test Dept.
For each component a document covering:
- Product Application: Details the product regarding type and serial number.
- Installation and Operation: Concise information on the installation, the
adjustment and the operation of the product
- Test Instructions: Manufacturer’s standard test procedure for the product
- Test reports: Results from the manufacturer’s standard test procedures for
the product.
- CE Compliance Certification: Formal certification stating that the
equipment provided complies with CE requirements.
- Parts List and Drawings: Complete bill of materials listing including
assembly drawings associated with the product
Mechanical Drawings
-
All mechanical drawings necessary for the installation and maintenance
of the equipment, stating dimensions, weights and attachment points
-
All mechanical interface drawings for cable trays, cable entry and
termination
-
Electrical drawings comprising:
-
Overall functional block diagram (with reference to the equipment by
drawing, or equipment number)
-
Block or simplified functional diagram of the individual equipment
(amplifiers)
-
Test points and test values
-
Terminal lists
-
Cable list comprising cable number, cross section and quality, length and
destination
-
Drawing list of the delivered drawings
Copies of all Non-conformance Reports and Requests for Waiver
Manufacturing Inspection Report
Acceptance test plans, test procedures and test reports
System Operation Manual
The system operation manual shall describe the aspects of the operation of the
equipment in a logical order, to ensure a safe and proper use. This manual shall contain
the following chapters:
Pre-operational checks
Start-up and safe shut-down
Operation of equipment and auxiliaries
Inspections
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
11
Space Environment Test Dept.
Note: This document should be written such that it can be used as a stand-alone manual for the facility
operator without necessarily consulting the other documents.
Maintenance manual
The maintenance manual shall describe the aspects of preventive and corrective maintenance. This
document shall clearly distinguish between activities that require the special knowledge of the
supplier and the activities that can be done by trained KARI personnel.
In addition specific needs for tools or instrumentation shall be included in this section. The shakers’
Subcontractor shall identify parts with a limited lifetime.
Amplifier and shaker foot print manual
The amplifier and shaker footprint manual section shall describe activities, to be performed by trained
KARI personnel, to carry out periodic amplifier and shaker signature tests.
Repair manual
The repair manual section shall assist the maintenance engineer in case a malfunction has to be
corrected. It shall advise on the steps to be done to replace or repair, with references to the spare parts
list and functional checks required thereafter.
Spare part list
A recommendation concerning the spare-parts list covering a period of 5 years of operation shall be
made and the guarantee that spare-parts can be made available for another 10 years thereafter shall
be given.
Delivery time shall be stated for all for spare parts.
Attached documents
The attached documents which compile information, data sheets, instruction for use, of those
deliverable items, which are not covered by the above manual sections (e.g. instruments, auxiliary
equipment etc.)
Minutes of the Acceptance Review Board
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
12
Space Environment Test Dept.
3.6 WP S6000 Assistance to Installation and Commissioning of the
Integrated System
Support shall be given during the installation of the integrated system and associated auxiliaries and
to the System Provisional Acceptance tests of the integrated system, as well as during the guarantee
period leading to the System Final Acceptance.
The work package shall include giving support for:
3.6.1
Fixing interfaces issues
3.6.2
Bolting the shakers inside the seismic foundation
3.6.3
Aligning the shakers with respect to the QHE
3.6.4
Attending integrated acceptance test campaign
3.6.5
Any other related activities necessary to ensure a successful Provisional and Final
acceptance of the integrated system.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
13
Space Environment Test Dept.
4. Management reporting Meetings and Deliverables
The hardware deliveries shall include, as a minimum, the following:
Item
No.
Part name
Qty
Description
1
One shaker & amplifier system for
Quad Vibration System
1
- 160 kN Electrodynamic shaker
- Including amplifier and related auxiliaries
- Including matching transformer
-
All needed Cables for new installation
place
2
Improvement of existing three
shakers
&
amplifiers
of
LDSV984(Quad Vibration System)
3
-
160 kN Electrodynamic shaker
-
All needed Cables for new installation
place
-
Same lifetime as new ones
3
One shaker & amplifier system for
Large Vibration System
1
-
More than 280kN Electrodynamic shaker
-
Including amplifier and related auxiliaries
-
Including matching transformer
-
All needed Cables for new installation
place
4
Shaker Interface equipment
3
-
2.0m Head-expander
-
1.3 or 1.2m Head-expander
-
1.2m Slip table
-
Related auxiliaries for interface
Kick-off/PDR/CDR/MRR/TRR/FAR reviews shall be held.
Review
Purpose
Kick-off
-Review the requirements of the system
-Understand and agree the design baselines
Design Review
- Verify the compatibility of the design definition
and predicted performance with system requirements
- Verify the coherency of the equipment
specifications with the subsystem specification
Test Readiness
Review
- Review test plans, sequences and procedures
FAR (Factory
Acceptance
Review)
Review test results (Checking key requirements’
performance consistency)
- Final acceptance of quad-shakers in Factory
FAR (Final
Acceptance
Review)
-Review test results (Checking key requirements’
performance consistency)
- Final acceptance of quad-shakers in KARI
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
14
Space Environment Test Dept.
5.
KARI’s undertakings related to the shakers
The following items are provided as KARI’s Undertakings:
1. PCU4 and MACU
2. Amplifier modules
3. Access to existing overhead cranes, lifting eyes and lifting slings
4. One office with 1 telephone and 1 PC connected to Internet + access to 1 FAX machine
during the installation and commissioning
5. Raw water cooling outlets in the amplifier room
6. Disposal facilities for water and consumables
7. Cable trays located as per system layout drawing
8. Compressed air outlets located close to the vibrators
9. Electrical mains supply at agreed outlets in the plant room and vibrator area
10. Dedicated earth star point located in the plant area close to equipment
11. Four shaker armature interconnecting plate (if required)
12. Qualified operators for instrumentation, operation and data acquisition during acceptance
testing
13. On-site access to the existing vibration system data package if required
14. Access to building layout if required
15. Specialized equipment required to complete the agreed acceptance procedure
16. Access to on-site workshop for small mechanical correction work
17. On-site car parking for company vehicle
18. Finished final location to allow the installation of the shakers
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
15
Space Environment Test Dept.
6. Warranty
6.1
The system shall be warranted for a duration of 1 years from the date of definitive
acceptance on the site against any operational faults. The date of acceptance is the
date when the whole system is completely installed and its function is approved
perfect in a written format by KARI or its representative.
6.2
The warranty covers the replacement of faulty parts, the labor required for repair,
traveling cost, living fees and all associated necessary costs.
6.3 For the upgrading of three shakers used in quad-shakers, contract shall take the
responsibility for the normal operation especially in amplifiers system for 5 years.
In case of new shakers including amplifiers are supplied, it takes Warranty 6.1.
6.4
The contractor or A/S teams shall submit the written plan for repair within 48 hours
after the reception of the notification of fault. The contractor or A/S teams shall
completely finish the repair within 30 days after the reception of the notification of
fault.
6.5
For an urgent service during important testing period, the deadline for action is 5
days from the reception of the notification of service. To meet the deadline of the
urgent service, KARI will notify the contractor of the test start date and the period 2
weeks before the test start date. The contractor shall stand by the A/S crews at
contractor's convenient place during the test period (up to 4 weeks).The contractor
shall include a plan for these requirements in the proposal.
6.6
To meet these requirements, the contractor shall propose a detailed plan for the
prompt repair in the proposal. The detailed information (location, number of crews,
resume, phone and FAX numbers, e-mail address, etc.) of the A/S teams shall be
shown in the proposal and shall be approved by KARI.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
16
Space Environment Test Dept.
7. Product supply schedule
The contractor shall meet the key points schedule as below;
Items
Key Points Schedule
Quad vibration
System
(Item #1 & #2)
-
Arrival at KARI : January 2016
-
Installation & Finish site acceptance : February 2016
-
Existing three shakers are available to contractor at November
2015
Large Vibration
System
(Item #3)
-
Arrival at KARI : January 2017
-
Installation & Finish site acceptance : February 2017
Interface equipment
(Item #4)
-
Arrival at KARI : April 2017
-
Installation & Finish site acceptance : May 2017
*For the detailed description for item #, refer to hardware deliveries in 4.Management
reporting Meetings and Deliverables
8. Payment Condition
8.1
KARI may terminate this Contract, in whole or in part, ONLY IF GOVERNMENT
TERMINATES THE PROGRAM WHICH IS DIRECTLY RELATED TO THIS
CONTRACT for its convenience, with sixty (60) days’ prior written notice to
Contractor.
8.2
KARI’s Payment Schedule for this Contract can be adjusted by Government
budget profile.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
17
Space Environment Test Dept.
II. Technical Requirements
1.
Total System Configuration
This document covers the technical requirements applicable to the shakers, associated
equipment (power amplifiers, remote control….) and interface (head expander, slip table).
The first intention is to purchase standard equipment i.e. new shakers and amplifiers with
associated remote control and to modify the existing 3X LDS shakers 984 LS and 3x DPA-
K amplifiers of 2004. The system will be used only in quad-shaker configuration. The
second intension is to purchase standard equipment of shaker and amplifier over 280kN
excitation force. The third intension is to purchase the designed interface for shaker. The
requirements listed below only cover the aspects that are important for our application.
2.
Technical Requirements for Quad Vibration System
The work scope for quad vibration system is firstly to purchase standard equipment i.e.
one shaker and amplifier with associated remote control, secondly to upgrade the existing
3X LDS shakers 984 LS and 3x DPA-K amplifiers to meet the technical requirement for
quad-shaker and to have same useful duration as new one. In case of three existing shaker
system, it has been more 11 years since it is produced. In this document, quad-shaker
means shakers including new shaker and three of existing shakers
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
18
Space Environment Test Dept.
2.1
Quad-Shakers Requirements
In this proposal, quad shakers consist of new shaker of one and three shakers in KARI. By
upgrading work for the three shakers, three shakers shall meet the same requirements
described below.
[Q_Sha_1] Shaker performance
The quad-shakers shall have the following minimum performances:
Frequency range
Sine
3-2000 Hz
Random
10-2000 Hz
Shock
5-2000 Hz
Nominal maximum Thrust
Sine
160 kN peak
Random
133 kN RMS
Shock
>160 kN peak
Nominal maximum
no load acceleration
Sine
100 g
random
30 grms
shock
100 g
Nominal maximum velocity
sine
1.6 m/s
Nominal maximum displacement
Sine
38 mm peak-peak
Half
sine
bump
50.8 mm
Typical maximum sine level test with head expander of 2800 kg + specimen of 300 kg
Acceleration profile
0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
18.000
20.000
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
Acc
e
le
ra
tion [
g]
Velocity profile
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
V
e
loc
ity
[c
m/
s
]
Displacement profile
0
2
4
6
8
10
12
14
16
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
Dis
pla
c
e
me
nt
[mm]
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
19
Space Environment Test Dept.
[Q_Sha_2] Armature Cross-Motion
The cross acceleration measured at the periphery of the armature shall be
< 10% from 5-200 Hz
< 10% from 200-900 Hz except 1 peak at 40%
[Q_Sha_3] Armature acceleration homogeneity
The in-axis acceleration difference between any sensors located on top of the armature shall be:
< 4% from 5-200 Hz
<20% from 200-900 Hz
[Q_Sha_4] Alignment capabilities
Tools shall be provided for fine lateral and vertical adjustment of the shaker position in the seismic
block (accuracy better than 0.5 mm)
[Q_Sha_5] Armature vertical positioning
Provision shall be foreseen so that the armatures vertical position of the 4 shakers can be adjusted
within ±1 mm prior to connection to the QHE
[Q_Sha_6] Transport within KARI
Lowering shakers inside the seismic block shall be done using the existing crane (maximum capacity
20 tons)
[Q_Sha_7] Armature and body movement monitoring
It is required to monitor the armature and body movement close to the shaker and close to the remote
control. remark: automatic control of the body zero position shall be foreseen.
[Q_Sha_8] Shaker body link
Depending on the selected body configuration, i.e. solid trunions or isolated shakers, disposition for
linking the body shall be foreseen.
[Q_Sha_9] Shaker Configuration
Dimension of new shaker shall be same dimension of existing 3-shakers
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
20
Space Environment Test Dept.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
21
Space Environment Test Dept.
2.2 Quad-Amplifiers
Requirements
[Q_Amp_1] Amplifier performances
The amplifiers shall be designed such that they allow to achieve the shakers performances listed in
[Q_Sha-01]
[Q_Amp_2] Signal distortion
For the whole frequency range 5-2000 Hz, the signal distortion measured with a resistive load shall
be:
< 0.3 % under full load
< 1% under 10% load condition
Remark: the factory verification can be limited to the frequency range 20-2000 Hz
[Q_Amp_3] Power distribution
The load shall be distributed into four power distribution cabinets. The distribution shall be approved
by the KARI during the design review.
[Q_Amp_4] Harmonic distortion
The content of harmonic currents in the power supply lines shall not exceed the values as
described in the standards IEC 61000-3-9 CD “limit for harmonic current emission”
Additional net filtering to meet the above standard shall be part of the delivery and
installation as required
[Q_Amp_5] Local control
The amplifier local control shall comprise but not necessarily be limited to the following items:
Indicators for output voltage and current
Illuminated push-buttons for amplifier ON/OFF, auxiliary ON/OFF
key switch for local/ remote control
Adjustable trip levels for output over current
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
22
Space Environment Test Dept.
Re-settable interlocks for output over voltage and current, supply over current, auxiliary
voltages, vibrator over travel, vibrator cooling, field power supply, fuses and external trip
signal
Amplifier gain control
Emergency stop
[Q_Amp_6] Remote control
The amplifier remote control shall interface with the KARI vibration control console, composed of
an LMS SCADAS III front-end piloted from a PC.
The remote control shall be located in the new control room located on the ground floor, and shall
have the following functionality:
Control and monitoring of four vibrators acting as the Multishaker
The remote control shall therefore be equipped
Switch ON-OFF of amplifiers and auxiliaries in Multishaker mode
Master gain control and input attenuator for low level testing
Phase control equipment
Indicators for output current and voltage
Additional set of voltage and current measuring converters incl. suitable signal conditioning
(for additional measurement interface)
Transformer tap changing device if applicable (contr. Voltage 240 V ac)
The equipment building the remote controls shall be mounted in 19”racks. The front panel design,
especially with respect to layout, engraving and labelling shall be approved by the KARI during the
design review. The 19”racks shall be on wheel to allow easy displacement.
[Q_Amp_7] Gain control unit (GCU)
The gain control unit shall be able to handle:
The customers vibration signal of 10 volt peak to peak, a frequency range between 3 Hz and 2500 Hz,
a signal to noise ratio better than 90 dB.
The unit shall be equipped with:
An insulating pre-amplifier.
A low pass filter with a corner frequency of 2500 Hz with a roll-off of 80 dB/decade
(optional)
A front panel mounted selector switch to bypass the filter (optional)
A step-attenuator with the following attenuator factors (voltage ratio): 1%, 2.5%, 5%,
10%, 20%, 40%, 50%,60%, 80% and 100% with front panel indicator, selector device.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
23
Space Environment Test Dept.
A single master gain potentiometer for the Multishaker configuration comprising a front
panel mounted single-turn device with a dial in percentage of the output voltage
[Q_Amp_8] Vibrator performance display unit (VPDU)
Output voltage and current measuring converters shall be provided to facilitate additional measuring
outputs.
Vibrators voltage converters with single ended buffered output, providing an output of 50
mV/Vvibr.
Vibrator current converters with single ended buffered output, provided with the following front
panel labelled selectable outputs: 66.66 mV/Avibr, 20 mV/Avibr, 6.66 mV/Avibr and 2 mV/Avibr.
BNC connectors or Cables with BNC connector shall be provided for all the monitoring output
[Q_Amp_9] Amplifier accommodation
The amplifiers shall be installed in the basement close to the seismic block in room.
The allowable floor load for this area is 10 kN/m2
The room has no gantry crane or other installed lifting equipment
[Q_Amp_10] Lifting and transport
The installation of the amplifiers to the basement will have the following constraint:
-
Lowering to the basement with a car-crane through a hatch:
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
24
Space Environment Test Dept.
[Q_Amp_11] Mechanical requirements
This describes the general rules to be applied. Some exceptions can be accepted if this
would imply a modification to the standard line of the product but does not have an impact
on safety issues.
[Q_Amp-11-01]Frames
The amplifier cabinets shall have free-standing self-supporting frames, which will rest on a flat
concrete floor. Shims or adjustable feet shall be incorporated if necessary.
In case the assembled equipment consists of more than one cabinet, the frames shall be aligned
and bolted together firmly after positioning on site.
[Q_Amp-11-02] Enclosures
The amplifier cabinets shall have metal enclosures which shall meet the protection class IP-20
as described in EN 60529/ IEC529, or better, as well as the requirements specified by the
“ European Electromagnetic Immunity Standards” as far as applicable for this purpose.
Removable panel sections and doors shall have suitable (lift-out) hinges for easy removal.
Door-locks shall be preferably to the 5mm DIN standard.
Removable panels and doors shall be positioned in such a way that easy access to vital
components is guaranteed.
Hinges should allow for a door opening of 135o minimum.
All doors in a row should open in the same direction.
[Q_Amp-11-03] Panel internal wiring and termination
Equipment internal cabling/ wiring shall run in metal or plastic cable conduit with removable
covers.
Flexible hoses to prevent damage shall protect cables and wires attached to front door mounted
equipment or swing-out racks.
Only stranded wire and multi-core cables are allowed.
Single wire termination shall be with “Crimp-type” wire terminals unless cage-clamp screw-
less terminals are applied.
Soldering of stranded wire is not allowed.
Terminals and connectors to manufacturers standard.
A wiring identification system shall be provided for all circuit with non-loosening terminal and
wire markers.
[Q_Amp-11-04] External and interface cabling
Interface cabling between equipment and between equipment and external interfaces shall
enter the enclosures from the bottom.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
25
Space Environment Test Dept.
Cables should either enter the cabinet through properly sized compression type cable glands or
clamped to a metal bar for stress relief.
Cables between interfaces shall run in one length. Joints are not permitted.
Spare wires of multi-core interface cables shall be put on terminals
Cable conductors in excess of 16 mm2 (A.W.G. 5) may directly be connected to the
components concerned if convenient (e.g.. main switches).
Power cables and cables carrying large currents should be kept separate from control cables.
Power cables and cables carrying dangerous voltage levels shall be connected to clearly
marked terminals and be separated from other terminals by separator plates and labelled
covers.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
26
Space Environment Test Dept.
2.3 Quad Vibration System Requirements
[Q_Sys_1] Armature background noise
With grounded amplifier inputs at remote control console input, the maximum allowed acceleration
noise level measured on the empty shaker armature centre shall be less than 50 10-3 grms in the
frequency band 20-2000 Hz.
[Q_Sys_2] Switch ON-OFF transient
The maximum allowed peak value of a shock impulse, induced by switching ON or OFF the
amplifiers shall be less than 0.5 g measured on the empty shaker armature centre
[Q_Sys_3] Total harmonic distortion
The total harmonic distortion measured on an accelerometer response located on the centre of the
armature shall be:
-
< 10% from 10 –1000 Hz
[Q_Sys_4] Shaker relative response
Equipment shall allow driving simultaneously the 4 shakers with 1 common drive signal [10V peak
to peak].
The amplitude difference between the shakers acceleration response (armature centre) shall be
-
< 3 % or 20 mg from 10-200 Hz
-
< 10 % or 20 mg from 3-1500 Hz
The phase difference between the shakers acceleration response (armature centre) shall be
-
< 3 from 10-600 Hz
-
< 9 from 5-1500 Hz
[Q_Sys_5] Shaker relative response- protection
Adjustable protection shall be provided in case of amplitude difference between the shakers. This
shall trigger a smooth shutdown of the system.
[Q_Sys_6] Smooth shakers shutdown
Any malfunctions of the overall system that requires a test abort shall result in a smooth shutdown
of the test run.
A smooth shutdown is:
- a controlled decrease of the acceleration down to zero, whereby the acceleration at the payload
interface do not exceed the specified acceleration of the on-going test. The decay time shall be
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
27
Space Environment Test Dept.
adjustable.
- simultaneous on the 4 shakers
At shakers level, the delay measured between the initiation of the shutdown on the 4 shakers shall
not result in a phase difference between the armature acceleration in excitation axis larger than 3 or
50 s whichever is the largest.
Note: It is understood that some of the amplifiers internal malfunction might not lead to a
simultaneous shutdown of the 4 shakers.
[Q_Sys_7] System auto protection
The shakers and amplifiers shall be equipped with the necessary interlocks to guarantee that their
malfunction are detected by the system and that failure propagation is prevented.
[Q_Sys_8] External protection
Provision shall be foreseen to connect external safety device (minimum 2) that would also initiate a
smooth shutdown of the system.
[Q_Sys_9] Maintenance
For maintenance purposes, it shall be possible to operate 1 shaker individually. This is restricted to 1
shaker at a time. The control may be limited to the local control.
[Q_Sys_10] Configuration
Quad shaker shall be installed as below configuration and shall be performed maintenance without
shaker movement.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
28
Space Environment Test Dept.
2.4 Quad Vibration System General Requirements
[Q_Gen_1] Electrical Safety
The amplifiers, shakers, auxiliary equipment, terminal box and cable installation shall be compliant
with the Dutch Safety regulation regarding electrical installations “NEN 1010, issue5 (IEC364-485)”
[Q_Gen_2] EMC compliance
With respect to the EMC compliance, the total installation at site has to fulfil the requirements as
stipulated in the generic emission standard for industrial environments “EN 61000-6-6:2001” as well
as the generic immunity standard “EN 61000-6-3:2001”.
If the actual performance requires such, KARI shall verify the emission standard by measurement
and the immunity standard by verification of the design, calculations and manufacturing trajectory.
During the design phase the following aspects shall be addressed:
Faraday cages and system compartmentalization
Filter interconnections between compartments
3 phase and single phase mains filtering
Segmented wiring
Defined earth returns for filter functions
Choice of components with low equivalent series inductance and resistance
(ESL/ESR)
Optical coupling of logic signals
Screened cables in sensitive areas
Common mode chokes for symmetrical currents
Note: the same aspect was looked at during the installation of the renewal of the old amplifiers.
[Q_Gen_3] Earthing and screening
Proper earthing screening of the shakers and amplifiers shall be put in place
[Q_Gen_4] Cabling and cabling routing
All electrical cables shall be labelled at both ends. Power cables and signal cables shall be routed
separately.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
29
Space Environment Test Dept.
2.5 Quad Vibration System Operation, maintenance and repair
requirements
[Q_Main_1] Operators and maintenance personnel training
A comprehensive and effective operation and maintenance training of the KARI personnel shall be
performed, preferably during the acceptance test phase at site.
The training shall be limited to those aspects involved with the application of new technology and
equipment since a large expertise of the existing and remaining equipment is assumed.
[Q_Main_2] Spare parts
A comprehensive spare-parts list shall be part of the delivery. The list shall include OEM names and
part numbers.
Unless justified, parts used shall be commercial off-the-shelf in order to ensure cost effective
approach of spare parts procurement.
[Q_Main_3] Diagnostic aids
To facilitate inspections, preventive maintenance and repair, diagnostic aids shall either be
incorporated or additionally supplied.
Examples of diagnostic aids shall include:
Identified test points on electronic circuit boards
Pre-wired test connectors
Fault condition signs by LED’s (In case of abort, indicating the first event which has
triggered the abort)
Dedicated test modules
Adaptor cables for use with standard instruments
[Q_Main_4] Alignment and calibration
The design shall be such that alignment and calibration effort shall be kept to a minimum.
All elements requiring alignment shall have good accessibility.
Alignment shall be carried out with standard tools and instruments.
If however special tools/ equipment is required it shall be part of the delivery.
After acceptance at least one year without maintenance is expected.
2.6 Product Assurance requirements
The contractor shall ensure that the equipment is built, installed and commissioned in accordance
with the approved design and manufacturing baseline, in a planned and controlled manner.
Any deviation from the specified requirements shall be reported to the KARI in accordance with a
procedure to be contractually agreed. The Contractor shall operate a formal non-conformance control
system.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
30
Space Environment Test Dept.
3.
Technical Requirements for Large Vibration System
3.1 Shaker requirements
To increase the horizontal shaker capability, 3mx3m slip table system will be designed and
built. The work scope for lateral-shaker is to purchase shaker system with associated
remote control.
[S_sha-1] Shaker performance
The shaker shall have the following minimum performances:
Frequency range
Sine
3-2000 Hz
Random
10-2000 Hz
Shock
5-2000 Hz
Nominal maximum Thrust
Sine
280 kN peak
Random
260 kN RMS
Shock
>800 kN peak
Nominal maximum
no load acceleration
Sine
75 g
random
60 grms
shock
180 g
Nominal maximum velocity
sine
2.0 m/s
Nominal maximum displacement
Sine
50.8 mm peak-peak
Half
sine
bump
63.5 mm
Armature suspension stiffness
-Axial(nominal)
-Cross axial at insert level
-Rotational stiffness
91N/mm
71800M/mm
10700kNm/rad
Armature resonance frequency
>1300Hz
Mechanical resonance of vibrator
body
less than 2.5Hz
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
31
Space Environment Test Dept.
[S_sha-2] Armature Cross-Motion
The cross acceleration measured at the periphery of the armature shall be
< 10% from 5-200 Hz
< 10% from 200-900 Hz except 1 peak at 40%
Acceleration profile
0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
18.000
20.000
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
Acc
e
le
ra
tion [
g]
Velocity profile
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
180.00
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
V
e
loc
ity
[c
m/
s
]
Displacement profile
0
2
4
6
8
10
12
14
16
0
10
20
30
40
50
60
70
80
90
100
Frequency [Hz]
Dis
pla
c
e
me
nt
[mm]
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
32
Space Environment Test Dept.
[S_sha-3] Armature acceleration homogeneity
The in-axis acceleration difference between any sensors located on top of the armature shall be:
< 4% from 5-200 Hz
<25% from 200-900 Hz
[S_sha-4] Alignment capabilities
Tools shall be provided for fine lateral and vertical adjustment of the shaker position in the seismic
block (accuracy better than 0.5 mm)
[S_sha-5] Armature vertical positioning
Provision shall be foreseen so that the armatures vertical position of the shaker can be adjusted within
±1 mm
[S_sha-6] Transport within KARI
Lowering shakers inside the seismic block shall be done using the existing crane (maximum capacity
20 tons)
[S_sha-7] Armature and body movement monitoring
It is required to monitor the armature and body movement close to the shaker and close to the remote
control. remark: automatic control of the body zero position shall be foreseen.
[S_sha-8] Shaker body link
Depending on the selected body configuration, i.e. solid trunions or isolated shakers, disposition for
linking the body shall be foreseen.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
33
Space Environment Test Dept.
3.2 Amplifier Requirements
[S_Amp-1] Amplifier performances
The amplifiers shall be designed such that they allow to achieve the shakers performances listed in
[S_Sha-01]
[S_Amp-2] Signal distortion
For the whole frequency range 5-2000 Hz, the signal distortion measured with a resistive load shall
be:
< 0.5 % under full load
< 2% under 10% load condition
Remark: the factory verification can be limited to the frequency range 20-2000 Hz
Output
Voltage
Output
Power
20Hz ~ 40Hz
(THD)
400Hz ~ 1kHz
(THD)
2kHz ~ 3kHz
(THD)
100V
100%
0.5%
0.5%
0.8%
50V
25%
0.6%
0.6%
0.8%
10V
1%
2%
2%
2%
[S_Amp-3] Power distribution
The load shall be distributed into four power distribution cabinets. The distribution shall be approved
by the KARI during the design review.
[S_Amp-4] Harmonic distortion
The content of harmonic currents in the power supply lines shall not exceed the values as
described in the standards IEC 61000-3-9 CD “limit for harmonic current emission”
Additional net filtering to meet the above standard shall be part of the delivery and
installation as required
[S_Amp-5] Local control
The amplifier local control shall comprise but not necessarily be limited to the following items:
Indicators for output voltage and current
Illuminated push-buttons for amplifier ON/OFF, auxiliary ON/OFF
key switch for local/ remote control
Adjustable trip levels for output over current
Re-settable interlocks for output over voltage and current, supply over current, auxiliary
voltages, vibrator over travel, vibrator cooling, field power supply, fuses and external trip
signal
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
34
Space Environment Test Dept.
Amplifier gain control
Emergency stop
[S_Amp-6] Remote control
The amplifier remote control shall interface with the KARI vibration control console, composed of
an LMS SCADAS III front-end piloted from a PC.
The remote control shall be located in the new control room located on the ground floor, and shall
have the following functionality:
Control and monitoring of single vibrator
The remote control shall therefore be equipped
Switch ON-OFF of amplifiers and auxiliaries in single mode
Master gain control and input attenuator for low level testing
Phase control equipment
Indicators for output current and voltage
Additional set of voltage and current measuring converters incl. suitable signal conditioning
(for additional measurement interface)
Transformer tap changing device if applicable (contr. Voltage 240 V ac)
The equipment building the remote controls shall be mounted in 19”racks. The front panel design,
especially with respect to layout, engraving and labelling shall be approved by the KARI during the
design review. The 19”racks shall be on wheel to allow easy displacement.
[S_Amp-7] Gain control unit (GCU)
The gain control unit shall be able to handle:
The customers vibration signal of 10 volt peak to peak, a frequency range between 3 Hz and 2500 Hz,
a signal to noise ratio better than 90 dB.
The unit shall be equipped with:
An insulating pre-amplifier.
A low pass filter with a corner frequency of 2500 Hz with a roll-off of 80 dB/decade
(optional)
A front panel mounted selector switch to bypass the filter (optional)
A step-attenuator with the following attenuator factors (voltage ratio): 1%, 2.5%, 5%,
10%, 20%, 40%, 50%,60%, 80% and 100% with front panel indicator, selector device.
A single master gain potentiometer for the single shaker configuration comprising a front
panel mounted single-turn device with a dial in percentage of the output voltage
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
35
Space Environment Test Dept.
[S_Amp-8] Vibrator performance display unit (VPDU)
Output voltage and current measuring converters shall be provided to facilitate additional measuring
outputs.
Vibrators voltage converters with single ended buffered output, providing an output of 50
mV/Vvibr.
Vibrator current converters with single ended buffered output, provided with the following front
panel labelled selectable outputs: 66.66 mV/Avibr, 20 mV/Avibr, 6.66 mV/Avibr and 2 mV/Avibr.
BNC connectors or Cables with BNC connector shall be provided for all the monitoring output
[S_Amp-9] Amplifier accommodation
The amplifiers shall be installed in the basement close to the seismic block in room.
The allowable floor load for this area is 10 kN/m2
The room has no gantry crane or other installed lifting equipment
[S_Amp-10] Lifting and transport
The installation of the amplifiers to the basement will have the following constraint:
-
Lowering to the basement with a car-crane through a hatch:
[S_Amp-11] Mechanical requirements
This describes the general rules to be applied. Some exceptions can be accepted if this
would imply a modification to the standard line of the product but does not have an impact
on safety issues.
[S_Amp-11-01]Frames
The amplifier cabinets shall have free-standing self-supporting frames, which will rest on a flat
concrete floor. Shims or adjustable feet shall be incorporated if necessary.
In case the assembled equipment consists of more than one cabinet, the frames shall be aligned
and bolted together firmly after positioning on site.
[S_Amp-11-02] Enclosures
The amplifier cabinets shall have metal enclosures which shall meet the protection class IP-20
as described in EN 60529/ IEC529, or better, as well as the requirements specified by the
“ European Electromagnetic Immunity Standards” as far as applicable for this purpose.
Removable panel sections and doors shall have suitable (lift-out) hinges for easy removal.
Door-locks shall be preferably to the 5mm DIN standard.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
36
Space Environment Test Dept.
Removable panels and doors shall be positioned in such a way that easy access to vital
components is guaranteed.
Hinges should allow for a door opening of 135o minimum.
All doors in a row should open in the same direction.
[S_Amp-11-03] Panel internal wiring and termination
Equipment internal cabling/ wiring shall run in metal or plastic cable conduit with removable
covers.
Flexible hoses to prevent damage shall protect cables and wires attached to front door mounted
equipment or swing-out racks.
Only stranded wire and multi-core cables are allowed.
Single wire termination shall be with “Crimp-type” wire terminals unless cage-clamp screw-
less terminals are applied.
Soldering of stranded wire is not allowed.
Terminals and connectors to manufacturers standard.
A wiring identification system shall be provided for all circuit with non-loosening terminal and
wire markers.
[S_Amp-11-04] External and interface cabling
Interface cabling between equipment and between equipment and external interfaces shall
enter the enclosures from the bottom.
Cables should either enter the cabinet through properly sized compression type cable glands or
clamped to a metal bar for stress relief.
Cables between interfaces shall run in one length. Joints are not permitted.
Spare wires of multi-core interface cables shall be put on terminals
Cable conductors in excess of 16 mm2 (A.W.G. 5) may directly be connected to the
components concerned if convenient (e.g.. main switches).
Power cables and cables carrying large currents should be kept separate from control cables.
Power cables and cables carrying dangerous voltage levels shall be connected to clearly
marked terminals and be separated from other terminals by separator plates and labelled
covers.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
37
Space Environment Test Dept.
3.3 Large Vibration System Requirements
[S_Sys-1] Armature background noise
With grounded amplifier inputs at remote control console input, the maximum allowed acceleration
noise level measured on the empty shaker armature centre shall be less than 50 10-3 grms in the
frequency band 20-2000 Hz.
[S_Sys-2] Switch ON-OFF transient
The maximum allowed peak value of a shock impulse, induced by switching ON or OFF the
amplifiers shall be less than 0.5 g measured on the empty shaker armature centre
[S_Sys-3] Total harmonic distortion
The total harmonic distortion measured on an accelerometer response located on the centre of the
armature shall be:
-
< 10% from 10 –1000 Hz
[S_Sys-4] Shaker relative response
Equipment shall allow driving simultaneously the 4 shakers with 1 common drive signal [10V peak
to peak].
The amplitude difference between the shakers acceleration response (armature centre) shall be
-
< 3 % or 20 mg from 10-200 Hz
-
< 10 % or 20 mg from 3-1500 Hz
The phase difference between the shakers acceleration response (armature centre) shall be
-
< 3 from 10-600 Hz
-
< 9 from 5-1500 Hz
[S_Sys-5] Shaker relative response- protection
Adjustable protection shall be provided in case of amplitude difference between the shakers. This
shall trigger a smooth shutdown of the system.
[S_Sys-6] Smooth shakers shutdown
Any malfunctions of the overall system that requires a test abort shall result in a smooth shutdown
of the test run.
A smooth shutdown is:
- a controlled decrease of the acceleration down to zero, whereby the acceleration at the payload
interface do not exceed the specified acceleration of the on-going test. The decay time shall be
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
38
Space Environment Test Dept.
adjustable.
Note: It is understood that some of the amplifiers internal malfunction might not lead to a
simultaneous shutdown of the shaker.
[S_Sys-7] System auto protection
The shakers and amplifiers shall be equipped with the necessary interlocks to guarantee that their
malfunction are detected by the system and that failure propagation is prevented.
[S_Sys-8] External protection
Provision shall be foreseen to connect external safety device (minimum 2) that would also initiate a
smooth shutdown of the system.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
39
Space Environment Test Dept.
3.4 Large Vibration System
General Requirements
[S_Gen-1] EMC compliance
With respect to the EMC compliance, the total installation at site has to fulfil the requirements as
stipulated in the generic emission standard for industrial environments “EN 61000-6-6:2001” as well
as the generic immunity standard “EN 61000-6-3:2001”.
If the actual performance requires such, KARI shall verify the emission standard by measurement
and the immunity standard by verification of the design, calculations and manufacturing trajectory.
During the design phase the following aspects shall be addressed:
Faraday cages and system compartmentalization
Filter interconnections between compartments
3 phase and single phase mains filtering
Segmented wiring
Defined earth returns for filter functions
Choice of components with low equivalent series inductance and resistance
(ESL/ESR)
Optical coupling of logic signals
Screened cables in sensitive areas
Common mode chokes for symmetrical currents
[S_Gen-2] Earthing and screening
Proper earthing screening of the shakers and amplifiers shall be put in place
[S_Gen-3] Cabling and cabling routing
All electrical cables shall be labelled at both ends. Power cables and signal cables shall be routed
separately.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
40
Space Environment Test Dept.
3.5 Large
Vibration
System
Operation, maintenance, repair
requirements
[S_Main-1] Operators and maintenance personnel training
A comprehensive and effective operation and maintenance training of the KARI personnel shall be
performed, preferably during the acceptance test phase at site.
The training shall be limited to those aspects involved with the application of new technology and
equipment since a large expertise of the existing and remaining equipment is assumed.
[S_Main-2] Spare parts
A comprehensive spare-parts list shall be part of the delivery. The list shall include OEM names and
part numbers.
Unless justified, parts used shall be commercial off-the-shelf in order to ensure cost effective
approach of spare parts procurement.
[S_Main-3] Diagnostic aids
To facilitate inspections, preventive maintenance and repair, diagnostic aids shall either be
incorporated or additionally supplied.
Examples of diagnostic aids shall include:
Identified test points on electronic circuit boards
Pre-wired test connectors
Fault condition signs by LED’s (In case of abort, indicating the first event which has
triggered the abort)
Dedicated test modules
Adaptor cables for use with standard instruments
[S_Main-4] Alignment and calibration
The design shall be such that alignment and calibration effort shall be kept to a minimum.
All elements requiring alignment shall have good accessibility.
Alignment shall be carried out with standard tools and instruments.
If however special tools/ equipment is required it shall be part of the delivery.
After acceptance at least one year without maintenance is expected.
3.6 Product Assurance requirements
The contractor shall ensure that the equipment is built, installed and commissioned in accordance
with the approved design and manufacturing baseline, in a planned and controlled manner.
Any deviation from the specified requirements shall be reported to the KARI in accordance with a
procedure to be contractually agreed. The Contractor shall operate a formal non-conformance control
system.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
41
Space Environment Test Dept.
4.
Technical Requirements for Interface Equipment
4.1 2.0m Head expander requirements
A guided head expander of 2.0m diameter is installed at shaker and allow vertical axis
testing where the size or mass of the payload are greater than can be accommodated on
the standard shaker armature table.
[I_HE 2.0-1] Head-expander performance
The head-expander shall have the following minimum performances:
Load support capability
6000kg(combined with vibrator load support)
Table size
2000mm Diameter
Useable stroke
2 in D/A
Moment resistant
40kNm
Useable frequency
5Hz ~ 2kHz
First major resonance
> 400Hz
Interface
-
Single shaker interface
-
LDS V994 armature table
[I_HE 2.0-2] Mechanical Construction
The head-expander shall have the following minimum mechanical construction:
Top face
2000 mm diameter
Flatness tolerance
≤ 0.05 mm/m between top and bottom faces
Material
-Frame: steel
-Expander, extender and adaptor plate:
magnesium
Finish
Air drying, polyurethane paint on all
external surfaces except top and bottom faces.
Weight (expander and guidance system)
Less than 4200kg
Air supply pressure
Less than 7 bar
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
42
Space Environment Test Dept.
[I_HE 2.0-3] Arrangement of head expander
The complete head expander system shall consists of:
-
A fabricated magnesium table and extender bolted together. The table upper surface
carries the payload and the extender is connected via an adaptor plate to the single
shaker system in this proposal and also V994 armature which has been used in
KARI .
-
A steel support structure bolted to the shaker top plate, including a steel cruciform in
which is mounted a guidance system comprising two hydrostatic journal bearings on a
common shaft.
-
A load support system comprising eight airbags
-
Four outrigger supports with airbag for attachment to the top of the vibrator supports
to assist the vibrator Lin-E-Air suspension.
-
A free-standing hydraulic power supply with connecting hoses.
-
Pneumatic controls and hoses for connecting to the vibrator Lin-E-Air suspension and
pneumatic control panel.
-
Expander lock-outs protected by interlocks.
-
Tuned damper and flat damper installed
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
43
Space Environment Test Dept.
[I_HE 2.0-4] Mechanical insert patterns
The head expander table shall be fitted with M12 stainless steel inserts in the pattern specified by
KARI. Tightening torque is 90 N m
For the adapter plate, to avoid damage to the expander, special steel washers shall be fitted at the
bottom of the counter bores. The tightening torque is 100 N m.
[I_HE 2.0-5] Guidance system
To avoid overloading the shaker guidance system, the head expander shall have its own guidance
system.
Two hydrostatic guide bearings shall be located in the central vertical axis of the expander assembly.
The bearings shall be pressurized using the free-standing hydrostatic power supply described later in
this section.
[I_HE 2.0-6] Lifting device
Lifting device shall be supplied based on following configuration
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
44
Space Environment Test Dept.
4.2 1.2m Head expander requirements
A guided head expander of 1.2m ~ 1.3m diameter is installed at shaker and allow vertical
axis testing where the size or mass of the payload are greater than can be accommodated
on the standard shaker armature table.
[I_HE 1.2-1] Head-expander performance
The head-expander shall have the following minimum performances:
Load support capability
2000kg(combined with vibrator load support)
Table size
1200 ~ 1300mm Diameter
Useable stroke
2 in D/A
Moment resistant
>15 kNm
Useable frequency
5Hz ~ 2.7Hz
First major resonance
> 800Hz
Interface
-
Single shaker interface
Moving of head expander system
-
1200 mm in diameter
-
1300 mm in diameter
-
Less than 400kg
-
Less than 440kg
[I_HE 1.2-2] Mechanical Construction
The head-expander shall have the following minimum mechanical construction:
Top face
1200 ~ 1300 mm diameter
Flatness tolerance
≤ 0.05 mm/m between top and bottom faces
Material
-Frame: steel
-Expander, extender and adaptor plate:
magnesium
Finish
Air drying, polyurethane paint on all
external surfaces except top and bottom faces.
Weight (expander and guidance system)
Less than 4200kg
Air supply pressure
Less than 7 bar
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
45
Space Environment Test Dept.
[I_HE 1.2-3] Arrangement of head expander
The complete head expander system shall consists of:
-
A fabricated magnesium table and extender bolted together. The table upper surface
carries the payload and the extender is connected via an adaptor plate to the single
shaker system armature which has been used in KARI .
-
A steel support frame connected to the vibrator body via extensions to the suspension
pillars.
-
A steel cruciform mounted on the support frame and in turn supporting
o a bearing shaft on which run the expander and extender bearings
o four double load support airbags
-
Four outrigger supports with airbag for attachment to the top of the vibrator supports
to assist the vibrator Lin-E-Air suspension.
-
A free-standing hydraulic power supply with connecting hoses.
-
Pneumatic controls and hoses for connecting to the vibrator Lin-E-Air suspension and
pneumatic control panel.
-
Expander lock-outs protected by interlocks.
[I_HE 1.2-4] Mechanical insert patterns
The head expander table shall be fitted with M12 stainless steel inserts in the pattern specified by
KARI. Tightening torque is 90 N m
For the adapter plate, to avoid damage to the expander, special steel washers shall be fitted at the
bottom of the counter bores. The tightening torque is 100 N m.
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
46
Space Environment Test Dept.
[I_HE 1.2-5] Guidance system
To avoid overloading the shaker guidance system, the head expander shall have its own guidance
system.
Two hydrostatic guide bearings shall be located in the central vertical axis of the expander assembly.
The bearings shall be pressurized using the free-standing hydrostatic power supply described later in
this section.
[I_HE 1.2-6] Lifting device
Lifting device shall be supplied based on following configuration.
Complete expander assembly shall be lifted using the special brackets
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
47
Space Environment Test Dept.
4.3
1.2m Slip table requirements
A Slip table of 1.2m x 1.2m interface is connected to shaker and allow the lateral axis
testing. Slip table is designed to produce vibration from the shaker, supporting the payload
and moving in the horizontal axis. Dynamic resistance shall be provided by 9 hydrostatic
bearings to prevent excessive cross axial movement reducing the wear and tear on the
shaker.
[I_SL 1.2-1] Slip table performance
The slip table shall have the following minimum performances:
Load support capability
2000kg(combined with vibrator load support)
Table size
1200 x 1200mm Diameter
Useable stroke
2 in D/A
Number of hydraulic journal bearings
9 bearings
Useable frequency
5Hz ~ 2,000Hz
First major resonance
> 500Hz
Interface
Single shaker interface
Cross axis performance
-X-axis
Better than 15% 5~ 500Hz except for 3 peaks
Better than 20% 500~ 1kHz except for 1 peak
-Z-axis
Better than 15% 5~ 500Hz except for 3 peaks
Better than 20% 500~ 1kHz except for 1 peak
Moving of head expander system
Less than 450kg
[I_HE 1.2-2] Mechanical Construction
The slip table shall have the following minimum mechanical construction:
Top face
1200 x 1200 mm (interface area)
Flatness tolerance
≤ 0.03 mm/m
Material
-Frame : steel
-Sip table : magnesium alloy type AZ31B with
a stiffness of E=44.1 x 109 Nm2
Air supply pressure
Less than 7 bar
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
48
Space Environment Test Dept.
[I_HE 1.2-3] Arrangement of slip table
The complete slip table system shall consists of:
-
Slip table is designed to produce vibration from the shaker, supporting the payload and
moving in the horizontal axis.
-
Dynamic resistance shall be provided by 9 hydrostatic bearings to prevent excessive
cross axial movement reducing the wear and tear on the shaker.
-
The driver is attached to the armature by each of load attachment insert positions in
the vertical axis and after rotation of the vibrator to the horizontal axis.
-
To prevent oil volatilisation, the slip table plate shall be fitted with an oil moat seal.
-
Slip table shall be supplied ad stand alone type
[I_HE 1.2-4] Slip table bearing
▣ Free type bearing
-
Support load > 65 kN
-
Maximum stroke > 75 mm
-
Moving (effective) mass < 6 kg
-
Operating oil pressure : 170 bar +/-10 bar
-
Bearing housing to slip table securing torque : 60 Nm +/- 5Nm
-
Bearing support to steel base securing torque : 70 Nm +/- 5Nm
-
Hydraulic oil : Shell Tellus 68 or Mobil Delvac 1
-
Built-in compliance for thermal expansion
-
6EA
▣ Fixed type bearing
-
Support load > 65 kN
-
Maximum stroke > 75 mm
-
Moving (effective) mass < 6 kg
-
Operating oil pressure : 170 bar +/-10 bar
-
Bearing housing to slip table securing torque : 60 Nm +/- 5Nm
-
Bearing support to steel base securing torque : 70 Nm +/- 5Nm
-
Hydraulic oil : Shell Tellus 68 or Mobil Delvac 1
-
Built-in compliance for thermal expansion
-
3EA
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
49
Space Environment Test Dept.
[I_HE 1.2-4] Mechanical insert patterns
The slip table shall be fitted with M12 stainless steel inserts in the pattern specified by KARI.
Tightening torque is 90 N m
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
50
Space Environment Test Dept.
III. Format of Proposal
The proposal shall consist of 10 section(S).
S 1 : Bidder's Qualification Document
S 2 : Executive Summary (Overview)
S 3 : Technical Proposal
S 4 : Warranty Proposal
S 5 : Maintenance Proposal
S 6 : Training Proposal
S 7 : Transport - Handling - Storage Proposal
S 8 : Work Schedule for Manufacturing, Assembly, Installation, and Interface
S 9 : Acceptance Test Plan Proposal
S 10 : Acceptance Data Package (Documentation)
S 11 : Resume of Key Personnel
S 12 : Bidder's Confirmation Document for Fully Understanding of the RFP
S 13 : Price Proposal
The bidder shall present 6 copies of the proposal. A4 or letter size paper shall be used. The bidder is
requested to strictly follow the following illustrated format (tabular form). This is very important
to compare and evaluate different bidders’ proposal. Consequently, disregard for this rule may end
up with disqualification. Also, well-prepared and well-organized proposal will be highly appreciated
and evaluated. The landscape orientation will be acceptable for tables. The suggested contents in
each WP are minimum requirements and works for reminiscences. Ambiguous expression will act
adversely to the bidder.
S 1 : Bidder's Qualification Document
(*) Bidder's Qualification : The followings shall be included in WP1.
The participants shall have experience in manufacturing and delivery of a quad-shakers system for a
guidance head expander (above 3 x 3 m) for the purpose of vibration test.
The followings shall be included in this Section.
(a) Bidder's last 5 years experience on the prescribed system in this "Request for Proposal" including :
(1) design
(2) manufacturing
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
51
Space Environment Test Dept.
(3) installation (specifications, performance, purchaser, supplied year, and price)
(4) training (operation and maintenance) of the facility
(b) The certification of export license for the items to be delivered.
(c) The installation information (including personnel's information in charge of the facility, address,
FAX number, etc.) from the well known institutes or companies which are using the facilities
installed by the bidder and/or subcontractor.
(d) The bidder's separate balance sheets of recent 5 years, which is certified by Certified Public
Account, including annual turnovers, assets and liabilities (This should be submitted separately
for bidder's company only and the total group).
(e) Other information
1. Total Employees
- Total number of Employees (Engineer / Technician)
- Number of Employees for the directly related area
2. Plant Scale
- Total area of space
- Factory & Building area
3. General brochure
4. Any documents with which the bidder can show his/her financial and technical abilities
(e.g. technical awards, bank balance, etc.)
(4) training (operation and maintenance) of the facility for foreign countries
(f) Bidder’s Qualification Evidence Documents to show the Part I Section 2 in this RFP. The
documents include personnel's information in charge of the facility, address, FAX number and the
others from the world well known satellite testing institutes or companies which are using the
facilities installed by the bidder
(g) Other information
1. Total Employees
- Total number of Employees (Engineer / Technician)
- Number of Employees for the directly related area
2. Plant Scale
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
52
Space Environment Test Dept.
- Total area of space
- Factory & Building area
3. General brochure
4. Any documents with which the bidder can show his/her financial and technical abilities
(e.g. technical awards, bank balance, etc.)
S 2 : Executive Summary (Overview)
This WP shall include the summary of the all section (3 through 12). The tabular form is
recommended.
S 3 : Technical Proposal
This WP (Technical Proposal) shall be written in English. Concise and clear expression is required.
A long sentence should be broken down into several sentences. Detailed block diagrams, figures and
photos are recommended for clear illustration.
All the descriptions in this RFP is minimum requirements and the bidders can suggest the
better one to improve the overall performance and cost. But in this case, the proposal should
clearly indicate the improvements on the KARI’s requirements with their detail drawings and explicit
calculation results.
The contents of proposal will be the measurement of the bidder’s technical capabilities.
Bidder’s proposal will be reviewed by a number of experts at KARI and other institutes.
The bidder shall prepare tables for the check list to show the bidder’s compliance with the “Request
for Proposal”. This table shall be located in front of the Technical Proposal part. The articles in the
“Part III Work description” and “Part II Technical Requirements” of the RFP shall be completely
enumerated in the table. The table format is as follows:
Check Lists for “Part I Overview work description” and “Part II Technical Requirements
ANR
: Article Number in the “Part II & III Technical Requirements” in the RFP.
Y/N
: Compliance (Yes or No.)
CAP
: Corresponding Article number in the bidder’s Proposal to ANR
AAM
: Article number of Added Material in the bidder’s proposal which is not mentioned in the
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
53
Space Environment Test Dept.
RFP.
Part
I
Or
Part
II
ANR
Y/N
CAP
Remark
AAM
Remark
1)
yes
1)
ditto
2)
yes
2)
ditto
3)
yes
3)
ditto
4)
yes
4)
The specifications look
old. We updated them.
N/A
N/A
N/A
N/A
5)
We currently
developed
a
new method.
5)
yes
6)
ditto
6)
no
7)
The resolution is high
above the necessity. The
current technology for the
system …..
7)
yes
8)
ditto
8)
no
9)
This specification is not
compatible with 8) in the
proposal. We suggest other
approach.
9)
yes
10)
ditto
# ditto : The same as stated above or before
Due to the interface issue, the bidders shall deliver a complete design file(AutoCAD or CATIA) or
drawings which have the following information :
-
Whole set of drawings of slip table system and driver bar with the detail layout of
interface-related system
-
Slip table base plan
-
Distribution network(electricity, oil, cooling water, etc) layout drawings
-
Interface details with the test building
-
All the calculation notes proving that the total system will be fully compliant with the
technical specifications.
S 4 : Warranty Proposal
4.1 Baseline warranty (1 years)
- plan for the prompt repair
- information on A/S team
4.2 Extended warranty (amplifiers of upgrading three shakers)
- 5 years extended warranty for the normal operation under contractor responsibility
or equivalent proposal for lifetime of facilities
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
54
Space Environment Test Dept.
S 5 : Maintenance Proposal
5.1 General description
5.2 Spare parts
5.3 Hardware updating
S 6 : Training Proposal
6.1 The training program
- contents, location, period, etc.
S 7 : Transport-Handling-Storage Proposal
- plan for packaging
- list of special parts and their treatment plan
- storage plan of products for assembly, installation, and interface
S 8 : Work Schedule for Manufacturing, Assembly, Installation, and Interface
The work schedule and installation plan shall be shown as in detail as possible in chronological
way. The installation plan shall be detailed enough to figure out daily progress and include the
methods and procedures for interface between the equipment and KARI SITC building(electricity,
cooling water, etc)
S 9 : Acceptance Test Plan Proposal
9.1 General description
9.2 Acceptance test
9.3. Back-up plan
For the case that the bidder can not meet the requirements or other contractual binds after the
2014. 12
Vibration shakers & Interface Equipment for Large Vibration Facility
55
Space Environment Test Dept.
contract is awarded, the bidder shall proposed the back-up plan.
- detailed plan and schedule
S 10 : Acceptance Data Package
10.1. Documentation
-
document list (contents, number of page and figure) to be delivered.
S 11 : Resume of Key Personnel
The table shall include the information of the followings :
(a) Overall project manager
(b) Mechanical and electrical lead designer
(c) Other section project leader
(d) Subcontractor personnel (if any)
S 12 : Bidder's Confirmation Document for Fully Understanding of the RFP
This document shall confirm that the bidder has completely understood the whole RFP, which was
written in Korean and English.
S 13 : Price Proposal
Price proposal in Euro
APPENDIX
1. General Terms and Conditions