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In today's impossible engineering, the
amount of weight that it's capable of
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lifting is what makes this aircraft
unique. The largest helicopter in the U
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military arsenal.
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The Superstallion has redefined what
heavy lift helicopters are.
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I'm still surprised by the capabilities
it has.
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and the pioneering historic innovations
that
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made
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the impossible possible.
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Storm 11 runway 23 at Delta, wind 220 at
7, clear for takeoff.
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Marine Corps Air Station, New River,
North Carolina.
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Today, at this vast facility, Squadron
Commander Lieutenant Colonel Hawkins and
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his team are preparing for an artillery
training exercise designed to simulate a
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very real conflict situation.
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We must be ready to move heavy equipment
over long ranges from the fee to the
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objective to ensure Marines have what
they need when they need it.
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to ensure that the Marine Corps is fully
equipped and ready to respond no matter
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where conflict arises.
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They turn to the sky and a helicopter
with some jaw -dropping capabilities.
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This is the CH -53 Echo Super Stallion.
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Measuring 99 feet long and standing over
8 feet tall, this vast aircraft is
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designed to transport troops and
equipment anywhere on Earth.
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Powered by three massive turboshaft jet
engines.
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Combined, they produce more horsepower
than 13 Bugatti Veyron supercars.
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Spinning seven main rotor blades with a
diameter just under 80 feet, the Super
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Stallion can reach a top speed of around
200 miles per hour.
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Designed to be able to move huge cargo
loads into position, it can carry up to
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55 troops or seven pallet loads of
supplies internally or over 35 ,000
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weight externally.
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Across the base, inside squadron HMH
-464's locker room,
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Super Stallion pilot Captain Clayton
Cottrell is preparing for today's
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Our mission today, we're doing an
artillery raid in support of 10
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Marines.
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My role is the Dash 3 aircraft
commander. We're utilizing three
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53s to conduct the raid.
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And so I'll be the aircraft commander in
the last aircraft.
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So with me in the aircraft, I'll have
two additional co -pilots, one crew
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and then two additional aerial observers
and gunners. And then as we do these
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external lifts, they're vital to
position the external hooks in the right
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so that underneath the aircraft, the
helicopter support team personnel can
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up the load.
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Once airborne, Captain Cottrell, as well
as two other super stallion personnel,
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will be lifting and moving 9 ,000 -pound
howitzer artillery guns,
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ready to be fired by the Marines on the
ground.
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Heavy lift externals are kind of the
bread and butter for the 53, and I love
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doing that.
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With the final pre -flight checks
complete, the
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team is ready to take to the sky in this
formidable machine.
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But how have engineers built an aircraft
capable of moving the approximate
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weight of 10 family cars through the
air?
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It is extremely difficult to design and
build a helicopter capable of lifting 36
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,000 pounds.
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Engineering a machine capable of lifting
and flying the Marines' vast arsenal of
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heavy -duty weapons and vehicles into
position is a major challenge.
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So when the Marine Corps enters into a
conflict, it takes a lot more than just
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the Marines to make that operation
happen.
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The Marine Corps has a multitude of
assets, whether it's vehicles or heavy
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weapons systems that have to be
transported.
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I move throughout the battle space.
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But moving something like a 13 -ton
lightly armored vehicle hundreds of
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air requires the Super Stallion to have
some distinct capabilities not found in
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other helicopters.
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In order to lift heavy cargo or supplies
underneath the aircraft, you have to
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have a stable platform.
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You have to have a lot of power.
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And then you need an aircraft frame.
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that's capable of withstanding those
forces throughout the entire operation.
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So could a blueprint for the perfect
heavy -lift helicopter design lie in the
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innovations of the past?
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In Missouri, Doug Cyperski and his team
are tackling a huge and problematic
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engineering project.
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00:06:21,360 --> 00:06:24,500
We're out here east of St. Louis
installing lattice -type power line
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Each piece of these giant towers can
weigh almost 20 ,000 pounds, which makes
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getting them into position in remote
locations like this one a big challenge.
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Generally, when they call us, you can't
get conventional cranes out to the sites
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where they need the structure standing.
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For a solution, Doug and his team must
turn to the sky and a historic machine
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unlike any other on planet Earth.
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This is the S -64 air crane.
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Originally designed in the 1960s, this
game -changing flying machine was built
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with a simple goal.
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To transport more weight by helicopter
than ever before.
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Created by aviation pioneer Igor
Sikorsky.
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It was first used by the U .S. Army
during the Vietnam War.
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Offering unparalleled transport and
aircraft recovery capabilities, the S
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was incomparable to any other helicopter
of the time.
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It's very unique to itself, yeah, and
everybody knows when they see one of
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that it's the only one shaped like this.
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Based on a design that's more than 60
years old, today the air crane remains
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of the world's most powerful heavy -lift
helicopters.
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Currently, we're in the external load
configuration for setting anything from
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power line structures to HVAC units.
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What makes this feat of engineering
possible are two massive turboshaft jet
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engines, producing a combined total of
around 9 ,000 horsepower.
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They're big engines.
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They're Pratt & Whitney engines, but
they're 4 ,700 horsepower apiece.
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capable of lifting us up to 25 ,000
pounds external load.
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This huge amount of power means the S
-64 can lift almost the equivalent
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of two African elephants.
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But to put this power to good use, Doug
and the crew also need a way to control
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it with millimeter precision.
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This is our aft -facing pilot position,
and it is what makes the Skycrane so
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special. Facing backwards, flying the
aircraft,
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allowing us with this great visibility
so we can get these giant lattice towers
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set precisely.
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We have full control back here. It's a
smaller window.
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They say we only have 10%, but you do
have full control back here.
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If this wasn't invented, what I would
have to do is you stick your head out
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bubble on the left.
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and you fly your external loads on a
long line.
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It'd be a lot more difficult, more
dangerous.
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This engineering combined has created a
helicopter with a set of mind -blowing
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capabilities.
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So what does it take to fly this
powerful machine?
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And how can its engineering help the
Sikorsky Super Stallion
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team? make the military's toughest heavy
lift helicopter a reality.
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Over 60 years after its design, the S
-64 air crane is still in use today.
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Its innovative aft -facing pilot
position allows operators to move heavy
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with incredible precision.
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00:10:00,650 --> 00:10:04,870
Generally speaking, the right seat pilot
is flying the aircraft.
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We'll position over near the load to
where the AFC guy can start picking up
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we're picking up into his visibility.
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He gives the rigging to the guys on the
ground. They'll hook us up.
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00:10:23,940 --> 00:10:27,820
AFC pilot picks the load up off the
ground out of the fly yard.
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00:10:34,720 --> 00:10:38,600
As we get close to where it needs to be
set, when the guy in the AF seat can see
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where he needs to set the unit, it's
just a verbal exchange of flight
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at that point, and the AF seat guy takes
over flying.
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00:11:18,120 --> 00:11:23,080
The S -64 air crane changed how heavy
lift helicopters are engineered around
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world.
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Due to its unique capabilities at facing
pilot, its stance designed for external
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load, obviously it's still being used
today for different applications.
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Doing what I do in the heavy lift
industry, I'd say this is the best tool
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there is.
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Today, the team has taken the
engineering at the core of the F -64 air
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evolved it for modern warfare.
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And high in the skies above North
Carolina, Captain Cottrell and his crew
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route to tackle the first task of their
training mission.
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By using the Super Stallion's external
load hook system,
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the crew is able to carry the
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four and a half ton howitzer artillery
gun with ease.
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This vast machine has taken the heavy
lift helicopter concept to a whole new
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level.
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The aircraft itself has a single main
rotor with seven main rotor blades. And
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then you can see the tail rotor with the
four blades on the tail.
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Another unique capability of this
aircraft.
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to be able to fold the blades as well as
the tail for shipboard operations in
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that smaller footprint.
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Additionally, we've got three General
Electric engines that all provide power
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and input into that main gearbox to
supply ultimately that lift to the main
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rotor head for the 53.
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Six tons heavier than the pioneering S
-64 air crane.
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but capable of lifting over seven tons
more weight.
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00:14:03,930 --> 00:14:08,850
The Super Stallion's incredible
capability comes from its three massive
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each one producing over 4 ,000
horsepower.
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00:14:12,890 --> 00:14:16,890
All right, so now that we're coming into
the cabin of the aircraft, you can see,
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kind of get a scale for how big the
cabin of the aircraft is.
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On either side, we've got seats on
either side. This is where Marines would
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with their gear.
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It's capable of accommodating up to 55
Marines and their gear internally.
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And for external lifts, two innovative
hook systems allow the Super Stallion to
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transport vehicles or other aircraft
with ease.
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Conducting external operations, we'll
either use our dual -point system, which
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are on either side of me here, or we'll
use the single -point system. And what
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we'll do is we'll open this door.
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And then that hook system, this A -frame
drops down, and we extend that hook
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directly underneath the center of the
aircraft in order to conduct those
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operations.
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All right, so up here is where we have
our pilots.
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So you can see the array of our flight
instruments up on the front, and then
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kind of what our vantage point looks
like out over the dash and to the sides
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the aircraft.
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Piloting the 53 is really no different
than any other helicopter.
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You've got the same basic controls with
your collective, giving you your up and
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down, your cyclic, your fore and aft,
and your lateral motion for the
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and then your pedals up front, which
control the yaw.
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Up top, we've got our speed control
levers, which control those engines.
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And then up front, we've got all of our
instruments that provide us that
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information about those engines.
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But when it's time for this huge
helicopter to pick up a load, it's not
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pilots who guide it into position.
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Me as the pilot up front, flying the
aircraft, I'm primarily looking outside
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over my shoulder to pick up reference
with the ground.
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And then primarily I'm listening to our
crew chiefs in the back.
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So we saw the hole in the cabin floor,
which is where the crew chiefs will
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position themselves in order to maneuver
the helicopter over the external load.
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So really I'm getting through our
intercommunication system all of my cues
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where exactly to put those hooks that
are about 20 feet behind me from the
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chiefs in the back as I'm looking
outside the aircraft to maintain a
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hover.
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But carrying big loads with a helicopter
that already weighs more than six
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shipping containers creates a problem.
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When we're conducting external
operations with an external load
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aircraft, It's going to create a higher
fuel burn and therefore less flight
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time.
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Unladen, the Super Stallion has a range
of over 500 miles.
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At maximum lift capacity, this is
reduced to around 100 miles.
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To overcome this problem, engineers have
given the Super Stallion a feature
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rarely found on helicopters.
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One of the key things that facilitates
us being able to conduct helicopter air
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refueling is the system that extends
this probe to approximately double the
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length that you see right now.
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What that does is provides us the
clearance to be able to make contact
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refueling asset and be able to take on
that fuel safely.
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After rendezvousing with a tanker
midair.
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The pilot must guide the Super
Stallion's refueling probe into a drogue
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measuring just 25 inches in diameter.
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First time I conducted air -to -air
refueling as a 53 pilot, it amazed me
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close we have to get to the tanker.
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Flying that close to a tanker takes a
lot of crew coordination and precision
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flying that close to another aircraft.
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The team has designed one of the most
useful aircraft on the battlefield.
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But controlling this massive machine
with all three engines at full power
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presents a challenge.
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00:18:41,810 --> 00:18:45,170
The rotor head turns at approximately
180 RPM per minute.
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which is a lot of power.
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00:18:47,570 --> 00:18:51,810
For a solution, they must turn to the
great innovations of the past.
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At first glance, you might think that
this aircraft is a helicopter because of
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00:18:55,930 --> 00:18:59,290
that spinning rotor up there, but
actually it's something slightly
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00:19:04,070 --> 00:19:08,630
Getting the Marine Corps' biggest pieces
of essential warfighting equipment to
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00:19:08,630 --> 00:19:12,530
the front line requires a machine with
some incredible capabilities.
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00:19:13,610 --> 00:19:17,310
This is the CH -53 Echo Super Stallion.
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00:19:22,170 --> 00:19:24,870
The largest helicopter in the U .S.
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military inventory.
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00:19:26,550 --> 00:19:31,850
It's three times longer than a Cessna
light aircraft and weighs more than two
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00:19:31,850 --> 00:19:33,170
-16 fighter jets.
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00:19:34,710 --> 00:19:40,670
Its vast external fuel tanks allow it to
fly over 500 miles without refueling.
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at just under 180 miles per hour.
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But so much power presents a problem.
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How do engineers deal with the forces
created by a nearly 80 -foot diameter
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00:19:59,450 --> 00:20:01,550
rotor spinning at high speed?
230
00:20:03,830 --> 00:20:06,550
Aircraft maintainer Master Sergeant
Rowe.
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00:20:06,920 --> 00:20:10,620
It's part of the team responsible for
servicing this complex piece of
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00:20:10,620 --> 00:20:11,620
engineering.
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00:20:11,900 --> 00:20:16,820
The CH -53 Echo has three turboshaft
engines, and they produce just under 5
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00:20:16,820 --> 00:20:17,860
shaft horsepower each.
235
00:20:18,600 --> 00:20:22,680
During operations, the rotor head turns
at approximately 180 RPM per minute,
236
00:20:22,900 --> 00:20:24,120
which is a lot of power.
237
00:20:27,540 --> 00:20:32,900
It's this rapid turning of the main
rotor that produces lift, allowing the
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00:20:32,900 --> 00:20:34,280
stallion to get off the ground.
239
00:20:35,240 --> 00:20:39,880
But immense forces are created when
seven blades cut through the air at such
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00:20:39,880 --> 00:20:44,300
high speed, a factor that complicates
the design. As rotors turn, you have
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00:20:44,300 --> 00:20:47,500
multiple forces working against it, like
torque, lift, and drag.
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00:20:48,260 --> 00:20:52,020
Without being able to control the
adjustments of blades in flight, it
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00:20:52,020 --> 00:20:53,020
cause a disparity.
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00:20:53,560 --> 00:20:57,780
Left unchecked, these forces could
create more lift on one side of the
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00:20:57,780 --> 00:21:02,340
helicopter than the other, potentially
causing it to roll and ultimately crash.
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00:21:02,680 --> 00:21:07,080
To ensure that this doesn't happen,
Engineers must look to the aeronautical
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00:21:07,080 --> 00:21:09,020
pioneers of the past for a solution.
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00:21:22,060 --> 00:21:24,620
On an airfield just outside London.
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00:21:27,640 --> 00:21:28,880
I'm already in the air.
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00:21:30,160 --> 00:21:32,200
I was taking this contraption.
251
00:21:35,780 --> 00:21:40,140
Physicist Andrew Steele is taking to the
skies in a type of flying machine that
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00:21:40,140 --> 00:21:41,640
revolutionized aviation.
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00:21:45,080 --> 00:21:48,720
At first glance, you might think that
this beautiful aircraft is a helicopter
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00:21:48,720 --> 00:21:51,040
because of that enormous spinning rotor
up there.
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00:21:51,280 --> 00:21:54,620
But actually, it's something slightly
different called an autogyro or
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00:21:54,620 --> 00:21:57,700
gyrocopter. And it works on a rather
different principle.
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00:22:00,970 --> 00:22:04,810
in this auto gyro is provided by a
propeller on the back of the aircraft
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00:22:04,810 --> 00:22:07,990
what that means is that it moves us
forwards as we move forward the air
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00:22:07,990 --> 00:22:10,930
over that main rotor which spins it
around and around and of course this
260
00:22:10,930 --> 00:22:14,730
aircraft doesn't have any wings so this
is very much like a four pair of wings
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00:22:14,730 --> 00:22:17,830
spinning around very very rapidly over
our heads keeping us in the air
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00:22:17,830 --> 00:22:24,790
this machine might seem like the perfect
fusion between aircraft
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00:22:24,790 --> 00:22:25,790
and helicopter
264
00:22:26,550 --> 00:22:29,450
But unfortunately, when engineers were
trying to construct these things back in
265
00:22:29,450 --> 00:22:31,470
the early 1900s, they ran into a
problem.
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00:22:31,690 --> 00:22:34,510
That problem was that as you move
forward, you can get a different amount
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00:22:34,510 --> 00:22:37,730
lift on each side of the rotor blades.
And that can cause the aircraft to roll
268
00:22:37,730 --> 00:22:39,110
and, well, basically crash.
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00:22:39,590 --> 00:22:42,690
So the engineers needed to find a way to
control those rotor blades more
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00:22:42,690 --> 00:22:43,690
precisely.
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00:22:47,470 --> 00:22:53,270
In 1923, Spanish pilot and inventor Juan
de la Cierva came up with an ingenious
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00:22:53,270 --> 00:22:55,090
solution to this complex problem.
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00:22:57,290 --> 00:23:01,850
And at the de Havilland Aircraft Museum,
Andrew is getting up close to the
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00:23:01,850 --> 00:23:04,710
engineering brilliance behind one of his
early designs.
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00:23:07,950 --> 00:23:10,350
Look at this piece of aviation history.
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00:23:10,590 --> 00:23:12,670
This is the Sierra C -24.
277
00:23:13,030 --> 00:23:17,230
It was first flown in 1931, and this is
the only version of this model ever
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00:23:17,230 --> 00:23:18,230
built.
279
00:23:19,410 --> 00:23:24,870
De La Sierra developed the C -24 in
relative secrecy at the Stag Lane
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00:23:24,870 --> 00:23:25,870
near London.
281
00:23:25,929 --> 00:23:30,130
But before it was a reality, he faced a
problem that plagued engineers for
282
00:23:30,130 --> 00:23:31,130
years.
283
00:23:32,750 --> 00:23:35,950
The problem Siever faced is called
dissimetry of lift.
284
00:23:36,150 --> 00:23:38,590
What that means is a different amount of
lift on different sides of the
285
00:23:38,590 --> 00:23:41,910
aircraft. So let's imagine the aircraft
is moving forward and, of course, the
286
00:23:41,910 --> 00:23:43,170
rotor blades are spinning round.
287
00:23:43,430 --> 00:23:46,790
This blade here that's advancing into
the oncoming air is going to experience
288
00:23:46,790 --> 00:23:49,790
greater amount of lift than this blade
here that's receding away from it.
289
00:23:50,230 --> 00:23:52,890
What that means is you've got a greater
lift on this side than on this side of
290
00:23:52,890 --> 00:23:53,890
the aircraft.
291
00:23:53,960 --> 00:23:56,740
Unless you do something about it, that
means the aircraft's going to roll and
292
00:23:56,740 --> 00:23:58,160
potentially you could crash.
293
00:23:59,240 --> 00:24:04,240
To overcome this problem, Sierva
designed his rotor control system around
294
00:24:04,240 --> 00:24:05,240
hinges.
295
00:24:05,520 --> 00:24:08,460
This system is called a fully
articulated rotor.
296
00:24:08,720 --> 00:24:12,200
And the way that it works is it gives
the blade some freedom to move in
297
00:24:12,200 --> 00:24:13,200
different directions.
298
00:24:13,360 --> 00:24:15,540
There are three hinges in this system.
299
00:24:15,800 --> 00:24:19,300
First, we've got the flapping hinge,
which gives the blade freedom of
300
00:24:19,300 --> 00:24:20,860
to flap up and down a little bit.
301
00:24:21,440 --> 00:24:24,120
Then we've got the drag hinge, which
gives it a little bit of freedom in the
302
00:24:24,120 --> 00:24:25,120
horizontal direction.
303
00:24:25,460 --> 00:24:27,920
And finally, we've got the feather
hinge, which allows the whole thing to
304
00:24:27,920 --> 00:24:29,140
rotate about its axis.
305
00:24:29,360 --> 00:24:33,320
And all of this allows the blade just to
compensate for that change in lift on
306
00:24:33,320 --> 00:24:34,320
either side of the aircraft.
307
00:24:35,480 --> 00:24:39,020
It feels quite counterintuitive that
just letting the blades flap around a
308
00:24:39,020 --> 00:24:42,760
could possibly solve this problem, but
actually it does work to balance the
309
00:24:42,760 --> 00:24:44,500
forces on either side of the gyrocopter.
310
00:24:51,470 --> 00:24:52,630
Back in the air.
311
00:24:55,470 --> 00:24:56,730
This is amazing.
312
00:24:57,330 --> 00:24:59,190
You can do such tight turns in this
thing.
313
00:24:59,770 --> 00:25:03,890
Andrew is getting the opportunity to put
Sierra's game -changing machine to the
314
00:25:03,890 --> 00:25:04,890
test.
315
00:25:05,330 --> 00:25:06,490
What an amazing machine.
316
00:25:09,590 --> 00:25:12,090
Sierra's contribution to aviation was
enormous.
317
00:25:12,510 --> 00:25:16,790
The auto -gyro was groundbreaking, and
the fully articulated controls on rotor
318
00:25:16,790 --> 00:25:19,730
blades were what's allowed helicopters
to exist, as we know them today.
319
00:25:28,360 --> 00:25:32,580
From the prototype for the modern
helicopter to the most advanced and
320
00:25:32,580 --> 00:25:34,600
maneuverable heavy lift chopper the U
.S.
321
00:25:35,040 --> 00:25:42,000
military has ever seen, the team behind
the
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00:25:42,000 --> 00:25:47,060
CH -53 Echo Super Stallion will need to
take the engineering behind Sierva's
323
00:25:47,060 --> 00:25:50,080
autogyro rotor system and supersize it.
324
00:25:52,140 --> 00:25:53,240
When the U .S.
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00:25:53,580 --> 00:25:57,700
Marine Corps needs to do some heavy
lifting out on the battlefield, they
326
00:25:57,700 --> 00:25:58,700
this.
327
00:26:01,760 --> 00:26:05,060
The CH -53 Echo Super Stallion.
328
00:26:07,280 --> 00:26:12,620
This vast heavy -lift helicopter can
operate in all weather on all terrains.
329
00:26:14,380 --> 00:26:18,980
Capable of taking off from a ship at sea
with a load weighing up to 16 tons
330
00:26:18,980 --> 00:26:24,760
attached, it can go 100 miles before
delivering its cargo to troops on the
331
00:26:24,760 --> 00:26:25,760
line.
332
00:26:27,370 --> 00:26:31,490
Its potential is unmatched by any other
helicopter in the U .S.
333
00:26:31,950 --> 00:26:32,950
military arsenal.
334
00:26:39,090 --> 00:26:41,330
In the skies above North Carolina,
335
00:26:42,570 --> 00:26:47,810
Captain Cottrell and his crew are
halfway through their training mission
336
00:26:47,810 --> 00:26:51,630
route to drop the artillery pieces to
the Marines on the ground at the landing
337
00:26:51,630 --> 00:26:52,630
zone.
338
00:27:14,380 --> 00:27:19,380
Making this feat of aeronautical
engineering possible is Sierva's fully
339
00:27:19,380 --> 00:27:21,000
articulated rotor system.
340
00:27:48,040 --> 00:27:52,600
And back at the hangar, Master Sergeant
Rowe is getting up close to this vital
341
00:27:52,600 --> 00:27:53,600
component.
342
00:27:54,060 --> 00:27:55,760
The rotor head itself is massive.
343
00:27:56,140 --> 00:27:58,280
It's large enough for multiple people to
sit on.
344
00:27:58,640 --> 00:28:01,580
Everything that happens with the
aircraft goes through the rotor head.
345
00:28:01,780 --> 00:28:05,340
And up here we have the articulated
rotor head. The articulated rotor head
346
00:28:05,340 --> 00:28:09,300
system is a part of the aircraft and
makes it possible to do what the
347
00:28:09,300 --> 00:28:10,300
is capable of.
348
00:28:12,720 --> 00:28:17,260
The Super Stallion's fully articulated
rotor system works in the same way as
349
00:28:17,260 --> 00:28:23,080
autogyros. The drag hinge, flapping
hinge, and feathering hinge all work
350
00:28:23,080 --> 00:28:27,100
together to ensure that the forces
acting on the blades in flight remain
351
00:28:27,100 --> 00:28:28,100
balanced.
352
00:28:30,980 --> 00:28:35,560
Also located on the giant rotor head is
the engineering system that translates
353
00:28:35,560 --> 00:28:38,220
the pilot's controls on the stick into
movement.
354
00:28:39,820 --> 00:28:43,500
So this large component right here is
what we call the swashplate, and this
355
00:28:43,500 --> 00:28:47,380
rotating swashplate here is what
controls all seven blades at the same
356
00:28:47,380 --> 00:28:48,380
each position of movement.
357
00:28:48,860 --> 00:28:52,480
As the pilots are making inputs down in
the cockpit, the power adjustment is
358
00:28:52,480 --> 00:28:54,480
transferred to the rotor head via the
flight controls.
359
00:28:54,700 --> 00:28:59,260
Right here at this rod is where the
input to the blade goes, which changes
360
00:28:59,260 --> 00:29:01,780
pitch of the blade and in turn controls
the aircraft.
361
00:29:02,580 --> 00:29:07,120
As the swashplate moves, the input is
transferred to the blade, changing their
362
00:29:07,120 --> 00:29:11,040
angle. allowing the helicopter to
ascend, descend,
363
00:29:12,000 --> 00:29:15,580
move forwards, backwards, left, and
right.
364
00:29:15,820 --> 00:29:19,880
The response is almost immediate from
the pilot's input to the rotation of the
365
00:29:19,880 --> 00:29:20,960
aircraft at the blades.
366
00:29:22,820 --> 00:29:25,480
For the size of the aircraft, it's
incredibly responsive.
367
00:29:25,980 --> 00:29:31,480
The team may have found a way to control
this huge helicopter, but they now face
368
00:29:31,480 --> 00:29:35,560
a problem that has the potential to
render the super stallion almost
369
00:29:35,560 --> 00:29:36,560
unusable.
370
00:29:38,430 --> 00:29:39,430
Brownout.
371
00:29:42,250 --> 00:29:46,130
The best way I can describe brownout
condition is when you're going and
372
00:29:46,130 --> 00:29:47,170
in a sandy environment.
373
00:29:47,710 --> 00:29:51,810
As the aircraft gets down lower and
closer to the ground, all the loose dirt
374
00:29:51,810 --> 00:29:53,470
dust comes up and engulfs the aircraft.
375
00:29:54,830 --> 00:30:00,070
Caused by downwash from the helicopter's
seven rotor blades, brownout is one of
376
00:30:00,070 --> 00:30:04,170
the most challenging and dangerous
situations pilots and aircraft can face.
377
00:30:04,790 --> 00:30:07,330
It's going to reduce the visibility of
the pilots and crew.
378
00:30:07,929 --> 00:30:12,110
and it can also have an effect on the
operation of the engine by sucking in
379
00:30:12,110 --> 00:30:15,330
and reducing the amount of airflow that
goes into the engine to create power.
380
00:30:16,550 --> 00:30:19,990
The less power you have, the less lift
you're going to be able to provide in
381
00:30:19,990 --> 00:30:22,370
order to keep the aircraft and the crew
in the air and safe.
382
00:30:25,250 --> 00:30:29,410
The problem engineers face is that a
traditional filter would rapidly become
383
00:30:29,410 --> 00:30:31,110
blocked, rendering it useless.
384
00:30:31,770 --> 00:30:35,290
To overcome this challenge, the team has
devised a solution.
385
00:30:36,510 --> 00:30:38,330
This is the EAPS system on the aircraft.
386
00:30:38,650 --> 00:30:42,810
What this does is it acts like a giant
filter for all the air that's going in
387
00:30:42,810 --> 00:30:43,810
and out of the engine.
388
00:30:44,090 --> 00:30:48,570
The strata tubes here are cyclone
filters that, as the air and debris are
389
00:30:48,570 --> 00:30:50,170
in, they spin around.
390
00:30:50,530 --> 00:30:52,290
It goes through into the chamber of the
EAPS.
391
00:30:52,510 --> 00:30:56,910
All the dirt gets sucked out here via
the blower, which allows the clean air
392
00:30:56,910 --> 00:30:57,990
go into the front of the engine.
393
00:31:00,510 --> 00:31:05,150
As dirty air is drawn into the engine,
it's spun into a vortex, causing it to
394
00:31:05,150 --> 00:31:06,150
speed up.
395
00:31:06,670 --> 00:31:09,590
increasing the amount of centrifugal
force acting upon it.
396
00:31:10,330 --> 00:31:15,110
This causes larger pieces of debris to
be pushed out and allows clean air to
397
00:31:15,110 --> 00:31:16,150
pass into the engine.
398
00:31:17,830 --> 00:31:20,370
The EAPS is definitely an important part
of the aircraft.
399
00:31:20,670 --> 00:31:23,970
It helps keep our engines running
efficiently and helps reduce engine
400
00:31:23,970 --> 00:31:25,610
degradation from debris going through.
401
00:31:28,490 --> 00:31:32,610
The Super Stallion has redefined what a
helicopter is capable of.
402
00:31:33,130 --> 00:31:36,830
But now the Marines must turn their
attention to what happens if they come
403
00:31:36,830 --> 00:31:38,070
fire on the battlefield.
404
00:31:39,270 --> 00:31:43,410
Anytime we're out there flying, this
large helicopter is going to present a
405
00:31:43,410 --> 00:31:44,410
target.
406
00:31:44,530 --> 00:31:48,750
For a key solution, they must look to
the great innovations of the past.
407
00:31:48,950 --> 00:31:53,270
If the fuel tank was penetrated by a
projectile or a bullet, the fuel tank
408
00:31:53,270 --> 00:31:55,110
leak fuel, it could catch on fire.
409
00:32:00,110 --> 00:32:03,670
This is the CH -53 Echo Super Stallion.
410
00:32:11,850 --> 00:32:17,050
Capable of transporting up to 55 troops,
or the equivalent weight of over 40
411
00:32:17,050 --> 00:32:18,050
grand pianos.
412
00:32:20,210 --> 00:32:25,650
It's powered by three jet engines that
give this huge aircraft over 70 times
413
00:32:25,650 --> 00:32:28,830
more horsepower than the world's first
mass -produced helicopter.
414
00:32:32,640 --> 00:32:35,640
allowing it to operate anywhere on the
face of the planet.
415
00:32:38,760 --> 00:32:43,540
Today, in the skies above North
Carolina, Captain Cottrell and his crew
416
00:32:43,540 --> 00:32:45,340
nearing the end of their training
mission.
417
00:33:19,120 --> 00:33:24,280
Capable of flying over 500 miles before
needing to refuel, the Super Stallion
418
00:33:24,280 --> 00:33:26,480
has a huge amount of range for its size.
419
00:33:31,100 --> 00:33:35,900
But flying thousands of gallons of a
highly flammable liquid, hundreds of
420
00:33:35,900 --> 00:33:38,100
in the sky presents a dangerous problem.
421
00:33:41,400 --> 00:33:45,940
As you can see, it's a pretty large
helicopter, so anytime we're out there
422
00:33:45,940 --> 00:33:48,600
flying, you know, this larger helicopter
is going to present.
423
00:33:48,920 --> 00:33:51,380
a big target for the enemy.
424
00:33:52,100 --> 00:33:57,380
Really, any damage to the aircraft is
going to impact the air crew's ability
425
00:33:57,380 --> 00:34:01,020
operate the helicopter, and it's going
to impact their decisions in the
426
00:34:01,020 --> 00:34:03,000
continuation of the operation.
427
00:34:04,100 --> 00:34:08,659
But there's one part of the aircraft in
particular that, if damaged, can present
428
00:34:08,659 --> 00:34:10,900
a multitude of problems for the crew on
board.
429
00:34:12,340 --> 00:34:15,040
It's two massive external fuel tanks.
430
00:34:15,760 --> 00:34:20,860
If there's any damage taken to the
aircraft and there's leaking fuel,
431
00:34:20,860 --> 00:34:23,719
that's going to impact the amount of
flight time available.
432
00:34:24,060 --> 00:34:29,440
There's a potential, with that being a
flammable liquid, of that igniting and
433
00:34:29,440 --> 00:34:31,639
causing a hazard to the aircrew.
434
00:34:31,920 --> 00:34:36,100
It's going to be a very serious
situation for the aircrew to have to
435
00:34:36,820 --> 00:34:41,659
To overcome this potentially life -and
-death problem, engineers must look to
436
00:34:41,659 --> 00:34:43,880
the innovations of the past for
inspiration.
437
00:34:52,810 --> 00:34:55,350
At the Palm Springs Air Museum in
California,
438
00:34:56,370 --> 00:35:01,610
pilot Tom Nightingale is examining a
life -saving innovation hidden within
439
00:35:01,610 --> 00:35:04,010
of the most iconic aircraft of World War
II.
440
00:35:13,530 --> 00:35:17,290
Okay, so this is the P -51 Model D
Mustang.
441
00:35:18,590 --> 00:35:19,710
Fantastic fighter.
442
00:35:20,050 --> 00:35:21,550
My favorite airplane of all time.
443
00:35:22,690 --> 00:35:24,770
Airplane is so nice to fly.
444
00:35:25,010 --> 00:35:26,810
It has incredibly balanced controls.
445
00:35:27,250 --> 00:35:28,690
Very, very responsive.
446
00:35:29,130 --> 00:35:30,970
Just a super, super airplane to fly.
447
00:35:35,150 --> 00:35:40,190
Designed to escort Allied bombers
hundreds of miles into enemy territory,
448
00:35:40,190 --> 00:35:43,410
-51 was one of the most capable aircraft
of the era.
449
00:35:43,950 --> 00:35:48,090
But covering such vast distances came
with a dangerous catch.
450
00:35:50,540 --> 00:35:54,300
So if we're standing back here in the
back, we can see relative to the size of
451
00:35:54,300 --> 00:35:57,760
the airplane how big the fuel tanks are.
The fuel tanks are going to be from
452
00:35:57,760 --> 00:36:03,400
about here to about here, all the way
probably here to the front. And there
453
00:36:03,400 --> 00:36:07,480
also an 85 -gallon fuel tank about right
here behind the pilot.
454
00:36:08,560 --> 00:36:13,260
Carrying this much highly flammable fuel
was a necessity, but it presented two
455
00:36:13,260 --> 00:36:15,720
distinct dangers to the pilot at the
controls.
456
00:36:16,540 --> 00:36:21,340
One would be if the fuel tank was
penetrated by a projectile or a bullet,
457
00:36:21,340 --> 00:36:24,400
fuel tank would leak fuel. B, it could
catch on fire.
458
00:36:24,620 --> 00:36:27,520
So in that case, of course, if you had a
fire and you burned a wing off, you'd
459
00:36:27,520 --> 00:36:31,220
have to bail out. Or if it just leaked
fuel and didn't catch fire, you may not
460
00:36:31,220 --> 00:36:35,200
have enough fuel to get back to home
base. So you may end up landing in the
461
00:36:35,200 --> 00:36:37,060
English Channel, landing in France or
somewhere.
462
00:36:38,800 --> 00:36:43,120
To ensure that neither of these
situations happened, engineers employed
463
00:36:43,120 --> 00:36:44,120
ingenious solution.
464
00:36:46,960 --> 00:36:53,460
In 1918, inventor George Murdoch
patented the self -sealing fuel tank, a
465
00:36:53,460 --> 00:36:56,620
-saving idea that would revolutionize
aircraft design.
466
00:36:57,520 --> 00:37:02,120
Constructed from layers of vulcanized
and natural rubber, when penetrated, the
467
00:37:02,120 --> 00:37:06,820
fuel is able to mix with the untreated
parts of the tank, causing the natural
468
00:37:06,820 --> 00:37:09,220
rubber to become a gel plugging the
hole.
469
00:37:15,340 --> 00:37:20,060
Fitted to almost all Allied bombers and
fighter aircraft during World War II,
470
00:37:20,600 --> 00:37:23,040
Murdoch's innovation saved countless
lives.
471
00:37:24,400 --> 00:37:25,100
I
472
00:37:25,100 --> 00:37:39,260
think
473
00:37:39,260 --> 00:37:45,840
the advent of the self -stealing fuel
tank... It definitely had a huge impact
474
00:37:45,840 --> 00:37:48,660
the effectivity of these airplanes and
the safety of the pilot.
475
00:37:48,920 --> 00:37:52,840
And in my opinion, definitely helped
this airplane turn the tide of the war.
476
00:38:00,620 --> 00:38:05,820
To effectively operate the military's
most capable heavy lift helicopter to
477
00:38:05,820 --> 00:38:10,320
and keep crews safe in the process. I'm
amazed to be part of the team that flies
478
00:38:10,320 --> 00:38:11,320
an incredible aircraft.
479
00:38:12,110 --> 00:38:16,490
The Super Stallion team will need to
bring Murdoch's World War II innovation
480
00:38:16,490 --> 00:38:18,270
into the 21st century.
481
00:38:19,790 --> 00:38:22,410
This aircraft really is an incredible
piece of engineering.
482
00:38:24,470 --> 00:38:30,090
At Marine Corps Air Station New River,
George Murdoch's 1918 self -sealing fuel
483
00:38:30,090 --> 00:38:34,570
tank design has been reimagined for
modern warfare and applied to one of the
484
00:38:34,570 --> 00:38:36,630
military's most impressive aircraft.
485
00:38:37,000 --> 00:38:41,800
The CH -53 Echo Sikorsky Super Stallion
Heavy Lift Helicopter.
486
00:38:42,080 --> 00:38:46,200
And it's up to Master Sergeant Rowe and
his team to maintain these essential
487
00:38:46,200 --> 00:38:47,320
pieces of engineering.
488
00:38:49,440 --> 00:38:51,820
The fuel itself is stored here in the
sponson.
489
00:38:52,280 --> 00:38:56,160
The quantity of fuel contained in each
sponson is about 490 gallons.
490
00:38:56,700 --> 00:38:59,640
Inside the sponson, there's a rubber
bladder, which is a self -sealing fuel
491
00:38:59,640 --> 00:39:00,640
tank.
492
00:39:00,760 --> 00:39:04,360
Over 100 years since Murdoch first
patented his idea.
493
00:39:04,960 --> 00:39:08,600
The concept behind the self -sealing
tank remains the same.
494
00:39:08,800 --> 00:39:12,040
In the event of a puncture on one of the
fuel bladders, the self -sealing
495
00:39:12,040 --> 00:39:14,620
compound will take over and seal the
hole to prevent leakage.
496
00:39:15,860 --> 00:39:20,800
These highly classified pieces of
critical engineering are located inside
497
00:39:20,800 --> 00:39:23,000
aircraft's two external sponsons.
498
00:39:25,660 --> 00:39:30,140
Constructed from a specially coated
nylon polymer, they're flexible,
499
00:39:30,140 --> 00:39:33,080
them to withstand vibrations and
movement in flight.
500
00:39:33,900 --> 00:39:37,580
On the inside, a natural rubber layer is
still used.
501
00:39:37,820 --> 00:39:42,980
If the tank is punctured, it makes
contact with the fuel, forming a gel and
502
00:39:42,980 --> 00:39:44,840
plugging the hole within two minutes.
503
00:39:46,360 --> 00:39:50,720
Proven in the field, the self -sealing
fuel tank is a life -saving invention.
504
00:39:51,020 --> 00:39:54,540
I have seen a fuel tank punctured, and
the self -sealing compound does what
505
00:39:54,540 --> 00:39:55,499
designed to do.
506
00:39:55,500 --> 00:39:57,700
This aircraft really is an incredible
piece of engineering.
507
00:40:02,480 --> 00:40:09,440
Back on board the aircraft, after
completing their
508
00:40:09,440 --> 00:40:16,020
training mission, Captain Cottrell and
the crew are touching down back at base.
509
00:40:16,940 --> 00:40:18,120
So the mission went well.
510
00:40:19,040 --> 00:40:25,040
So, you know, doing heavy lift, you got
to watch the gearboxes, the temperatures
511
00:40:25,040 --> 00:40:26,040
and the oil.
512
00:40:27,380 --> 00:40:31,820
Our aircraft today performed very well.
For the Marine Corps, that's what marine
513
00:40:31,820 --> 00:40:34,260
aviation is all about, is supporting the
Marine on the ground.
514
00:40:42,300 --> 00:40:46,360
The Super Stallion has redefined what a
helicopter can do.
515
00:40:47,960 --> 00:40:50,700
Throughout my career, I've been around a
lot of different types of helicopters.
516
00:40:51,530 --> 00:40:55,850
Every day I see the super stallion, I'm
amazed to be part of the team that flies
517
00:40:55,850 --> 00:40:56,850
an incredible aircraft.
518
00:41:02,170 --> 00:41:09,110
By looking to great pioneers of the past
for inspiration, adapting their ideas,
519
00:41:10,050 --> 00:41:15,310
refining their design, and overcoming
monumental challenges.
520
00:41:16,770 --> 00:41:19,430
I'm extremely proud to be involved with
this aircraft.
521
00:41:20,710 --> 00:41:23,910
I had a lot of opportunities and a lot
of different choices when I came in.
522
00:41:24,250 --> 00:41:25,470
This is where I want to be.
523
00:41:26,970 --> 00:41:31,490
Out of all the aircraft and all the
helicopters that are in the Marine
524
00:41:31,890 --> 00:41:38,290
I'm exceptionally proud and humbled to
be a part of the 53 Echo and the Super
525
00:41:38,290 --> 00:41:39,290
Stallion community.
526
00:41:42,230 --> 00:41:48,990
Engineers have constructed something
radical and succeeded in making the
527
00:41:48,990 --> 00:41:51,660
impossible. He figured you four out,
pal.
528
00:41:52,400 --> 00:41:53,400
Possible.
529
00:41:53,450 --> 00:41:58,000
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