The structural optimization of a spreader bar for twin lift helicopter operations

An optimization study was performed to develop a minimum weight spreader bar to allow two helicopters to lift the same payload. With this arrangement, the maximum payload that can be lifted is almost doubled without the expense of designing and building a new helicopter. The concept has had some limited use by civil helicopter operators using small helicopters and has been demonstrated in large scale by two CH-54's which successfully lifted a total load of 20 ton. To this point, rather heavy available beams or tower structures have been used for the spreader bar. Since the weight of the bar not only detracts from payload but also adds to the logistics problem, there are more than the usual incentives to minimize weight. Since the design requirement is for classic beam column with uniform side loads resulting from bar weight and aerodynamic drag, the design problem is particularly amenable to optimization. A study has been performed at Sikorsky to establish the minimum weight for a spreader bar sized to carry a load equal to the capacity of two Army BLACK HAWK helicopters. Toward this end, a computer program was written to analyze the spreader bar deflections and stresses and coupled to the NASA developed CONMIN optimization routines.