Department of Mechanical Engineering

Institute of Technology

Banaras Hindu University

Telephone: 9335416507, 0542-2307020

Established by the Parliament Act no.225, 1916

Ref. No.:- IT/ME/09-10/FIST-4152/187/L Dated: 06-02-2010

To,

The Coordinator

Computer Centre,

Banaras Hindu University

Varanasi

Subject:- Advertisement for Open Tender at the BHU Web page.

Dear Sir,

Please find enclosed an Open Tender Notice for purchasing a Flexible Manufacturing and Reconfigurable System (FMRS) through a Dev. A/c- Scheme No. 4152 of FIST programme Phase II of Department of Science and Technology (SERC Division)

Programme.

I request you to kindly display this advertisement at the BHU Web page for its wide access.

Thanking you

Yours faithfully

( J.P. Dwivedi)

PROFESSOR & HEAD

Encls:

i)  Copy of the tender notice and tender document.

ii)  Soft copy of (i) above.

BANARAS HINDU UNIVERSITY

(NOTICE INVITING TENDER)

On behalf of the Vice-Chancellor, BHU, sealed item rate tenders from manufactures (or their ‘authorized’ dealers by submitting letters/certificates, in original, from the manufacturers that they have been authorized to quote in response to this NIT) of the following items are invited:

Sl. No. / Tender no. / Specifications & quantity of the item / Estimated cost
1. / MECH/2009-2010/ FIST -4152/187/L
Dated: 06.02.2010 / Please see enclosure 1 / Rs.61.00 Lakhs

The Tender Documents for items will be on two-Bid System consisting of Technical Bid and Price Bid. The Tender Documents will be submitted item-wise in two separate sealed covers clearly mentioning on the envelope the details of items for which bid is submitted. Any firm may bid for any number of items against the purchase of Tender Document but each offer must be item-wise in two bid cover enclosing item-wise EMD with Technical Bid.

The Tender Document (non-transferable) along with detailed specifications, terms and conditions may be purchased by the interested supplier on submission of a written application to the undersigned along with payment of non-refundable Tender price as mentioned below. The Tender price may be paid in the form of Bank Draft in favour of Registrar, Banaras Hindu University payable at Varanasi. The Tender document may be collected during office Hrs. (from 10.30am to 5.00pm) on all working days (Monday to Saturday) either in person or by post from the office of the undersigned. It can also be downloaded from the BHU website. The postal charges of Rs. 100/- (Rupees Hundred only) will be charged extra if tender document is required to be sent by post.

a) Price of Tender Document: Rs. 500/- (five hundred Non-refundable).

This should accompany the tender, if the document has been downloaded from the BHU website.

b) Date of commencement of sale of Tender Document: From the date of issue of the tender notice

c) Last date for sale of Tender Document: Three weeks from the issue of the tender notice.

d) Last date and time for receipt of Tender Document: Six weeks from the date of issue of tender notice in the news paper during the Office hours up to 5 pm. The tender should be addressed to the undersigned and should be delivered in person or sent by Registered post so as to reach the University by the due date. No tender will be accepted after the due date and time.

All Tender Documents must be accompanied with the Bid Security Form/Earnest Money Deposit (Refundable) equivalent to 2% of estimated cost of each item. The Earnest Money Deposit is to be paid in the form of Bank Draft in favour of the Registrar, Banaras Hindu University payable at Varanasi. The Bid Security Form/Earnest Money Deposit Bank Draft must be enclosed with Technical Bid. The details of Bank Draft Number of Earnest Money Deposit must be endorsed on top of envelop containing Technical Bid.

The University shall not be responsible for any delay in receiving Bids/sending of Tender Document by post.

The University reserves the right to accept or reject any bid, without assigning any reason thereof. No correspondence in this regard will be entertained.

Earnest Money shall be forfeited in case it is found at any stage that information/particulars regarding supply of tendered item(s) is false.

Head

Department of Mechanical Engineering

Institute of Technology,

Banaras Hindu University

Varanasi – 221005, U.P., INDIA

Enclosure – I

GLOBAL TENDER INVITATION FOR FLEXIBLE MANUFACTURING AND RECONFIGURABLE SYSTEM

TECHNICAL SPECIFICATIONS

1.  FLEXIBLE MANUFACTURING SYSTEM (01)

A five axes robot tending to a CNC machining Centre

a)  Five Axes Robotics System

Maximum Payload / 4kg (with reduced acceleration)
2kg (Full speed)
Axis Movement / Range
Axis 1: Base rotation / 276°
Axis 2: Shoulder rotation / 153°
Axis 3: Elbow rotation / 214°
Axis 4: Wrist pitch / 202°
Axis 5: Wrist roll / 737°
Speed / 1.9 m/sec
Number of Axes / 5 rotational axes and gripper
Repeatability / ± 0.05 mm (0.002")
Position Feedback / Incremental optical encoders with index pulse on each axis
Homing / Optical switch and encoder index pulse on each axis
Transmission / Harmonic drives and timing belts
Teach Pendant / Hand Held Teach Pendant with advanced features like
·  Manual movement of axes
·  Move to position commands
·  Position recording
·  Position insertion and deletion
·  Speed setting
Controller
Type of control / Real-time; PID; PWM
Path control / Joint; Linear; Circular
Speed control / 10 speed settings; Travel time definitions
Communication / USB cable connection to PC; Plug and play without rebooting;
Integrated RS232 for teach pendant;
Inputs / 16 digital inputs: 24V max., sink/source configurable;
4 analog inputs(8-bit resolution): input voltage 0-10V
Outputs / 16 digital outputs: 24V max.; 4 relays; 12 open collector, sink/source configurable; 2 analog outputs: output voltage 0-10V
User power supply / 12 VDC (1A) and 24 VDC (2A) terminals, for connection of remote switches, sensors, etc.
Programming / Windows based programming software, with Multi tasking – Up to 100 concurrent programs, in-program parameter manipulation, built in Scripting, ON line Graph With PWM and position error
Position definition / XYZ coordinates; Joint coordinates (degrees); Encoder counts; Absolute and relative positions; In program position manipulation
Safety features / Certified for CE safety compliance;
It should stop automatically upon detection of impact

b)  CNC Machining Centre (01)

The machine should be able to work with the robot with complete program triggering function based on robot signals. The machine should be equipped with pneumatic vice and shield opener to facilitate robot integration.

Axis travel / X Axis: at least 300 mm
Y Axis: at least 150 mm
Z Axis: at least 240 mm
Open height: at least 270 mm
Work area / Nickel plated table size: 436 mm x 127 mm
Spindle / Spindle: 746 W
Motor type: DC permanent magnet
Dual speed range: low 0-3,000 RPM; high 0-6000 rpm
Automatic Tool Changer / Four station Automatic Tool Changer with tools
Air Blast System / The machine should be equipped with air blast system to avoid accumulation of debris on the work piece.
Accuracy / Repeatability: 0.013 mm or better
Resolution (half step): 0.004 mm or better
Axis drive motors / Feed rate: 2-3810 mm/min
Rapid traverse: at least 3.8 m/min
Interfaces / PCI connections to PC and robot controller
Illuminated robotic interface 8 inputs 8 outputs
Interpolation / Rapid, linear, circular and helical interpolation
Circular interpolation with center point or radius input
Programming standards / EIA RS274-D standard G&M codes
Fanuc-compatible NC code subset
Programming and control / Windows based programming and control software
Safety features / Certified for CE safety compliance
Transparent Lexan safety shield with gas-operated shock for easy opening
Emergency stop switches: on front panel; on keyboard

c)  Accessories

a.  All necessary hardware should be supplied for integration of the FMS

b.  Gravity Parts Feeder

It should be a local storage system in the FMS supplying parts to the cell. It should have a microswitch sensor to check for part availability and communicate the same to the robot via I/O’s

c.  CAD/CAM Software

Basic CAD/CAM software which should develop NC part programs from drawings prepared in the CAD module.

2.  AUTOMATIC STORAGE AND RETRIEVAL SYSTEM (01)

A fully automatic ASRS with a five axes robot tending to a storage system

a)  Five Axes Robotics System

Mechanical structure / Vertically articulated
Degrees of freedom / 5 rotational axes + gripper
Payload capacity / at least 2 kg
Axis Range /  Axis 1: Base rotation: 310°
 Axis 2: Shoulder rotation: +130° / -35°
 Axis 3: Elbow rotation: ±130°
 Axis 4: Wrist pitch: ±130°
 Axis 5: Wrist roll: Unlimited (mechanically); ±570° (electrically)
Reach / at least 600mm end of gripper
Speed / at least 700 mm/sec
Gripper / Servo motor, parallel fingers
Repeatability / ±0.2 mm or better
Teach Pendant / Hand Held Teach Pendant with advanced features like
·  Manual movement of axes
·  Move to position commands
·  Position recording
·  Position insertion and deletion
·  Speed setting
CONTROLLER
Type of control / Real-time; PID; PWM
Path control / Joint
Linear
Circular
Speed control / 10 speed settings
Travel time definitions
Communication / USB type A cable connection to PC
Inputs / 8 digital inputs
4 analog inputs
Outputs / 8 digital outputs
2 analog outputs
User power supply / Two +12VDC terminals, for connection of remote switches, sensors, etc.
Programming / Windows based programming software
Safety features / Certified for CE safety compliance
Automatic shut-down upon detection of overheating, PC failure, communication error, impact

b)  Storage System

Design

·  Table-top mounting

·  6 storage cells on 3 tiers

·  Black anodized aluminium

Additional components

·  6 templates (part-holding trays) and pin sets

C). Material Handling System:

Automated guided vehicle(AGV) give detailed specification of Load carrying capacity, Maximum travel sped, Min. turning radius, Guidance, Load transfer mechanism, Obstacle sensor should be able to interface with the robot/CNC/Conveyor/ASRS

3.  CIM Management, Simulation and Control Software (with user License) (01)

A)

Real-time communication / It should use multi-level, hierarchical communication network design, based on commonly used industrial communication networks; allowing user to practice and understand different communication networks and protocols.
TCP/IP protocol for real-time communication between the manager PC and device drivers
CIM layout design / ·  User should be able to design, create and modify the CIM layout and components.
·  Object library should include different kinds of robots, CNC machines, additional machines and stations (like welding, laser engraving, pneumatic sorting), positioning devices (like jigs, XY tables), quality control devices (like machine vision, CMM, LSM, calipers), sensors and I/O devices; storage devices and feeders; conveyor and PLC control unit; tables, workbenches, computers.
·  Conveyors and tables should be automatically created according to user-defined width/length dimensions.
Data acquisition and visualization / ·  Online 3D graphic tracking should show movement of robots, machines, parts, conveyor and other CIM elements in a dynamic simulation of the shop floor.
·  Gantt charts should present planned and actual scheduling of manufacturing processes.
·  Status views should allow user to track production through various screens that display data such as manufacturing orders; status of storage locations; current activity of all machines, robots and devices; status of pallets; log of all transmitted messages, etc.
·  Report generator should allow user view and print ten types of predefined reports (e.g., machines, ASRS contents, manufacturing orders), or an unlimited number of own user-defined reports using Crystal or other report generating software.
·  All data should be written and stored in standard industrial database format to enable easy access, manipulation and use by any software application.

B)

Fanuc NC GUIDE Software, for offline simulation (five seats)

Ladder editing software

Mastercam (Latest version)

CIM Software

4. Quality Control Station ( 01) (Please quote item wise)

A)

Work Probe
Spindle Probe with the following specification
Transmission type / 360° infra red optical transmission
Turn on control / Machine M code or auto start.
Turn OFF control / Machine M code or timer.
Operating range / Upto 5 m
Sense direction / Omni- directional: + X, + Y, +Z
Unidirectional repeatability / 0.25 µm (2 Sigma ) with 50 mm stylus length, at test velocity of 240 mm/min, or better.
Stylus over travel / XY plane + 11°, +Z direction 6mm, or better.
Stylus trigger force / XY plane 0.06 N, + Z direction 2.55 N, typical minimum
Maximum recommended Stylus length / 200mm or more
Probing software / Renishaw inspection plus (or similar) probing software for common probing application such as width/ depth/ angle/ center measurement.

4. B)

Tool probe
contact type tool probe or equivalent with following specification
Tool range for Probing / Length and diameter measurement of milling cutters and twist drills on machining center
Transmission type / Infrared
Operating range / Upto 5 m
Styli / Disc and Square type
Sense direction / Omni- directional: + X, + Y, +Z
Overtravel / XY plane + 3.5 mm and Z direction 6 mm, or better
Stylus trigger force / 2 N (typical)
Repeatability / 1 µm (2 Sigma) with 35 mm stylus length, at test velocity of 480 mm/m or better
Protection against excessive overtravel / A weak link break stem or a similar mechanism
Tool setting software / (Renishaw part no. A- 4012- 0548 or similar) for the intended probing applications.

C) Signal Receptor: Twin –signal type receptor of reputed brand (Please mention the brand), to suit twin probing.

D) The CIM assembly and quality control station with a horizontally articulated (SCARA) robot

Assembly and inspection processes are both performed at this station.

The robot performs part manipulation and assembly operations, and places parts on jigs or Positioning devices to enable their inspection.

Assembly and quality control station should include a number of tools and devices that enable a variety of assembly and inspection scenarios, such as:

__ Ball feeder

__ Automatic glue dispenser

__ Linear positioning table

__ Dual-axis pneumatic vise

__ Palletizing racks

__ Parts bin

__ Machine vision system

__ Other automatic inspection devices

In addition to the station's integration within a complete CIM system, each of the station elements can be operated as stand-alone systems.

5. Computers and LAN network