Battlelab initiative improves flight deck safety

  • Published
  • By Tech. Sgt. Scott T. Sturkol
  • U.S. Air Force Expeditionary Center Public Affairs
FORT DIX, N.J. (AFPN) --  Aircrews flying KC-135 Stratotankers to hot climates may have an easier way to keep their flight decks cool when on the ground thanks to the Air Mobility Battlelab's KC-135 Hot Weather Cooling Sock initiative.

"This initiative addresses a current problem where aircraft maintainers use a standard flexible duct connected to aerospace ground equipment to cool the KC-135 flight deck in hot climates," said Master Sgt. Eric Allain, the AMB's project manager for the initiative. "The duct is difficult to maneuver, impairs entry and emergency egress from the flight deck hatch and prevents closure of the crew entry gate -- all safety concerns."

The proposed solution to the problem is a lightweight, flexible, canvas, hot weather cooling sock that will allow obstruction-free entry and egress from the flight deck hatch during ground cooling operations, Sergeant Allain said. 

"This installation will allow the crew entry gate to fully close, eliminating potential tripping hazards and other safety concerns," he said.

The first step to build progress on the initiative was to fabricate the cooling sock and hold a concept demonstration. Enter the 161st Air Refueling Wing at Sky Harbor Airport in Phoenix, Ariz., and a manufacturer who makes a name brand acrylic fabric.

"We took a commercially-made canvas acrylic fabric and had it sewn into a cylindrical hose approximately 15- to 16-feet long with an air sealing web nylon cinch belt," Sergeant Allain said, "There are buckle tie-downs on one end of the sock connecting it to a standard flexible duct and four strap webbings with a spring buckle on the other end to tie it down to the ladder. When the sock is completely rolled up, it is approximately the size of a small sleeping bag."

Airmen in the 161st ARW parachute shop fabricated the cooling sock at a cost of $78 in parts and four and a half hours of labor, Sergeant Allain said.

"With our cooling sock made, we went to work on how well it would operate on a KC-135 to cool the flight deck down in the Arizona sun," Sergeant Allain said.

During the demonstration held in June, they completed five objectives. First, they determined the capability of the cooling sock to cool the flight deck during ground operations. 

Second, they looked at whether the cooling sock would allow an obstruction-free entry and egress from the flight deck. 

Third, they determined whether the cooling sock would allow for complete closure of the flight deck crew entry during ground cooling operations. 

And, lastly, they checked whether the cooling sock would meet existing Air Force cooling and heating flexible duct specifications, and they assessed whether or not the cooling sock would impart forces on the crew access ladder that would exceed the maximum loading stress limits on the ladder's hardware.

"The cooling sock met all of our objectives and I commend the 161st parachute shop for building a great end product to meet the specifications of the objective," Sergeant Allain said. "The idea for a sock like this also has implications for heating operations in a cold weather climate as well, but we'll have to look into using a different material for heating. Overall, it was a successful demonstration."

In his recommendation to Air Mobility Command officials, Lt. Col. Jeffrey Lathrop, AMB commander, urged finding a suitable material for both heating and cooling and then field the sock to the Air Force's KC-135 fleet.

"This initiative proved itself to not only help with safety but with capability," Colonel Lathrop said. "It's a great design that can create implications across the KC-135 tanker fleet. That's why we recommended it for fielding."

The Air Mobility Battlelab was established in 2001 to identify and demonstrate the utility of innovative concepts with potential to enhance Mobility Air Force capabilities. AMB will deactivate in September 2008 as part of an Air Force cost-saving initiative.

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