REQUEST FOR PROPOSAL · 2018. 4. 27. · Obtain completion certificate for release of payment. 9. Maintaining the installation up to stipulated period of warranty. ... .As regards

Space Applications Center | Indian Space Research Organization | Govt. of India

REQUEST

FOR

PROPOSAL

Payload Integration

and testing Fixture

Space Applications Center,

Ahmedabad 380015

Document No:

CS3-00-TEL-PIF-001-RF1-R0


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CONTENTS

1. INTRODUCTION ...............................................................................................................................1

2. SCOPE OF WORK .............................................................................................................................6

3. RESPONSE TO THE RFP .................................................................................................................7

4. SPECIFICATION ...............................................................................................................................8

6. PERFORMANCE AND FUNCTIONALITY TEST ..................................................................... 10

7. CONTAINERS FOR DISPATCH .................................................................................................. 10

8. INSTALLATION AND COMMISSIONING ................................................................................ 10

9. WARRANTY .................................................................................................................................... 10

10. DELIVERABLES ......................................................................................................................... 10

11. DELIVERY SCHEDULE ............................................................................................................ 11

Annexure 1 ................................................................................................................................................ 12


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Page | 1

1. INTRODUCTION

Space Applications Center is interested in developing a payload integration and test fixture for the

alignment and testing of state of art electro-optic payloads in axis horizontal and axis vertical

configuration. This fixture would comprise of structure with automation for maneuvering of payload

during various stage of integration and testing. These items will also expose to vacuum during

development of payload.

PAYLOAD INTEGRATION FIXTURE

Payload is of cylindrical shape having three lugs. Overall dimensions and C.G of payload is shown in

Figure-1. Total mass of the payload is 700 Kg. Payload integration fixture is required to integrate it in

axis vertical condition and to test in axis horizontal condition. Configuration of payload with integration

fixture is shown in figure-2 (in Axis Horizontal condition). Axis definition is also shown in figure-2

Figure-2 Payload with Payload integration fixture (Only Schematic and not for fabrication)

Figure-1 CG of EOM and Overall size of Payload

2850 mm

Dia

14

40

mm

1000mm

(TBD)

C.G.

Pitch (X)

Roll (Y)

Yaw (Z)


Page | 2

Tentative configuration of payload integration fixture is shown in figure-2 to 6; vendor may suggest his

configuration at the time of submitting quote. CAD model of configuration shown in fig-2 to 6 can

be provided to vendor upon request, (this is not for fabrication purpose).

+1.5° -1.5°

P/L mounting plane

Figure-3 Top view: Payload with Payload integration fixture

(Only Schematic and not for fabrication)

P/L CG

plane


Page | 3

Ø 1750 mm(TBD)

30

00

mm

max

(TB

D)

((((

99

(ten

4400mm max (TBD)

Figure-4 Front view: Payload with Payload integration fixture


4700mm (TBD)

Figure-5 Front view: Payload with Payload integration fixture



Page | 4

Figure-6 Sectional view: Payload mounting interface with Payload integration fixture



Page | 5

Figure-7 Payload to Payload integration fixture mounting interface

PCD DIA.

1300(TBD)


Page | 6

2. SCOPE OF WORK

The outline of scope of work to be carried out by the vendor is as under:

1. Review of the requirements and specifications of proposed payload integration fixture with

automation.

2. Propose design and implementation plan including details of hardware design, interface

methodology for mounting payload in form of PDR (preliminary design review) followed by

CDR (Critical design review), this will be reviewed by SAC/ISRO for clearing it for further

action. Vendor shall incorporate the suggestions given by SAC/ISRO during these review.

3. Procurement of the raw material, Z-stages, linear actuators, Jack, control systems, power

supply, display, switches, harness & its routing, any other accessory or tooling will be in scope

of vendor.

4. Fabrication and assembly of the payload integration fixture including automation elements.

5. Demonstrate performance to meet the specifications at vendor's premises for pre-dispatch

clearance.

6. Packing in a suitable container and shipment to SAC/ISRO.

7. Installation and commissioning at SAC/ISRO.

8. Obtain completion certificate for release of payment.

9. Maintaining the installation up to stipulated period of warranty.

10. Supplier shall ensure that all instruments operating on electrical power meet the requirements of electrical safety regulation.

11. Whole fixture should have electrical grounding to earth conductively; all electrical instrumentations should have standard 3 pin power interface with its body connected to Earth.

12. Appropriate protection mechanism and scheme shall build to prevent over-current, over-voltage, over-heating, etc. Provide scheme for safety measures to be implemented.

13. Electrical Cable Wire type should be Teflon / Kapton and vacuum qualified. 14. Operating and troubleshooting manuals, sketches, drawings, and electric circuit and interface

diagrams should be provided in a separate document.

15. Fabrication and delivery of payload mounting ring is in the scope of vendor (refer fig-6 for payload mounting ring).

16. The vendor should submit all design calculations for the structural, motion and drive elements. 17. The vendor shall have selected the brought out components from reliable and proven sources

with COC, to ensure its quality and reliability.

18. The fabrication materials should have test reports, with COC. 19. The vendor should demonstrate their Quality Management System for design and well as

fabrication during PDR.

20. The vendor should perform the Failure Mode Effect Analysis for the fixture design, and work out payload safety measures in case of fixture failures.


Page | 7

3. RESPONSE TO THE RFP

Vendors should provide a detailed offer in response to the request for proposal for the proposed

automation. The offer should contain the following information:

4.1 Vendor should quote in two parts (one is technical bid + un-priced commercial bid and second

is commercial bid with price).As regards to detail instruction on two part bid requirement,

please refer separate instructions attached with this tender.

4.2 Un-priced commercial bid should be attached with the technical bid.

4.3 All the literature should be in English Language only.

4.4 Compliance statement to all the specifications of each item as per this RFP. Offers without

compliance sheet may not be considered during tendering process. Sample compliance table is

shown in table-1

4.5 Introduction by the vendor including technical capabilities relevant to proposed development. Vendor may add clientele details where similar installations are made.

4.6 Work plan for fabrication of the proposed items. 4.7 Previous automation and fabrication carried out of a similar nature. 4.8 Delivery schedule.


Page | 8

4. SPECIFICATION

Technical specification for optical payload integration fixture:

1) Size of the fixture:

4700 mm length (max) X 4400 mm width (max) X 3000 mm height (max).

2) Rotation of Axis: Pitch(X)

Rotation: ± 1.5 degree about pitch axis (automation).

Resolution: ≤ 1 arc second

Speed: 10Arc second/second (Typical)

3) Rotation of Axis: Roll axis(Y)

Rotation: -2 to +90 Degree rotation of payload about roll axis form axis vertical to axis Horizontal,

Jack-A shall have capability to rotate payload about roll axis. (Refer fig 5 for details of angles), It shall

have sufficient range to clear all appendages of fixture while rotating -2 to + 90 degree. Axis of rotation

shall be from C.G, also there shall be provision to adjust axis of rotation to pass it from C.G.

Resolution and Range: 1 arc second over -1.5 to +1.5-degree range, refer fig-3. And 0.5 Degree

over -2 to + 90 degree range.

Speed: 10Arc second/second (Typical) over -1.5 to +1.5 degree range, 20degree/minute (typical)

over -2 to + 90 degree range

These rotations shall be motorized. Noiseless and smooth rotation and jerk free start and stop are to be

ensured.

4) Rotation of Axis: - Yaw (Z)

Resolution and range: 1 arc second over -1.5 to +1.5 degree range, refer fig-3. And 0.5 Degree

over 0 to 360-degree range

Speed: 10Arc second/second (Typical) over -1.5 to +1.5-degree range, 20 degree/minute

(typical) over -0 to 360-degree range

This rotation shall be motorised. It shall have suitable ball/guide bearings along with ratchet

arrangement for locking at 0°, 90, 180°, 270° angle. Noiseless and smooth rotation and jerk free start

and stop are to be ensured.

5) Orthogonality among all three axis ≤ 1 Degree

6) Load capacity of the fixture ≥ 750 kgs.

7) Total mass of the payload integration fixture (without payload) ≈ 1000 kgs.

8) Control panel and display: Control panel shall be provided for electrical supply to the system and

display unit of not smaller than 9 inch (typical) touch screen for operating functionality of the system.


Page | 9

Display unit shall show absolute current positions (w.r.t home reference position). It shall be able to

control all stage and actuator independently.

9) Encoders: Suitable encoders shall be used for feedback of actual position of tilt in three axes (i.e.

Pitch, Roll and Yaw).

10) Locking arrangement: All rotational axis shall have locking arrangement to lock before testing

of the payload after final position is achieved.

11) Material of construction: Base frame structure shall be made from stainless steel (preferably SS

304/316)/ aluminum alloy, it shall be non-corrosive.

12) Fixture mounting foot print: Vendor shall propose fixture mounting foot print to SAC, which

will be reviewed by SAC for clearing it for fabrication.

13) Footprint for payload mounting: Footprint for payload mounting on to fixture is shown in figure-

6. Flatness required on payload to fixture mounting interface shall be better than 50 microns.

Appropriate spherical ball joint spacer shall be provided to accommodate flatness error.

14) Cutout: Fixture shall have 1135 mm (typical) inside hole on payload foot print area for various

payload element integration\testing, while mounted of payload fixture, refer figure-4.

15) Lifting brackets: Fixture shall have provision to lift (preferably four point lifting brackets) for

easy handling of the fixture.

16) Limit switch: Fixture shall have limit switches for rotational axis Pitch and Roll axis.

17) Fixture rigidity: No noticeable deformation (change in flatness of payload mounting interface shall

be < 100micron with payload mass) should be observed when a load (payload mass) is applied on

platform. To be demonstrated using a 750 kg load on the payload mounting interface of fixture.

18) Lubrication: sealed non-grease lubricants for the moving subassemblies, shall not degas in vacuum

environment (1E-6 mbar).

19) Clean room and Vacuum compatibility: Entire system shall comply with the requirements of a

clean room class 100,000 and vacuum level of 1E-6 mbar.

20) Aesthetics/Safety: The equipment shall have good aesthetic look. The equipment should be safe in

all aspects. Sharp corners, open electrical points, exposed moving parts will all be adequately taken

care of in design.

21) Temperature limit: Entire system shall comply with temperature limits for operating (22 ± 15°C)

and non-operating (-10°C to 50°C) conditions.

22) Cables with feed through connector: Necessary two sets of cables (power supply cable, data

cables, etc) shall have minimum 5m length with feed through connectors (preferably LEMO, plug

in type) for operating fixture from outside of thermos vacuum chamber (fixture inside thermos

vacuum chamber). Electrical Cable Wire type should be Teflon / Kapton and vacuum compatible.

23) Jack-B: Refer figure-5 for configuration of it. It shall have lifting range of ±50mm, with resolution

of ≤ 1mm. This lifting shall be motorized, with the option of operating it in pair of two or Four

together.

24) Load sensor: load sensors shall be placed at each support locations of payload integration fixture

(at four locations below ball joints). Measurement range of load shall be capable to take care of

payload weight +payload integration fixture weight.


Page | 10

25) GUI: GUI shall display all load sensor results, all z stages displacement\angle results, position of

jack-A and Jack B. There shall be provision to take all stage to home position, also when power is

off, all stage position shall retain to last commended position, and it shall start from last position

upon powering on. GUI shall have provision for both absolute and incremental commanding for

all stages and actuators.

26) Wireless remote: GUI mentioned above shall be loaded in mobile handheld wireless unit with

9inch (Typical) display.

27) Payload mounting ring: Suitable payload mounting ring shall be design and deliver by vendor

along with payload integration fixture. (Refer figure-6 for schematic and section view of payload

mounting ring).

5. DESIGN REVIEW: Before start of fabrication, vendor needs to present design to SAC team in form of PDR (preliminary design review) and (CDR) Critical design review, all suggestion made

by SAC needs to be incorporate in design. Written approval of SAC is required before start of

fabrication.

6. PERFORMANCE AND FUNCTIONALITY TEST After fabrication and assembly at vendor's premises, payload integration fixture will undergo

functionality tests. These tests will include noise during operation, smoothness of rotation, and rigidity

of platform under dummy load. (Dummy load simulating mass and C.G of payload shall be arranged

by vendor, refer fig-1 for payload C.G details) These tests will be carried out in the presence of

SAC/ISRO appointed engineers at vendor's premises. If all the specifications are met, the hardware will

be cleared for dispatch to ISRO.

7. CONTAINERS FOR DISPATCH The container and packing of all the sub-systems shall be robust enough to survive the rigors of handling

and transportation between the vendor’s premises and ISRO. The manufacturer shall provide handling

and storage instructions for the deliverables.

8. INSTALLATION AND COMMISSIONING

The vendor shall be responsible for installation and commissioning of all the supplied items at SAC.

Vendor shall arrange all tools, accessories and man power necessary for installation. Performance and

acceptance tests shall be repeated as per section 5 and satisfactory performance of payload integration

fixture shall be ensured by the vendor to SAC for issuing of completion certificate necessary for release

of payment.

9. WARRANTY All the systems supplied by the vendor shall have on-site warranty period of 3 years from date of

installation. Included in the warranty will be provision for rectifying malfunctioning of sub systems,

breakdown and regular maintenance as required. System performance shall be guaranteed during this

period.

10. DELIVERABLES

Payload Integration fixture as per this RFP = 2 No.


Page | 11

Note - The vendor shall provide the details like specifications, model and make of all bought out

items like motors, encoders, controllers etc.

11. DELIVERY SCHEDULE

Order signing and acceptance T0

Proposal and presentation at SAC -PDR T0 + 1 month

Finalization of design (CDR) and clearance of fabrication

T0 + 2 months

Completion of fabrication T0 + 4 months

Acceptance testing and dispatch at vendors premises T0 + 4.5 months

Installation at SAC

T0 + 5 months

SAC have all rights for onsite inspection during development of fixture at vendor’s premises.

Note: Only vendors, who are confident to complete design with meeting indent specification in

first two attempt ( i.e. PDR and CDR) needs to submit quote. Vendor failing in completion of

design in first two attempt ( i.e PDR and CDR) will be disqualified and SAC will have rights to

cancel order.


Page | 12

Annexure 1

Table-1 Compliance matrix

(to be filled in by vendor)

Sr

No Parameter Specification

Vendor’s

compliance

(to be filled in by

vendor)

Compliance

(Yes/No)

(to be filled in

by vendor)

1 Size of the

fixture

4700 mm length (max) X 4400

mm width (max) X 3000 mm

height (max)

2 Rotation of Axis:

- pitch (X)

Rotation: ± 1.5 degree about

pitch axis (automation).

Resolution: ≤ 1 arc second

Speed: 10Arc second/second

(Typical)

3

Rotation of Axis:

- Roll axis (Y)

Rotation: -2 to +90 Degree

rotation of payload about roll

axis form axis vertical to axis

Horizontal, Jack-A shall have

capability to rotate payload

about roll axis. (Refer fig 5 for

details of angles), It shall have

sufficient range to clear all

appendages of fixture while

rotating -2 to + 90 degree. Axis

of rotation shall be from C.G,

also there shall be provision to

adjust axis of rotation to pass it

from C.G.

Resolution and Range: 1 arc

second over -1.5 to +1.5-degree

range, refer fig-3. And 0.5

Degree over -2 to + 90 degree

range.


(Typical) over -1.5 to +1.5

degree range, 20degree/minute

(typical) over -2 to + 90 degree

range

These rotations shall be

motorized. Noiseless and

smooth rotation and jerk free

start and stop are to be ensured.

4 Rotation of Axis:

- Yaw (Z)

Resolution and range: 1 arc

second over -1.5 to +1.5 degree

range, refer fig-3. And 0.5

Degree over 0 to 360-degree

range


(Typical) over -1.5 to +1.5-degree


Page | 13

range, 20 degree/minute (typical)

over -0 to 360-degree range

This rotation shall be motorised. It

shall have suitable ball/guide

bearings along with ratchet

arrangement for locking at 0°, 90,

180°, 270° angle. Noiseless and

smooth rotation and jerk free start

and stop are to be ensured.

5

Orthogonality

among all three

axis

≤ 1 Degree

6 Load capacity of

the fixture ≥ 750 kgs

7

Total mass of the

payload

integration

fixture (without

payload)

≈ 1000kgs.

8 Control panel

and display

Control panel shall be provided for

electrical supply to the system and

display unit of not smaller than 9

inch (typical) touch screen for

operating functionality of the

system. Display unit shall show

absolute current positions (w.r.t

home reference position). It shall be

able to control all stage and actuator

independently.

9 Encoders

Suitable encoders shall be used for

feedback of actual position of tilt in

three axes (i.e. Pitch, Roll and

Yaw).

10 Locking

arrangement

All rotational axis shall have

locking arrangement to lock before

testing of the payload after final

position is achieved.

11 Material of

construction:

Base frame structure shall be made

from stainless steel (preferably SS

304/316)/ aluminum alloy, it shall

be non corrosive.

12 Fixture mounting

foot print

Vendor shall propose fixture

mounting foot print to SAC, which

will be reviewed by SAC for

clearing it for fabrication

13

Footprint for

payload

mounting

Footprint for payload mounting on

to fixture is shown in figure-6.

Flatness required on payload to

fixture mounting interface shall be

better than 50 microns. Appropriate

spherical ball joint spacer shall be

provided to accommodate flatness

error.

14 Cut-out

Fixture shall have 1135 mm

(typical) inside hole on payload foot

print area for various payload

element integration\testing, while


Page | 14

mounted of payload fixture, refer

figure-4.

15 Lifting brackets

Fixture shall have provision to lift

(preferably four point lifting

brackets) for easy handling of the

fixture.

16 Limit switch Fixture shall have limit switches for

rotational axis Pitch and Roll axis.

17 Fixture rigidity

noticeable deformation (change in

flatness of payload mounting

interface shall be < 100micron with

payload mass) should be observed

when a load (payload mass) is

applied on platform. To be

demonstrated using a 750 kg load

on the payload mounting interface

of fixture.

18 Lubrication

sealed non-grease lubricants for the

moving subassemblies, shall not

degas in vacuum environment (1E-

6 mbar).

19

Clean room and

Vacuum

compatibility

Entire system shall comply with the

requirements of a clean room class

100,000 and vacuum level of 1E-6

mbar.

20 Aesthetics/Safety

The equipment shall have good

aesthetic look. The equipment

should be safe in all aspects. Sharp

corners, open electrical points,

exposed moving parts will all be

adequately taken care of in design.

21 Temperature limit

Entire system shall comply with

temperature limits for operating (22

± 15°C) and non-operating (-10°C

to 50°C) conditions.

Cables with feed

through connector

Necessary two sets of cables (power

supply cable, data cables, etc) shall

have minimum 5m length with feed

through connectors (preferably

LEMO, plug in type) for operating

fixture from outside of thermos

vacuum chamber (fixture inside

thermos vacuum chamber).

Electrical Cable Wire type should

be Teflon / Kapton and vacuum

compatible.

23 Jack-B

Refer figure-5 for configuration of

it. It shall have lifting range of

±50mm, with resolution of ≤ 1mm.

This lifting shall be motorized, with

the option of operating it in pair of

two or Four together.

24 Load sensor

load sensors shall be placed at each

support locations of payload

integration fixture (at four locations

below ball joints). Measurement

range of load shall be capable to

take care of payload weight

+payload integration fixture weight.


Page | 15

25 GUI

GUI shall display all load sensor

results, all z stages

displacement\angle results, position

of jack-A and Jack B. There shall be

provision to take all stage to home

position, also when power is off, all

stage position shall retain to last

commended position, and it shall

start from last position upon

powering on. GUI shall have

provision for both absolute and

incremental commanding for all

stages and actuators

26 Wireless remote

GUI mentioned above shall be

loaded in mobile handheld wireless

unit with 9inch (Typical) display.

27 Payload mounting

ring

Suitable payload mounting ring

shall be design and deliver by

vendor along with payload

integration fixture. (Refer figure-6

for schematic and section view of

payload mounting ring).

Documents

REQUEST FOR PROPOSAL · 2018. 4. 27. · Obtain completion certificate for release of payment. 9. Maintaining the installation up to stipulated period of warranty. ... .As regards