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39 Annexure-1 SPECIFICATIONS OF FIBER PLACEMENT SYSTEM 1. GENERAL a) The scope includes Manufacture, Supply, Installation, Commissioning & Training of a CNC Fiber Placement System (with two interchangeable heads- Fiber Placement Head and Tape Layup Head- on a single Ram) at Composites Entity, VIKRAM SARABHAI SPACE CENTRE (VSSC), ISRO, Thiruvananthapuram, India on TURN-KEY basis. b) The bid shall be offered by the machine manufacturer only. c) Bidder should have manufactured and supplied at least 3 similar machines during the last five years. d) The bidder should provide a comprehensive list of the machines supplied with overall configuration / features of the machines supplied, full address of the clients and contact persons with telephone / fax / e- mail details. e) Quotations / offers received from bidder without the above information will be rejected. f) Along with their bid, the manufacturer shall submit a compliance check list in the format provided. Relevant proof / supplementary document for the compliances are to be furnished and should be referenced to the technical bid. Technical justifications for deviations / variations/ modifications proposed are to be clearly spelt out. g) The technical part of the offer shall be evaluated by the customer. Technically qualifying bidders shall be further evaluated for compliance, at their site, as per the details given in Section 20(a). Order shall be placed with technically acceptable lowest bidder. Page 1 of 24

40 2. PURPOSE This machine is intended for CNC controlled fully automated lay up of the specified composite materials on customer specified mould surfaces in the required fibre orientation (0 0 to 90 0 ), at the required location with the specified accuracy. Description of the required mould configurations, composite materials to be laid-up & accuracies of the ply layup are listed in the subsequent chapters. 3. SYSTEM ENVELOPE (Indicative Values) Direction APPROACH (Nominal) ACCURACY as per ISO X Longitudinal 6000 mm ±0.10 mm/ m or better Y Cross 3000 mm ±0.10 mm/ m or better Z Vertical 1500 mm ±0.10 mm/ m or better FIBER PLACEMENT HEAD - TRAVELS AND ACCURACIES (Indicative Values) Direction Fiber Placement Head (FP head) rotary traverses Tow spooling, tensioning, feeding, guiding, cutting, compacting on FP head, spooling of backing paper, local heating, etc APPROACH (Nominal) In accordance with the mould geometry and ply orientation. Axes nomenclature & details to be provided by vendor. Continuous. Axes nomenclature & details to be provided for each feature. ACCURACY as per ISO In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. Page 2 of 24

41 Tool (mould) rotation (between head stock and tail stock for operations on cylinder mould referred in Sec. 4, Sl. No. 2) Continuous. Servo interpolated with the rest of the machine traverse axes. ±25 arc-sec or better TAPE LAYUP HEAD - TRAVELS AND ACCURACIES (Indicative Values) Direction APPROACH (Nominal) ACCURACY as per ISO Tape Lay-up Head rotary traverses (A, B & C) Tape unwinding, tensioning, feeding, guiding, cutting, compacting, spooling of backing paper, local heating, etc. In accordance with the mould geometry and ply orientation. Axes details to be provided by vendor. Axes nomenclature & details to be provided for each feature. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. Other axes shall be sized to enable lay up as per Sec. 4. The global positioning accuracy at the tow delivery point shall not exceed 0.5 mm. The vendor shall provide the nominal system envelope and all axes traverse/ drive details with suitable sketches etc. 4. MOULD SURFACE CONFIGURATIONS & SIZES Moulds used by customer on which the composite materials are to be laid are generally made of Aluminium alloy, Composite material, Cast Iron or Steel. The machine configuration shall enable composite material layup on the following type of mould surface for the specified envelope: Page 3 of 24

42 Sl. No. Mould surface Effective layup dimensions on mould Mould Dimension s (maximum) Mould support configur ation & mould weight Sketch 1 Flat 3.5m x 2.5m 4m x 3m On ground, stationary Mould weight : 8000 Kg 2 Outer surface of Cylindrical mould Min. Diameter : 0.5m Max. Diameter : 2m Max. Length : 2.5m Cylinder portion length: 3m Central shaft : 0.4m extension at both ends Between head stock & tail stock, Rotating Mould weight : 5000 Kg 3 Shaped parabolic convex (focal length, F : 0.3m to 2.5m) Min Diameter : 0.5m Max. Diameter : 2.5m Diameter : 3m On ground, stationary Mould weight : 5000 Kg Page 4 of 24

43 Min Diameter : to be specified by party 4 Part of cylinder (male mould, Sector angle : 60 degree) Max Diameter : 5 m Length : 4m Note: Vendor shall also specify the maximum and minimum diameters of part of cylinder that can be effectively laid up on a female mould. On ground, stationary Mould weight : 5000 Kg MATERIALS TO BE LAID The machine shall enable continuous lay-up of the following materials in the specified forms on to the mould surfaces specified in section 4: Sl. No. Material form Material Source & Designation (same or equivalent) Remarks 1 Uni-directional Preimpregnated tow and slit tape : 6.35mm width Hexcel: M55J / M18 Hexcel: M55J / Cytec: M55J / HTM 143 Thickness of ply : From 0.1mm to 0.2mm The material shall be in Page 5 of 24

44 (For Fiber Placement Head) Uni-directional Preimpregnated tape : 75 mm width (For Tape Layup Head) Tencate: M55J / TC 410 Hexcel: HTS / M18 T300 / epoxy matrix T800 / epoxy matrix T1000 / epoxy matrix the form of spools (with central core: 10 for M55J and 3 for HTS, T300, T800 & T1000) having protective paper on one side. NOTE: VENDOR SHOULD SPECIFICALLY CONFIRM CONTINUOUS LAY-UP OF M55J BASED PRE-IMPREGNATED TOW AND SLIT TAPE LISTED ABOVE USING THE EQUIPMENT QUOTED. 6. ESSENTIAL REQUIREMENTS OF THE FIBRE PLACEMENT SYSTEM 6.1 PROCESS FEATURES 1. Continuous lay-up from 4 spools of the materials specified in Section The ply material shall be placed on the mould surface in accordance with the part program, in the required orientation, at the specified location with the specified accuracy. Accuracies of material placement (Nominal): (Please specify ISO standard) Angular orientation tolerance : +/ degrees Max Gap between bands : 0.2 mm Steering radius : 2500 mm No gap between tows in a band. The global positioning accuracy at the tow delivery point shall not exceed 0.5 mm. 3. First ply adherence to the mould surface shall be ensured by appropriate & suitable design of the material lay-down system. Page 6 of 24

45 4. The process shall not introduce twist in the material from the spool/ creel to the lay-down point. 5. The process shall not result in the removal of the resin or breakage of the fibre from spool/ creel to lay-down point. Fibre breakage detection shall be enabled & the process to be stopped automatically in case of fibre breakage with suitable software interlock. The system shall allow re-start of the process from the last lay-down point after appropriate repair and/ or manual intervention. Suitable software interlock should be incorporated to automatically stop the system in case of any abnormality like difference in (a) tension (b) temperature (c) compaction force, etc. with a proper feedback on display system. 6. Maintain the programmed tension in the tow/ roving. Feedback of tension in the tow/ roving to be provided. 7. Maintain alignment of tows to avoid twist & misplacement. 8. Automatic removal & spooling of protective paper before lay-down point. 9. Precise & confined programmable pre-heating of tow near lay-down point to maintain required tackiness. Feed back of temperature to be provided. 10. Automatic cutting/ adding and restart of the individual tow/ roving to conform layup to specified product boundary. Minimum material wastage should be ensured. 11. Maintain uniform compaction pressure through mould-surface-conformable rollers. The compaction force shall be programmable. 12. Layup shall be without wrinkles or fibre breakage and without gaps between the adjacent prepreg tows. The process shall not lead to detachment/ misalignment of the previous plies or lead to edge lift-off. 13. The spools/ creels shall be preferably located as close as possible to the laydown point. The spools shall be contained in a controlled temperature environment. The system shall detect the quantity of material available in each spool for layup and alert to be given for spool change. Page 7 of 24

46 14. The system shall enable layup on the entire mould area over honeycomb cores in sandwich constructions. Honeycomb core material is aluminium alloy (hexagonal cell or flex-core). The process shall not lead to crushing/ damage/ displacement of the honeycomb core. 15. The system shall enable layup having local layup thickness variation, local honeycomb patches/ ramps (up to 20 degrees with respect to vertical plane), local cut-outs, etc. 16. Layup process may be uni-directional or bi-directional. 17. The elements of the fibre placement head shall be non-contaminating (no oil or hydraulics). 18. The configuration of the fibre placement head shall permit easy access for maintenance, cutting blade change, roller change, spool change, etc. 6.2 SOFTWARE FEATURES 1. Software solution for offline design of composite laminate, programming and simulation, including all required components, platform and add-ons necessary for the solution to work shall be provided. 2. The programming software shall provide an environment for design, analysis and manufacturing of composite structures. The software shall generate the fiber placement paths that will comprise each layer of the composite part. The software shall be capable of generating the fiber placement paths for composite material lay up on mould surfaces in Sec. 4, including conics within the specified system envelope. 3. Post processing of the ply data to generate the part program, where the ply data can be imported in the form of CATIA file or Siemens FiberSIM. 4. Verifier for simulation of the layup process. Full virtual simulation (animation) of the layup process as per the part program shall be simulated including 3D featuring of the machine (with actual configuration & kinematics), current ply being laid, collision detection, feed-back of non-compliance like excessive Page 8 of 24

47 steering, gaps, etc. User friendly graphical user interface shall be provided. Collision avoidance detection shall be enabled. 5. Uploading of the part program to the system controller. 6. Software should have possibility to export laser projection system data. 7. User friendly graphical user interface for the machine operation. The essential production data should be instantaneously displayed. Vendor shall provide lifetime licence for the software with free upgrades. Vendor shall provide detailed software specifications, features & control architecture in the quotation. 7. OVERALL MACHINE CONFIGURATION, STRUCTURE AND SCOPE The configuration of the basic machine shall be: Fibre placement head (interchangeable with Tape layup head) mounted on the ram of a gantry type machine with raised moving bridge. 1) The fibre placement machine shall be suitably sized, configured and designed to lay down 4 tows of the materials indicated in section 5, effectively & accurately onto the moulds as indicated in section 4. The design of the system shall result in effective execution of the functionalities listed in Section 6. Details to be provided. 2) The system shall have required number of CNC controlled interpolated axes to enable the layup on moulds listed in section 4. The controller should have the capability to configure enough number of axes required to carry out the functions specified in Section 6. The moulds mentioned in Sl. No. 1, 3 & 4 of Section 4 shall be positioned on the ground and shall be stationary during the layup process. The mould mentioned in Sl. No. 2 of Section 4 shall be rotating between head stock and tail stock. Page 9 of 24

48 3) The system structure shall be designed & sized by means of the latest technological tools available for static, thermal and dynamic loads, which will enable efficient, stable and safe operation of the machine under all possible load conditions & under prescribed operating environments. Details to be provided. 4) The system should be suitably configured & built to have kinematic characteristics which ensure adequate access & approach all over the envelope of the part for accurately laying & compacting the material tows on to the parts as per the part program. The details of the machine kinematics with respect to the operations to be carried out on the mould configurations specified shall be provided. 5) The system structure should be suitably designed & built and made thermally stable to hold and support the fiber placement head while moving in all orientations for laying & compacting the ply materials on to the parts effectively & accurately. Details to be provided. 6) All linear & rotary axes shall be provided with suitable drive and control mechanisms with position feedback & closed loop CNC control for high speed & fine positioning. Details to be provided. 7) The linear axes traverses of the machine shall be on LM guide ways with adequate number of pads and shall be sized to ensure the requisite stiffness & strength. The rotary axes shall be guided by appropriate bearings. The lubrication system for the guide ways shall ensure that no contamination occurs on the part layup. The guide ways shall be provided with protective covers. Details to be provided. 8) The linear axes drives shall be through Siemens servo motors coupled with ball lead screws & pre-loaded nut OR through rack & pinion system. The design of the drive elements shall ensure the requisite stiffness & strength and shall eliminate the backlash errors. The drive elements shall be provided with protective covers. Details to be provided. Page 10 of 24

49 9) The rotary axes drives shall be through Siemens servo motors coupled with gear train. The design of the drive elements shall ensure the requisite stiffness & strength and shall eliminate the backlash errors. Details to be provided. 10) Direct position feedback for all moving axes shall be either through high accuracy linear scales or through high accuracy rotary encoders to ensure specified accuracy. These elements shall be located under protective covers. Details to be provided. 11) If any hydraulic counterbalancing system is incorporated, provision should be available for recovery of oil drop for preventing part pollution. 12) The system structure should have adequate space for loading & unloading the spools/ creels manually. Details to be provided. 13) The system structure should have adequate access & space for loading & unloading the parts/ moulds using an EOT crane. 14) System (hardware & software) for referencing of the mould with respect to the machine axis shall be provided. Details to be provided. 15) The entire machine shall be tropicalized for trouble free operation in the environmental conditions at Thiruvananthapuram. 8. FIBER PLACEMENT HEAD (FPS Head) : CONFIGURATION 4 tows/ slit tapes of 1/4 resulting in a total band width of 1. Separate servo-controlled actuators to be used for each single tow / slit tape for better dynamics and accuracy. The fiber lay-up head shall have requisite number of CNC controlled axes to facilitate the lay-up of tow and slit tape onto the mould surface. The fiber layup head shall have the capability of independent unwinding, guiding, laying and cutting of the tows and slit tapes. The system shall cut/ clamp & restart any individual tow /slit tape, as required. Complete description of the FPS head outlining its characteristics & features shall be provided by the vendor in their technical offer. Page 11 of 24

50 FPS HEAD: MAIN CHARACTERISTICS The FPS head shall have the following main characteristics. Standard number of tows / slit tapes: 4 nos. Standard tow / slit tape width: ¼. All tows and slit tapes to be individually guided & controlled from creel to lay-down point. Cut/ Add capability up to 60 m/min. Heating: Infra-Red device for epoxy resin system Two different guide paths for even and odd tows / slit tapes. Additional pneumatically actuated axis, if required, to ensure proper compaction of the tows / slit tapes. Cutting system should cut the tow and slit tape at the ultimate system speed. Transmission roller to synchronize the tows and slit tapes to the placement speed to ensure the correct position of the tows and slit tapes when restarting on the mould surface. Compaction roller located at the bottom of the head t o ensure proper compaction of the tows/ slit tapes. The compaction roller shall be flexible / conformable for proper adaptation to curved surfaces. The resin in the tow and slit tape shall not adhere to the compaction roller or to any other part / feature of the FPS head in the tow / slit tape path from creel to lay-down point. The creel shall preferably be mounted, together on the head to avoid the tow length variation between the creel and the head. Bi-directional lay-up capabilities. Cut & add on the fly to eliminate stop/ start conditions during cut/ add of each individual tow. Dynamic pin-point heating system to provide required heat at the laydown point. Page 12 of 24

51 TOW GUIDING SYSTEM The tension of each tow and slit tape shall be maintained and controlled via CNC, allowing the tow and slit tape to unwind and rewind, if required and maintain tension by means of a suitable tensioning system. Details to be provided. ON-LINE COMPACTION SYSTEM In order to account for the actual deviations of the mould surface with respect to its theoretical programmed surface, the head shall be fitted with a floating compaction system. The system shall use pneumatic actuators in order to achieve floatability by accommodating out of nominal mould / mandrel surface, combined with a measuring system in order to feedback the CNC and control the head position in closed loop. This device shall absorb out of nominal mould / mandrel deviations of up to +/-5 mm. Details to be provided. MATERIAL HEATING SYSTEM: INFRARED An infrared system shall be provided to increase the temperature of the material in a controlled fashion at any layup speed. The heat transmission shall be programmable according to the main parameters of the fiber placement process like lay-up speed, material in use, etc. Feedback of temperature to be provided. Details to be provided. CREEL HOUSE The creel house capacity shall be 4 spools. A cabinet shall be used to store and feed the system with the required amount of fibre. The tension required to do steering trajectories (non-geodesic trajectories) shall be a programmable bidirectional value. There shall be provision to adjust/ program the tension through the CNC panel/ part program. The temperature required inside the creel house shall be controlled to avoid resin build up and tow sticking problems. Page 13 of 24

52 Standard Creel specifications shall be I. Quick spool change. II. III. IV. Brake system to stop the spools and to keep fibers under tension. Re-spooling unit for the backing film. Sensors to control whether the spools turn or not and whether the fiber tension just after the spool is not higher than a nominal value. V. The system shall stop (with audio-visual alarm) if fiber is broken, VI. VII. VIII. IX. spool is empty or fiber has not been restarted for a new path. Hygrometry measurement. The creel shall be cooled to 15 C. Creel shall be placed on the head or close to head to minimize distortion of tow / slit tape. The quantity of material available in any spool at any point of time should be fed back to the system. X. Spool change alert. EMPTY SPOOL EXTRACTION Suitable means should be available to remove empty spool rollers. Details to be provided. 9. MOULD ALIGNMENT SYSTEM The purpose of this system is to measure a series of calibrated balls on the mould surface. These measurements shall enable the mould alignment and the beginning of the fibre placement process. The system shall be (i) a laser mounted on the head, which measures the calibrated balls without contact and (ii) a RMP Renishaw probe, which can be assembled into the head. Details to be provided. a) Laser Optical Sensor This system shall be used to take the reference tooling balls and compare them with the theoretical position coming from the part program and subsequently Page 14 of 24

53 execute a 3D rotation / translation of that program, which allows the execution of the CNC program in the right place. The position of tooling balls shall be defined by the software solution provided. b) RMP Contact Probe This probe shall be used to measure a series of calibrated balls on the mould surface to enable the mould roto-translation and the beginning of the fiber placement process. 10. HEADSTOCK AND TAILSTOCK The machine shall be provided with a powered Headstock (rotational) and a power operated Tailstock (for linear movement) capable of supporting and rotating the moulds mentioned in Section 4 with a weight upto 5 Tons. Only EOT crane will be available at site. Suitable mounting & holding jigs and fixtures for easy loading & unloading of this mould between the Headstock & Tailstock is the responsibility of the Vendor. Details to be provided. Headstock: The headstock movement shall be continuous and servo interpolated with the rest of the machine traverse axes. Details regarding drive system, rating and speed range to be provided. Tailstock: The powered tailstock shall be controlled from the main operator panel and from a local operator panel / hand held unit located close to the tailstock. Details to be provided. 11. ANTI-COLLISION SYSTEM Collision avoidance shall be performed by means of suitable simulation package. Details to be provided. 12. CONTROL SYSTEM The fiber placement machine shall have a Computer Numerical Control Page 15 of 24

54 Siemens 840 DSL or later version dedicated to axes control & fiber placement processing with user friendly software for system control, process control and human system interface control including networking to the systems at site. The control system shall fully & seamlessly integrate all the features / systems / operations of the machine so as to result in the final intended functionalities. Detailed specifications & features and order code/designation of the modules proposed for the controller shall be clearly listed in the quotation. Quality control and data acquisition of main process parameters should be part of the supply. The machine shall be equipped with an operator panel housing the Siemens HMI interface unit & other machine control switches. This panel shall also house the necessary display screens to show the status of the current task via user friendly GUI. This panel shall be suitably located so as to offer maximum operator ergonomics, visibility and without hindering the loading / unloading of mould / mandrels. Note: Vendor shall confirm the supply of Siemens controller. 13. ELECTRICAL SUPPLY 3 phase, 415 V +/- 10%, 50 Hz +/- 3%. Total power requirement to be defined by the vendor. 14. ELECTRIC / ELECTRONIC EQUIPMENT (a) ELECTRIC CABINETS The electric cabinets shall include the following main elements: Transformers and power supply conditioners / protection circuitry necessary for the controller. Siemens control system elements complete. Electrical / electronic control elements for all peripheral / auxiliary systems. Protection mechanisms like fuses, circuit breakers, etc. Page 16 of 24

55 Automatic main switch. Safety switches / emergency stops. Light inside the cabinet. Cabinet mounted AC units for cooling the cabinet interior. Filters to avoid dust. Rodent protection systems. Earthing systems. Details to be provided. (b) ELECTRIC INSTALLATION All the wiring used to connect the different elements of the system shall be protected with conduits and provided on drag chains to avoid damage and twisting/stretching. The installation shall comply with all the applicable Indian/ International regulations. 15. SAFETY FEATURES Operator protection: I. The System shall comply with the relevant International Safety Standard II. The protection of the operator shall consist of: - Lateral fix mesh panels to close the working area. - Safety railings at both ends of X axis. - Safety railings between the working area and the operator station. III. The modes of operation inside the different system safety areas shall comply with current safety regulations. IV. As soon as the operator is inside the working area, the system shall automatically reduce the feed rate to a safe speed that allows the operator to work around the system. Page 17 of 24

56 V. Adequate lighting as per the standards in vogue shall be provided at all the zones of the machine. VI. Emergency stops to be provided at appropriate locations on the machine considering all the possible operator activities. Protection to the equipment: i. Feed stop in case of faulty cooling of drive motors. ii. Feed stop in case of faulty vertical counterbalancing or motor overload. iii. Feed stop in case of power failure (without path control) and ability to continue from stopped path position after power returns. iv. Feed stop in case of dirt accumulation on the measuring scales. v. The carriage shall be mechanically clamped in case of a vertical counterbalancing error or an electrical fault. vi. EMC (electromagnetic compatibility). 16. DIAGNOSTICS The offered system shall have following diagnostic features. I. Data shall be provided to notify the operator of system status information and to help maintenance personnel troubleshoot system problems. II. Alarm Monitor: Current alarm information shall be displayed at the system. Specific CNC alarms shall be displayed through the Siemens CNC display screen. Specific and general CNC alarms shall be displayed through a display screen. III. Self-Diagnostics to check the following: a. Fault of feedback system b. Fault of position control unit c. Fault of servo system d. Overheat e. Fault of CPU f. Fault of ROM Page 18 of 24

57 g. Fault of RAM h. Fault of data transfer between CRT/ MDI i. Fault of part program storage memory 17. UTILITIES & SITE REQUIREMENTS The supplier shall provide the indicative layout drawing of the machine, clearly mentioning the dimensions, location of the various peripheral devices & their sizes. The supplier shall provide the foundation requirements, drawings, electrical, special earthing or other infrastructure requirements well in advance. Customer shall prepare the foundation as required by the supplier. 18. PAINTING Needed. The colour and scheme shall be reported by the party. 19. ESSENTIAL ACCESSORIES WHICH WILL BE PART OF THE MACHINE a) Wireless Pendant Control b) Tape lay-up head for lay-up of 75 mm wide uni-directional tapes of the materials mentioned in Section 5 on mould surfaces mentioned in Section 4. The tape lay-up head shall be configured as interchangeable with the fibre placement head. Vendor shall clearly indicate the additional elements/ configuration changes needed in the basic system (hardware and software) to accommodate both heads. TAPE LAY-UP HEAD: CONFIGURATION The tape lay-up head shall have the following characteristics: It should be capable of laying tape (width 75 mm) on large flat, simple contours and compound curves (open). The tape should be laid precisely at the programmed orientation. The tape lay-up head shall have requisite number of CNC controlled axes to facilitate the lay-up of tape onto the mould surface. The tape has to be laid with constant compaction pressure, without any Page 19 of 24

58 wrinkle and air entrapment. The compaction force should be programmable and evenly distributed across the tape. A suitable compaction roller may be adopted for this purpose. The compaction roller shall be flexible for proper adaptation to curved surfaces. The system shall enable layup on the entire mould area over honeycomb cores in sandwich constructions. Honeycomb core material is aluminium alloy (hexagonal cell or flex-core). The process shall not lead to crushing/ damage/ displacement of the honeycomb core. The system shall enable layup having local layup thickness variation, local honeycomb patches/ ramps (up to 20 degrees with respect to vertical plane), local cut-outs, etc. The tape lay-up head shall house suitable tape cutting mechanism, which should automatically cut the tape at the end of the segment as per program. The tape lay-up head should be equipped with suitable collision sensors, so that in the event of head hitting the mould it should be able to stop. It should also have a sensing mechanism to sense whether the tape is available on the roller. The lay-up should stop automatically once the tape is completed or required tension in the tape is absent. The tape lay-up head shall have the capability of unwinding, guiding, cutting and laying of tape. The system shall cut/clamp & restart any individuality of the tapes as required without needing to decrease speed. Heating: Infra-Red device for epoxy resin system. Layup process may be uni-directional or bi-directional. The elements of the head shall be non-contaminating (no oil or hydraulics). The configuration of the tape head shall permit easy access for maintenance, cutting blade change, roller change, spool change, etc. Page 20 of 24

59 20. MAJOR STEPS IN ORDER PLACEMENT & EXECUTION (a) BIDDER EVALUATION/ TECHNICAL DEMONSTRATION After evaluation of technical part of the offer by the customer, technically qualifying bidders shall organize a technical demonstration of the quoted equipment to ascertain the technical specifications. In the technical demonstration, the bidder should clarify the following aspects: Working envelope of the machine i. Number of axes and the capacity of each axis ii. Interpolation capabilities iii. Control system features iv. Fiber placement head and it s performance (capabilities to handle Hexcel: M55J / M18 Uni-directional Pre-impregnated tow and slit tape) v. Tape Layup head and it s performance (capabilities to handle Hexcel: M55J / M18 Uni-directional Pre-impregnated tape) vi. Capabilities of software including safety interlocks vii. Accessories and their suitability to carry out the required functions viii. Any other function, as may be warranted, for ascertaining the suitability of the machine as decided by a technical committee. Venue and timing of the technical demonstration to be mutually agreed upon between the bidder and customer. Materials necessary for this demonstration will be provided by customer. (b) ORDER PLACEMENT After Bidder Evaluation/ Technical Demonstration, order shall be placed with technically acceptable lowest bidder. (c) PRE-DESPATCH ACCEPTANCE AT MANUFACTURER S WORKS Following pre acceptance tests will be performed at manufacturer s works before dispatch in the presence of customer representatives: Page 21 of 24

60 i. Geometrical tests to check specified travels & accuracies. ii. Laser interferometer test to check straightness of the required axes. iii. Demonstration of capabilities of software including safety interlocks iv. Generation of fiber placement paths and post processing of the ply data to generate the part program v. Layup test by laying a standard test part to check quality of laying, cutting, compaction and positioning of layup boundaries. Raw materials will be provided by customer. MOULD (to be mutually agreed upon between the vendor and customer) TO BE PROVIDED BY VENDOR. vi. Inspection and acceptance of each layer for compliance to the material placement accuracies. vii. Any other tests needed to be outlined by the vendor in the quotation. (d) POST ERECTION ACCEPTANCE CRITERIA AT CUSTOMER S SITE Following acceptance tests will be performed at customer s site i. Geometrical tests to check specified travels & accuracies. ii. Laser interferometer test to check straightness of the required axes. iii. Demonstration of capabilities of software including safety interlocks iv. Generation of fiber placement paths and post processing of the ply data to generate the part program v. Layup test by laying a standard test part to check quality of laying, cutting, compaction and positioning of layup boundaries. Raw materials and moulds will be provided by customer. vi. Laying up of mutually agreed trial parts (two numbers- flat and outer surface of cylindrical mould). vii. Inspection and acceptance of each layer for compliance to the material placement accuracies. viii. Any other tests needed to be outlined by the vendor in the quotation. Page 22 of 24

61 (e) TRAINING Training to be imparted in following fields for three Engineers for three weeks at manufacturer s works during pre-dispatch inspection & acceptance and eight weeks at customer s site after final acceptance & prove out. i. Operation & programming ii. Process & Process evaluation iii. Mechanical Maintenance iv. Electrical / Electronics & System Maintenance. Vendor shall station one of their engineers at customer s site for the duration to be specified in the quotation that would be required for the establishment of entire layup process for the above parts 21. WARRANTY 24 months from final acceptance at customer s site or 30 months from date of dispatch whichever is earlier. Warranty terms (for machine hardware and software) must be clearly defined. 22. AMC The supplier shall agree for a life time AMC for the entire system. 23. DOCUMENTATION Two sets of hard copies & one set of electronic copy of the following documentation shall be supplied before final acceptance of the system. Operation & Programming Manual. Mechanical, Electrical, Electronics & System Maintenance Manual. Auxiliary equipment & subsystem manuals. Any other relevant manuals. 24. SPARE PARTS Following lists to be provided: Item wise list of consumables and spares with individual item prices. Page 23 of 24

62 Item wise list of spares supplied free of cost for warranty maintenance. 25. GENERAL TERMS & CONDITIONS 1. The bidders should furnish the configuration of the equipment quoted with reference to each of the mould surfaces specified in Section 4 to ascertain the basic capacities and working envelope of the equipment. 2. The bidders should provide a comprehensive list of the OEM components used in the machine. The offer should include the technical brochure in English language indicating clearly the model used for each part / component. 3. The bidder should enclose a copy of the acceptance test chart of a similar machine supplied recently. 4. The bidder shall be the manufacturer of the machine. 5. The tender should be necessarily submitted in two parts: Part 1 Technical & commercial (excluding price detail) and Part 2 Commercial including price detail 6. The bidders should have requisite facilities for manufacture/testing and inspection as per international standards. 7. Reference list of organizations to which similar equipment has been supplied by the bidder and performance certificates issued by few reputed users of similar equipment in recent past may be furnished along with the offer. 8. Technical leaflet/ brochure (in English) and write-up 9in English) of the proposed model of the machine must be furnished by the bidder along with the quotation. 9. The manufacturer shall submit a compliance check list in the format provided along with the specifications. Relevant proof / supplementary document for the compliances are to be furnished and should be referenced to the technical bid. Technical justifications for deviations / variations/ modifications proposed are to be clearly spelt out. Page 24 of 24

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65 FIBER PLACEMENT SYSTEM COMPLIANCE CHECK LIST Sl.No. Specifications/Requirements Comply / Not comply 1 GENERAL Reason if not comply 1a The scope includes Manufacture, Supply, Installation, Commissioning & Training of a CNC Fiber Placement System (with two interchangeable heads- Fiber Placement Head and Tape Layup Head- on a single Ram) at Composites Entity, VIKRAM SARABHAI SPACE CENTRE (VSSC), ISRO, Thiruvananthapuram, India on TURN-KEY basis. 1b The bid shall be offered by the machine manufacturer only 1c Bidder should have manufactured and supplied at least 3 similar machines during the last five years 1d The bidder should provide a comprehensive list of the machines supplied with overall configuration / features of the machines supplied, full address of the clients and contact persons with telephone / fax / details 1e Quotations / offers received from bidder without the above information will be rejected. 1f Along with their bid, the manufacturer shall submit a compliance check list in the format provided. Relevant proof / supplementary document for the compliances are to be furnished and should be referenced to the technical bid.

66 Sl.No. Specifications/Requirements Comply / Not comply Technical justifications for deviations / variations/ modifications proposed are to be clearly spelt out. Reason if not comply 1g The technical part of the offer shall be evaluated by the customer. Technically qualifying bidders shall be further evaluated for compliance, at their site, as per the details given in Section 20(a). Order shall be placed with technically acceptable lowest bidder. 2 PURPOSE This machine is intended for CNC controlled fully automated lay up of the specified composite materials on customer specified mould surfaces in the required fibre orientation (0 0 to 90 0 ), at the required location with the specified accuracy Description of the required mould configurations, composite materials to be laid-up & accuracies of the ply layup are listed in the subsequent chapters 3 SYSTEM ENVELOPE (Indicative Values) Direction APPROACH (Nominal) ACCURACY as per ISO X Longitudinal 6000 mm ±0.10 mm/ m or better Y Cross 3000 mm ±0.10 mm/ m or better Z Vertical 1500 mm ±0.10 mm/ m or better

67 Sl.No. Specifications/Requirements Comply / Not comply Reason if not comply FIBER PLACEMENT HEAD - TRAVELS AND ACCURACIES (Indicative Values) Direction Fiber Placement Head (FP head) rotary traverses Tow spooling, tensioning, feeding, guiding, cutting, compacting on FP head, spooling of backing paper, local heating, etc Tool (mould) rotation (between head stock and tail stock for operations on cylinder mould referred in Sec. 4, Sl. No. 2) APPROACH (Nominal) In accordance with the mould geometry and ply orientation. Axes nomenclature & details to be provided by vendor. Continuous. Axes nomenclature & details to be provided for each feature. Continuous. Servo interpolated with the rest of the machine traverse axes. ACCURACY as per ISO In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. ±25 arc-sec or better

68 Sl.No. Specifications/Requirements Comply / Not comply TAPE LAYUP HEAD - TRAVELS AND ACCURACIES (Indicative Values) Direction APPROACH (Nominal) ACCURACY as per ISO Reason if not comply Tape Lay-up Head rotary traverses (A, B & C) Tape unwinding, tensioning, feeding, guiding, cutting, compacting, spooling of backing paper, local heating, etc. In accordance with the mould geometry and ply orientation. Axes details to be provided by vendor. Axes nomenclature & details to be provided for each feature. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. In order to achieve a global positioning accuracy of less than 0.5 mm at the tow delivery point. Other axes shall be sized to enable lay up as per Sec. 4. The global positioning accuracy at the tow delivery point shall not exceed 0.5 mm. The vendor shall provide the nominal system envelope and all axes traverse/ drive details with suitable sketches etc.

69 Sl.No. Specifications/Requirements Comply / Not Reason if not comply comply 4 MOULD SURFACE CONFIGURATION & SIZES : Moulds used by customer on which the composite materials are to be laid are generally made of Aluminium alloy, Composite material, Cast Iron or Steel. The machine configuration shall enable composite material layup on the following type of mould surface for the specified envelope Sl. No. Mould surface Effective layup dimensions on mould 1 Flat 3.5m x 2.5m 4m x 3m Mould Dimensions (maximum) Mould support configuration & mould weight On ground, stationary Mould weight : 8000 Kg Cylinder portion length: 3m 2 Outer surface of Cylindrica l mould Min. Diameter : 0.5m Max. Diameter : 2m Max. Length : 2.5m Central shaft : 0.4m extension at both ends Between head stock & tail stock, Rotating Mould weight : 5000 Kg

70 Sl.No. Specifications/Requirements Comply / Not comply Reason if not comply 3 Shaped parabolic convex (focal length, F : 0.3m to 2.5m) Min Diameter : 0.5m Max. Diameter : 2.5m Diameter : 3m On ground, stationary Mould weight : 5000 Kg 4 Part of cylinder (male mould, Sector angle : 60 degree) Min Diameter : to be specified by party Max Diameter : 5 m Length : 4m Note: Vendor shall also specify the maximum and minimum diameters of part of cylinder that can be effectively laid up on a female mould. On ground, stationary Mould weight : 5000 Kg

71 Sl.No. Specifications/Requirements Comply / Not comply 5 MATERIALS TO BE LAID Reason if not comply The machine shall enable continuous lay-up of the following materials in the specified forms on to the mould surfaces specified in section 4: Material form Material Source & Designation (same or Remarks Uni-directional Preimpregnated tow and slit tape : 6.35mm width (For Fiber Placement Head) Uni-directional Preimpregnated tape : 75 mm width (For Tape Layup Head) equivalent) Hexcel: M55J / M18 Hexcel: M55J / Cytec: M55J / HTM 143 Tencate: M55J / TC 410 Hexcel: HTS / M18 T300 / epoxy matrix T800 / epoxy matrix T1000 / epoxy matrix Thickness of ply : From 0.1mm to 0.2mm The material shall be in the form of spools (with central core: 10 for M55J and 3 for HTS, T300, T800 & T1000) having protective paper on one side. VENDOR SHOULD SPECIFICALLY CONFIRM CONTINUOUS LAY-UP OF M55J BASED PRE- IMPREGNATED TOW AND SLIT TAPE LISTED ABOVE USING THE EQUIPMENT QUOTED.

72 Sl.No. Specifications/Requirements Comply / Not comply 6 ESSENTIAL REQUIREMENTS OF THE FIBRE PLACEMENT SYSTEM Reason if not comply PROCESS FEATURES Continuous lay-up from 4 spools of the materials specified in Section 5 The ply material shall be placed on the mould surface in accordance with the part program, in the required orientation, at the specified location with the specified accuracy. Accuracies of material placement (Nominal): (Please specify ISO standard) Angular orientation tolerance : +/ degrees Max Gap between bands : 0.2 mm Steering radius : 2500 mm No gap between tows in a band. The global positioning accuracy at the tow delivery point shall not exceed 0.5mm First ply adherence to the mould surface shall be ensured by appropriate & suitable design of the material lay-down system The process shall not introduce twist in the material from the spool/ creel to the laydown point

73 Sl.No. Specifications/Requirements Comply / Not comply The process shall not result in the removal of the resin or breakage of the fibre from spool/ creel to lay-down point. Fibre breakage detection shall be enabled & the process to be stopped automatically in case of fibre breakage with suitable software interlock. The system shall allow re-start of the process from the last lay-down point after appropriate repair and/ or manual intervention. Suitable software interlock should be incorporated to automatically stop the system in case of any abnormality like difference in (a) tension (b) temperature (c) compaction force, etc. with a proper feedback on display system. Reason if not comply Maintain the programmed tension in the tow/ roving. Feedback of tension in the tow/ roving to be provided. Maintain alignment of tows to avoid twist & misplacement Automatic removal & spooling of protective paper before lay-down point Precise & confined programmable pre-heating of tow near lay-down point to maintain required tackiness. Feed back of temperature to be provided Automatic cutting/ adding and restart of the individual tow/ roving to conform layup to specified product boundary. Minimum material wastage should be ensured

74 Sl.No. Specifications/Requirements Comply / Not comply Maintain uniform compaction pressure through mould-surface-conformable rollers. The compaction force shall be programmable Reason if not comply Layup shall be without wrinkles or fibre breakage and without gaps between the adjacent prepreg tows. The process shall not lead to detachment/ misalignment of the previous plies or lead to edge lift-off The spools/ creels shall be preferably located as close as possible to the lay-down point. The spools shall be contained in a controlled temperature environment. The system shall detect the quantity of material available in each spool for layup and alert to be given for spool change The system shall enable layup on the entire mould area over honeycomb cores in sandwich constructions. Honeycomb core material is aluminium alloy (hexagonal cell or flex-core). The process shall not lead to crushing/ damage/ displacement of the honeycomb core. The system shall enable layup having local layup thickness variation, local honeycomb patches/ ramps (up to 20 degrees with respect to vertical plane), local cut-outs, etc. Layup process may be uni-directional or bi-directional The elements of the fibre placement head shall be non-contaminating (no oil or hydraulics). The configuration of the fibre placement head shall permit easy access for maintenance, cutting blade change, roller change, spool change, etc.

75 Sl.No. Specifications/Requirements Comply / Not comply 6.2 SOFTWARE FEATURES Reason if not comply Software solution for offline design of composite laminate, programming and simulation, including all required components, platform and add-ons necessary for the solution to work shall be provided. The programming software shall provide an environment for design, analysis and manufacturing of composite structures. The software shall generate the fiber placement paths that will comprise each layer of the composite part. The software shall be capable of generating the fiber placement paths for composite material lay up on mould surfaces in Sec. 4, including conics within the specified system envelope. Post processing of the ply data to generate the part program, where the ply data can be imported in the form of CATIA file or Siemens FiberSIM Verifier for simulation of the layup process. Full virtual simulation (animation) of the layup process as per the part program shall be simulated including 3D featuring of the machine (with actual configuration & kinematics), current ply being laid, collision detection, feed-back of non-compliance like excessive steering, gaps, etc. User friendly graphical user interface shall be provided. Collision avoidance detection shall be enabled Uploading of the part program to the system controller Software should have possibility to export laser projection system data

76 Sl.No. Specifications/Requirements Comply / Not comply User friendly graphical user interface for the machine operation. The essential production data should be instantaneously displayed Reason if not comply Vendor shall provide lifetime licence for the software with free upgrades. Vendor shall provide detailed software specifications, features & control architecture in the quotation. 7 OVERALL MACHINE CONFIGURATION, STRUCTURE AND SCOPE The configuration of the basic machine shall be: Fibre placement head (interchangeable with Tape layup head) mounted on the ram of a gantry type machine with raised moving bridge. The fibre placement machine shall be suitably sized, configured and designed to lay down 4 tows of the materials indicated in section 5, effectively & accurately onto the moulds as indicated in section 4. The design of the system shall result in effective execution of the functionalities listed in Section 6. Details to be provided The system shall have required number of CNC controlled interpolated axes to enable the layup on moulds listed in section 4. The controller should have the capability to configure enough number of axes required to carry out the functions specified in Section 6.

77 Sl.No. Specifications/Requirements Comply / Not comply The moulds mentioned in Sl. No. 1, 3 & 4 of Section 4 shall be positioned on the ground and shall be stationary during the layup process. Reason if not comply The mould mentioned in Sl. No. 2 of Section 4 shall be rotating between head stock and tail stock. The system structure shall be designed & sized by means of the latest technological tools available for static, thermal and dynamic loads, which will enable efficient, stable and safe operation of the machine under all possible load conditions & under prescribed operating environments. Details to be provided The system should be suitably configured & built to have kinematic characteristics which ensure adequate access & approach all over the envelope of the part for accurately laying & compacting the material tows on to the parts as per the part program. The details of the machine kinematics with respect to the operations to be carried out on the mould configurations specified shall be provided. The system structure should be suitably designed & built and made thermally stable to hold and support the fiber placement head while moving in all orientations for laying & compacting the ply materials on to the parts effectively & accurately. Details to be provided

78 Sl.No. Specifications/Requirements Comply / Not comply All linear & rotary axes shall be provided with suitable drive and control mechanisms with position feedback & closed loop CNC control for high speed & fine positioning. Details to be provided Reason if not comply The linear axes traverses of the machine shall be on LM guide ways with adequate number of pads and shall be sized to ensure the requisite stiffness & strength. The rotary axes shall be guided by appropriate bearings. The lubrication system for the guide ways shall ensure that no contamination occurs on the part layup. The guide ways shall be provided with protective covers. Details to be provided. The linear axes drives shall be through Siemens servo motors coupled with ball lead screws & pre-loaded nut OR through rack & pinion system. The design of the drive elements shall ensure the requisite stiffness & strength and shall eliminate the backlash errors. The drive elements shall be provided with protective covers. Details to be provided The rotary axes drives shall be through Siemens servo motors coupled with gear train. The design of the drive elements shall ensure the requisite stiffness & strength and shall eliminate the backlash errors. Details to be provided Direct position feedback for all moving axes shall be either through high accuracy linear scales or through high accuracy rotary encoders to ensure specified accuracy. These elements shall be located under protective covers. Details to be provided. If any hydraulic counterbalancing system is incorporated, provision should be available for recovery of oil drop for preventing part pollution