Innovative Tactical Bulk Fuel Delivery System Restraint System
Navy SBIR 2014.2 - Topic N142-097
NAVAIR - Ms. Donna Moore -
Opens: May 23, 2014 - Closes: June 25, 2014

N142-097 TITLE: Innovative Tactical Bulk Fuel Delivery System Restraint System

TECHNOLOGY AREAS: Air Platform, Materials/Processes, Human Systems


RESTRICTION ON PERFORMANCE BY FOREIGN NATIONALS: This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120-130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign nationals may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign national who is not in one of the above two categories, the proposal may be rejected.

OBJECTIVE: Develop and demonstrate an innovative restraint system for the CH-53K tactical bulk fuel delivery system.

DESCRIPTION: The tactical bulk fuel delivery system (TBFDS) is an air transportable system capable of range extension and offload fuel delivery. Internally carried by the CH-53K, the system has a maximum design capacity of 2,400 gallons. Each system contains provisions for two refueling points. The forward area refueling equipment (FARE) pump is rated at 120 gallons per minute (gpm) allowing for dual point operations at 45 gpm and single point operations at 75 gpm. The TBFDS consists of three 800 gallon tank assemblies.

The TBFDS tank is of composite structure with an internal bladder. It is approximately a 60 inch (in) cube with a 33 in centered circle that must remain free of restraints due to fitting locations on the top side of the tank. The three tanks are separated by 20 in.

The CH-53K cargo floor is roughly 300 in in length and incorporates a 463L rail locking system on an 88 in bias; 20,000 pound (lb) (20k) and 10,000 lb (10k) tie-down rings are utilized for securing loads in the cargo compartment. There are six rows of rings down the floor establishing a 20 in grid; the 20k rings are located along each side wall while the 10k rings comprise most of the internal four rows. There are twelve 20k ring locations that have been placed within the internal rows, comprising three 60 in squares.

Cargo ring ultimate retention strength for crash loading is defined as 1.5 times the ring rating.

The 463L rail locking system may be employed in conjunction with the cargo rings to secure the TBFDS.

Existing systems are cumbersome, requiring empty fuel tanks and excessive man power to on and offload in the event of a down aircraft. Current restraint capabilities restrict the volume of fuel to be safely carried during operations.

An innovative CH-53K TBFDS restraint system that reduces crew efforts and weight while increasing operational capability, reliability, maintainability and affordability is sought. It shall be practical to manufacture, install and remove and capable of restraining the TBFDS to NAVAIR crash g-load requirements +/- 20 g longitudinal, +/- 20g vertical, and +/- 10 g lateral (20/20/10) and NAVAIR environmental requirements to include MIL-STD 810G.

The TBFDS restraint system shall be capable of the following:

1. Restraining the TBFDS to the NAVAIR crash acceleration loading requirements (20/20/10) applied separately without failure.

2. Restricting translational movement of the TBFDS tank with any amount of fuel loading throughout the CH-53K flight, ground, and landing operation envelope, under slosh conditions, due to aircraft vibration and under crash acceleration loading as specified above. Translation of the tank under flight, ground, and landing operational envelope, under slosh conditions, due to aircraft vibration is not acceptable. Under crash acceleration loading translation is limited to not impacting aircraft structure or other cargo (Threshold), or no translation (Objective).

3. Limiting gross deformation of the top of the tank to ensure that tank connections to the fuel system are not dislodged throughout the CH-53K flight, ground, and landing operational envelope, under slosh conditions, and due to aircraft vibrations.

4. MIL-STD 810G will be used to verify solution for the environmental compliance within the CH-53K operational envelope to include vibration, salt/fog, sand/dust, humidity, and temperature.

5. Address ease of on/offload and human factors.

6. Provide credible analytical and/or experimental verification of the concept as appropriate to demo feasibility.

PHASE I: Develop an innovative approach to restrain the CH-53K TBFDS. Concept must address ease of on/offload and be capable of restraining the TBFDS to NAVAIR crash g-load requirements (20/20/10) as demonstrated through analysis and verification using validated models/simulation.

PHASE II: Fully develop the concept and demonstrate practical implementation of a production scalable prototype TBFDS restraint. Evaluate the prototype restraint through demonstration testing under conditions representative of a military aircraft cargo compartment.

PHASE III: Transition the system concept to the CH-53K platform and demonstrate adaptability to other fleet platforms through modification.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: An innovative TBFDS restraint system can be adapted for transition onto other airframes or be utilized in guiding future platform designs, which will improve capabilities, safety, and reliability.

1. Robertson Aviation Crashworthy Extended Range Fuel Systems, July 2008, Helicopter Support, Inc. A Sikorsky Aerospace Services Company.

2. Trafford, M., Klein, S., and Meiranke, D., 2011, Qualification and Full-Scale Test of the Airbus A400M Barrier Net. SAE International, 4(2):710-723.

3. Viisoreanu, A., Rutman, A., and Cassatt, G., Analysis of an Aircraft Cargo Net Barrier Using MSC/NASTRAN. Boeing Commercial Airplane Group,

4. Avery, J., 1965, Cargo Restraint Concepts for Crash Resistance, US Army Aviation Materiel Laboratories,

5. A Study of Helicopter Crash Resistant Fuel Systems, Federal Aviation Administration, 2002,

KEYWORDS: Fuel; Safety; Cargo; Affordable; Crashworthy/Survivability; Lightweight Restraint

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