This case study describes a systematic lightweight screening for the interior equipment and additional modules of armored cars, trucks and commercial vehicles in civilian and military use. The aim is to reduce the mass of fixtures and interior elements while retaining all functionalities in order not to exceed the maximum permissible total mass of 3.5 tons for civilian vehicles. To achieve this, a holistic approach was used that combines system, structural and material lightweight construction with analytical and FEM-based optimization methods.
The initial situation
A leading manufacturer of special civilian armored vehicles is increasingly confronted with the goal of implementing vehicle armoring with full interior equipment below the 3.5-ton limit. Previous models clearly exceed this limit due to heavy seats, partition walls, air conditioning modules, communication equipment and other special modules.
The challenge
To achieve the target mass, all sources of mass in the interior must be identified, evaluated and optimized. The balancing act between comfort, protection, ergonomics, usability and mass reduction must be mastered.
In particular, the following system groups must be considered:
Seats and seat consoles (incl. anti-shock mountings), partition walls and cladding modules, communication and IT infrastructure, air conditioning and supply technology, weapon mounts and additional superstructures, power supply (batteries, UPSs)
In our approach, a multi-stage lightweight construction process was used:
- Holistic mass screening: Recording of all fixtures with geometry, mass, function and integration structure
- Lightweight system construction: Identification of unnecessary redundancies, functional integration, reduction of electrical reserve power
- Lightweight structure: FEM-based optimization of brackets, frames, consoles (topology/topography)
- Lightweight material construction: Substitution by CFRP/hollow profile combinations, hybrid materials, aluminum sandwich structures
- Variant calculation: Simulation of worst-case combinations with regard to load, temperature, acceleration
- Integration in the total mass book with target/actual comparison
The result
Through the systematic approach, 136 kg of weight-saving potential was identified in the interior arean, which corresponds to around 8.1 % of the previous interior mass. In conjunction with previous armour optimization, this leaves a reserve of 27 kg below the 3.5-ton limit for further mission modules. The FEM analyses used confirmed the structural integrity and vibration resistance of all new lightweight components in the vehicle.
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