This case study describes the systematic derivation of a functional mass breakdown for a medium-sized modern tank. The focus is on typical potential savings in the development phase, which can be achieved through targeted measures in system, structural and material lightweight design. Mass management and mass control are decisive for the performance, mobility and protective effect of combat vehicles.
The initial situation
As part of a research study for armoured vehicles, the investigation and holistic optimization of the weight distribution of a new medium tank (approx. 35 tons) was carried out. The aim was to create a functional mass breakdown to identify potential mass savings across all lightweight construction areas while maintaining the performance requirements.
The challenge
The biggest challenge in the early development phase was to ensure a consistent allocation of mass proportions to functional groups (e.g. drive, chassis, armament, protection systems). In addition, potential weight savings were to be identified without compromising the functional requirements for protection, mobility and effectiveness. Particular attention was paid to the balance between structural integrity, protection class and mobility in accordance with STANAG specifications.
The procedure
The functional mass fraction is derived in several steps:
- Classification of all assemblies according to function and integration level.
- Application of system replacement models and implementation of mass flow analyses along the system structure.
- Evaluation of each module based on specific weight factors (kg/kW, kg/m², kg/protection level).
- Use of benchmarks from existing systems (e.g. CV90, ASCOD) for plausibility checks.
- Simulation of potential reduction measures using lightweight construction principles:
- Lightweight material construction (replacement of armor steel with hybrid composites, investigation of bulletproofing with hybrid composites made of a bionic arch structure.
- Lightweight structural engineering (combined topology/topography optimization of support structures).
- Lightweight system construction (holistic functional integration, e.g. active protection in supporting structure).
The result
The final functional mass breakdown shows the following distribution:
| Function group | Mass fraction [%] | Absolute mass [kg] (at 35 t) |
|---|---|---|
| Protection systems | 32 | 11.200 |
| Drive system | 18 | 6.300 |
| Drive & chain | 14 | 4.900 |
| Weapon system & ammunition | 10 | 3.500 |
| Electronics & Sensors | 8 | 2.800 |
| Structure / Tub & Tower | 18 | 6.300 |
Targeted measures have made it possible to save up to 3.4 tons.
Literature
- Hufenbach, W. et al: "Leichtbau - Grundlagen, Werkstoffe, Fertigung", Springer Vieweg, 2020
- Bundeswehr: Technical-logistical usage data of armored vehicles, 2021
- NATO STANAG 4569 - Protection Levels for Logistic and Light Armored Vehicles
- VDI 2221: Methodology for the development and design of technical systems and products
- Lightweight Construction Atlas Germany, Fraunhofer IWU, 2022
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