MONSTER GARAGE. Saves Air Force $57M. Trainer Development Flight. Hammerheads

Transcription

1 MONSTER GARAGE Trainer Development Flight Hammerheads Winners: 2015 USAF Modeling and Simulation annual award in the field of Modeling and Simulation Cross-Functional Training Platforms 2018 AETC General Larry O. Spencer Innovation Award (Trainer Development Team category) Saves Air Force $57M Retired technicians known as Hammerheads, along with SOW personnel, have filled the hangar with unwanted and discarded military aircraft and refurbished them into training platforms used by thousands of airmen. These recycled hulks have saved the USAF upward of $57 million. Some aircraft cost the Air Force approximately $150K per hour to fly, while the cost of using trainers is little more than the cost of turning on the lights in the Monster Garage. Simulation and training technologies Training from live flights to ground-based options. Expensive or impossible to create with live aircraft Reduced risk to pilots, while cutting down on flying aircraft costs. It s low cost and much faster than we could it get it done anywhere else, said Lt Col Lee, 2017 Commander for the 58th TRS. The following Monster Garage articles have been posted: th Special Operations Wing, Training Squadron, Kirtland Air Force Base, NM Located at base of Sandia Mountains of Albuquerque, NM 1

2 SPECIAL OPERATIONS AIRCREW TRAINING 58th Training Squadron, Special Operations Wing, Kirtland Air Force Base, NM 58th SOW Located on Kirtland Air Force Base (AFB), the 58 th Special Operations Wing (58 th SOW) serves as the premier training site for Air Force special operations aircrews. The wing provides undergraduate, graduate, and refresher aircrew training for special operations, combat search and rescue (CSAR), missile site support, and distinguished visitor airlift in direct support of Air Expeditionary Forces (AEF) for the world s best aerospace force. The wing teaches courses in aircrew positions including pilot, navigator, electronic warfare officer, flight engineer, communications system operator, loadmaster, and aerial gunner. Additionally, the wing responds to worldwide contingencies and provides search and rescue support to the local community. In Airmen trainees find the hands-on training of the aircraft's capabilities more beneficial than simulating the procedures in a classroom environment. Airmen can schedule training to fit around their own timeframe with the permanent C-130 simulator on the base. Squadrons do over 50 percent of their annual requirement training on a static trainer such as a C-130. This is the ideal training device. 2

3 AIR FORCE SAVINGS Presented: Advantages of a Newsletter Add Value to Your Newsletter Second Story Another Story Back Page Story Monster Garage The 58th TRS/DOF Monster Garage projects represent a tremendous force multiplier that produces quality training devices at 1/20th the cost of flight line aircraft assets. An example of cost-saving designs on the floor of the facility: According to an Air Force press release from 2014, a military contractor wanted $15 million to make an equivalent piece of technology. Instead, the Monster Garage technicians managed to create one for roughly $250,000. Airmen now train about hours a day on the system. Col Anderson (2015 Commander) said that using old trainers was similar to using a 1960s Corvette to teach a mechanic how to fix a 2013 Corvette. With a little ingenuity and a lot of elbow grease, the 58th Training Squadron s Trainer Development Flight, the Monster Garage, is saving the Air Force millions of dollars. Lt Col Augustine (2016 Commander) said about 70 percent of the training on those platforms can be done with simulation, although that number changes based on the particular aircraft. Flight training on a C-130 model, for example, can be done almost 100 percent on the ground, whereas the CV-22 sits at about 70 percent through simulation. 3

4 MONSTER GARAGE MISSION Trainer Development Hammerheads 58th SOW The mission of the 58th Trainer Development, as part of the 58th Training Squadron, at Kirtland AFB, NM, is to design, develop, fabricate, and assemble training devices in support of the 58th SOW and other AETC units at Kirtland AFB. In Trainer Development has a highly qualified team of Air Force professionals dedicated to meeting the very specialized needs of the customer. The personnel in this unique organization afford the organizations they support the knowledge, skills, and abilities of numerous disciplines including those of flight chief, technical writer, electronics engineer, electronics technician, welder, sheet metal machinist, draftsman, two exhibits maker modelers, woodworker, assembler, painter, and administrative personnel. Hangar 482 was built in World War II ( ) to house B-24 Liberators. Airmen Trainer Development is capable of designing, manufacturing, and writing technical manuals for Special Operations Aircrew Training devices. Such trainers include Part Task Trainers (PTT), Cockpit Familiarization Trainer, Cockpit Procedures Trainer, Mobile Training Sets, Resident Training Equipment, Egress Procedures Trainer, Academic Trainer, Aircraft Systems Trainer, Miscellaneous Type Trainers, and Mission Essential Support Items. The training equipment and devices range from helicopters (UH-1N Huey and HH-60 Pave Hawk) to fixed-wing aircraft (MC-130H Talon II and MC/HC-130J). Training devices are designed and manufactured to meet specific trainer requirements. We have the experience and capabilities to fabricate static, dynamic, and mock-up procedures trainers: A static trainer has no power requirements; components may have movement, but no operation. Dynamic trainers require power and have actuating mechanisms to simulate realistic operation. The 58 TRS/DOF produces first-rate trainers despite having less than 20 percent of the manning than other teams. Mock-up procedures can be static or dynamic trainers configured to replicate an actual system or component but designed to accommodate specific training tasks.. 4

5 TRAINERS AND SIMULATORS Of the equipment in the garage, 85 percent came at no cost to the wing or was purchased for $1. The crew scours the Boneyard, Defense Logistics Agency Disposition Services yards even big-box stores for low-cost equipment that can be used in training. HC-130J PTT Cost $1,604, Yearly PTT Savings $8,541, MC-130J PTT Cost $2,595, Yearly PTT Savings $3,792, HC-130 P/N PTT Cost $614, Yearly PTT Savings $6,923, This PTT provides formal training for loadmasters in pre-flights, cargo-onload, tie-down, and cargo-off load, airdrop procedures, paratroop operations, and emergency operations in a controlled and stable training environment. Training: Loadmaster training for the Virtual Cargo Compartment (VCC). Loadmaster training for the Visual Awareness Recognition Screen (VARS). Meets over 50% of annual This PTT provides formal training for loadmasters in pre-flights, cargo-onload, tie-down, and cargo-off-load, airdrop procedures, paratroop operations, and emergency operations in a controlled and stable training environment. The MC-130J is replacing the MC-130H Talon 2 as the dedicated Special Operations and Personnel Recovery fixed wing platform. Training: Loadmaster training for the Virtual Cargo Compartment (VCC). Loadmaster training for the Visual Awareness Recognition Screen (VARS). Meets over 50% of annual This PTT provides formal training for loadmaster and flight engineers in preflights, cargo-on-load, tie-down, and cargo-off-load, air-drop procedures, paratroop operations, and emergency operations in a controlled and stable training environment. The PTT extends the range of combat search and rescue helicopters by providing air refueling. Training: Dedicated fixed-wing personnel recovery platform. Provide expeditionary, all-weather personnel recovery. Meets over 50% of annual 5

6 TRAINERS AND SIMULATORS The wing teaches courses in aircrew positions including pilot, navigator, electronic warfare officer, flight engineer, communications system operator, loadmaster and aerial gunner. Additionally, the wing responds to worldwide contingencies and provides search and rescue support to the local community. UH-1N Huey (on stand) PTT Cost $149, Yearly PTT Savings $1,309, A high-performance rescue hoist assembly provides realistic training in the hoist operation. The UH-1N Procedural Instrument Trainer allows students to practice instrument flying procedures and practice the motor skills necessary to operate the various controls and instrumentation of the UH-1N Helicopter. The trainer simulates the flight instrument switches and controls as found on the actual UH-1N helicopter. Training: Operation and litter and forest penetrator use. Tree-like obstacle provides the illusion that the helicopter is drifting to the rear and down. Rescue hoist operation, correcting hoist malfunctions, NVG use, and intercom. Engine startup/shutdown procedures, cockpit familiarity, and emergency procedures emphasizing cockpit instrument indications. Maintenance technicians Meets over 50% of annual UH-1N Huey (on floor) PTT No Cost Saves $1,000, per year Tail Number Donated by California Marine Corps Air Station. Loaded into an MC-130H and delivered to Kirtland AFB, NM. Meets over 50% of annual CV-22 Wing and COFT PTT Cost $893, PTT Yearly Savings $21,474, The primary use of this trainer is to provide interim hands-on training capability for CV-22 flight engineers to acquire and sustain the skills required to perform CV flight engineer tasks as described in the training syllabus. The trainer aids aircrew and maintainers in hands-on training for numerous systems to include the nacelle and pro-rotor components. A separate cabin trainer aids aircrew training for pre-flight, hotrefueling, and tail-scanner procedures. The CV-22 Wing Training Device provides the capability to identify and service the PRGB, TAGB, engine, generators, fire suppression system, avionics components, drive shaft system, fuel system, wiring harnesses, and the rotor system. Tail Number: Training: Began CV-22 aircrew training with the first two production aircraft in August Meets over 50% of annual 6

7 TRAINERS AND SIMULATORS Trainer Development tests, inspects, adjusts, repairs, and makes necessary alterations to aircraft systems trainers to ensure their proper operation and continued serviceability. Additionally, Trainer Development develops and publishes technical manuals for each training device fabricated. A technical manual contains pertinent information on trainer operation and maintenance of locally fabricated training equipment. HH-60G PTT Cost $67, Yearly PTT Savings $1,893, HH-60G AIE/Weapons trainer provides procedures training on the 7.62mm Minigun. The simulated gun control unit provides the students to experience hands-on operation of and gain familiarity with the aircraft s minigun weapon system controls. The TGCU simulates the controls for the GAU-2C 7.62mm minigun weapon system installed on an HH-60G aircraft. Additionally, it provides hands-on preflight procedures for the hoist and HBar/FRIES bar training, which are used on the real aircraft. Training: Alternate insertion extraction procedural trainer. Fully configured external hoist with cockpit and cabin controls to simulate malfunctions. Flight engineers and aerial gunners. 7.62mm Minigun procedures. Hands-on preflight procedures: Hoist HBar/FRIES bar Meets over 50% of annual J Floor PTT Cost $70, Yearly PTT Savings $284, This mockup trainer uses aircraft parts to accurately portray the C-130J floor for loadmaster training, including floor, wheel wells, non-stick surface, tie-downs, dual rails, locks, CVRs, and rollers. The mockup J Floor Trainer (C-130J aircraft floor) and wheel wells were designed and fabricated (non-motion landing gear design and construction) to familiarize the student with the operation of equipment, procedures, and any other features affecting use as a stand-alone training device. The J Floor Trainer is used as an enhanced preflight and loading trainer. The landing gear is used as an emergency landing gear tiedown trainer. Four struts allow a Loadmaster to practice manual gear extension and gear tiedown (using chains and/or MLG tiedown fixtures) on the ground prior to an actual gear emergency. A CNI-MU Emulator can be easily modified for loadmaster training. Designed and fabricated (non-motion landing gear design and construction) as a stand-alone device. Enhanced preflight and loading trainer. Emergency landing gear tiedown trainer. Meets over 50% of annual requirement training. 7 War Wagon PTT Cost $312, Yearly PTT Savings $4,538, The War Wagon effectively trains vertical lift SMA students on GAU2 and M240B, while qualifying them to competently and safely operate a gun system and cutting costs associated with aircraft training events. Live-fire trainer. Controlled environment. Limited risk. Cuts costs associated with aircraft training events. Meets over 50% of annual

8 TRAINERS AND SIMULATORS It would be prohibitively expensive to train all those airmen on operational aircraft, and the aircraft would be tied up for coursework instead of flying. That inspired the Monster Garage idea. MC-130H PTT Cost $422, Yearly PTT Savings $7,853, The MC-130H Combat Talon II provides formal training for loadmaster and flight engineers in pre-flights, cargo-on-load, tie-down, and cargo off-load, air-drop procedures, paratroop operations, and emergency operations in a controlled and stable training environment. Tail Number 559 Introduced in Assigned the designation Combat Talon in Began 58th SOW aircrew training in Meets over 50% of annual Fuel Pod PTT Cost $10, Yearly PTT Savings $399, The Fuel Pod Trainer is designed and fabricated as follows: Provides actual look and feel of switches and indicators of unit on the C-130 aircraft. Provides the environment necessary to train, test, and/or evaluate students. Emulates all functionality on the aircraft (Aerial Refueling POD). Stand and standalone electric, hydraulic, and interface systems. Portability and ease of handling and operation in a classroom setting. The CNI-MU computer allows the operator to control all functionality of the fuel pod, including powering-on systems, extracting and/or retracting the boom, and displaying status using lights on the fuel pod. Meets over 50% of annual requirement training. 8

9 TRAINERS AND SIMULATORS Trainer Development s goals are to design and build high-quality trainers that will perform complex tasks, are simple in design, and are easy to maintain; keep trainer production costs to a minimum by using commercially reliable, readily available, low-cost parts; create, manufacture, modify, repair, and refurbish trainers in a timely and costeffective manner. HC-130J & MC-130J Yearly PTT Savings $8,500, Graduate training on the loadmaster Fuselage Trainer (LFT), Special Operations aircrew positions are loadmaster, pre-flights, cargo-on-load, tie-down, cargo-off-load, air-drop procedures, paratroop operations, emergency operations, and infiltration/ exfiltration procedures. Electronic Warfare Systems An extensive electronic warfare suite enables the aircrew to detect and avoid potential threats. If engaged, the systems will protect the aircraft from both radar and infrared-guided threats. The purpose of electronic warfare has remained much the same: deny the enemy the information to locate, identify, and attack airborne forces. The only J device currently in the Monster Garage (not the team s) is a Lockheed/BAE provided loadmaster flight trainer (LFT), which accurately models the interior of the HC/MC-130J including the cockpit controls and panels applicable to the loadmaster. The LFT is used for the loadmaster training only and is not suitable for preflight training or anything else requiring accurate exterior modeling. This device is basically a semi-trailer with the C-130 fuselage interior (no wings, no flaps, no landing gear, etc.). Features include: designed and fabricated (non-motion landing gear design and construction) as a standalone device, enhanced preflight and loading trainer, and emergency landing gear tiedown trainer. The trainer meets over 50% of annual The HC-130J and MC-130J are replacing the MC-130 P/N as the dedicated Special Operations and Personnel Recovery fixed wing platform. 9

10 UH-1N HUEY RESCUE TRAINING UH-1N Medical Evacuation The UH-1H (Huey) Alternate Insertion/Extraction Trainer was designed and fabricated by the 58 th Trainer Development, Monster Garage, Kirtland Air Force Base, New Mexico. The UH-1H Alternate Insertion/Extraction Trainer is used by instructors for training in hoist operations, correcting hoist malfunctions, NVG use, Intercom operation, litter and forest penetrator use. The trainer is used in alternate insertion/extraction training for UH-1H Helicopter flight engineers. A high-performance rescue hoist assembly was installed to provide realistic training in the hoist operation and correction of malfunctions that can be induced. The trainer at Kirtland Air Force Base is situated on top of a steel tower that was custom designed and constructed. Why the Christmas tree? By Lt Col Kevin R. Lee (2017 Commander) When helicopter pilots are conducting hovers in order to hoist, they cannot see the personnel/survivors they are hoisting. This requires the Special Mission Aviators (SMAs) to provide the pilot feedback on, if the aircraft is drifting up/down and/or forward/back/left/right. It was realized that during flight training, crews were spending a significant amount of time teaching SMAs the basics of what drift looked like. UH-1N Huey Hoist Operation An enterprising program manager realized that they could simulate that movement in the Monster Garage using a garage door opener and a Christmas tree. The garage door opener is mounted on an incline and controlled by the instructor, so when it is engaged, the Christmas tree simulates that the aircraft is drifting up and forward, or that it is drifting back and down. This setup, which we lovingly refer to as the lowest-tech virtual reality available, has saved countless flight hours by providing a basic understanding of what drift looks like to SMAs working on their basic aircraft qualifications. UH-1N Huey Rescue Training 10

11 UH-1N HUEY SIMULATOR STORY Donated Huey The 58th Training Squadron s Trainer Development Flight, Monster Garage, found a UH-1N, or Huey, that was no longer needed at Marine Corps Base Camp, Pendleton, CA. The group shipped the helicopter to Kirtland Air Force Base, NM, and converted it from a Marine Corps training device to something that suited Air Force purposes, according to Maj Faith, then the Assistant Operations Officer, for the Trainer Development Flight. Not counting the cost of transportation or man-hours, the Huey cost about $3,000 in materials, Faith said. The Huey eliminated about 6 hours of instruction on a static trainer per student. The training costs the Air Force $12,000 per student, and about 100 students come through a year, he said. The Monster Garage came into the helicopter by lucky coincidence, Faith said. The fabricators there known as Hammerheads had been looking for a Huey for some time, when retired Tech Sgt Lasher, who happened to be at Camp Pendleton, heard about one that was set to be retired. Since around 1980, every Marine Corps crew chief had trained on the helicopter, Faith said. The body of the Huey has plenty of hammer marks and other signs of its extensive use. They might have taken it out and made it a target on a shooting range, Faith said. If the Hammerheads were willing to take care of the transportation, the Air Force could have the Huey for free, Faith said. Even though the old Huey had served its purpose for the Marines, a group of leathernecks gathered to see the helicopter, which was named The November, packed into the Air Force cargo plane the fall of Anthony Tapia, fabrication supervisor at the Monster Garage, was one of a group of seven personnel from Kirtland, who flew out on an MC-130H Talon II to help move the helicopter. UH-1N Huey into an MC-130H Talon II The Marines were ready to cry, Tapia said. They remarked, Oh, the November is leaving. Tapia said, To me, it s just a helicopter. Getting the Huey into the MC-130H was no small task, though, Tapia said. The helicopter is nearly the width of the plane s cargo bay. I couldn t move around from the front to the back of the plane, he said. The rotors and tail were removed and placed under the landing gear, with just 3 inches of clearance to the top of the cargo bay, he said. It was the first time we know of (since the Vietnam War) that a Huey was loaded into a C-130, Faith said. Once the Huey was flown to Kirtland and reassembled, fabricators removed the Marine Corps-specific components, such as flair dispensers and infrared countermeasure components. Even those parts will be used, Tapia said. Some parts went onto the shelves at the 58th Training Squadron, and others went to Andrews Air Force Base, MD. Fabricators finished fabricating and installing all the Air Force-specific parts for the simulator, Faith said. Then, it was inspected by those who do the training. Every UH-1N mission pilot, instructor pilot, special mission aviator, special mission instruction aviator, and requalification or transition student will use this trainer, Faith said. 11

12 Training Equipment Request Prepare an AETC Form 375, Training Equipment Request, as shown in the following step-by-step instructions. Block 1 Enter your organization name and office symbol. Block 7 Enter quantity required. Block 2 Enter the date request is submitted. Block 8 Enter applicable Force Activity Designator (FAD) Code (I, II, III, IV, V). Block 3 Enter the date training equipment is required. I = Combat II = Combat Readiness IV = Active & Reserve V = Other III = Display Readiness Block 3a Enter the date training equipment is required. Block 9 & Block 10 Place an "X" in the applicable box or boxes. Block 3b Block 4 Block 5a Block 6 Enter the date training will have to be deviated to if project is not completed by the date required. Enter the following: N/A 58 TRS/DOF 1960 Eileen Avenue SE Kirtland AFB NM, Enter the name of training equipment. Block 11 Description of service required. Include the following: a.operating functions/special requirements. b.scale required. c.additional information showing unique mounting, etc. d.audio/visual requirements. e.specifications for training aid (e.g., will trainer be moved frequently from room to room, building to building, opening through which trainer must pass [height and width], etc.). f.other pertinent information that may aid in the design and development of trainer. g.a statement that the commercial equivalent is not available or the requested trainer is more cost-effective than commercial or GSA equivalent. NOTE: If necessary, continue explanation on a separate sheet of paper and attach to Form. 12

13 Training Equipment Request (continued) Prepare an AETC Form 375, Training Equipment Request, as shown in the following step-by-step instructions. Block 12 Give a brief explanation of how trainer will be used. Include the following: a.who will use the trainer? Who are the students? b.purpose of the trainer. Explain how students and instructors will use trainer to achieve performance of objectives. c.how many students in the class, number of classes per year, and length of training. d.where will the trainer be used? Give the geographical location, physical location on your base, or in your unit. e.why is the trainer necessary? Explain why using less expensive means such as films, VCR tapes, photographs, charts, handouts, etc., cannot fulfill the training requirement. NOTE: If necessary, continue explanation on a separate sheet of paper and attach to Form. Block 13 List all attachments submitted with the request (drawings, photographs, design specifications, blueprints, any other information that will assist in the evaluation of request). Block 14 Supply copy of completed AF Form 601 and mark box Yes. Block 15 Supply copy of completed DD Form and mark box Yes. (The instructions for filling out a DD Form are located in Attachment 27B-4 of the AFM V2 Pt2, Chapter 27.) Block 16 Enter Stock Number for existing trainer, if known. If this is a new trainer, leave blank and Trainer Development will obtain the number. Block 16 Enter name, grade, title, and unit of requestor (person who will be working with Trainer Development, overseeing the project from start to finish). 13

14 Training Equipment Request (continued) Prepare an AETC Form 375, Training Equipment Request, as shown in the following step-by-step instructions. Block 18 Enter name, grade, title, and unit of requestor's Flight Commander or higher authority. Obtain signature and date. If non-aetc (MAJCOM) request, leave Blocks blank and send Form to: 2AF/LRRT 721 Hangar Road, Suite 102 Keesler AFB, MS Block 19 If 58 SOW request, have immediate Flight Commander (or higher authority) sign and date. Block 20 Type the following: OR CC Commander, 58 TRS DO Operations Officer, 58 TRS 14

15 Training Equipment Request Flowchart 15