This case study is based on an analysis of potential and describes how the mass of typical armored vehicles - such as civilian protection vehicles - can be reduced below the critical driver's license limit of 3.5 t by applying holistic lightweight construction methods. Significant weight reductions can be achieved by combining analytical methods, CAD-based functional structure analysis and non-linear FEM simulations. The aim is to optimize the vehicle structure, interior, armouring and add-on parts while maintaining the protective function and driving dynamics.
The initial situation
A leading European manufacturer of armored cars and trucks is aiming to develop a new civilian-approved vehicle with ballistic protection in accordance with VPAM BRV.
The challenge
Despite the armoring, special equipment and safety components, the permissible total mass of 3.5 t must not be exceeded - a decisive criterion for approval and operability with driving license class B. The requirements include ballistic protection (e.g. against 7.62 mm AP), pressure wave resistance, comfortable interior fittings and the integration of additional systems such as communication, power supply and air conditioning. The typical vehicle weight without optimization is over 4.2 tons. A reduction of more than 700 kg is required. At the same time, the integrity against impact, shock, temperature and vibration must be ensured.
Our approach is divided into the following steps:
- Systematic functional structure analysis with mass survey
- Application of potential classes according to TGM (primary, secondary, tertiary mass)
- Categorization of components according to optimization potential (technology, geometry, material)
- Topology and topography optimization for load-bearing parts
- Multiphysical FEM simulations (impact, crash, dynamics, thermal)
- Material substitution (e.g. steel → aluminum / hybrid / UD-CFRP)
- Development of a weight management system (mass book, target/actual comparison, variant evaluation)
By applying the methods mentioned become Weight saving potential of over 760 kg shown.
The decisive contribution came from:
- Lightweight structural design through optimization of support frames and reinforcements
- Substitution of interior supports and cladding elements with hollow chamber profiles and sandwich structures
- Optimization of seat configurations and fastenings
The final vehicle reaches a total weight of 3.4 tons incl. ballistic protection and additional systems. The protective effect in accordance with VPAM BRV 2009 VR7 has been retained.
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