BULLETIN OF DEFENCE RESEARCH AND

DEVELOPMENT ORGANISATION
ISSN : 0971-4413
Technology
Vol. 18 No. 5 October 2010
I
nfantry combat vehicles ICVs
are used as means of armoured
transportation designed to
move infantrymen to the battlefield
to follow up after tanks and capture
combat areas I n the era of
conventi onal combi ned arms
operati ons and peacekeepi ng
operations ICVs have evolved into a
real force multiplier. Infantry-based
forces are common throughout the
world Though these forces have
some armour they mainly rely on
dismountedor motorisedinfantryfor
the bulk of their combat power Such
armies normally mount at least
per cent of their forces in armoured
vehicles. In terms of equipment size
the range forms from small forces
fielding outmoded equipment to
largecapableforces fieldingstate-of
the art weapons Significant techno-
logies that mark this class are in fire
support andtarget acquisition
Mechanisedinfantry battalions of
the Indian Army are equipped with
ICVs BMP-2/2K, which is of 1980s
vintage. The BMP-1 was first testedin
combat in the 1973 Yom Kippur War
where it was used by Egyptian and
Syrian Forces. Based on the lessons
learned from this conflict and early
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Ongoing transformation of forces has placed an
increased emphasis on balanced forces capable
of rapid deployment in a range of circum-
stances. In many countries, heavy armour is
also being phased out in favour of lighter and
more flexible formations. DRDO is engaged in
design and development of various kinds of
wheeled, tracked, and combat engineering
systems to provide mobility solutions to the
Indian Armoured Forces.
Future Combat Systems for Futuristic
Infantry Combat Vehicles
Virtual prototyping.
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experiences in the Soviet War in
Afghanistan, a new version,
with improved fighting qualities
was developed. It was accepted by
theServices inAugust 1980. Approxi-
mately, 1900 ICVs BMP-2/2K are in
service with the Indian Army and are
likely to remain operational till
An effort to modernise part of the
fleet to enhance the useful life is also
2017.
BMP-2
in progress Besides, Army has
projected requirements of approxi-
mately 2600 Futuristic ICVs (FICV) to
replace the existing fleet and also
to cater for force expansion/
restructuring.
To fill the technological gap of
new generation ICV companion to
MBT, the programme 'Abhay', a
. multidisciplinary and multi-lab
project was launched by Vehicles
Res ear ch and Devel opment
Establishment (VRDE), a constituent
establishment of Defence Research
and Development Organisation
DRDO to develop an indigenous
ICV as a technology demonstrator,
incorporating a blend of state-of-
the-art technologies with impressive
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From the Desk of Special Editor
Vehicles ResearchandDevelopment Establishment VRDE oneof thepremier labs
of Defence Research and Development Organisation (DRDO), is engaged in design
and development of various kinds of wheeled tracked and combat engineering
systems to provide mobility solutions to the Armoured Forces The combat vehicles
and ground support vehicles for strategic weapon systems will continue to be the
major thrust areas of DRDO to maintain its overall growth. Expertise in the field of
combat vehicles and engineering is definitely an added advantage to conquer upon
the enemy. Developing futuristic and Beyond the Horizon technologies, in long-term interest are
nowbecomingaprimefactor tohelpgrowthof combat vehicles andengineering
International light- and medium-armoured vehicle forces have undergone dramatic changes in
role and focus over the last years. The radical ongoing transformation of militaries has placed an
increased emphasis on balanced forces capable of rapid deployment in a range of circumstances In
many countries, heavy armour is also being phased out in favour of lighter and more flexible
formations
This issue of gives an overview of development of technologies for Futuristic
Combat Systems. The issue also discusses technologies of virtual prototyping, advance running gear
systems, shock-resistant seats, anddesignvalidationbeingdevelopedbyVRDE.
I specially thank Dr CPRamanarayanan, Director, VRDE, andhis designteamfor their untiringefforts
andcontributions inbringingout this special issue
R Shankar
Director
Combat Vehicles and Engineering
DRDO HQ New Delhi
and member Editorial Committee
of
Technology Focus
Technology Focus
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fire power, excellent mobility, and
hi gh degr ee of pr ot ect i on.
Indigenous development of the
'Abhay' has led to the creation of
technology base and know-how for
the envisaged development of FICV
The programme has also enabled
identification of suitable industry
partners, and has created pools of
excellence in development of ICV
sub systems The system integration
capability at lab level has enhanced
to a significant level, which will
facilitate undertaking technology-
intensiveprogramme.
Devel opment of FI CV was
derived mainly due to breakthrough
technologies and developments in
automobile industry worldwide and
to meet the long-term requirements
of the Services To realise the FICV
within the time frame visualised by
the Army and to use the lead time
available DRDO has taken the
initiative to commence a technology
demonstration project, Develop-
ment of Enabling Technologies for
FICVtodevelopa virtual prototypeof
complete vehicle along with system
hardware and technology for the
followingsystems
Virtual prototyping refers to
design simulation and testing of
new ideas, concepts, products,
schemes or a process in a synthetic
b u t i n t e r a c t i v e c o mp u t e r
envi ronment. I t i ncreases the
understanding of physics of the
mechanical system leading to more
efficient lighter systems and helps
the designers to make critical
decisions earlier in development. As
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t he pr oj ect pr ogr es s es , t he
simulations become more refined,
leading to greater accuracy and
reducing the need for expensive
testing by getting the design right in
first time.
The extensive use of virtual
prototypes and testing and DCAD
systems for generationof -Dmodels
of components and sub-assemblies
have been demonstrated in the
development of latest ICVs such as
PUMA and ASCOD family of vehicles.
These methodologies, reportedly
have enabled the participating
companies to exchange the models
among t hem and st udy t he
interfaces at an early stage before
makingfinal bindingspecifications.
An MBD (Multi-body Dynamic
modelling based simulation driven
de s i gn pr oc e s s f or v i r t ua l
prototyping of tracked vehicle is
being established at VRDE Main
tool LMS Virtual Lab-Tracked Vehicle
MBD software and other essential
software such as CATIA, Hyperworks,
and suitable workstations have been
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Virtual Prototyping Process
installed to implement the design
process This simulation-driven
process is expected to enable virtual
prototyping of complex vehicle
systems such as FICV, and predict
thei r dynami c behavi our and
performance before building the
physical prototypes. This procedure
would enable driving the virtual
vehicle on various terrains and
obstacles, like a physical prototype
and evaluate the effects on different
systems. With this procedure, it
would also be possible to carry out a
number of other simulations such as
simulation of gun control system
under various terrain inputs This
process would reduce time and cost
of building and testing multiple
physical prototypes
The virtual prototyping pro-
cedure established at VRDE involves
thefollowingmajor steps:
Conceptual models in software
such as Autodesk Maya, Vortex, E
solids, etc.
Solid modelling of systems
components in software such as
CATIA Solidworks etc.
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Sub-systems of a tracked vehicle.
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Generation definition of input
parameters required for carrying
out MBD modelling of tracked
vehicles
Development of a super-element
trackmodel
Development of a discrete track
model
Development of a discrete track
model withflexibodies
Experimental model analysis and
other field measurements for
validationandcorrelation
Design optimisation.
Devel opment of det ai l ed
walkthrough models depicting
thedesignevolved
Concepts ideas are given shape
quickly using software such as
Autodesk Maya The procedure
includes modelling of components
rendering, etc.
After finalising the conceptual
model design of the components
and systems are made. Solid models
of the components and systems are
made using software such as
Solidworks, CATIA, etc.
Generation of input parameters is
an essent i al st ep i n vi r t ual
prototyping of tracked vehicles
Experimental testing or simulation
can be done on components
systems
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Conceptual Infantry Combat
Vehicle Models
Solid Modelling of Components
Generation of Input Parameters
Conceptual models of an infantry combat vehicle.
Solid models of the components made using CATIA.
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Multi body Dynamic Models
Super element Track Model
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Multi body dynamic analysis of a
tracked vehicle is carried out in a
number of steps Super element
track model discrete track model,
discretetrackmodel withflexibodies,
and correlation with experimental
testingandvalidation.
A simulation model of a light
tracked vehicle has been made in
software LMS Virtual Lab using
super element track model In the
super element model the dynamics
of the track are idealised with a
condensed formulation in the
software LMS Virtual LabandADAMS
ATV to represent the motion of the
road wheel and road arm pairs and
their interaction with the track
which is looped around drive
sprocket idler, and the road wheels
Nonlinear characteristics of hydrogas
suspension units have been defined
andsuccessfullysimulated.
The virtual prototyping pro-
cedure developed by VRDE has been
successfully validated using data
obtained from physical testing of a
reference demonstrator ICV. Analysis
done following the established-
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vi rtual prototypi ng procedure
includes successful evaluation of
effect of damping configurations on
the pitch and bounce acceleration of
thevehicle
The track system is modelled in
detail with mass and inertia of each
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DiscreteTrackModel
individual track link and definition of
connections and impacts with other
tracksystemcomponents
A facility in the software LMS
Virtual LabandADAMS, nowmakes it
possible to use a finite-element (FE)
model of the hull structure to
produce a flexibody representation
of the vehicle structure that deforms
andvibrates inasimilar fashiontothe
physical hull structure Work is under
progress tocarryout this task
Experimental measurements
used for validation of MBD based
vi r t ual pr ot ot ypi ng i ncl ude
capturing of physical motion of the
vehicle while it traverses on defined
surface inputs measurement of
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Discrete Track Model with
Flexibodies
Correlation and Validation of
Simulation Results
(a) (b) (c ) Testing of suspension; Stiffness measurement of road wheel; and stiffness
measurement of track assembly.
Super element of track model of futuristic infantry combat vehicle.
Discrete track model of an infantry combat vehicle.
Vol. 18 No. 5 October 2010 06
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vibration acceleration at various
locations dynamic track tension, and
strain and experimental model
analysis.
Experimental model analysis is
one of the essential testings required
to validate the FE and flexibody
models This experiment can be
c ar r i ed out us i ng por t abl e
electrodynamic shakers sledge
hammers rubber springs accelero-
met er s , and PC- bas ed dat a
acquisitionsystems
The technologies undertaken for
the development of advanced
running gear system include in-arm
hydrogas suspension, composite
road wheel, lightweight axle arm,
and remotel y operated track-
tensioningmechanism
The in arm hydrogas suspension
wheel station uses the proven
technology from the hydrogas
suspension, and has been optimised
for minimal volume and low weight
It is fully shielded from conta-
minants The in armsuspension with
alloy casing is expected to provide
40 per cent reduction in weight in
comparison to the existing hydro
strut axlearmconfiguration
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In armHydrogasSuspension -
One-dimensional simulation has
been carried out
to optimise the damping and
stiffness characteristics. MBD model
of in arm hydrogas suspension has
been made using Hyperworks
Gas spring has also been
incorporated in the model FE
analysis has been carried out at five-
time the static load at bounce The
uni t has been opti mi sed f or
minimum weight The suspension
units areunder manufacturing
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using DSH software
software
Composite Road Wheel
A road wheel assembly is one of
the important sub-assemblies
alloy for road
wheel assembly. However, advent of
advanced composite materials has
of the
running gear systemof a tracked ICV.
It is a rollingelement, whichrolls over
the track and causes movement of
thevehicle.
Thecurrent worldwidetrendis to
use light metals like Al
Salient Specifications: In-arm Hydrogas Suspension
Static wheel load (kg) : 2000
Wheel travel mm
Bounce :
Rebound :
Dynamicfactor : times
Type of dampers : In built multi orfice belli vellewasher
Weight kg :
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300
100
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Bump 100 mm and the test vehicle; location of accelerometer (centre); and data acquisition system.
In-arm suspension along with road wheel (left) and a prototype.
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07 Vol. 18 No. 5 October 2010
made it possible to consider use of
composites as a material for road
wheel a s s embl y f or newer
l i ght t r acked vehi cl es . Thi s
t ec hnol ogi c al l y- c hal l engi ng
pproach is expected to reduce the
weight of road wheel assembly by
about per cent. 40
a
Lightweight Axle Arm
Even with the emergence of in
arm hydrogas suspension, axle-arm
hydro strut combination is still a
potent alternate for light tracked
vehicles Since it is a main load
carrying member between hull and
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ground, it forms a major load
transferring component between
the vehicle and the ground. To
withstand these heavy loads, it is
generally made of forged alloy steel
In the present task effort is being
made to reduce the weight of axle
arm using high strength alloy steel
MDN developed by MIDHANI
Hyderabad
The basic system is a passive
grease activated unit. The correct
tension is achieved by pumping the
required quantity of grease into the
track tensioner proportional to the
stroke length of the piston The basic
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Remotely-Operated Track
Tensioning Mechanism
Salient Specifications: Composite Road Wheel
Type : Twin rubberised
Material : Carbon epoxy composite
Overall diameter (mm) : over rubber tyre
Rubber thickness (mm) :
Rubber width (mm) :
Weight per assembly (kg) :
600
30
100
50
Die for compression moulding. Composite road wheel.
Axle arm: solid model. Axle arm with road wheel.
Vol. 18 No. 5 October 2010 08
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system is designed with only one
tension setting. The grease needs to
be pumped externally using a
separategreasepump A concept
has been worked out to convert the
basic systemas aremotely controlled
system using a pneumatically
operated grease pump and valves
with three tension settings High
static, and low This system enables
the driver to select normal or high
tension depending on the expected
terrainfromhis seat
During the explosion of an
anti tank mi ne or I mprovi sed
Explosive Device (IED) under an
infantry vehicle, significant impulse
l oads are transmi tted to the
occupant through the vehicle-
occupant interfaces such as the floor
and seat. If these loads are not
attenuated to survivable levels, it
normally leads to fatality of the
occupant.
One of the protective techniques
i s shock-resi stant or energy-
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absorbing seats that cushions the
occupant against the shock pulses
by absorbing the kinetic energy of a
mine blast through deformation of
various energy-absorbing elements
thereby, attenuating acceleration
pulses transmitted from the vehicle
structure to the occupant to
survivable levels. The seats are
designed in such a way that neither
the parts of seats nor the seated
occupants are in direct contact with
the floor of the vehicle The absence
of support from the floor aids in
prevention of direct transfer of
shock acceleration through the
mechanical fixtures to the seat
Shock-absorbing mechanism is a
vital element of blast resistant seats
A mechanism utilising the plastic
deformation of crush tube and
bending of metallic strip has been
evolved The mechanism gets
act i vat ed at a set val ue of
acceleration force
Water propulsion system for ICV
needs to be designed to meet the
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requirement of effective negotiation
of specified water current. This is an
important requirement as far as
amphibian capability is concerned.
Water jet propulsion system has
many advantages, especially for
amphibian military vehicles, because
of its good manoeuvrability at low
speed good operating ability in
shallow water high thrust at low
speed to aid manoeuvrability and
exit from water, etc. Drag evaluation
is one of the essential requirements
for design or selection of water jet
Minimisation of drag results in
reduction of required thrust, and
thus, thesizeof thewater jet
Scaling technique has been
evolved for fabrication of scale
models of water jet and the vehicle
Experimental dragevaluationcarried
out using th scale model
provided satisfactory correlation
withCFDresults. Axial type water jets
ar e cons i der ed s ui t abl e f or
amphibiantrackedvehicles duetoits
compactness. Availability of CFD
analysis tools inpresent time enables
efficient design of water jets that are
otherwisecomplextooptimse.
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Floating 1/10th scale model. Virtual testing of shock absorbing mechanism.
09 Vol. 18 No. 5 October 2010 09
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T
he Indian AEW C system being developed by DRDOwith CABS as
the nodal agency will detect identify, and classify threats present
in the surveillance volume and will act as a Command and Control
Centre to support air defence operations The system with its multiple
Communication and Data Links can alert and direct fighters against threats
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The Mission System Controller (MSC) is the
nerve centre of the Airborne Early Warning
and Control (AEW&C) system offering sensor
data fusion to obtain recognisable air
situation picture, identification and
classification of targets, evaluation of threat,
and control and guidance of friendly
interceptor fighters of the Indian Air Force.
while providing Recognisable Air
Si t uat i on Pi ct ur e RASP t o
commander s at t he Gr ound
Exploitation Stations GES that are
strategically located The AEW C
system can thus support the Indian
Air Force in offensive strike missions
and assist Forces in the tactical battle
area
The Electronic and Communi-
cation Support Measures (ESM &
CSM) of the systemcanintercept and
counter unfriendly radar trans-
mi ssi ons and communi cati on
signals. The AEW C system thus
comprises a number of major sub
systems viz Primary Radar PR
Secondary Surveillance Radar (SSR)
or Identification Friend or Foe IFF
Electronic Support Measures ESM
Communication Support Measures
CSM Mission Communication
System (MCS) that includes the 'C'-
band and 'Ku'-band SATCOM Data
Links and the V/UHF Voice and Data
Link (DL), Self-protection System
(SPS), Data Handling and Display
System(DHDS), andMSC.
The MSC is the most important
sub system of the AEW C system
The MSC serves as a central mission
computer which is integrated with
all theAEW Cmissionsub systems
The MSC performs the following
functions
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,
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:
Functionalities
Mission System Controller for Airborne
Early Warning and Control System
Mission System Controller for Airborne
Early Warning and Control System
Semantics of airborne early warning and control system.
10 Vol. 18 No. 5 October 2010
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Fusion of sensor data from
onboard sensors like radar IFF
etc
Identification and classification of
fuseddata
Creation and management of Air
SituationPicture ASP data
Threat evaluation and assess-
ment based on data received
fromother sensors
Weaponassignment
Vect or i ng of f i ght er s f or
interception
Guiding fighters for recovery to
thenearest safelandingarea
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Dynami c threat eval uati on
considering beyond visual range
(BVR) missileenvelope
Gui di ng fi ghters for stri ke
refueling andescort missions
Enablingthe operator onboardto
control various sensors and
equipment in accordance with
theoperational requirements
Providing information on hostile
emitters obtained from ESM and
CSM
Recording and playback of the
missionfor post missionanalysis
Monitoring health of onboard
avionics
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Coordination and monitoring of
functions of all mission sub
systems
Scheduling mission-related tasks
accordingtopre-definedpriority
Communication of information
from to AEW C to systems such
as other AEW Cs AWACS
fighters ADDCs etc
Enablingswitchingof the mission
among other AEW Cand AWACS
systems
Control of air to ground data
communication.
S uppl y of mi s s i on da t a
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LAN
MSC
Aircraft
Transmitters/
Receivers
FMS Blanking in
RADAR IFF ESM SPS CSM
DATA
LINK
MCS DHDS
INS
Blanking out
1553B
ARNIC
Extreme connectivity of MSC for data transfer.
RADAR IFF ESM CSM
DATA
LINK
MCS DHDS
DTU
ATR 1 ATR 2 TDU
Mission
Storage
MSC
LAN
Line replaceable units of MSC.
Rack C
Line replaceable units of MSC.
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navigation data and time data to
other systems.
Management of various tactical
data items like vulnerable areas
vulnerablepoints boundarylines
etc
Enabling onboard simulation and
training.
Interface between onboard
sensors andDHDS.
Pulse level blanking to avoid
mutual interferences.
Missionstorage.
Missionplanningandanalysis.
Recording and playback of
operator work stations' audio and
video
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The ATR and ATR are the main
computing and interfacing LRUs of
theMSC
The Mission Storage Unit MSU
stores the mission record data which
includes audio video from the five
operator workstations OWSs and
raw data from selected sensors The
MSU has storage capacity of two
Terabyte so that it can store multiple
missiondata
The Ruggedised Time Synchro-
nisationUnit RTDU synchronises all
the AEW C mission sub-systems for
meaningful data fusion and Global
Ai r Si t uat i on Pi ct ur e GASP
construction
The Data Transfer Unit DTU
uploads pre programmed mission
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MissionData Storage
Time Synchronisation
DataTransfer
related data into airborne segment
through removable media and
downloads the current mission data
for off-line analysis The tactical
missiondataandpre flight messages
from Ground Mission Planning and
Analysis Station are copied on to the
removable media and loaded on to
the airborne MSC for the current
mission/operation. Also the onboard
stored data is copied on to the
removable media at the end of the
mission and brought to Mission
Planning and Analysis Station
MIPAS for off-line data audio, and
videoanalyses.
Multi Sensor Data Fusion MSDF
aims at situation awareness to
enable faster and more reliable
decisions and thus significantly
enhances mission effectiveness
MSDF fuses all data geometric
kinematics attributes pertaining to
one target object into one single
identified and classified track. This
data fusion process is supported and
controlled in accordance with the
actual task and mission. The ultimate
goal of MSDF is a crucial contribution
towards information superiority,
which results in an identified and
classified track with optimised
accuracy stability continuity, and
reliabilityfor eachtarget object.
The various sensors and sources
considered for fusion include PR
secondary radar ESM DLs, and
knowledge bases The sensor data
integration module performs Multi
Sensor Tracking MST by combining
the data from multiple sensors and
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( )
Sensor Data Fusion
Identification and Classification
performing a track level fusion This
module performs all required pre-
pr oces s i ng, s uch as s ens or
registration data alignment time
alignment data estimation and data
and track association prior to fusion
This module also performs track to
track fusiontoenhance the quality of
the track The identification and
classification module identifies and
classifies the unknown but refined
track by fusing and correlating data
from sensors and sources. This
modul e perf orms f l i ght pl an
correlation ESM correlation and IFF
correlation to achieve the desired
objectives. The threat assessment
module evaluates the threat for the
identified tracks with respect to
AEW C and the desired vulnerable
areas and vulnerable points The
module alsoevaluates the threat and
pr ovi des necessar y al er t s t o
operators of the AEW C
The command and control
functionalities of the AEW C system
are carried out in the intercept
control segment of MSC. The module
carries out threat assessment
weapon assignment interception
guidance, and recovery. The module
acts as a decision-aid to the operator
and provides the threat level
considering the reachability and
weapon envelopes of the target
intentionandcapability of thethreat
and the asset priorities The module
alsoprovides the confidence level on
t he sui t abi l i t y of pai r i ng of
interceptors against targets for
operator selection. The module
generates intercept solutions based
on the type and configuration of the
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Intercept Control
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, esVdkWQ gkml] fnYyh Dr AL Moorthy
Shri R Shankar
Shri Sudhir K Mishra
Shri RK Uppal
, Director, DESIDOC, Metcalfe House, Delhi
Director of Materials, DRDO
, Director of CV&E, DRDO New Delhi
Director of Naval Research & Development
DRDO
, Director of Missiles, DRDO
, SO to SA to RM, DRDO , New Delhi
Bhavan,
Bhavan
Coordinator
Members
Dr Sudarshan Kumar
Cmde PK Mishra
, Bhavan
,
Bhavan
Bhavan
, New Delhi
, New Delhi
, New Delhi
Editorial Committee
interceptor and weapons onboard
the interceptor using guidance
algorithms such as collision course,
of f s e t a nd pur s ui t or a ny
combination of these. The module
also gives the time to interception,
the launch point and the kill point
for operator's situation awareness
and sends this information to be
relayed to the fighters.
The LRUs of the MSC are at
various stages of being qualified for
ai rborne use The embedded
software in the MSC are also
undergoi ng the i ndependent
verificationandvalidationprocess A
functionally provenMSCis already in
active use integrating all other sub-
systems of the AEW&C with their
'nerve-centre' calledMSC.
.
.
Printed & published by Director, DESIDOC, on behalf of DRDO
MhvkjMhvks dh vksj ls funskd] MslhMkWd }kjk eqfnzr ,oa izdkfkr
RNI No. 55787/93
Telephone: 011-23902475
Fax:011-23819151; 011-23813465
E-mail: director@desidoc.drdo.in
Internet: www.drdo.gov.in/drdo/pub/techfocus/welcome3.htm
Director@desidoc.drdo.in
www.drdo.gov.in/drdo/pub/techfocus/welcome3.htm
Threat assessment weapon assignment, intercept control guidance and recovery.
Target Detected
Time-based Solution
Assigned
Interceptor
Interceptor 1
Balanced
Solution
Suitability-based
Solution
Interceptor 3
AEW&C
Interceptor 2
ICDL