TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PMS 400D, Aegis New Construction Program, ACAT 1

OBJECTIVE: Explore the development of alternatives to traditional roller bearings design configurations through the application of novel concepts and advanced material solutions to allow for improved performance, minimized maintenance and reduced life-cycle costs for the DDG 51 Helicopter Hanger Door.

DESCRIPTION: Legacy roller bearings which support the opening and closing of Helicopter Hangar Doors have been failing at a much higher rate than the desired 4800 cycles. The bearings used are currently traditional, spherical roller type with a high-load, self-lubricating liner system. There are two bearings installed per door. The bearings themselves support a door which weighs approximately 10,000 lbs. Under normal operations, the expected even loading of each bearing is 5,000 lbs. However it is believed that the actual loading seen by each bearing may, at times, exceed 10,000 lbs due to door misalignment, ship flexing and the drive motor adding unknown stresses due to continued operation after door has been closed. Previous attempts at resolving this issue have involved material changes of the bearing, additional lubrication methods and different swaging methods, but the problem still remains. Failure of the roller bearings limits the operation of the doors. Past modes of failure include, but are not limited to, contamination or encrustation as a result of the direct exposure of the bearing themselves to the marine environment as well as mechanical failure due to industrial grit contamination as well as unexpected or un-even loading. The inability to either close or open the hangar doors can negatively impact flight operations as well as expose the interior of the hangar to unwanted environmental factors and potentially introduce hazardous situations.

The topic seeks non-traditional, innovative approaches to resolve a long-standing life-cycle management issue for the DDG 51 Helicopter Hanger Doors. Proposers are encouraged to explore alternative design solutions and material systems with robust mechanical properties to withstand the harsh operating environment seen by these bearings both on a daily basis and in the event of a catastrophic event. Proposed concepts will be required to meet existing Navy shock qualifications as well as other applicable naval standards and requirements (see references). Meeting these shock requirements while providing operational reliability and maintainability in a maritime environment represents the most significant challenge associated with designing a roller-bearing replacement design solution.

PHASE I: Demonstrate the feasibility of an Improved Roller Bearings for Helicopter Hangar Door (HHD) system. The proposer shall identify suitable candidate materials as well as any applicable manufacturing processes and methods of installation anticipated to enable the development and integration of the proposed system. Establish performance goals and metrics to analyze the viability of the proposed solution. Develop a test and evaluation plan to contain discrete milestones for product development to be utilized for verifying performance and suitability.

PHASE II: Develop, demonstrate and fabricate a prototype system as identified in Phase I. In a laboratory environment, demonstrate that the prototype system meets the performance goals established in Phase I. Verify and provide results for final prototype system installation methodologies in a representative laboratory environment. Develop a cost benefit analysis for Total Ownership Cost, as well as Phase III testing and validation plan.

PHASE III: Construct a full-scale prototype system based on the Phase II results for testing in a shipboard environment. Working with government and industry, install onboard a selected DDG 51 class hull and conduct extended shipboard testing.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Roller Bearings have many applications in the marine industry. Any bearing replacement solution proposed for this topic could have the potential to be sized appropriately to meet the varied needs of the commercial sector.

REFERENCES:
1. Design Data Sheet for DDG 51 Class Helicopter Hanger Doors � Available Upon Request

2. http://www.nstcenter.com/milspecs.aspx?milspec=3135 : Deck Covering Underlay Materials

3. http://www.nstcenter.com/milspecs.aspx?milspec=23236 : Coating Systems For Ship Structures

4. http://www.nstcenter.com/milspecs.aspx?milspec=24441 : Paint, Epoxy-Polyamide, General Specification

5. http://www.nstcenter.com/milspecs.aspx?milspec=24596 : Coating Compounds, Nonflaming, Fire Protective (Metric)

6. http://www.nstcenter.com/milspecs.aspx?milspec=24613 : Deck Covering Materials, Interior, Cosmetic Polymeric

7. http://www.nstcenter.com/milspecs.aspx?milspec=24635 : Coating Systems, Weather-Resistant, Exterior Use

8. http://www.nstcenter.com/milspecs.aspx?milspec=24647 : Paint System, Anticorrosive And Antifouling, Ship Hull

9. http://www.nstcenter.com/milspecs.aspx?milspec=24667 : Coating System, Non-Skid, For Roll Or Spray Application

10. http://www.nstcenter.com/milspecs.aspx?milspec=24763 : Enamel, Emulsion Type, For Shipboard Use

11. https://assist.daps.dla.mil/quicksearch/ MIL-SPEC-901D (NAVY): Shock Tests H.I. (High Impact) Shipboard Machinery, Equipment and Systems

KEYWORDS: roller bearing; hangar door; corrosion; uneven loading; shock

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between November 10 and December 12, 2010, you may talk directly with the Topic Authors to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting December 13, 2011, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (11.1 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 11.1 topic under which they are proposing.

If you have general questions about DoD SBIR program, please contact the DoD SBIR Help Desk at (866) 724-7457 or email weblink.