REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 1 OF 9 TABLE OF CONTENTS 1. SCOPE:...2 2. REFERENCES:...3 3. PARTS/PROCESS INFORMATION:...3 4. EQUIPMENT SPECIFICATIONS:...4 5. SPECIAL INSTRUCTIONS:...8 6. QUOTATION:...8 7. REVISIONS:...9 For further information contact: CENTRAL ENGINEERING TEAM: Marcin Żywczok - Sr. Prototype Mfg. - Project Engineer +48 724 950 375 marcin.zywczok@nexteer.com Maciej Brylak- Controls Engineer +48 724 950 580 Maciej.brylak@nexteer.com NEXTEER Automotive World Headquarters 3900 Holland Rd Saginaw, MI 48601 USA Nexteer Automotive Poland Sp. z o.o. ul. Towarowa 6 43-100 Tychy POLAND
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 2 OF 9 1. SCOPE: 1.1 This document outlines the requirements for the design, build, poka-yoke, acceptance testing and installation of one (1), Prototype Operation s Press Machine for our Nexteer factory #77, located in Tychy, Poland. 1.2 This machine is intended to press several different types of parts depending the press tool installed in it. Servo motion and load cell monitor are displayed on the HMI. Several program and process data are exported to Nexteer Prototype Center Traceability system. 1.3 This equipment shall be available for acceptance at the supplier s factory not later than September 25, 2017. 1.4 The equipment shall conform to the current safety regulations of European Community and Nexteer equipment safety standards, per Nexteer master machinery specification SD-001 section 5. This conformance includes all aspects of CE required documentation. 1.5 The intent of this specification is to communicate the general requirements of the contract, and in no way does it relieve the vendor of their responsibility to provide rugged, accurate, and safe equipment.
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 3 OF 9 2. REFERENCES: The following specifications, in addition to the requirements set-forth in this document shall apply to this equipment unless otherwise agreed to in writing: 2.1 SD-000 Machinery and Equipment Specifications (Revised 22AU16) (SD-000 is an itemized list of all the specs you are required to follow, please use the web site) Go find all the specifications, and the Cad Drawing Tool kit for Nexteer at https://nexteerdataexchange.com/vendor_documents/delphi-s/ 3. PARTS/PROCESS INFORMATION: 3.1 This machine is intended to press several different types of parts depending the press tool installed in it. 3.2 The design of the example press tooling will be delivered for reference in order to allow the supplier to design proper interface. 3.3 The part prints are included in the RFQ package. 3.4 Product CAD models and prototype samples will be provided upon project kick-off. 3.5 Part Number(s): As the machine is intended to be used in Prototype Operation area there are no specific part prints/numbers available. 3.6 Production Rate: As the machine is not intended to be used in regular production we do not have specific CT requirements. Generally, the machine cycle time shall be below 60 sec. 3.7 Concept of the Process Sequence: 3.7.1 MAN: Place and install proper tooling in the press. 3.7.2 MAN: Place, install and connect if required additional load cell and LVDT displacement sensor. An automatic recognition of the max load of the additionally connected load cell and maximum travel for the displacement sensor shall be quoted. 3.7.3 MAN: Select proper press program. This shall be possible to be done manually from the press HMI or scanning the barcode from the PFC document. 3.7.4 MAN: Load parts to be processed into the tooling. 3.7.5 MAN: Exit light curtain. 3.7.6 MAN: Start press cycle. 3.7.7 AUTO: Execute press program.
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 4 OF 9 3.7.8 AUTO: Return home position after the press program is finished. 3.7.9 MAN: Remove finished product. 3.7.10 AUTO: Export program and process data to Traceability system. 3.7.11 End of Cycle. 4. EQUIPMENT SPECIFICATIONS: 4.1 General Requirements: 4.1.1 The machine shall conform to our ergonomic and safety guidelines for Poland. 4.1.2 The equipment supplier shall be responsible for the original CE certification and documentation of this machine. 4.1.3 The machine frame and structures shall be constructed in accordance with the Nexteer requirements. 4.1.4 As the press the servo ball-screw system shall be used. 4.1.5 The press shall be equipped with the appropriate load cell for accurate force control and monitoring. 4.1.6 The press capacity (both directions: push and pull) shall be 55kN minimum. The press drive stroke shall be 450mm minimum. 4.1.7 The machine shall be equipped with the work light. Because there is various tooling which will be used in the machine the work light shall have a possibility to be adjusted to illuminate work area and process details. 4.1.8 The bottom frame of the machine shall be robust, steel frame as follows: 4.1.8.1 Painted steel body to Nexteer standard. (See SD-001 for details); 4.1.8.2 The working height of the table shall meet ergonomic requirements and shall be adjustable between 775 mm and 950 mm; 4.1.8.3 Table plate shall be made of 25mm steel with dimensions about 1100 mm x 900 mm; 4.1.8.4 Table load 1000 kg; 4.1.8.5 Equipped with the wheels to allow quick machine replacement and adjustable vibro-isolation feet for stable and leveled positioning. 4.1.9 The top guards shall be from light extruded aluminum profiles frame. Access to work area shall be protected by transparent ESD safe panels. It is allowed, that the guarding is to be made of the still mesh. (Painting color shall follow Nexteer requirements.) Safety rules shall be considered in this case. 4.1.10 The machine guarding shall allow easy access for the press tooling exchange. Side panels shall be openable with hinges and safety locks. There shall be a possibility to easy exchange the side panels in case of necessity to process parts with excessive dimensions. 4.1.11 Access from the front of the machine shall be protected with safety feature like light curtain or safety doors or other method which ensures safe machine operation but shall allow ability for visual monitoring of the process and easy access for loading and unloading operations.
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 5 OF 9 4.1.12 Press working frame shall be: 4.1.12.1 4-column press with large tool area. Stiff, compact screwed plate construction, plates machined all over. 4.1.12.2 Base and top bearings guided moving plate with T-slots and center hole for easy tooling installation. 4.1.12.3 Distance between bottom and top moving plate shall be 600 mm or more. 4.1.12.4 Distance between columns from all sides shall be 500 mm or more. 4.1.13 The machine shall have a hand held bar code scanner to read 2D codes from the part labels or PFC. The part number and part serial numbers shall be recorded and shall be connected with the process data. 4.1.14 The press software control shall allow us to prepare press programs with a lot of flexibility with the control and monitoring of the press force vs. displacement. It shall allow us to generate the press graphs. It shall allow to set different type of control gates on various press stages or steps in the program. During one press cycle between different press distances it shall be possible to change the press speed, load limits, press targets between absolute, relative and press to load etc. 4.1.15 All other electrical & pneumatic components shall be as per specification SD-007. 4.1.16 The HMI shall be mounted on the side of the machine front on the hinged arm such that, if necessary, it can be located from the left or right side of the machine. 4.1.17 The positioning ability of the servo is expected to be accurate to within 0.015 +/-mm. The machine shall have ability to connect additional LVDT which will allow us to control the travel of the press tool in relative to the external components. 4.1.18 The load cell shall be fatigue rated and the load cell accuracy is expected to be 2% or better. 4.1.19 The HMI shall have a screen to display the results from the last 30 cycles as minimum. 4.1.20 The HMI shall have a screen to provide graphical representation of the position vs. load through the range of servo travel. 4.1.21 The supplier shall provide: the test devices, and a procedure to confirm the force and distance, calibration, accuracy, and linearity of the press system. (SD-001.3.13 & SD-003.6.5.11) [It may include: hand held device with load cell, and a digital indicator.] Provide load cell as needed by the load ranges. There shall be a designated place to store the a/m calibrating tools inside the machine frame. The mentioned hardware items shall be quoted (with detailed list of items) as an option. 4.1.22 The supplier shall utilize the Nexteer example Excel graph to document force and distance accuracy in the owner s manual. 4.1.23 The machine fixtures shall be quick change, with locators & fasteners that can be secured in place by hand, without or with standard tools. 4.1.24 The machine shall have a place designed to hold the set of tools required for fixture changeover when they are not in use. 4.1.25 Note that the error-proofs identified in this project include the following: Load cell confirms peak press force results are within set-point limits Servo confirms final press position results are within set-point limits
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 6 OF 9 Automatic/mechanical, safety latch prevents accidental falling of the upper tooling 4.2 Controls Requirements: All control circuits, components, and documentation shall conform to all specifications referenced in the Machinery and Equipment Specification, (SD-000). Any deviations from these specifications must be approved in writing. The following requirements are covered by these specifications but are frequently overlooked during the quoting phase: 4.2.1 The supplier may be required to be involved in a formal risk assessment process during the equipment design phase as a function of the Design-In Health and Safety Specification, (SD- 012). 4.2.2 Nexteer Automotive s approach to safety circuits, as documented in the Specification for Safety Circuits, (SD-011 and SD-012), has been realigned with the European and ISO standards. It is highly advisable for the supplier to understand this approach. 4.2.3 Electrical and Fluid Power control drawings and Bill of Material must be approved for build by Nexteer s controls engineering department prior to design implementation and purchasing of components. 4.2.4 The equipment s overcurrent protective devices and power distribution devices shall be suitable for use on circuits capable of delivering 50,000 amperes symmetrical (rms), 50/60 hertz of short circuit current. This SCCR value is to be documented on the electrical prints and machine nameplate. 4.2.5 All electrical receptacles shall be Ground Fault Circuit Interrupting (GFCI) protected. A Residual Current Detection (RCD) breaker (30 ma or lower) and industrial rated receptacle will be allowed for non-north America installations. 4.2.6 Part quality inputs from monitoring devices shall be "Good Part" signals not "Reject Signals". Certain devices do not utilize this philosophy and will not be acceptable contact the controls engineer for more clarification. 4.2.7 Machine logic shall follow the Programmable Logic Controller Application Specification, (SD-1032) and Nexteer sample design templates. 4.2.8 The PLC used in the machine shall be selected from the Approved Components List (SD-007). The Controls Engineer in charge shall be consulted and must approve the selection. 4.2.9 The software and its version for the PLC program shall be approved by the Controls Engineer in charge. 4.2.10 HMI design shall follow the Human Machine Interface Application Specification, (SD-1020) and Nexteer sample design templates. 4.2.11 All software provided with the machine shall be registered to Nexteer Automotive. 4.2.12 The supplier will be responsible for all hardware and software needed to startup and commission the equipment through machine qualification process. 4.2.13 The following items are not referenced within SD-000 but are requirements:
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 7 OF 9 4.2.13.1 A programming port shall be provided on each machine/station at a readily accessible location on the exterior of a control enclosure. Note: A receptacle for use by the programming equipment shall be provided, located adjacent to the programming port. The voltage and receptacle type shall be appropriate for the receiving plant. 4.3 Documentation: 4.3.1 PLC ladder logic English 4.3.2 Machine manuals Polish & English 4.3.3 Maintenance manuals and procedures Polish & English 4.3.4 PC software - English 4.3.5 Drawings and part's list - English 4.3.6 Video Display (HMI) Polish & English 4.3.7 Operator interface devices and Warning Labels Polish & English 4.3.8 Machine device tags Polish & English (machine tags must match electrical prints) 4.3.9 Control drawings and parts list English 4.3.10 Machine drawings English 4.3.11 Others not listed Consult the Nexteer Engineer in charge
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 8 OF 9 5. SPECIAL INSTRUCTIONS: 5.1 Project Management: Bi-weekly status reports and a project timeline must be provided. 5.2 Mechanical Drawing Approval: Concept and detail drawings must be approved for build by Nexteer Engineer in Charge prior to construction and purchasing of components. 5.3 Design Format: Mechanical concept design must be in 3D format. Final delivery will include both the 3D model in Parasolid format, and the 2D Auto-Cad drawings, as per Nexteer specification SD-003 section 3.2.4. Also see Nexteer specification SD-001 appendix A items 22 & 23. 5.4 Schematics Drawing Approval: Electrical controls and pneumatic drawings must be approved for build by Nexteer controls engineering department prior to design implementation and purchasing of components. Final schematics must be in ACAD format utilizing Nexteer titleblocks. 5.5 Electronic Files: NOTICE: the final payment cannot be made until all the files are approved by Nexteer Reprographics Department, see Nexteer specification SD-003 section 2.1.3.2. 5.6 Programmable Electronic Devices Programs: Programmable logic programs must also be reviewed and approved by the Nexteer controls engineering department once a preliminary functional program is written but prior to equipment run-off and acceptance. 5.7 Acceptance Testing: As the machine is not the production equipment it shall be considered as special machine equipped with measuring systems: force cells and displacement sensors. The complete equipment will undergo acceptance tests, as per specification SD-005 and SD-002. The requirements for gage R&R shall be met. The quality team of the equipment supplier will make pre-qualification tests. The supplier is responsible to debug the equipment before the Nexteer Engineer in Charge arrives to conduct the acceptance testing. A sixteen (16) hour dry cycle test is required before the acceptance test. The machine qualification / acceptance run at supplier s floor shall demonstrate flawless operation of the machine system. The R&R study will be performed during acceptance. This testing shall also include examination of the bar code readers and traceability logic. 5.8 Deviations: Any deviations, requested after a purchase order is issued, must be approved in writing by the Nexteer Engineer in Charge. 5.9 Final Approval: The Nexteer Engineer in Charge must provide written approval that the equipment supplier has permission to ship the equipment. Equipment received without that document singed in will be returned at supplier s charge. 5.10 Service: Machine start up service is required at Nexteer factory #77 in Tychy, Poland. It is presumed that the supplier and Nexteer are mutually prepared to run machine qualification process immediately after startup. See section 6.
REVISION: 1.0 REV. DATE: 2017-01-31 SHEET: 9 OF 9 6. QUOTATION: 6.1 Please fulfill the Supplier Format/Buyer Format cost breakdown, provided by our buyer. 6.2 Identify any subcontractors in your proposal. 6.3 Itemize start up service as follows: One field service engineer & one electrical engineer, travel to each Nexteer factory, work five days, return to supplier s office. At the end of the project, the purchase order will be adjusted to reflect actual time spent. Presume that Nexteer will group the purchase of machines to obtain the correct amount of total field service. 6.4 Your main proposal must include the statement: We agree to conform to Nexteer Specifications including, TPCT 0001 PROTOTYPE OPERATION PRESS MACHINE. 6.5 Attach your recommendations if they are not in agreement to this specification (specification SD-001.9.1) 6.6 Any and all deviations to these specifications must be approved prior to issuance of our purchase order. 6.7 All deviations to these specifications shall be itemized in the proposal attachment. 7. REVISIONS: 7.1 1.0 As released 7.2 1.1 Equipment availability date modified (paragraph 1.3). 7.3 1.2 Modifications of some requirements. (Modified paragraphs 3.6, 3.7.2 and 5.7.) (Modified or new requirements are marked with yellow background.)