I.G (U) Reel HandlerTransporter System Requirements_v6.pdf

U

Reel Handler/Transporter

System Requirements

Prepared by:

Robert Cutler

Code 159 robert.f.cutler2.civ@us.navy.mil

Sensors and SONAR Systems Department

Naval Undersea Warfare Center Division, Newport

1176 Howell St.

Newport, RI 02841

Revision 5

17 September 2026

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

1. Physical Characteristics

a. Overall space envelope not to exceed 8ft 6in (width) by 9ft 6in (height) by 16ft (length)

b. Shall conform to National Highway Transportation Safety Administration (NHSTA) standards. Also to include:

i. Suspension system capable of supporting specified Gross Trailer Weight at highway speed; design to be Approved by the Buyer

ii. Electric brake mechanism to be included at each wheel, sufficiently sized for the

Gross Trailer Weight specified.

iii. Safety chains and brake disconnect to be incorporated.

iv. Brake and signal lights to be recessed and/or otherwise protected from damage via operation/ foot traffic. Tow vehicle electrical interface to consist of a 7-pin traditional trailer side plug.

c. Design to include commercially available provisions (pintle, 2 5/16 ball hitch or similar) for towing via truck.

d. The tow vehicle shall not be required for operation of the system, nor shall it be expected to resist forces resulting from operations within the limits specified herein.

e. Handler shall include a 4-wheel design; the axle located forward, from the perspective of the direction of travel, shall have a provision to be steered when unit is used off-highway. The steering function shall be able to be secured into fixed position to accommodate transportation of the unit over the public roadways. The rear axle shall have a fixed wheel orientation.

f. Shall be capable of carrying a 7,000lb load, not to exceed a Gross Trailer Weight of 12,000lbs.

g. Lifting features rated for overhead lifting of the unit while loaded to maximum capacity to be included. These features shall account for the unit’s center of gravity and allow for stable, controlled hoisting. If required, lifting fixtures and strapping to be included with the design of handler to alleviate interference with sub-components.

h. Unit to incorporate a 4-point leveling feature which will have the capability to level the unit when positioned on a 10% grade in both roll and pitch directions. Control of this feature shall be accommodated at a common location on the handler. Indicators shall be implemented to alert the operator when the handler has achieved acceptable level state.

i. Have provisions to store, at minimum, one commercial off the shelf 8.5 KW (continuous) portable generator with fuel storage capacity to run for 4 hours at 100% duty cycle. The handler unit shall be able to safely secure the portable generator for highway use, but allow for offloading and/or replacement using typical tools of the trade (e.g., rated straps, welded D-links). Both the generator and its secured location shall be designed to accommodate overhead lifting for removal and onboarding.

j. All power supplied to the handler unit shall be routed through a NEMA 6-50R receptacle, housed in a NEMA 3R enclosure coupled with a rated “IN USE” cover. For robustness, non-metallic covers shall not be permitted. Two GFI protected NEMA 5-15R 125VAC receptacles shall be provided on the unit for general use. All cabling shall have a minimum insulation rating of 600VAC and be suitable for portable power equipment for us in outdoor applications. This includes the portable cable connecting the generator to the 50-amp handler receptacle.

k. Shall include at least one lockable storage container with minimum contained volume of 20 cu ft. This container shall be watertight and must be located in an accessible location regardless of the orientation of the system.

l. Task lighting to be included which will cast sufficient illumination for all operator touch points, controls and indicators.

2. Performance Requirements

a. Shall include and accommodate a removable reel with hub diameter of 60in (+0in/- 1.0in), flange diameter of 87in (+0in/-0.75in) and width of 68in (+0in/-0.5in).

b. The stowage reel shall be mounted to the handler (via a 2 7/8” reel bar) so the axis of the reel, when performing reeling operations, is in the level orientation. The design shall permit continuous (360 deg) rotation of the reel about this shaft.

c. The support structure of the reel shall include a turret with a minimum of 180 degrees of pivot orthogonal to the reel axis (powered or unpowered), with a positive locking function available in 10 degree increments.

d. The handler shall be capable of stable, safe reeling (minimum 4x safety factor for any structural component) in any combination of the aforementioned orientation while performing within the specified reeling speed and back tension ranges. Operating within these ranges shall at no time cause the handler to overturn when the leveling feature has been deployed.

e. Stowage reel to accommodate reeling speeds of 0-15 RPM (0 to 235 fpm) on first wrap, in both directions, with provisions for operator adjustment (+/-5ft) and indication.

f. Reeling function must incorporate emergency stop function which immediately ceases motive force to the stowage drum upon single operator action. Feature to be co-located with reeling adjustment and indication.

g. A mechanical interlock shall be included to limit all movement of the stowage reel during transportation. This feature shall not rely on the previously mentioned electric/hydraulic power system.

h. Handler to be capable of providing adjustable back tension in both retrieval and offload operations from a range of 0 to 650lbs. Operator shall have the ability to adjust, with indication, the observed back tension within +/-20lb tolerance. Maximum back tension capability shall be available when the stowage drum is both fully loaded and empty.

i. Motive force for the stowage reel to be supplied by a self-contained hydraulic or electric system which is driven by a 240VAC single phase electric motor. Maximum continuous current draw limited to 35 amps.

j. A chute assembly with telescoping feature shall be included to assist operators in winding the stowage reel by hand. This assembly shall be stowed on the unit and allow minimal operator input to position (i.e., through the use of the existing hydraulic/electric power plant). The chute assembly shall include non-marring devices (i.e., rollers) which limit scuffing of the body being reeled.

3. Maintenance Requirements

a. The system and all associated components shall be designed to operate and be stored in an unconditioned space, exposed to a marine environment (i.e., salt spray).

i. Acceptable methods for coating shall include two-part epoxy, powder coating and plating with corrosion resistant materials. In no case shall ferrous metals be left exposed.

ii. The handler shall not allow the accumulation of water due to rain or sea spray.

Water intrusion should be discouraged through the use of covers and weep holes which permit drainage of the unit without operator input.

b. Service life of handler to be designed for 20 years minimum.

i. Maximum use of commercial off-the-shelf components.

ii. All service or consumable components to accommodate replacement using typical tools of the trade

iii. Sufficient clearance shall be integral to the design to allow for replacement of common wear items to include but not limited:

1. Tires

2. Grease fittings

3. Start/Run Capacitors

4. Electric Motor centrifugal switch

5. Hydraulic hoses

6. Circuitry

iv. Contractor to include technical manual which details operation, maintenance and parts schematics (electrical and/or hydraulic) of the complete handler and associated accessories.

v. Recommended quantities of spares.