N252-077 TITLE: Tactical Sled Loader (TSL) Material Handling System and Cargo Sled

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Sustainment

OBJECTIVE: Develop a Tactical Sled Loader (TSL) to provide the Marine Corps with the capability to rapidly load/offload munitions and cargo with an emphasis on speed to avoid enemy detection and targeting cycles plus the capability to transfer equipment and supplies with a variety of dimensions and weights to and from aircraft and ground transportation assets.

DESCRIPTION: The need for a newly developed TSL originated from a Deliberate Universal Needs Statement (DUNS) from INDOPACOM. The DUNS was vetted through the capabilities portfolio integration board and received a decision memo to pursue and develop solutions. The TSL consists of a Sled Loader hereafter referred to as the Loader and a Cargo Sled hereafter referred to as the Cargo Sled. The Cargo Sleds shall vary in size (primarily their width) to accommodate the various aircraft Cargo cabin dimensions (MV-22 Osprey, CH-53K, C-130). The Loader shall be one size and able to be transported in an MV-22 Osprey (the smallest transport aircraft).

The TSL system shall be equipped with a Loader designed to facilitate the efficient loading and unloading of cargo-laden Sleds to and from assault support aircraft, including but not limited to the MV-22, CH-53K, and C-130.

Tactical Sled Loader (TSL) Requirements

1. Shall employ a combination of manually operated winches and friction-reducing devices (such as rollers) to enable operators to smoothly transfer the loaded Cargo Sled between the Loader and the aircraft’s Cargo drop down hatch.
2. Shall have an adjustable height between 25" and 45", ensuring compatibility with various assault support aircraft mentioned above by accommodating differences in Cargo hatch height and facilitating the loading and unloading of the aircraft (MV-22 lowest point and C-130 highest point) and allowing for independent modification of the Loader's pitch and roll. (Note: The platform of the Loader must remain integrated and move uniformly during adjustments. Any height adjustments must be performed manually, requiring continuous user input, and must not damage the Cargo. All hydraulic systems used for this purpose shall employ braided steel lines.)
3. Shall be designed for easy towing and repositioning, both when loaded and unloaded, utilizing standard tow vehicles or by hand.
4. Shall be equipped with tie-down points and parking brakes to ensure stability and safety during loading and unloading operations. (Note: These parking brakes must be sufficiently robust to securely hold a fully loaded TSL, preventing any risk of tipping or slipping when stationed on a flight deck or in a hangar. Some sort of visual indicators that can warn an operator that the load is reaching an unsafe position (e.g., dial indicator) should be considered.
5. Shall contain an integrated, adjustable guide system incorporated into the Loader design to prevent the Cargo Sled from deviating off course during loading and unloading procedures, ensuring a secure and controlled operation; to enable the Loader to expand by a minimum of 8 inches on each side to accommodate Cargo Sleds designed for use in larger aircraft such as C-130 and CH-53K; that is easily retractable to accommodate smaller Cargo Sleds used on MV-22 osprey aircraft; to prevent any lateral movement of the Cargo Sled, ensuring it remains securely on the Loader during operations; to avoid any damage upon contact between the Cargo Sled and the Loader; and to adjust to accommodate Cargo Sleds ranging from 63 to 85 inches in width.
6. Shall feature a versatile four-wheel steering configuration, designed for both towing behind military vehicles and manual pushing or pulling.
7. Shall interface seamlessly and provide adequate support to the small Cargo Sleds developed specifically for MV-22, and large Cargo Sleds designed specifically for C-130, and CH-53K aircraft, collectively referred to as the aircraft, during both loading and unloading operations.
8. Shall be constructed robustly to able to withstand the stresses, shocks, vibrations, and other conditions associated with towed movement and rail, truck, and air transport.
9. Must be compatible for towing with a variety of small vehicles typically found at air terminals, in addition to military vehicles. [Ref 4].
10. Must enable controlled transfers of loaded Cargo Sleds to and from the aircraft Cargo area with all equipment necessary for these transfers, such as winches, rollers, and guide rails, permanently integrated into the Loader. (Note: Leveraging the aircraft's winch system for transferring Cargo Sleds from the Loader to the aircraft is permissible.)
11. Shall incorporate a manually operated winch system, potentially comprised of multiple winches, that must facilitate the movement of the Cargo Sled from the aircraft’s Cargo area to the Loader; and should provide pulling capabilities at the front-center, front-right, and front-left of the Cargo Sled. (Note: Simultaneous pulling from the front-right and front-left shall be equivalent to a central pulling load. The intent is to reduce the personnel required to operate this system for cargo movements over legacy methods.)
12. Must not exceed dimensions of 140 inches in length, 65 inches in width, and 25 inches in height in its storage configuration; the height shall be adjustable from 25" to 40" and the width shall be expandable from 65" to 85".
13. Shall not exceed 3,500 lbs in weight, inclusive of all operating fluids and hydraulic reservoir at operational levels.
14. Must be capable of handling loads up to 10,000 pounds (i.e., the "rated load").
15. Must maintain stability when lifted via forklift in an unloaded state, and should allow lifting from both sides, adhering to section 3.3.4.2 of MIL-S-8512D. (Note: Reinforced forklift tine guides, preferably pockets, must be provided for safe and positive insertion, ensuring no damage occurs during lifting. The center of gravity of the Loader, when unloaded, shall be clearly marked on the Loader itself.)
16. Lift/Tie down points conforming to MIL-STD-209K, Interface Standard for Lifting and Tie-down Provisions for all forms of transportation, which serve multiple purposes: lifting the Loader, tying down the Loader, and securing the Cargo Sled to the Loader. (Note: The Loader must not be lifted in a loaded state but should be secured adequately when loaded.)
17. Must be capable of operating in temperatures ranging from -25° to +125°F, capable of operating in 6" Threshold, 24" Objective and near salt water, and compatible with amphibious and commercial shipping.
18. Must be capable of operating in day and night conditions and be capable of providing adequate operator-adjustable lighting for night operations.
19. Must have axle weights (front and rear) that meet the weight restrictions of a C-130, CH-53K, and MV-22 military aircraft.
20. Must be equipped with service brakes capable of stopping and holding the TSL with rated load either forward or backward on a 30-degree slope; and a parking brake that must restrain the TSL with rated load on at least a 30-degree slope.
21. Must be capable, with rated load, of negotiating both an angle of approach and an angle of departure of at least 20 degrees for negotiating the ramp of a landing craft and shall be able to negotiate a longitudinal slope of at least 45 percent in both forward and reverse at a speed of not less than 2 mph; and of negotiating at a 15 percent cross slope in full circle operation in both directions at maximum steer angle without any tire leaving the ground.
22. Must be capable, with rated load, of traversing uneven and unprepared surfaces (rough terrain) to include sand, snow, and mud.
23. Must be capable, with rated load, of traveling forward on flat firm ground at speeds of at least 8 mph and of executing a 360-degree turn.
24. Must be equipped with pneumatic tires that meet the load requirements of the TSL.
25. Must be corrosion resistant (i.e., must meet or exceed current ground equipment protection standards) during unprotected storage and from the effects of a salt-water environment.
26. Must be equipped with a 24-volt negative-ground electrical system or at a minimum have a 12/24 dual system with 24-volt alternator, 24 starter and battery equalizer. (Note: A NATO standard electrical slave receptacle shall be provided.)
27. Must contain commercial standard diagnostic capabilities. (Note: Design shall be such that maintenance and repair can be conducted with common tools wherever possible. No unusual mechanical skill should be required at any echelon of maintenance.)
28. Must be equipped with a rear axle that can oscillate above and below the horizontal axle centerline.
29. Must be equipped with integral tie-down brackets, a rear towing pintle and appropriate lifting eyes. (Note: The towing pintle hook shall be accessible for removal or adjustment.)
30. Must meet applicable DoD human engineering, health, and safety standards and employ user-friendly features for personnel operating in or near the TSL throughout its life cycle. (Note: The TSL design and engineering must be able to achieve certification to handle conventional ordnance and transportability onboard MV-22, CH-53K, and C-130 aircraft.)
31. Must be capable of being embarked and disembarked, without disassembly, aboard all roll-on/ roll-off (RO/RO) ships and amphibious shipping/craft.

For Chemical, Biological, Radiological, and Nuclear, Biological, (CBRN) Survivability, only Chemical, Biological, and Radiological contamination survivability is required. Nuclear survivability is not required.

Two types of Cargo Sleds will be developed to accommodate the dimensions of the supported aircraft: a small Cargo Sled designed for use with MV-22 and a large Cargo Sled developed for use with CH-53k and C-130 aircraft.

Cargo Sled Requirements

1. Shall have side, forward, and aft fork pockets to enable lifting from all sides.
2. Shall have a weight capacity of 10,000 lbs. (i.e., "rated load").
3. Must interface with the aircraft Cargo deck rollers and floor locking systems of aircraft.
4. Must have adequate tie down points to accommodate a range of loads.
5. Will have weapons interface adapter positions for the install of bomb saddles and or missile cradles to support the All Up Round Transport of Weapons as with the MHU-110 munitions trailers.

PHASE I: Develop concepts for a TSL and Cargo Sleds that meet the requirements described above. Demonstrate the feasibility of the concepts in meeting Marine Corps requirements. Establish that the concepts can be developed into a useful product for the Marine Corps. Feasibility will be established by material testing and analytical modeling, as appropriate. Provide a Phase II development plan with performance goals and key technical milestones, and that will address technical risk reduction.

PHASE II: Deliver two working TSL prototypes and three Cargo Sleds for evaluation to determine their capability in meeting performance goals defined in the Description above. Demonstrate technology performance through prototype evaluation and modeling over the required range of parameters. Evaluation results will be used to refine the prototype into an initial design that will meet Marine Corps requirements; and for evaluation to determine its effectiveness in an operationally relevant environment approved by Government. Prepare a Phase III development plan to transition the technology to Marine Corps use. The technology should reach Technology Readiness Level (TRL) 6/7 at the conclusion of this phase.

PHASE III DUAL USE APPLICATIONS: Support the Marine Corps in transitioning the technology for Marine Corps use. Support the Marine Corps for test and validation to certify and qualify the system for Marine Corps use. The prototypes shall be TRL 8 at the conclusion of testing.

Commercial applications may include, but not be limited to, airline industry, logistics, and warehouse/manufacturing operations.

REFERENCES:

1. Department of Defense. "MIL-STD-8512 Rev. D, MILITARY SPECIFICATION: SUPPORT EQUIPMENT, AERONAUTICAL, SPECIAL, GENERAL SPECIFICATION FOR THE DESIGN OF." 19 February 1974. http://everyspec.com/MIL-SPECS/MIL-SPECS-MIL-S/MIL-S-8512D_7455/#:~:text=19%20FEB%201974)-,MIL%2DS%2D8512D%2C%20MILITARY%20SPECIFICATION%3A%20SUPPORT%20EQUIPMENT%2C,specifications%20for%20specific%20items%20of
2. Department of Defense. "MIL-STD-209K, INTERFACE STANDARD FOR LIFTING AND TIEDOWN PROVISIONS." 22 February 2005. https://www.sddc.army.mil/sites/TEA/Functions/Deployability/TransportabilityEngineering/Modeling/Documents/MIL-STD-209K_2005-02-22.pdf
3. Department of Defense. "MIL-STD-913 Rev. A, REQUIREMENTS FOR THE CERTIFICATION OF SLING LOADED MILITARY EQUIPMENT FOR EXTERNAL TRANSPORTATION BY DEPARTMENT OF DEFENSE HELICOPTERS." 3 Feb 1997. http://everyspec.com/MIL-STD/MIL-STD-0900-1099/MIL_STD_913A_1130/
4. Department of Defense. "MIL-STD 810 Rev. H, ENVIRONMENTAL ENGINEERING CONSIDERATIONS AND LABORATORY TESTS." 18 May 2022. https://cvgstrategy.com/wp-content/uploads/2023/04/MIL-STD-810H-change-1.pdf
5. Department of Defense. "MIL-STD-461 Rev. G, REQUIREMENTS FOR THE CONTROL OF ELECTROMAGNETIC INTERFERENCE CHARACTERISTICS OF SUBSYSTEMS AND EQUIPMENT." 11 December 2015. http://everyspec.com/MIL-STD/MIL-STD-0300-0499/MIL-STD-461G_53571/
6. Department of Defense. "MIL-STD-464 Rev C, ELECTROMAGNETIC ENVIRONMENTAL EFFECTS REQUIREMENTS FOR SYSTEMS." 1 December 2010. https://www.ema3d.com/wp-content/uploads/downloads/MIL-STD-464C.pdf
7. Department of Defense. "MIL-STD-1472 Rev H, DESIGN CRITERIA STANDARD HUMAN ENGINEERING." 15 September 2020. https://quicksearch.dla.mil/Transient/B0F47915457A43BF887057CF3D723B7D.pdf
8. PDI Group. "MHU-110/M Munitions Trailer." https://www.thepdigroup.com/copy-of-manufacturing-our-approach

KEYWORDS: Material Handling; Munitions; Sustainment; Contested Logistics; Aircraft; Cargo; Transportability; Equipment; Distribution; Multi-Domain

TPOC 1: Dustin Hanson
[email protected]

TPOC 2: David Keeler
[email protected]

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