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TENDER FOR Electron Beam Welding machine

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Schedule of Tender

For

Electron Beam Welding machine

Central Manufacturing Technology Institute Tumkur Road, Bangalore – 560 022. INDIA


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Central Manufacturing Technology Institute Tumkur Road, Bangalore 560 022

“Electron Beam Welding machine” Schedule of Tender

(To be filled in by the tenderer and returned and duly signed along with enclosure to the Schedule of Tender)

1. Name of Purchaser Central Manufacturing Technology Institute

Tumkur Road, Bangalore 560 022

2. Place of delivery Central Manufacturing Technology Institute

Tumkur Road, Bangalore 560 022

3. Delivery of Machine Required Within 8 months after placing the purchase order

4. Date of receipt of the Tender On or before 30th Nov 2015.

5. Earnest Money Deposit Rs.25,000/- as EMD is payable by Demand Draft drawn in favour of Central Manufacturing Technology Institute, payable at Bangalore.

A tender fee amount of Rs. 1145/- is to be submitted along with the tender through a demand draft in favour of Central Manufacturing Technology Institute, Bangalore

6. Validity of the tender Tender should be valid for a period of not less than 3 months from the date of offer and unless otherwise specified by the tenderer, the tender shall be treated as valid even thereafter.

7. Technical details/ Requirements for which the tender is invited.

a. As per specification enclosed (Annexure-I).

b. All details that are required in the specification must be included in the offer. Incomplete tenders are liable to be rejected.

c. Wherever numerical values are specified, tenderer shall respond with numerical values that actually correspond to the product. Any additional features/ details pertaining to the product should be enclosed separately.

d. The equipment will be finally accepted based on the compliance of the equipment with the Acceptance Criteria. The final Acceptance Criteria will be based on mutual agreement and will be finalized at the time of placing the order. Hence, the bidder has to go through the Acceptance Criteria (Annexure-II) and convey their acceptance unambiguously. They may also suggest a suitable method of verification if the proposed method is not acceptable to the bidder.

8. Price offered a. The quotation should be furnished in TWO parts in different sealed covers in the following manner.

b. The first part should contain complete technical details of the item offered along with name and address of the manufacturer, full name and address of the authorised agent, guaranteed delivery period and 2 sets of the latest catalogues. This part should not contain the price details. The EMD as indicated should also be enclosed along with the technical details. The cover should be sealed and superscribed with “ Tender Enquiry Reference and Date” and “Electron Beam Welding machine”

c. The second part should contain the Price and other commercial terms. The price should be quoted F-O-R, Bangalore. The cover should be sealed and superscribed


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with “Tender Enquiry Reference and Date” and “Electron Beam Welding machine”

d. Both these covers should be put together in an outer cover sealed and superscribed with “Tender Enquiry Reference and Date” and “Electron Beam Welding machine”.

e. Break up cost for optional features and optional equipment/ accessories are to be clearly indicated.

f. If two different models to be offered, Both shall be produced in separate sealed covers.

9. Payment Terms To be indicated

10. Transit Insurance To be arranged by the supplier from supplier’s warehouse to the place of delivery and to be billed at actual.

11. Notes

a. Late offers will not be entertained or accepted.

b. All the items in the tender Specifications are to be filled in. In complete Tender Specifications may not be considered.

c. The Director of the Institute reserves the right to reject any tender / all tenders without assigning any reason.

d. In case of unsuccessful tender, the EMD will be refunded only after finalisation of contract.

e. In case of the tenderer whose offer is accepted, the EMD will be refunded only after receipt, inspection and acceptance of the equipment at CMTI, treating it as a security deposit.

f. If the supplier fails to fulfil the terms of purchase order or when the purchaser is satisfied that it is not in the interest of the purchaser to persist with the defaulting supplier, the EMD stands forfeited. Further the purchaser is at liberty to place the order on another supplier at the risk and cost of original supplier.

12. General Terms and Conditions Latest software release version to be given at the time of installation.

All software provided should be licensed to CMTI. Maintenance, Enhancement, automatic up-gradation, and

Support for 1 year for all software User manuals, all necessary training and training material

to be provided. Original Software to be supplied on CD-ROM / DVD-ROM

media. Installation commissioning testing training and proving all

the features and functions of the system supplied should be the responsibility of the vendor.


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Technical Specifications of

Electron Beam Welding machine


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Annexure - I Technical Specifications of Electron Beam Welding Machine

A twin gun Electron Beam Welding Machine to weld microelectronic packages or seals. Machine has to serve welding requirements of both Micro and Macro scale as per the specifications below. Sl. No. Indicated Specifications Description Remarks

A. General Description

1 Machine Configuration Electron Beam Welding machine with vertically

and Horizontally mounted Electron guns, 1cu. ft.

working chamber, X and Y axes with CNC

interpolation capabilities. As per the Figure 1.

Essential

2 Materials to be welded Stainless steel & Stainless based alloys.

Titanium and Titanium based alloys.

Copper& Copper based alloys.

Aluminium and Aluminium alloys.

Nickel based super alloys.

Niobium & Niobium based alloys.

Kovar.

Essential

B. Electron Beam Guns

1. Gun mounting Two externally mounted Electron beam guns,

1. First one mounted on the top of Welding

chamber vertically centred.

2. Second one mounted horizontally to the right

side of the chamber when viewed from the

front.(Refer Fig. 1)

Note: These two guns will be interchangeable.

In case of any exigency one of the gun can be

used as stand by. The system shall be fitted

externally to the work chamber with a dedicated

mechanical sealing system under static and

dynamic conditions. During gun movement and

gun in operation mode it shall allow to work

with highest vacuum levels (in the range of 10-5

mbar) inside welding chamber and shall be used

with CNC gun movement system.

Essential

2. Type Direct heating triode gun

Essential


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Sl. No. Indicated Specifications Description

Remarks

B. 3. Gun Movement range External to chamber (For both Vertical and Horizontal guns)

1. Minimum ± 50mm travel (100mm Absolute

travel in X and Z direction) with a linear

speed of 10-2000mm/min. (Nominal). Driven

by Servo motor with CNC control.

2. Please provide positional accuracy or

resolution of Gun movement.

3. Manual override should be possible.

Essential

4. Accelerating Voltage (As Per ISO 14744)

1. 10 to 60 kV or better (steps of 1kV)

2. Ripple: 2% (peak to peak value)

3. Stability: ±1%

4. Reproducibility: ±1%

Essential

5. Beam current (As Per ISO 14744)

1. High Current Range: 0-65 mA or better (in

steps of 0.1mA)

2. Low Current Range: 0-10 mA or better (in

steps of 0.1mA)

3. Ripple: 5% (peak to peak value)

4. Stability: ±1%

5. Reproducibility: ±1%

Essential

6. Beam power 4kW- 6kW

Essential

7. Slope in and slope out Adjustable up to 1250mA/sec.

Essential

8. Beam focusing system (As Per ISO 14744)

1. Focus control by Magnetic lens.

2. Adjustable Focus current.

3. Ripple: 0.5% (peak to peak value)

4. Stability: ±0.5%

5. Reproducibility: ±0.5%

6. CNC based and manual beam focus control.

7. Focal Distance : 50 to 300 mm or better

Essential

9. Beam deflection system 1. X deflection angle : ± 3° or better

2. Y deflection angle : ± 3° or better

3. Independent setting of X and Y deflection.

4. Frequency : 0.1 to 2000 Hz or better

5. CNC based and manual beam deflection

control.

6. Oscillation of beam as per preferred function

generation by NC or controller

Essential


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Sl. No. Indicated Specifications Description Remarks

B. 10. Function generator 1. Sine, square, triangle, circle, ellipse, saw-

tooth and ∞

2. Two axes sine wave outputs for deflecting the

beam in a circular pattern.

3. Two axes DC deflection for positioning of

the electron beam.

4. Square wave forms for different workspace

ratio.

5. DC deflection shall be superimposed on the

AC outputs to provide for centering the circle

during welding operation.

Essential

11. Gun vacuum pumping

system

The two Electron guns shall have two separate

vacuum pumping system with the following

specifications

NOTE: The entire vacuum

components/pumps/valves of the gun shall be

from the same source/manufacturer

(Viz. Edwards, Leybold, Agilent & Pfeiffer.)

Essential

11.1 Working Vacuum

level

10-5 mbar or better Essential

11.2 Vacuum suction

time

Less than 3 minutes Essential

11.3 Ultimate vacuum

level

1X10-6 mbar or better

Essential

11.4 Pumps 1. One Primary pump.

2. One Turbo

molecular pump

Essential

11.5 Vacuum

Measurement and

instrumentation.

Vacuum measurement by Pirani/Penning/Wide

range gauge.

(Gauge/s make and model to be mentioned in the

technical offer)

Essential

11.6 Isolation Valve Pneumatic operated cut-off valve ensuring that

vacuum is maintained in the gun when the

chamber is vented.

Essential

From Reputed Manufacturers


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Remarks

B. 12. Viewing and Beam

Alignment

1. Coloured camera to achieve 10X

magnification at shooting distance from 50-

300mm inside chamber (From top to bottom

of the chamber).

2. Video to be displayed on HMI-PC.

3. Binoculars Viewing system for manual

focussing to be provided for both EB guns.

4. Provisions for aligning the joint with beam

before welding and during welding.

5. Suitable vapour protection for optics (like

stroboscopic system).

6. A cross hair shall be superimposed over the

image to allow the position of the beam on

the joint to be precisely adjusted before

welding.

7. Seam tracking by teach in & replay system by

interpolation.

Essential

C. Welding Chamber

1. Material Non-magnetic Stainless steel

Essential

2. Width x Length x Height 305mm x 305mm x 305mm or better

Essential

3. Wall thickness The thickness of the chamber walls shall be

designed to block X-ray radiation in accordance

with international regulations. (<1μSv/h

measured 100 mm from the walls).

Essential

4. Front access door Access door shall be hinged and open towards

the left of the welding chamber when viewed

from the front of the machine.

Essential

5. View port Viewing port Ø150mm lead glass and vapour

protective removable glasses for easy

replacement shall be located centrally on the

front door.

Essential

6. Sealing System 1. Sealed door, Access ports and Pumping

system with leakage ≤ 10-6 mbar.l/s

2. Suitable leak detection ports to be provided.

3. Door ,Access ports and Pumping system shall

have suitable compatible O ring Seals.

Essential


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C. 7. Chamber vacuum

pumping

The Welding chamber shall have separate

vacuum pumping system with following

specifications.

NOTE:

The entire vacuum components/pumps/valves of

the gun shall be from the same

source/manufacturer.


Essential

7.1 Working Vacuum

level

10-4 mbar or better Essential

7.2 Vacuum suction

time

Less than 4 minutes Essential

7.3 Ultimate vacuum

level and duration

5X10-5 mbar or better in

less than 5 minutes

Essential

7.4 Pumps 1. One Rotary pump.

2. One Roots pump.

3. One Turbo

molecular pump with safety

interlocks .

4. One rotary backup

pump for Turbo molecular

pump.

5. Valves

Essential

7.5 Vacuum

Measurement and

instrumentation.


range gauge.

(Gauge/s make and model to be mentioned in the

technical offer)

Note: Suitable provision shall be made for leak

detection in vacuum pumping line with leak

detection ports.

Essential

7.6 Over-ride Manual override provision for vacuum pumps

and valves through HMI.

Essential



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D. Work Handling System

1 Configuration Refer Figure 2

1. CNC controlled X and Y Table mountable on to chamber bottom with suitable arrangement for accurate fixturing.

2. Vertical Rotary manipulator with arrangement to swap in the place of XY table. This manipulator is mounted externally, on the bottom side of the working chamber.

3. Horizontal Rotary manipulator mounted externally, on the left of working chamber when viewed from front of the machine.

With Following Specifications,

NOTE: All the components of work handling system are made of Non-magnetic material.

Essential

2. X Y Table Essential

2.1 Table size 150mm X 150mm or better

2.2 Stroke length 1. X-axis : 100mm to 200mm 2. Y-axis : 100mm to 200mm

Essential

2.3 Accuracy 1. X-axis : 50 µm or better 2. Y-axis : 50 µm or better

Essential

2.4 X. and Y. Speed 1-2000mm/min or better

Essential

2.5 Load carrying capacity

Up to 20 kg.

Essential

3. Horizontal and Vertical Rotary Manipulators

The Rotary manipulator shall have axis accuracy of 100μm. The rotary manipulator shall have centrally sliding hardened shaft with proper vacuum seal, moves inside and outside of the vacuum chamber and provision to mount the chuck inside the vacuum chamber.

Essential

3.1 Shaft Size 25mm diameter x 450mm long hardened non magnetic shaft.

Essential

3.2 Positioning for Welding

Fully hardened collet clamping. Essential

3.3 Diameter of chuck

Non magnetic high precision 70mm three jaw self aligning chucks.

Essential

3.4 Rotating Speed Rotary speed adjustable from 1rpm to 60 rpm.

Essential

3.5 Speed stability ±1% of set speed Essential

3.6 Spindle Run-out 30µm or better Essential

3.7 Drive system Servo Motor (CNC controlled) Essential

3.8 Loading Capacity 20 kg or better Essential


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E. High voltage power

supply

High voltage power supply shall be with switch

mode power supply, variable bias supply for

beam current control with an adjustable and

stabilized supply for filament heating and it shall

have following features.

1. The power supply should have ANTI-FLASH

protection.

2. Less power dissipation.

3. High voltage proof.

4. Short circuit proof (supply needs to switch

off to avoid mis-welding and loss of

expensive work piece)

5. Zero beam current during HV recovery

(Defocusing of beam to avoid miss welding

and loss of expensive work piece)

6. Oil filled tanks and top lid easily removable

for maintenance.

Essential

F.

Control System

1 Configuration The control system to be based on Industrial

PLC, industrial HMI (Human Machine

Interface), a PC and numerical control system

which shall be of latest windows based CNC

system.

The PC shall be equipped with at least

• 2 Nos. of USB ports,

• 2 Nos. of serial ports

• 2 Nos. of Ethernet ports.

Essential

2. PLC The industrial PLC working with industrial

HMI-PC supervisory system with GUI shall be

able to control following parameters of Electron

Beam Welding Machine :

1. Welding chamber vacuum Sequence.

2. Electron gun Vacuum Sequence .

3. Electron gun Isolation valve control.

4. Electric supply of gun.

5. Safety interlocks/Security system

6. CNC Interface.

7. Alarms and Security.

8. Auto Diagnostic for Maintenance.

Essential


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F.

3. PC supervisory system CNC system shall work with industrial PC,

providing the operator interface in dialog mode

with an industrial HMI (Human Machine

Interface) standard supervisor system. The

supervision program uses standard software on

latest version of Windows. It shall be responsible

for the overall management of the machine, in

particular:

1. Management of start-up modes: immediate

or deferred.

2. Management of gun settings, including

conditioning and space charge.

3. Management of the video and cross-hairs.

4. The displays of pump units, power supplies

for the gun, mechanical movements etc.,

5. Management of faults, with history.

6. Tracking the duration of use of various

components, including cathode counter

(hours), filament, pumps, etc., in order to

facilitate preventive maintenance.

7. Troubleshooting with access to each PLC

input/output variable.

Essential

4 CNC system The welding programs shall be managed by

CNC system with the following specifications :

1. Fitted with a dedicated keypad and screen.

2. The welding programs shall be created,

executed and stored by CNC system

working to meet the requirements of

standards such as ISO 14744.

3. The control system shall include hand held

pendant with electronic hand wheel and foot

switch for precise adjustment of the CNC

axes in manual mode and necessary controls

for machine operation.

4. Programming language shall meet the

standards such as ISO.

5. Supervision program shall be with standard

software on latest version of Windows

based operating system.

Essential


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F.

4 CNC system 6. Control of mechanical welding axis and the

electrical settings for the beam (accelerating

voltage in kV, beam current in mA, focus

current in mA, X and Y beam deflection

amplitude in A), linear speed in X and Z

axis(Gun axes) & XY table axes in

mm/min, rotary speed in rpm and mm/min.

7. The welding programs include all the data

required to carry out the full welding cycle.

The complete welding program shall be able

to set ramp up, dwell time, ramp down.

8. Program storage capacity in CNC memory –

minimum 10 programs and mass storage

with PC hard disk shall be a minimum of

100GB.

9. Programs can be downloaded form from the

supervisor PC. The PC's hard disk shall

serve as mass storage in the event that a

large number of programs are used.

5 Parameters display Following operating parameters shall be

displayed at the control panel:

1. Display for vacuum level in welding

chamber and gun in mbar.

2. Speed and position of manipulators and X-

Y axes Table.

3. Speed and position of gun movement.

4. Accelerating voltage.

5. Beam current.

6. Focus current.

7. Beam deflection signal (by oscilloscope).

8. Indicators for diffusion pump ready.

9. Audio-visual display (Alarm) for air/water

failure.

10. Programming with HMI (Human Machine

Interface) shall include mimic display,

alarm status, quality data recording, error

indicators, operation screen for tooling,

vacuum and weld cycle recipes.

11. Programs shall be linked to build up a fully

automatic program consisting of tacking,

penetration, cosmetic pass, deflection,

stirring, etc.

Essential


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G. Safety

1. Radiation levels to be measured in

accordance with the ISO standard-14744 or

equivalent standards.

2. The chamber shielding shall ensure

radiation levels of less than 1µSv/hour, at a

distance of 100mm from any external

surface, with a defocused beam of

maximum power.

3. Radiation shield in the equipment shall meet

the requirement of annual whole body dose

limit of 50 mSv (maximum)

4. Illumination of red warning light when the

high voltage to the gun is on.

5. Water flow, water temperature and air

pressure switches to protect the vacuum

pumping system against power supply

failure. Audible warning of failure should

be provided.

6. All rotary drives shall be fully protected by

safety guards and noise from the machine

shall be less than 70 dB

7. Safety interlocks for preventing accidental

energizing of high-voltage without required

vacuum level, opening of isolation valve

etc., shall be incorporated

8. Beam shall not be “ON” without sufficient

vacuum in gun and chamber

9. System shall have automatic trips for over

kV, over mA, filament failure and auto-

diagnostic system.

Essential

H. Online data monitoring and storage

This system shall be fitted with the equipment

and shall have the following features:

The system shall have a minimum number of

channels and allows storing of the data of the

actual welding parameters as well to plot the

curves for each parameter all along the welding

cycle.

Essential


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Remarks

H. PC shall be equipped with a software program to

record the welding data with a minimum

sampling interval of 0.05 seconds. The data

recorded for each weld shall be provided in an

Excel spreadsheet.

The following parameters are to be recorded,

1. Accelerating voltage (kV).

2. Beam current (mA).

3. Focus current (mA).

4. Linear Gun table speed (m/min).

5. X Y table welding speed (mm/min)

6. Rotary welding speed (rpm).

7. Vacuum level in gun & chamber (mbar).

I. Cooling System Suitable closed loop water cooling system

indicating the temperature, flow rate, power etc.

Essential

J. Input Electrical Supply Voltage: 415±10% Three phase and Neutral

Power: 25 kVA±10%

Frequency : 50Hz ± 1%

Earth: ≤ 2Ω

Essential

K. Test data and Documents for Electron Beam Welding machine

All test data shall be recorded along with detailed checking of beam

equipment functions and components

1 Instruction manual Essential

2 Maintenance manual Essential

3 Diagrams for all mechanical assemblies with parts lists.

Essential

4 Mechanical,Electrical and Electronic diagrams

Essential

5 Technical documentation for the main components purchased.

Essential


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K. 6 Original licence for the

software which is

purchased.

Essential

7 One soft copy of all

the manuals and diagrams

in PDF format,

as well as the

specific programs

(PLC and man-

machine interface).

Essential

8 One re-

installation CD for the PC

Essential

9 Licensed version software

CD and replaceable hard

disk installed with all the

software shall be

included.

Essential

10 Calibration certificate for

all the vacuum gauges

shall be provided

Essential

11 Spare parts list with

source of supply and

prices

Essential

12 The supplier should

provide details regarding

the safety measures

adopted in the system.

Essential

13 Manuals of bought out

items incorporated in the

system

Essential

L. Pre-Dispatch Inspection and Training

1 Pre dispatch Inspection The inspection and calibration certifications

for compliance to specified requirements for

EB gun system, control system, X-ray

radiation safety and other requirements as per

specifications shall be conducted by Third

Party Inspection in presence of CMTI

personnel.

Essential


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Remarks

L. 1 Pre dispatch Inspection Dispatch clearance shall be provided by

CMTI representatives based on satisfactory

pre dispatch inspection and testing at OEM

based on CMTI acceptance criteria (As per

Annexure-II).

EB gun system, high voltage power supply

unit, rotary manipulator, required controls

and other supply items shall be demonstrated

by integrating with work chamber as per

acceptance criteria.

Quotation for Third party inspection to be

indicated separately in the commercial offer.

2 Training Training for 2 CMTI Engineers shall be provided

at OEM's place, for at least one week during pre-

dispatch inspection covering following areas,

Operation of machine, supervisory system,

CNC programming.

Mechanical and electrical system

maintenance

CMTI shall bear to/fro air travel, boarding

and other incidentals.

Essential

M. Packaging, Delivery, Installation, Commissioning and final Acceptance testing

1 Packaging and Delivery Machine along with all the necessary systems

to be delivered to CMTI, Tumkur Road,

Bangalore-560022.

Air worthy packing of machine under

supplier’s scope.

Delivery schedule shall be 8 months Max.

from the date of placement of purchase order.

Parties shall submit their price bid on Ex-

Works basis and also show C&F charges

separately.

Essential


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M. 2 Installation Installation of the equipment shall be carried out

at CMTI, Bengaluru.

Electric supply complying to details

mentioned above will be provided at

installation site. Suppliers to provide required

kVA ratings.

Supplier should provide the UPS requirements

of the Machine with preferred make and

model.

Pneumatic supply will be provided, supplier to

indicate pressure and flow requirements

Earthing requirements to be specified.

Foundation requirements for the machine

including drawings shall be communicated to

purchaser within one month of purchase order

placement to ready machine installation site.

Overall dimension of the system, requirements

of civil work and material handling system

need to be informed in advance.

Essential

3 Final Acceptance Final acceptance will be signed only after

satisfactory erection of entire system including

EB gun system, High voltage power source,

vacuum pumping system, control system,

cabling and wiring, complete integration, testing

and commissioning at CMTI.

Essential

4 Training at CMTI,

Bengaluru

At least one week training shall be given to

CMTI personnel at CMTI, BENGALURU, after

commissioning & acceptance.

N. Safety and

Certifications

All the necessary safety regulations such as CE

compliance, low voltage directives, EMC

regulations compliance details, Alarms and

emergency switch-off in case of any

malfunctioning must be provided. The system

must be equipped with all the necessary safety

interlocks.

Essential


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O. Warranty - inclusive of

parts and labor

The complete system and its associated

hardware / software should have a standard

warranty of 24 months from the date of

installation, commissioning and acceptance

of the system at CMTI.

Maintenance/ repair /replacement of any

hardware or software component of the

system during warranty period to be done

free of cost (including expenses of Engineer

from OEM) .

Supplier modification(s) / Software upgrades

shall be intimated and same will be made

available free of cost during the warranty

period.

Spares list required and their cost for 2 years

of operation after the warranty period shall be

indicated in the offer.

Essential

Additional 12 months extended warranty may be

quoted as an option.

Optional

P. Annual Maintenance

Contract

AMC per year basis and on bulk basis (for 3

years) including parts and labor to be quoted

separately. The terms, Conditions and amount

payable for AMC should be provided by the

vendor which shall include,

1. Preventive Maintenance

2. Breakdown Maintenance

Note: AMC terms and conditions shall be agreed

upon mutually before placement of Purchase

Order

Essential

Q. List of Users Provide a list of users for the quoted model in

India with full contact details.

Essential

R. Service Support The supplier should support the system

minimum for 10 years (post warranty, with all

spares and services). Exact lifecycle of the

offered unit has to be specified.

Essential


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Figure 1

Figure 2


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Annexure-II Acceptance Criteria for Electron Beam Welding Machine

Sl. No. Indicated Specifications Description Inspection

type

A. General Description

1 Machine Configuration Electron Beam Welding machine with vertical and Horizontally mounted Electron guns, 1cu ft. working chamber, X and Y axes with CNC interpolation capabilities. As per the figure 1.

Physical verification

2 Materials to be welded Stainless steel & Stainless based alloys. Titanium and Titanium based alloys. Copper & Copper based alloys. Aluminium and Aluminium alloys. Nickel based super alloys. Niobium & Niobium based alloys. Kovar

Functional verification. Demonstration of penetration in stainless steel material (10mm), Aluminium & Titanium (12mm). Testing material are in the scope of supplier.

B. Electron Beam Guns

1. Gun mounting Two externally mounted Electron beam guns,

1. First one mounted on the top of Welding

chamber vertically centred.

2. Second one mounted horizontally to the

right side of the chamber when viewed from

the front.

Note: These two guns will be interchangeable.

In case of any exigency one of the gun can be

used as stand by. The system shall be fitted

externally to the work chamber with a dedicated

mechanical sealing system under static and

dynamic conditions. During gun movement and

gun in operation mode it shall allow to work

with highest vacuum levels (in the range of 10-5

mbar) inside welding chamber and shall be used

with CNC gun movement system.


Interchangeability to be demonstrated


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Sl. No. Indicated Specifications Description Inspection type

B. 2. Type Direct heating triode gun Functional verification

3. Gun Movement range External to chamber (For both Vertical and Horizontal guns)

1. Minimum ± 50mm travel (100mm Absolute travel in X and Z direction) with a linear speed of 10-2000mm/min. (Nominal). Driven by Servo motor with CNC control.

2. Please provide positional accuracy or resolution of Gun movement.

3. Manual override should be possible

Functional verification Gun position accuracy to be demonstrated.

4. Accelerating Voltage (As Per ISO 14744)

1. 10 to 60 kV or better (steps of 1kV) 2. Ripple: 2% (peak to peak value) 3. Stability: ±1% 4. Reproducibility: ±1%

Functional verification at OEM's place by third party inspection

5. Beam current (As Per ISO 14744)

1. High Current Range: 0-65 mA or better (in steps of 0.1mA)

2. Low Current Range: 0-10 mA or better (in steps of 0.1mA)

3. Ripple: 5% (peak to peak value) 4. Stability: ±1% 5. Reproducibility: ±1%

Functional verification at OEM's place by third party inspection

6. Beam power 4kW- 6kW Functional verification at OEM's place by third party inspection

7. Slope in and slope out Adjustable upto 1250mA/sec. Functional verification at OEM's place by third party inspection

8. Beam focusing system (As Per ISO 14744)

1. Focus control by Magnetic lens. 2. Adjustable Focus current. 3. Ripple: 0.5% (peak to peak value) 4. Stability: ±0.5% 5. Reproducibility: ±0.5% 6. CNC based and manual beam focus control. 7. Focal Distance : 50 to 300 mm or better

Functional verification at OEM's place by third party inspection.

9. Beam deflection system 1. X deflection angle : ± 3° or better 2. Y deflection angle : ± 3° or better 3. Independent setting of X and Y deflection. 4. Frequency : 0.1 to 2000 Hz or better 5. CNC based and manual beam deflection

control. 6. Oscillation of beam as per preferred function

generation by NC or controller

Functional verification


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B. 10. Function generator 1. Sine, square, triangle, circle, ellipse, saw-

tooth and ∞

2. Two axes sine wave outputs for deflecting the

beam in a circular pattern.

3. Two axes DC deflection for positioning of

the electron beam.

4. Square wave forms for different workspace

ratio.

5. DC deflection shall be superimposed on the

AC outputs to provide for centering the circle

during welding operation.


11. Gun vacuum pumping system

The two Electron guns shall have two separate vacuum pumping system with the following specifications. NOTE: The entire vacuum components/pumps/valves of the gun shall be from the same source/manufacturer (Viz. Edwards, Leybold, Agilent & Pfeiffer.)

Physical

verification

11.1 Working Vacuum level

10-5 mbar or better Functional verification

11.2 Vacuum suction time

Less than 3 minutes Functional verification

11.3 Ultimate vacuum level

1X10-6 mbar or better


11.4 Pumps 1. One Primary pump. 2. One Turbo

molecular pump


11.5 Vacuum Measurement and instrumentation.

Vacuum measurement by Pirani/Penning/Wide range gauge. (Gauge/s make and model to be mentioned in the technical offer)


11.6 Isolation Valve Pneumatic operated cut-off valve ensuring that vacuum is maintained in the gun when the chamber is vented.




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B. 12. Viewing and Beam

Alignment

1. Coloured camera to achieve 10X

magnification at shooting distance from 50-

300mm inside chamber (From top to bottom

of the chamber).

2. Video to be displayed on HMI-PC.

3. Binoculars Viewing system for manual

focussing to be provided for both EB guns.

4. Provisions for aligning the joint with beam

before welding and during welding.

5. Suitable vapour protection for optics (like

stroboscopic system).

6. A cross hair shall be superimposed over the

image to allow the position of the beam on

the joint to be precisely adjusted before

welding.

7. Seam tracking by teach in & replay system by

interpolation.

Physical and

functional

verification

C. Welding Chamber

1. Material Non-magnetic Stainless steel Physical

verification

2. Width x Length x Height 305mm x 305mm x 305mm or better Physical

measurement

3. Wall thickness The thickness of the chamber walls shall be

designed to block X-ray radiation in accordance

with international regulations.

(<1μSv/h measured 100 mm from the walls)

Functional

verification at

OEM's place

by third party

inspection

4. Front access door Access door shall have hinged and open towards

the left of the welding chamber when viewed

from the front of the machine.

Physical

verification

5. View port Viewing port Ø150mm lead glass and vapour

protective removable glasses for easy

replacement shall be located centrally on the

front door.

Physical

verification

6. Sealing System 1. Sealed door, Access ports and Pumping

system with leakage ≤ 10-6 mbar.l/s.

2. Suitable leak detection ports to be provided.

3. Door ,Access ports and Pumping system

shall have suitable compatible O ring Seals.

Functional

verification.


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C. 7. Chamber vacuum

pumping

The Welding chamber shall have separate

vacuum pumping system with following

specifications.

NOTE: The entire vacuum

components/pumps/valves of the gun shall be

from the same source/manufacturer


Physical

verification

7.1 Working Vacuum

level

10-4 mbar or better Functional

verification

7.2 Vacuum suction

time

Less than 4 minutes Functional

verification

7.3 Ultimate vacuum

level and duration

5X10-5 mbar or better in

less than 5 minutes

Functional

verification

7.4 Pumps 1. One Rotary pump.

2. One Roots pump.

3. One Turbo

molecular pump with

safety interlocks .

4. One rotary backup

pump for Turbo

molecular pump.

5. Valves

Physical

verification

7.5 Vacuum

Measurement and

instrumentation.


range gauge. (Gauge/s make and model to be

mentioned in the technical offer)

Note: Suitable provision shall be made for leak

detection in vacuum pumping line with leak

detection ports.

Functional

verification

7.6 Over-ride Manual override provision for vacuum pumps

and valves through HMI.

Functional

verification



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D. Work Handling System

1 Configuration 1. CNC controlled X and Y Table mountable

on to chamber bottom with suitable

arrangement for accurate fixturing.

2. Vertical Rotary manipulator with

arrangement to swap in the place of XY

table. This manipulator is mounted

externally, on the bottom side of the working

chamber.

3. Horizontal Rotary manipulator mounted

externally, on the left of working chamber

when viewed from front of the machine.

With Following Specifications,

NOTE: All the components of work handling

system are made of Non-magnetic material.

Physical

verification

Replacement

of Vertical

manipulator by

XY table and

accurate

clamping to be

demonstrated

2. X Y Table Physical

verification

2.1 Table size 150mm X 150mm or better Physical

measurement

2.2 Stroke length 3. X-axis : 100mm to 200mm

4. Y-axis : 100mm to 200mm

Physical

measurement

2.3 Accuracy 3. X-axis : 50 µm or better

4. Y-axis : 50 µm or better

Physical

measurement

2.4 X. and Y. Speed 1-2000mm/min or better

Physical

measurement

2.5 Load carrying

capacity

Up to 20 kg.

Physical

verification

3 Horizontal and Vertical

Rotary Manipulators

The Rotary manipulator shall have axis accuracy

of 100μm. The rotary manipulator shall have

centrally sliding hardened shaft with proper

vacuum seal, moves inside and outside of the

vacuum chamber and provision to mount the

chuck inside the vacuum chamber.

Physical

measurement

3.1 Shaft Size 25mm diameter x 450mm long hardened non

magnetic shaft.

Physical

measurement


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D. 3. 3.2 Positioning for

Welding

Fully hardened collet clamping. Physical

measurement

3.3 Diameter of

chuck

Non magnetic High precision 70mm three jaw

self aligning chucks.

Physical

measurement

3.4 Rotating Speed Rotary speed adjustable from 1rpm to 60 rpm.

Physical

measurement

3.5 Speed stability ±1% of set speed Functional

verification

3.6 Spindle Run-out 30µm or better Physical

measurement

3.7 Drive system Servo Motor (CNC controlled) Functional

verification

3.8 Loading Capacity 20 kg or better Physical

verification

E. High voltage power

supply

High voltage power supply shall be with switch

mode power supply, variable bias supply for

beam current control with an adjustable and

stabilized supply for filament heating and it shall

have following features.

1. The power supply shall have ANTI-FLASH

protection.

2. Less power dissipation.

3. High voltage proof.

4. Short circuit proof (supply needs to switch

off to avoid mis-welding and loss of

expensive work piece)

5. Zero beam current during HV recovery

(Defocusing of beam to avoid miss welding

and loss of expensive work piece)

6. Oil filled tanks and top lid easily removable

for maintenance.

Physical

verification


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F.

Control System

1 Configuration The control system to be based on Industrial

PLC, industrial HMI (Human Machine

Interface), a PC and numerical control system

which shall be of latest windows based CNC

system. The PC shall be equipped with at least

• 2 Nos. of USB ports, • 2 Nos. of serial ports • 2 Nos. of Ethernet ports.

Physical

verification

2. PLC The industrial PLC working with industrial

HMI-PC supervisory system with GUI shall be

able to control following parameters of Electron

Beam Welding Machine :

1. Welding chamber vacuum Sequence. 2. Electron gun Vacuum Sequence . 3. Electron gun Isolation valve control. 4. Electric supply of gun. 5. Safety interlocks/Security system 6. CNC Interface. 7. Alarms and Security. 8. Auto Diagnostic for Maintenance.

Functional

verification

3. PC supervisory system CNC system shall work with industrial PC,

providing the operator interface in dialog mode

with an industrial HMI (Human Machine

Interface) standard supervisor system. The

supervision program uses standard software on

latest version of Windows. It shall be responsible

for the overall management of the machine, in

particular:

1. Management of start-up modes: immediate

or deferred.

2. Management of gun settings, including

conditioning and space charge.

3. Management of the video and cross-hairs.

4. The displays of pump units, power supplies

for the gun, mechanical movements etc.,

5. Management of faults, with history.

6. Tracking the duration of use of various

components, including cathode counter

(hours), filament, pumps, etc., in order to

facilitate preventive maintenance.

7. Troubleshooting with access to each PLC

input/output variable.

Functional

verification


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F.

4 CNC system The welding programs shall be managed by

CNC system with the following specifications :

1. Fitted with a dedicated keypad and screen.

2. The welding programs shall be created,

executed and stored by CNC system

working to meet the requirements of

standards such as ISO 14744.

3. The control system shall include hand held

pendant with electronic hand wheel and

foot switch for precise adjustment of the

CNC axes in manual mode and necessary

controls for machine operation.

4. Programming language shall meet the

standards such as ISO.

5. Supervision program shall be with standard

software on latest version of Windows

based operating system.

6. Control of mechanical welding axis and

the electrical settings for the beam

(accelerating voltage in kV, beam current in

mA, focus current in mA, X and Y beam

deflection amplitude in A), linear speed in

X and Z axis(Gun axes) & XY table axes in

mm/min, rotary speed in rpm and mm/min.

7. The welding programs include all the data

required to carry out the full welding cycle.

The complete welding program shall be

able to set ramp up, dwell time, ramp down.

8. Program storage capacity in CNC memory

– minimum 10 programs and mass storage

with PC hard disk shall be a minimum of

100GB.

9. Programs can be downloaded from the

supervisor PC. The PC's hard disk shall

serve as mass storage in the event that a

large number of programs are used.

Functional

verification


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F.

5 Parameters display Following operating parameters shall be

displayed at the control panel:

1. Display for vacuum level in welding

chamber and gun in mbar.

2. Speed and position of manipulators and X-Y

axes Table.

3. Speed and position of gun movement.

4. Accelerating voltage.

5. Beam current.

6. Focus current.

7. Beam deflection signal (by oscilloscope).

8. Indicators for diffusion pump ready.

9. Audio-visual display (Alarm) for air/water

failure.

10. Programming with HMI (Human Machine

Interface) shall include mimic display, alarm

status, quality data recording, error

indicators, operation screen for tooling,

vacuum and weld cycle recipes.

11. Programs shall be linked to build up a fully

automatic program consisting of tacking,

penetration, cosmetic pass, deflection,

stirring, etc.

Functional

verification

G. Safety 1. Radiation levels to be measured in

accordance with the ISO standard-14744 or

equivalent standards.

2. The chamber shielding shall ensure radiation

levels of less than 1µSv/hour, at a distance

of 100mm from any external surface, with a

defocused beam of maximum power.

3. Radiation shield in the equipment shall meet

the requirement of annual whole body dose

limit of 50 mSv (maximum)

4. Illumination of red warning light when the

high voltage to the gun is on.

5. Water flow, water temperature and air

pressure switches to protect the vacuum

pumping system against power supply

failure. Audible warning of failure should be

provided.

Functional

verification

along with

third party

inspection

wherever

necessary.


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G. Safety 6. All rotary drives shall be fully protected by

safety guards and noise from the machine

shall be less than 70 dB.

7. Safety interlocks for preventing accidental

energizing of high-voltage without required

vacuum level, opening of isolation valve

etc., shall be incorporated.

8. Beam shall not be “ON” without sufficient

vacuum in gun and chamber.

9. System shall have automatic trips for over

kV, over mA, filament failure and auto-

diagnostic system.

H. Online data monitoring and storage

This system shall be fitted with the equipment and shall have the following features: The system shall have a minimum number of channels and allows storing of the data of the actual welding parameters as well to plot the curves for each parameter all along the welding cycle. PC shall be equipped with a software program to record the welding data with a minimum sampling interval of 0.05 seconds. The data recorded for each weld shall be provided in an Excel spreadsheet. The following parameters are to be recorded, 1. Accelerating voltage (kV). 2. Beam current (mA). 3. Focus current (mA). 4. Linear Gun table speed (m/min). 5. X Y table welding speed (mm/min) 6. Rotary welding speed (rpm). 7. Vacuum level in gun & chamber (mbar).


I. Cooling System Suitable closed loop water cooling system indicating the temperature, flow rate, power etc.


J. Input Electrical Supply Voltage: 415±10% Three phase and Neutral Power: 25 kVA±10% Frequency : 50Hz ± 1% Earth: ≤ 2Ω

Functional Verification

K. Test data and Documents for Electron Beam Welding machine

All test data shall be recorded along with detailed checking of beam

equipment functions and components

1 Instruction manual Physical

verification


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K. 2 Maintenance manual Physical verification

3 Diagrams for

all mechanical assemblies

with parts lists.


4 Mechanical,Electrical and

Electronic diagrams


5 Technical documentation

for the main components

purchased.


6 Original licence for the

software which is

purchased.


7 One soft copy of all

the manuals and diagrams

in PDF format,

as well as the

specific programs

(PLC and man-

machine interface).


8 One re-

installation CD for the PC


9 Licensed version software

CD and replaceable hard

disk installed with all the

software shall be

included.


10 Calibration certificate for

all the vacuum gauges

shall be provided


11 Spare parts list with

source of supply and

prices


12 The supplier should

provide details regarding

the safety measures

adopted in the system.


13 Manuals of bought out

items incorporated in the

system



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L Safety and

Certifications

All the necessary safety regulations such as CE

compliance, low voltage directives, EMC

regulations compliance details, Alarms and

emergency switch-off in case of any

malfunctioning must be provided. The system

must be equipped with all the necessary safety

interlocks.

M Warranty - inclusive of

parts and labor

The complete system and its associated hardware / software should have a standard warranty of 24 months from the date of installation, commissioning and acceptance of the system at CMTI.

Maintenance/ repair /replacement of any hardware or software component of the system during warranty period to be done free of cost (including expenses of Engineer from OEM) .

Supplier modification(s) / Software upgrades shall be intimated and same will be made available free of cost during the warranty period.

Spares list required and their cost for 2 years of operation after the warranty period shall be indicated in the offer.

Additional 12 months extended warranty may be

quoted as an option.

N Annual Maintenance

Contract

AMC per year basis and on bulk basis (for 3

years) including parts and labor to be quoted

separately. The terms, Conditions and amount

payable for AMC should be provided by the

vendor which shall include,

1. Preventive Maintenance

2. Breakdown Maintenance

Note: AMC terms and conditions shall be agreed

upon mutually before placement of Purchase

Order


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Note:

1. The final Acceptance Criteria will be based on mutual agreement and will be

finalized at the time of placing the order. The equipment will be finally accepted

based on the compliance of the equipment with the Acceptance Criteria. Hence, the

bidder has to go through the Acceptance Criteria and convey their acceptance

unambiguously. They may also suggest a suitable method of verification if the

proposed method is not acceptable to the bidder.

2. Bidders are to provide technical specifications as per following guidelines.

Technical bid shall consist of

a. Index of items

b. Compliance Matrix

c. Machine Brochure - incorporating machine technical specifications.

d. Technical details or datasheets of all third party machine elements (pumps,

gauges, valves etc.)

e. List of certificates and documents along with quantity that will be provided

with the machine.

f. Complete list of spares for 2 years of operation.

g. Detailed Address of Indian service provider (if any) with Contact person

Name, email ID and Phone No.

h. Detailed Address of OEM with Contact person Name, email ID and Phone

No.

The above documents have to spiral bound. In Order, preferably as above.