A monthly house bulletin of Defence Research & Development Organisation

ISSN : 0971-4413

BULLETIN OF DEFENCE RESEARCH AND

DEVELOPMENT ORGANISATION

Vol. 31 No. 7

July 2011

Vol. 22 No. 2 April 2014

Indigenous Technologies and Sub-systems

for Armoured Fighting Vehicles

rmoured Fighting Vehicles (AFVs)

and development of armoured fighting vehicles

play an important role in any war

and specialised vehicles to enhance the combat

scenario. Particularly, the Main Battle Tank

capabilities of the Indian Army. Apart from design

(MBT) being the highly survivable and lethal

and development of the most prestigious product

combat vehicle, play as a game-changer in

Arjun MBT, CVRDE has developed various

conflict situations worldwide.

tracked vehicles and associated technologies

Combat

Vehicles

Development
(CVRDE),

laboratory
of DRDO in
Chennai,

is

engaged
in

design

Research

Establishment
constituent

and

and sub-systems for AFV applications.

This special issue of Technology

Focus brings out an overview of some

technologies
and
sub-systems
developed
by
CVRDE for AFV
applications.

of

the

From the Desk of Guest Editor

Arjun MBT is a flagship
product of CVRDE. The other
armoured vehicles developed
by CVRDE, which have gone
into production are: Armoured
Patrol Car, Armoured Recovery
Vehicle, 130 mm SP gunCatapult
on Vijayanta, Carrier Mortar
Tracked Vehicle, Carrier Command Post Tracked and
Missile Carrier Vehicle for Integrated Guided Missile
Development Programme (IGMDP) on BMP-II,
Bridge Layer Tank (BLT-72), Combat Improved Ajeya
and Armoured Ambulance. CVRDE has successfully
developed Unmanned Ground Vehicle based on
BMP-II platform for surveillance, NBC reconnaissance
and mine detection purposes. During late eighties,
CVRDE designed and developed Aircraft Mounted
Accessory Gear Box (AMAGB), Aircraft Bearings, PTO
Shaft, 5 kW Brushless DC Generator and Hydraulic
Filters for LCA Tejas. CVRDE has also enhanced its
infrastructure through creation of test facilities for
engine and suspension systems of AFVs, state-ofthe-art EMI/EMC Test Facility as per latest standards
and has developed Training Simulators for Arjun
MBT Drivers and Gunners.
Arjun MBT, the brain-child of CVRDE, has
been designed to meet Army's most stringent
requirements and provides high mobility, superior
firepower, enhanced protection and crew comfort.
Two regiments of Arjun MBT Mk-I have been
inducted into Army. Based on the expertise gained,
Arjun MBT Mk-II has been developed with enhanced
performance which includes Missile Firing Capability,
Improved Commanders Panoramic Sight, Track
Width Mine Plough, Automatic Target Tracking,

April 2014

Power Driven Air Defense Gun, Advanced Running

Gear System, Final Drive with reduction ratio, and
Improved Slip Ring. The improved performance of
Arjun MBT Mk-II has been successfully demonstrated
to the user.
On the technological front, CVRDE has excelled in
a gamut of technologies related to Combat Systems
which include In-Vehicle Networking with MultiBus Architecture, Inter Vehicle Information System,
Electronic Fuel Injection System, Commanders
Panoramic Sight, Advanced Fire Control Computer,
Laser Warning and Countermeasure System,
Digital Image Exploitation System for the driver
including Stereo Vision, Image Fusion and Map
display, Indigenous Fiber Optic Gyros and ATE
for Compact Electronics Unit, All Electric Drive,
400 hp Electronically Controlled Power pack for
BMP-II. CVRDE is currently working on projects such
as Arjun Armoured Repair and Recovery Vehicle
(Arjun ARRV) and Armoured Vehicle Engineering
(AVE). The establishment is spearheading the
National Mission Project for Development of
1500 hp Engine and Transmission.

Technology Focus is the medium through which

we get the opportunity to create awareness about
the technologies developed by DRDO. A special
issue on Indigenous Armoured Tracked Vehicles
was brought out in June 2011. This issue gives an
overview of some of the technologies developed for
AFV applications by CVRDE.

Dr P Sivakumar

Outstanding Scientist
Director, CVRDE

Air Cleaning System for Armoured

Fighting Vehicle
In Armoured Fighting Vehicle (AFV), the space is at
premium especially in the engine compartment. The
powerpack of an AFV consists of an engine coupled with
transmission and peripheral systems like cooling system,
air filtering system, and under armour fuel tanks. Even
though the air cleaning system is a static system, it is
important as well as critical for the better performance
of the engine. While in off-highway terrains, the dust
contents in the atmospheric air are of the order of
1 mg/m3 to 40 mg/m3, in the desert it is considered
to be in the order 2000 mg/m3. Moreover, ambient
temperature in the desert terrain is often around
50o C. Thus requirement of air filtration in desert
terrains is enormous and the air filtering system of the
AFV should filter down the air to 3-5 microns in order to
supply clean air to its engine. Also, air filtration system
of an AFV shall filter the combustion air up to a specified

Air Filtration System for Up-rated T-72

Engine
CVRDE has up-rated the power output of the
T-72 engine from 780 hp to 1000 hp by modifying
the peripheral sub-systems. Development of under
armour air filtration system for up-rated T-72 engine
was taken up with the help of Indian industry. The
air filtration system of the up-rated T-72 consists
of a primary filter with unidirectional flow cyclones
and a disposable secondary filter with dry-type resin
impregnated or equivalent paper filter elements.
The air filtration system has been configured within
the available space in T-72 engine compartment and
consists of the following major components: primary
cyclone filter assembly; secondary filter elements; filter
housing assembly; scavenge fan assembly with cable
and duct; and differential pressure sensor and status
indicator.
The Primary cyclone filter, the pre filter with
unidirectional flow cyclones, filters heavier dust
particles. The secondary filter elements filter the air

level, provide maximum efficiency, offer lesser pressure

drop, extract positive dust so that engine works to its
optimum level. CVRDE has developed the following air
filtration systems:

Air Filtration System for T-72 Base Engine

The two-stage air filtration system of a T-72

Figure 1. Primary filter

dust collected from the primary cyclone filter is drawn

up to 3 microns with an over all efficiency of 99.99 per

cent. The combat filter is easily replaceable/cleanable.
Primary cyclone filter and secondary filter elements
are housed in a filter housing assembly. Scavenge
fan assembly with cable and ducta positive dust
extraction system consisting of an axial fan driven by
an electric motorremoves the heavier dust particles

by exhaust scavenging.

filtered by the primary cyclonic filters. Differential

base engine consists of a primary cyclone filter and a

secondary barrier filter element. While the primary filter
is with reverse flow cyclones, secondary filter is a wettype wire wool cartridges. A pressure sensor indicates
the status of contamination in the drivers panel. The

April 2014

pressure sensor and status indicator sense and indicate

the pressure drop across the air filtering system in the
drivers panel.
Choking condition of the secondary air filter
elements is indicated by the signal provided by the
vacuum switch, which operates at the prescribed
limit. Full load running is possible only by cleaning the
secondary air filter elements or by replacement of the
elements.
Figure 2. Secondary filter installed in casing

Technical Specifications: Air filtration System of

Up-rated 1000 hp Engine

Figure 3. Assembly Air Cleaner

Figure 4. Scavenge fan assembly

April 2014

Air filter type

Dry

Number of stages

Two

Primary filter

Uni-flow cyclones

Cyclone material
:

High density poly

propylene

Airborne dust
concentration

2 gm/m3

Dust extraction

Positive dust extractor

fan 28 V, 40 amps DC

Purge rate
:

10 per cent of main

flow

Secondary filter
:
element

Resin impregnated
paper filter or
equivalent

Surface area of
filter paper

40 m2

Least particle size

to be filtered

3 microns absolute

Air flow rate

1.33 kg/s

Filtration efficiency :

99.99 per cent

(SAE Coarse)

Pressure drop
:

Clean air 250 mm WG

After choking 760 mm WG

The air filtration system with up-rated 1000 hp

Development of cooling system for operation

engine has been integrated in T-72 vehicle and trial

in Indian environment is a very challenging task.

evaluated for more than 2000 km for satisfactory

CVRDE has established technology for configuring

performance.

and developing cooling system for AFV applications.

Number of compact aluminum plate and fin matrices
with higher heat transfer surface area per unit volume
have been developed and adopted in various heat
exchangers utilising the infrastructure and expertise
available within India.
The cooling system has to meet the cooling
requirement up to 55C. The aluminium plate and
fin matrix used by CVRDE for the cooling system
has higher heat transfer area per unit volume up to
1800 m2/m3 compared to that used in commercial
vehicles (1100 m2/m3). The flow rate and head required
by the fan is very high for a given volume, hence

Figure 5. Air filtration system integrated in vehicle

Cooling System for AFVs

Armoured fighting vehicles are powered by high
specific output diesel engines. To dissipate the heat
rejected by engine coolant, engine oil, and charge air
and transmission oil, compact cooling system is used in
modern AFVs. AFVs in India, often operate at ambient
temperature higher than 50C. Space is premium in
AFVs as any increase in volume of the sub-systems
will lead to increase in weight. Therefore proper
configuration and design and development of cooling
system for AFVs is very critical.

efficient and high speed cooling fans have been used.

To reduce the pressure drop in cooling air, ducted
cooling system has been adopted as it also enables the
vehicle to undergo medium fording.
Due to space limitations, it is not possible to
provide cooling capacity up to 55 C. Hence to
control thermal load on cooling system, CVRDE has
incorporated automatic power regulation based on
coolant temperature at higher ambient temperature.
In modern AFVs, heat exchangers like engine oil
cooler, charge air cooler, transmission oil coolers are
placed inside the powerpack compartment and are
cooled by coolant. Only radiators are placed on the top

Cooling system of an AFV dissipates the rejected

of the powerpack and are cooled by the atmospheric air.

heat at all operating temperature. The pressure drop

CVRDE has developed variety of compact aluminium

through the system has to be kept minimum to reduce

plate and fin matrices for application in indigenous

the pressure head developed by the coolant pump and

powerpack. Multi-louvered fin and offset strip fin

cooling fans, which should be efficient to reduce the

(parallel) with heat transfer area per unit volume in the

power consumed by it.

range 1100-1700 m2/m3 have been developed. The

April 2014

following heat exchangers have been developed

evaluated and optimised

using these fins:

in

aa A 720 x 880 x 120 mm radiator with 380 kW heat

dissipation capacity

both

test

rig

and

vehicle.
This compact cooling

aa A 430 x 280 x 210 mm charge air cooler with 150 kW

heat dissipation capacity

system

aa A 500 x 200 x 76 mm LH and RH transmission oil

cooler with 75 kW heat dissipation capacity of
each

and aircraft applications

aa A 325 x 225 x 50 mm fuel cooler with 10 kW heat

dissipation capacity

technology

can

also be adopted for civil

where volume and weight
is very critical.

Figure 7. Cooling fan

Cooling System for T-72 Variants

Developing cooling systems, especially for the
engines of AFVs, to meet the rigorous environmental
conditions of high temperature and dust, have always
been challenging to Indian AFV technologists. Projects
connected with T-72, like Bridge Laying Tank (BLT) T-72,
1000 hp engine upgrade and Ex Tank, have necessitated
optimally designed higher capacity cooling systems
within the same spatial envelope of T-72 powerpack
configuration.
The radiators and engine oil coolers, the cooling
fan and the cooling water pump combined with the

Figure 6. Clockwise from top left: Radiator, charge air cooler,

transmission oil cooler LH and transmission oil cooler RH

components of the system. The indigenously

The cooling fan of an AFV has to ensue cool air

developed cooling system components would

flow with the specified pressure head overcoming

go into the regular series production of BLT

resistances in the cooling air flow passages. Since

T-72. The associated technologies and cooling

it requires to run at 5500 rpm, its radiographic

product developed are discussed herewith.

quality needs to be very good and the fan has to be

dynamically balanced. The cooling fans for AFVs have
been developed indigenously.
The cooling system, consisting of all the above
heat exchangers and cooling fan, has been integrated
with indigenous powerpack. The system has been

ballistic grills for air flow are the key aggregates/

April 2014

Heat ExchangersWater radiators and

Engine Oil Coolers
The radiators and coolers originally used in the
T-72 were grossly inadequate for effective cooling
in BLT T-72 under summer desert conditions. After
experimenting with different sizes of core thickness,

the radiators and oil coolers have been successfully

developed indigenously using aluminium core, plate
and fin type, furnace brazed with single pass liquid
flow between headers. These were tested extensively
under simulated conditions and by installation inside

Technical Specifications: Engine Oil Cooler LH and

Engine Oil Cooler RH
Heat dissipation

: 60 kW each

Oil flow rate

: 180 lpm

Oil inlet temperature

: 120C

Allowable pressure drop

on oil

: 1.7 bar

tanks.

Cooling air flow rate

: 2.50 kg/s

Cooling air inlet

temperature

: 50C

Allowable pressure drop on

cooling air

: 35 mm WG

Oil used

: SAE 20 W 50

Size of core matrix

: 610 x 460 x 63 mm

Cooling Water Pump

A high capacity centrifugal cooling water pump
has been indigenised for T-72 engine based variants
including BLT T-72. The pump made of aluminium alloy
is mounted on the tanks engine and in the same
Figure 8. Oil cooler LH (top) and Oil cooler RH

Technical Specifications: Radiator LH and Radiator RH

spatial and originally mounting configuration. The

pump has been precision manufactured with a highspeed impeller and mechanical seal. Prototype samples

: 105 kW each

have been tested at Engine Factory Avadis test facility.

Coolant flow rate

: 500 lpm

Installation on the engine also has been tried out. The

Coolant inlet temperature

: 115C

design is being fine tuned and development work is in

: 0.5 bar

Technical Specifications

Heat dissipation

Allowable coolant
pressure drop
Cooling air flow rate

: 2.50 kg/s

full swing.

: 65C

Type
:

Centrifugal pump
working in closed loop
system

Allowable pressure drop

on cooling air

: 35 mm WG

Body material
:

Aluminium alloy casting

or its equivalent

Size of core matrix

: 927 x 470 x 130 mm

Cooling air inlet

temperature

Input drive

Mechanical

April 2014

out. The first two have been established and third

technology is in the development mode. The fans have
been bench tested for high speed running, flow, and
power consumption. The sand cast and ring rolled
fans have been tested on prototype tanks and found
compatible.
Technical Specifications
Material
: High grade aluminium
alloy

Figure 9. Cooling water pump

Pump speed

Pump outlet
:

Maximum water
temperature
:

3000 rpm normal max.

610 lpm @ pressure
0.4 bar
up to 115C

Cooling Fan
A centrifugal cooling fan with aerodynamic
vanes has been developed indigenously for T-72
configuration. Unlike the riveted aluminium sheet
construction, the fan has been made using casting
and other forming processes. Sand casting, ring
rolling followed by CNC machining and Low-Pressure
Die-Casting (LPDC) processes are also being worked

Overall diameter

: 655 mm

Height

: 205 mm

No. of vanes

: 16 equally spaced

Ballistic Grills
Original table-top type louvres used in T-72 grills
(over the radiator) have been replaced by a different
type of section, which permits almost double the air
flow and less obstruction, but retains the ballistic
properties. The louvre sections have been formed
from armour grade EN 25 steel by special hot extrusion
method and other finishing processes. Grills (length:
460 mm; Breadth: 50 mm and thickness: 4.5 mm) made
with this section, have been tested as per approved
standards and found ballisitically superior.

Electronic Fuel Injection System

Conventional fuel injection pumps used in up-rated
1000 hp engine do not have features for regulating
Figure 10. Cooling fan

April 2014

fuel as function of charge air temperature, coolant

temperature and shutdown mechanism for low engine

oil pressure and low coolant level. These features are

the fuelling based on charge air temperature,

coolant temperature, etc., and met all the system

essential for operation at high ambient temperature

requirements.

and also for foolproof engine performance. CVRDE has

Up-rated 1000 hp Engine for T-72

Tanks

developed Electronic Controlled Fuel Injection System

(ECFIS) jointly with Indian Institute of Technology,
Chennai, to introduce electronic governor in place
of mechanical governor, to develop microprocessorbased engine controller unit and to introduce actuator
to regulate the fuel delivery for up-rated 1000 hp
engine.
The ECFIS consists of sensors, actuators, control
system and software. The system senses engine speed,

T-72 M1 tanks are powered by 780 hp engine. It is

a V type, 12 cylinders, four stroke, water cooled, direct
injection and mechanically supercharged engine
having 38.88 liters of swept volume. To meet the
Indian operating environment conditions, its power
output has been upgraded from 780 hp to 1000 hp to
enhance its mobility with the increased weight.

load, charge air temperature, coolant temperature and

accelerator pedal position. The input data is fed to
electronic controller, which gives signal to the actuator
and that in turn moves the control rack. Indigenously
developed

microprocessor-based

controllers

and

actuators have been integrated with the fuel injection

pump (FIP) and evaluated in FIP test bench. FIP
integrated with the engine has also been evaluated
in the test bed. The system successfully controlled
Figure 12. Up-rated 1000 hp Engine

Power enhancement was achieved by introduction

of turbochargers in place of mechanical super charger;
modification in the fuel injection system; introduction
of charge air cooling; introduction of enhanced capacity
water and oil pumps; introduction of new exhaust
manifold corrections and by modifying existing inlet
manifold.

Figure 11. ECFIS installed in the FIP test bench

The engine performance has been evaluated

and demonstrated on the engine test bed. Prototype
engines have been subjected to 100 hours of full
load test and 400 hours of endurance run. Details of
upgraded module are as follows.

April 2014

Engine Peripheral Systems for Vehicle

Integration
To cater for the requirement of up-rated 1000 hp
engine, the following modifications were carried out:
aa Introduction of compact aluminium plate and fin
heat exchangers in place of brass/copper tube and
fin type heat exchangers consisting of radiators,
engine oil cooler and transmission oil cooler

conducted at Rajasthan as it warranted to prove the

engine qualification at higher ambient temperatures
and at dusty environmental conditions. The engine
has successfully completed user trials at Pokhran and
validation trials by DGQA and MAG-6.

Sub-Systems for Gun Control System

aa Introduction of efficient aluminium aero foil profiled

cooling fan in place of fabricated cooling fan

Automatic Target Tracker

aa New air cleaning system consisting of cyclonic

primary filter, paper fine filter and positive dust
extraction system

gunner in automatically slewing the GMS mirror to the

aa Efficient engine oil filter

A prototype ATT has been developed and evaluated at

Automatic Target Tracker (ATT) is used to assist

selected target. ATT automatically tracks the selected
target using video available from the sighting system.

aa Positive closed breathing system

trial sites in and around Chennai, and at Suratgarh. The

aa Teflon corrugated stainless steel hoses in

place of rubber hoses for engine oil lubrication
connections.

ATT takes video input from the monitoring port of GMS

The prototype up-rated 1000 hp engine after

has been satisfactory evaluated and recommended by

evaluation at CVRDE test bench has been integrated

the users. ATT was trial evaluated at MFFR in the static

in a T-72 M1 vehicle. The vehicle field evaluation

observer to moving target, moving observer to static

has been conducted at Avadi trial site as well as

target and moving observer to moving target modes.

Figure 13. Up-rated 1000 hp engine with air filtration system

10

in Rajasthan. Most of the vehicle trials have been

April 2014

and swaps command signal of Gunners Control Handle

(GCH) in auto mode. This set-up, integrated on the tank,

Figure 14. Automatic target tracker unit

Trials were conducted in both, day and night, for

a range of 2 km and expected pixels accuracy was
achieved.
Salient Features
aa Relieves stress and fatigue of the gunner
aa Tracks the target during obscurations and even in
the cluttered environment.
aa Handy in undulation terrain, viz, desert area.

Digital Controller for Weapon

Platform Stabilisation
Main function of the Gun Control System (GCS)
in an AFV is to provide STAB (self-stabilisation) and
Figure 15. Digital controller

accurate slaving of the weapon platform to a stabilised

sighting system in spite of terrain disturbances. The

CVRDE has developed a compact digital controller

stabilisation and slaving accuracy should be below

to achieve high first round hit. The digital controller

the permissible limit to achieve high first round hit

has some inherent advantages; modification of filter

probability while firing in static/mobile modes. This

demands a highly precise controller for weapon
platform stabilisation.

parameters is easy as these are not designed through

discrete components and the software filters are not
dependent upon age or environmental factors and

The controller unit is the heart of a GCS

provides flexibility in altering the coefficients without

which houses all the electronics for control law

any hardware changes. The digital controller unit is

implementation. Basically the controller works in

compact and can be implemented with minimum

STAB and SLAVE mode. In the electro-hydraulic GCS,

the electrical output from the control handle drives
the turret and gun through the servo valves. In the
STAB/SLAVE modes of operation, the controller unit
controls the hydraulic flow to the actuators. In the STAB
mode of operation inertial stabilisation to the gun is
provided by counter moving the gun/turret to the hull
movements due to terrain disturbances. In the SLAVE
mode of operation, the gun is slaved to the master

hardware.
The controller is built with state-of-the-art digital
signal processor with high-speed 16 bit ADC and DAC.
Bilinear transformation technique has been used to
implement various compensators in digital domain.
The controller also comprises effective anti-aliasing
filters. The sampling frequency is optimally selected at
4 kHz.

stabilised sight. Position error signals through resolver

This system also provides both on-line and off-line

chain system are fed from the Fire Control System (FCS)

Built-in testing equipment (BITE). During system on,

to GCS. This mode is the primary mode of operation of

the on-line BITE gives health of the controller unit. The

Integrated Fire Control System (IFCS).

system also provides an off-line/manual BITE, wherein

April 2014

11

a reference signal is fed instead of the control handle

CVRDE has indigenously designed, developed,

signal and Linear Variable Differential Transformer

tested and productionised sub-systems, viz. Hydro-gas

(LVDT) signal is compared with a known reference. The

Suspension Unit (HSU), track adjuster, twin top roller,

system has provision of recording predefined events

tracks and assembly road wheel for Arjun MBT. All

and time stamping of the same.

these sub-systems have been subjected to elaborate

The digital controller comprises power supply

module, power supply and control logic module, and
DSP module. Additional functions of MIL-1553B and
Ethernet have been provided for digital communication
with other systems of the weapon platform.
The controller has been designed and developed
to the stringent specifications and qualifies ESS and
EMI/EMC tests. It has been thoroughly tested on bench

field trials in different terrain condition for around

70,000 km run and proven for their performance and
expected life. Besides, the variants of suspension
system, viz., in-arm hydro-gas suspension, tandem strut
for Ex-tank, hydro-gas strut for BMP, hydro-gas strut,
have also been successfully designed and developed
for heavy commercial vehicle and hydro-gas strut for
naval applications.

and then on tank before subjected to firing trial. This

unit was integrated with other sub-systems of the
weapon platform and underwent summer firing trials
in Rajasthan. Excellent results were achieved in both
static and dynamic mode of firing.

Suspension System for AFVs

Hydro-Gas Suspension System
Main Battle Tank (MBT) is a cross-country vehicle
with high mobility and superior ride comfort along
with other main characteristics like superior fire power,
high degree of protection, etc. Higher mobility power
is essential for an MBT vehicle to negotiate and

12

Figure 16. Running gear system/sub-systems mounted on tank

Hydro-gas Suspension Unit

manoeuvre faster in terrains such as hard and soft

The suspension system is intended for cushioning

grounds, ditches and steps, water obstacles and marshy

the impacts, shocks, and for damping the oscillations

patch, sand dunes and mountains in circumstances

of the hull when the vehicle moves over irregularities

having rapid dispersion of fighting forces during

of the terrain and also when obstacles are being

execution of counter attacks from unexpected

negotiated to provide crew comfort, protecting the

directions. A well-matched running gear system is very

sensitive on-board equipment and also to provide

essential to make use of the maximum torque available

stable platform for armament thereby improving fire

at sprocket through power train from engine.

performance accuracy.

April 2014

A modular HSU has been realised to meet the

functional requirements of the hydro-gas suspension
system.
The HSU consists of actuator and accumulator
cylinders with sliding piston, floating piston and inbuilt damping unit, crank assembled with piston rod,
axle arm assembly, cover assembly and road wheel
pair. Vehicle load is transmitted through the road wheel
support and trailing axle arm to the suspension unit.
The wheel loads are transmitted by means of a crank
pin with splined shaft, which is a structural extension
of the axle arm assembly through crank and piston rod
assembly to the HSU. By means of movement of sliding
piston and, thus, the oil through damper unit, the
vibration of vehicle is damped out. The gas under high
pressure in the accumulator cylinder acts as spring. In
the HSU, the main bearings are located internally in the
crank case, which is sealed to the atmosphere and is
independent of the axle arm assembly.

Figure 18. HSU for Arjun MBT

HSUTechnical Specifications
aa Spring characteristics : Non-linear spring
through gas medium
aa Damping
: Bi-directional in-built
damping
aa Wheel travel

: 535 mm

aa Static load

aa Dynamic load

: 19 ton

aa Oil used

SAE 10 W 30

aa Gas used

Nitrogen

aa Application
:

4.2 ton

Arjun MBT, 14 stations

per vehicle.

HSUSalient Features
aa Larger wheel travel possible
aa Good riding comfort due to non-linear spring
characteristics
aa Provide stable gun platform for firing on the move
aa Ease of maintenance
aa Low silhouette of vehicle
aa High effective inside volume
aa Pressure and spring rate can be independently
Figure 17. Schematic diagram of HSU with its parts

adjusted

April 2014

13

aa In-built damper units for better damping distribution

possible
aa High cross-country mobility

High-Pressure Piston Seals for Hydro-Gas

Suspension System
The HSU uses high-pressure piston seals to
exhibit greater sealing efficiency in dynamic loading
at various operating conditions, viz., varying ambient
temperature, high frequency and amplitudes at higher
wheel loads.
Figure 21. Sliding and floating pistons with assembly cylinders

to Bharat Earth Movers Limited (BEML), Bengaluru, for

fitment of the seals with production orders of HSU.
Efforts have been made to arrive at the performance
governing parameters by undertaking various tests
and trials on a lot of samples picked up from the raw
seal material, to use the results in the respective QAI
document. Service order has been placed to M/s CIPET,
Figure 19. Sliding piston

Figure 20. Floating piston

Seals Assembled on Floating Piston

Assembly

India. CIPET has carried out the necessary tests and

trials by using the samples provided by M/s Fluro
Carbon Seals, Chennai. The trial data have been filled

The 110 mm diameter seal configuration has

in the respective entry area of the QAI. Next batch of

been indigenously designed and composition of seal

samples will be taken up for yet another set of test and

constituents material identified to replace imported

trials to narrow down the uncertainty factors obtained

seals being used presently. So far three iteration of

from the previous tests.

testing for 50 hours have been completed and further

Technologies for Transmission

Systems

improvements on the performance of seals are being

carried out.
Further high-temperature, high-pressure piston

14

Chennai, Ministry of Chemical and Fertilizer, Govt of

Fluid Coupling and Retarder

seals have been developed and tested with HSU on

CVRDE is developing a 1500 hp fully automatic

Arjun-PPS XII tank. The tank has undergone 5000

hydrodynamic mechanical transmission system for

km trials so far without any failure. Based on the

AFVs. The system comprises various sub-systems, viz.,

performance of the seals, clearance has been given

speed change gearbox, direction change gearbox,

April 2014

mechanical steering unit, steering differential, torque

drive. Fluid coupling and retarder are required to

convertor, fluid coupling and retarder, etc.

function independently and also together.

Fluid coupling is a hydrodynamic coupling, which

Three prototypes of fluid coupling and retarder

consists of two major bladed components, namely,

assembly have been developed and tested in a

impeller and turbine. Oil is used as power transmitting

separate test-rig especially designed and developed for

media from impeller to turbine. The fluid coupling

testing of fluid coupling and retarder. Hydraulic circuit,

system used in 1500 hp transmission can transmit

having special oil inlet and outlet valves, has also been

170 kW power. The rated speed of this unit is

developed for supplying oil to both units at different

6720 rpm and it is used for driving the cooling fan

flow rates. The hydraulic circuit employs standard

through a suitable gear train and control the speed of

pumps, filters, pressure relief valves, flow meters and

cooling fan in accordance with coolant temperature.

solenoid valves for achieving the test requirements

Oil supply to fluid coupling varies according to coolant

of the test rig. Speed, torque, power and temperature

temperature, which results in change in slip as well as

data have been recorded and analyzed for studying

change in output speed.

fluid coupling characteristic behaviour and power loss

Retarder is a hydrodynamic device used for

at different input speeds and slips.

decelerating the vehicle and running the vehicle at

Development and testing of fluid coupling and

desired speed in downhill operation. Retarder and

retarder running at more than 6000 rpm have been

main brakes together provide high braking power to

done first time in India. Compact fluid coupling and

vehicle. Retarder also increases the life of main brake

retarder for high power rating (170-225 kW) and high

shoes by sharing its load. Both fluid coupling and

speed application (6700 rpm) is not available within

retarder are assembled in a single casing and receive

India. CVRDE has successfully designed and developed

drive from a common shaft. Input to this assembly is

prototypes and validated these successfully as an effort

from primary side of torque convertor through gear

for indigenisation of technology.

Development of 1500 hp and 550 hp Torque

Converters
The 1500 hp fully automatic hydrodynamic
mechanical transmission system for AFVs is being
developed.

Torque

multiplication

is

converter
major

used

for

sub-system

torque
of

this

transmission. Other sub-systems of transmission are

speed change gearbox, direction change gearbox,
mechanical steering unit, steering differential, fluid
coupling and retarder, final drive, etc. Torque converter
Figure 22. Fluid coupling testing arrangement

is a hydrodynamic device consisting of three major

April 2014

15

bladed components, namely, impeller, stator and

the test rig. Input and output torque, inlet, outlet

turbine. Impeller is connected with input drive (engine),

and lubrication flow rates, converter inlet and outlet

turbine is connected to load (wheel or sprocket) and

temperature, coolant and sump temperature, input

stator is coupled with a stationary casing through one

and output speeds, inlet and outlet pressure, lock-up

way clutch. Stator is a reaction member and thus gives

and lubrication pressure were recorded using online

torque multiplication. After the coupling point the

data acquisition system to analyse the performance

stator rotates along with impeller. Oil is used as power

characteristics curves of torque converter at constant

transmitting media from impeller to turbine. Torque

input speed of 2000 revolution per minute. The lock-

converter multiplies torque to provide quick start, easy

up clutch torque transmitting capacity was also test

gradient climbing and high acceleration to vehicle. It

evaluated for selected converter speeds and lock-up

makes gear-shifting smooth and absorbs jerks.

pressures and was found satisfactory. An endurance

Two torque converters have been developed for

1500 hp and 550 hp transmissions. The single-stage,
two-phase, three-element torque converters have
stall torque ratio of 2.4. The 1500 hp torque converter
is rated for a speed of 3000 revolution per minute. It
operates in two phasestorque converter mode and

testing to demonstrate the lock-up clutch was carried

out by continuously engaging and disengaging the
clutches by running the converter at a particular speed
ratio with the simulation of inertia. The converters
stall torque capability was determined by locking
the output shaft while running the converter at peak
torque condition for three input speeds.
Design and development of torque converter
was a critical area. As an effort for indigenisation of
technologies, design of torque converter has been
established including the bladed components for the
first time in India.

Figure 23. Assembly of 1500 hp torque converter

lock-up mode. When required, torque converter can

be bypassed through hydraulically actuated lock-up
clutch. Converter mode is used for starting and during
gear shifts for better fuel economy. The converter
remains in lock-up mode during the remaining period.
Three prototypes of torque converters have
been developed and tested for each power rating. A
dedicated test-rig, a hydraulic circuit consisting of
gear pumps, filters, pressure relief valves, pressure
and temperature gauges and flow meters have been
developed for achieving the test requirements of

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April 2014

Defensive Aids System for AFVs

Defensive Aids System (DAS) enhances the
survivability of AFVs against modern sensors and Antitank Guided Missiles (ATGM) detection systems. CVRDE
has developed indigenous DAS for AFVs. The system
comprises a Mobile Camouflage System (MCS) and an
Advanced Laser Warning and Countermeasure System
(ALWCS).

Mobile Camouflage System

The

MCS

provides

multi-spectral

signature

management for the AFVs to protect the vehicle against

Figure 24. Mobile camouflage system

Figure 26. Smoke grenade discharged from the tank

all sensors and smart munitions. The performance

and tanks fitted with laser range finder. ALWCS has

evaluation trials of MCS have been conducted at MFFR

been integrated with Arjun MBT and interfaced with

and system has been integrated in the Arjun MBT.

integrated fire control system (IFCS). The performance

Advanced Laser Warning Countermeasure

System
The ALWCS increases the survivability of the
combat vehicle against ATGMs with Semi Automatic

evaluation trials have been conducted at MFFR,

Rajasthan. This system is a major value addition for
Arjun MBT Mk-II.

Arjun MBT Troop Training Simulator

Command to Line-of-Sight (SACLOS) system, ATGMs

CVRDE has established a state-of-the-art Arjun

with a laser target designator, beam rider ATGMs,

MBT simulator training centre, the first of its kind in

India, for AFV crew training.
Three driving simulators
and three turret simulators
have

been

indigenously

developed and installed. The

simulators are configured
to provide individual crewlevel

technical

training

to integrated tank- and

troop-level tactical training.
This

innovative

training

facility caters for safer, costeffective and round-theclock training to the Arjun
Figure 25. Advanced laser warning countermeasure system

MBT crew without using

April 2014

17

the actual tank and ammunition. This saves enormous

operational procedure to be followed in the turret

expenditure required for training the newly recruited

compartment to engage and fire on the targets.

Army crew.

Salient Features

The crew gets familiarised on various technical

and tactical drills in the simulator with awareness to
handle emergencies during training, which is not
possible through actual tank. This enhances the
performance of the crew so that the actual tank can be
handled effectively and hence its fighting capability
can be explored to the maximum possible extent.
Instructor station monitors and controls the actions
of nine crew members during troop training. Online
evaluation with appropriate ranking and after action

aa Commanders override operations and surveillance

procedures training
aa Identification and prioritisation of targets with
battlefield lessons
aa Navigation training through global positioning
system
aa Target engagement, tracking, laying and firing
practices with main gun and machine gun
aa Training under different terrain, environment and
visibility conditions

review is provided at the

instructor station to assess
the strength and weakness
of the crew during training.
This indigenous effort has
enhanced self-reliance in the
area of AFV crew training
requirements of Indian Army.

Turret Simulator
Turret

simulator

com-

prises replicated Arjun MBT

Figure 27. Internal view of Commander's and Gunner's compartment

turret compartment hardware controls with day and

night visions for gunner, and
panoramic

and

episcope

vision for commander to

handle the battle conditions
effectively. The turret simulator helps to familiarise the
gunner

and

commander

on various functions and

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April 2014

Figure 28. Instruction station with consoles and turret cabin on motion system

Figure 29. L-R: Driver compartment internal view (front side); hatch open driving simulation and driver's cabin on motion system

aa Firing with explosion, dust, smoke and recoil

effects
aa Instructor console to plan, monitor the Gunner's
and Commander's actions and evaluates these with
ranking

Driving Simulator
The driving simulator helps the driver to get
familiarised on various hardware controls and
switches present in the compartment and operational
procedures to be followed while driving the tank.
The driving simulator is provided with actual driver
compartment hardware controls with periscope
vision for day time driving and Passive Night Vision
Devices (PNVD) for night time driving. This simulator
cabin is mounted on 6 DOF (degree of freedom)
electrical motion systems to provide the realistic
roll, pitch, and yaw feel to the driver. The hatch
open driving simulation provides with battlefield
sceneries projected on cylindrical screen to cover
200horizontal FOV and 45vertical FOV. This helps
the driver to get immersed under virtual reality based
motion, aural and visual cues synchronisation.
Salient Features
aa Lesson plans for the driver to prepare the vehicle
under different start up and stopping conditions
aa Driving practice on different terrain, time, seasons

and visibility conditions with emergencies and

obstacles
aa Gear selection for different driving conditions
aa Fording exercises with underwater effects
aa Lessons for hatch open and hatch closed driving
aa Collision effects and its synchronisation with motion
cues during driving
aa Instructor console to plan, monitor the driver actions
and evaluate him with ranking

Troop Training Simulator

Troop training simulators for MBTs are available in
various countries across the world. However, in India
this is the first troop training simulator developed
indigenously for Arjun MBT to train three gunners,
three commanders and three drivers together in a
simulated tactical mission plan environment. To meet
this tactical training three turret simulators and three
driving simulators were interconnected through high
speed LAN.
Each turret and driving simulators are mounted on
a 6 DOF electrical motion system to generate realistic
motion cues and disturbances experienced by the
crew inside the MBT. Six such motion systems were
commissioned in an air-conditioned high roof bay for

April 2014

19

troop training. Real-time response based on the

nine crew members actions during troop training
have been achieved realistically by synchronising
six motion cues, 36 visual cues and various aural
cues in the simulator.

Salient Features
aa Lesson plan to cater tactical training with
troop formation procedures
aa Scenario editing with proper mission plans for
each tank
aa Plan, monitor and control the crew actions
through instructor console
aa Record and replay the crew actions during
training
aa Monitoring of nine crew actions through single
instructor station during troop training

Figure 30. Three turret and driving simulators

aa Open hatch display system for driver with 200(H)

and 45(V) FOV

aa Communication among nine crew members and

instructor

aa PNVD and thermal imager for the crew during night

aa Emergency controls for six motion systems

aa Camera view to monitor the physical movement of

aa Training under different terrain and environmental

conditions

time operations
nine crew and six motion systems during simulator
operation

Technology Focus focuses on the technological developments in the Organisation, covering the products, processes and technologies.

20

April 2014