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Battlelab initiative aims to speed KC-10 cargo loading

  • Published
  • By Tech. Sgt. Scott T. Sturkol
  • U.S. Air Force Expeditionary Center Public Affairs
FORT DIX, N.J. --  Though the Air Mobility Battlelab deactivated here Sept. 24, one of its final initiatives shows great potential to help KC-10 crew members do their jobs faster and decrease aircraft weight.

With the KC-10 Lightweight Cargo Net and Hoist Initiative, the Air Mobility Battlelab, or AMB, sought out ways to make raising and lowering the aircraft's cargo net easier. The net acts as a safety barrier between the KC-10's cargo deck and passengers seated in the forward section of the aircraft, and must be moved out of the way every time cargo is loaded or unloaded. The current net's 235-pound weight makes it very awkward and time consuming for crew members to raise and lower, however. The AMB explored two options to improve the situation: installing a mechanical hoist to raise and lower the net, and using new materials to make the net lighter.

The Air Force Research Laboratory's Airbase Technologies Division at Tyndall Air Force Base, Fla., stepped up to the challenge of designing and building the hoisting device. Using in-house engineering expertise, the group built a system composed of two gear boxes that attach to the top of the net and are operated by a crew member standing on the cargo deck floor.

To demonstrate the concept of a lighter-weight net, the battlelab contracted with the AmSafe Corporation, a company with considerable experience building cargo nets for commercial aircraft. Using state-of-the-art high-strength materials, AmSafe was able to construct a cargo net that weighed only 115 pounds.

Master Sgt. Chris Sidoli, AMB's project manager for the initiative and a KC-10 boom operator, said, "The lightweight net was not only 120 pounds lighter, but had an 'integrated stowage' system that made it much easier to raise than the current net, which has to be lifted and secured using cargo straps. It has real potential."

The battlelab conducted its demonstration on McGuire Air Force Base, N.J., in mid-September. With a team of volunteers from the 305th and 514th Air Mobility Wings as well as representatives from AmSafe and the Air Force Research Laboratory, they accomplished six objectives in comparing the lightweight net against the current net.

"Our major objective was to see if there was a time savings during net raising and lowering between the two nets," Sergeant Sidoli said. "We found that the effort for the lightweight net took half as long as it does for the current net, even without using the hoisting device."

Using two experienced KC-10 boom operators, Staff Sgt. Matt Hauer from the 2nd Air Refueling Squadron and Airman 1st Class Dan Flenniken from the 305th Operations Support Squadron, as volunteers, the team found that it took 15 minutes, 21 seconds to fully stow the current net. In contrast, Sergeant Hauer and Airman Flenniken were able to stow the lightweight net in seven minutes, despite having received only minimal training.

In the remaining objectives, the demonstration team wanted to make sure the lightweight net was compatible with KC-10 while raised and when lowered to its fully-installed position. They also wanted to determine if the hoist system would work on both the current and lightweight nets, and if the hoist could be operated by one person.

"First, we found the lightweight net fits and doesn't interfere with the KC-10's built-in systems. Some minor modification would be necessary to make the net ready for fielding, however," Sergeant Sidoli said. "With the hoist system, we found that it did raise the nets quicker than if done manually. We also determined it was best to have two people operate the hoist, and we noted some modifications that would make the hoisting process more efficient."

In the battlelab's overall assessment, Lt. Col. Jeffrey Lathrop, AMB commander, determined the lightweight cargo net concept shows a lot of promise in reducing cargo loading and unloading times. It could also save the Air Force money in the long haul by lowering aircraft weight which, in turn, reduces fuel consumption.

"In addition to making the net much easier and safer to use, a 120-pound weight savings has the potential to save the Air Force approximately $1 million a year in fuel costs for the KC-10 fleet-wide." Colonel Lathrop said. "We recommended the lightweight net concept to Air Mobility Command for further development."

The Air Mobility Battlelab deactivated Sept. 24 as part of an Air Force cost savings initiative. It was a fixture in the U.S. Air Force Expeditionary Center on Fort Dix, N.J., for more than 10 years. For more on the USAF EC, visit http://www.expeditionarycenter.af.mil.