Previous articles in the series: Israel's defense industry. Part 1
Cars
The Merkava 4 tank is manufactured at a state-owned plant, but many national defense enterprises supply components for this tank.
If you start to remember the symbols of the Israeli defense industry, then the first, most likely, will pop up in the memory of the words Merkava, Galil and Uzi. The need for the production of high-quality weapons for its soldiers over the years has led the ground segment of the Israeli defense industry to develop a number of highly effective military equipment, whose success is largely due to the fact that it was created by people who often, after being called up from the reserve, have to fight on it on the battlefield. … Many of these weapons systems have also been successful in the export market
MERKAVA
In anticipation that a new long-term development program, launched by the Israeli Ministry of Defense under the name Rakiya, could provide new, lighter vehicles with sufficient protection and sufficient firepower to meet the challenges of both urban and traditional battlegrounds, the Israeli armed forces fight daily in the most protected combat vehicles that were created to meet national requirements - the Merkava main battle tanks. This tank is definitely not banned for sale in other countries, but the latest version of the Mk4 may seem very expensive to most potential customers. The Israeli main battle tank (MBT) is manufactured in state-owned factories, but about 40% of its components are manufactured by the Israel Military Industries (IMI) ground systems division. These components include the transmission (licensed by Renk), part of the suspension system, turret support ring, ballistic protection kit and main cannon. IMI has developed an improved version of the Mk3 cannon, which fires more powerful ammunition. However, the company is looking to the future and therefore its technology demonstrator has already passed its first firing tests. The new RG120 cannon weighs half the weight of the Merkava Mk4 cannon, 1800 kg versus 3600 kg; 1400 kg are for the rolling masses. The recoil stroke is 500 mm, while the recoil force is 350 kN. According to IMI, the reduction in weight was achieved mainly through technical improvements and optimization, as well as the elimination of expensive and exotic materials. The new cannon has an automatic bolt mechanism and is compatible with a muzzle brake, which further reduces recoil forces. In order to complete the development, IMI is looking for a launch customer, and the national customer will certainly be at the top of the list if the Merkava Mk5 variant is realized. The RG105 cannon is also available in a rifled version.
Based on the Merkava MBT, the Namer is one of the heaviest armored personnel carriers in the world. In the future, Israel sees in service a family of lighter vehicles
NAMER
IMI is also actively involved in the Namer program, for which it supplies ballistic and roof protectors, as well as a transmission and part of the suspension system. The company took part in the modernization of vehicles such as the M60, T-72, T-55 and M113, and also provided advice to the Indians on the creation of the Arjun tank. A major contract was signed with Turkey for the modernization of the M60 tank, where IMI was active in all areas: firepower, protection and mobility. The company is not averse to participating in several more similar programs. After modernization programs for the M113 armored personnel carrier of the Brazilian Marine Corps and another program for an AM-13 vehicle from an unnamed country, IMI recently received an upgrade contract from a customer in the Far East and is waiting for another one from the same region. A kit is also being offered that converts T-54/55 tanks into NATO-standard tanks, and according to IMI, customers should be announced soon.
The Wildcat armored personnel carrier is based on the Tatra 4x4 cross-country chassis with independent suspension. It has a total mass of 18.5 tons and can take on board three crew members and nine paratroopers.
WILDCAT
In addition to its participation in the development and production of heavy armored vehicles and their modernization, Israel Military Industries at the end of the 2000s developed the Wildcat armored personnel carrier on its own initiative. This armored personnel carrier is based on the Tatra 4x4 truck chassis, in the creation of which the company's experience in the field of independent swinging semi-axles was used, which made it possible to obtain very good off-road cross-country ability at a reasonable cost. The Wildcat has a single-volume hull and its V-shape provides good mine protection, although the levels of protection remain classified. In terms of ballistic protection, three sets are available, ranging from 7.62mm armor-piercing to 14.5mm armor-piercing and RPGs. The heavier the armor set, the lower the payload, which varies from 1.7 to 3.7 tons with a total weight of 18.5 tons. Directly behind the cab is a 325 hp Cummins engine. The Wildcat armored personnel carrier can accommodate a 3 + 9 crew, access to the vehicle is via the aft ramp and the second ramp on the port side. Wildcat is offered in various configurations: reconnaissance and operational management, combat support, ambulance, evacuation, cargo, police and border guard. Until now, this machine is waiting for its launch customer.
The Hurricane weighing 9.6 tons can carry up to 7 people. It is currently being produced on the assembly lines of the Hatehof company.
HURRICANE, NAVIGATOR, WOLF-HATEHOF
The Hatehof company, remaining in the military vehicle business, but turning to lighter systems, remains the main Israeli player in this area. The Golan Heights company is currently in the process of manufacturing its new Hurricane 4x4, which, when fitted with an A-kit, provides Level 2 ballistic protection and Level 3A / B mine protection; while it has a mass of 9.6 tons and a payload of 2.1 tons. However, the gross weight increases to 11 tons with the installation of the Kit-B kit, which provides Tier 3 ballistic protection and Tier 4A / B mine protection. The machine is equipped with a 245 hp Cummins engine; it accommodates up to seven people. The weight reduction compared to previous models is realized through the use of new special steel, but no composite materials were used, and all this in order to keep the cost within reasonable limits.
While the Xtream was designed for a special export program that was later closed, its Level 4 ballistic protection and Level 3B / 4A mine protection at a gross weight of 16.5 tonnes give hope of success in niche markets. According to the company Hatehof, which did not continue to develop, the Navigator armored car was intended for Turkey and at the same time its offer on the market for vehicles of the MRAP category. The Turkish version, known as Kirpi, was produced by a local BMC company, but production was halted due to financial problems. Here again, Hatehof could take a fresh look at this market following an RFP issued by the Turkish Defense Industry Secretariat. With a total mass of 18.5 tons and an unladen weight of 15 tons, the Navigator armored car can have protection corresponding to STANAG Level 4 when installing the B-kit, and when installing the C-kit, protection against improvised explosive devices (IEDs) and hand-held anti-tank grenade launchers (RPGs)). The machine is equipped with a 345 hp Cummins engine; the front cockpit accommodates two people and the troop compartment up to 11 people.
The Wolf remains the company's most successful car to date. With a mass of 8, 6 tons (own weight 7, 3 tons) with an A-kit (Level 2 ballistic, Level 1A / B anti-mine), the vehicle can accommodate up to nine soldiers. The flexibility of the project was demonstrated when Hatehof had to meet the requirement for a shorter version with a total weight of 7 tonnes and five seats. Wolf has also become the base platform for command and control and chemical-biological intelligence options developed by Hatehof's new RCB intelligence division. Of course, both options are equipped with an overpressure system, while the control center is equipped with a perimeter marking system, a meteorological station, a GPS system, a bi-directional wireless data transmission system and modern communication facilities, and the WMD reconnaissance option is also equipped with a Hapsite Viper chemical identification system, an external hand - a manipulator for sampling soil and liquids, an external probe for determining chemical and biological air pollution, a radiation detector, sealed storage containers and a disinfection system for small objects. The new division also developed a decontamination machine based on a truck chassis, which is currently in service with the Israeli Armed Forces.
The Navigator armored car, designed in accordance with Turkish requirements and produced by the Turkish company BMC, is an offer of Hatefof for the MRAP category vehicles market.
Wolf is one of Hatehof's bestsellers. It has been designed in short and long versions to meet customer requirements
Although IAI is a specialist in the aerospace field, it did not pass by ground systems and developed a maneuverable armored vehicle with protection corresponding to STANAG Level 3, which is in service with numerous military and paramilitary units.
RAM MKIII - RAMTA
Although the name of the company Israel Aerospace Industries does not hint at a connection with ground systems, its IAI Ramta division is engaged in the production of a light maneuverable armored vehicle known as the Ram MkIII. This latest version of the RBY platform, developed back in the 70s, features a rear-mounted 189 hp air-cooled Deutz engine mated to an automatic transmission with selectable 2x4 and 4x4 drive modes; the differential lock mechanism is installed at the request of the customer. The RAM MkIII vehicle has a load-bearing body, to which the power unit and chassis are attached, is made of ballistic steel, which makes it possible to obtain a bullet-proof mine-protected cabin.
The 12.5x20 MPT wheels chosen by Ramta are significantly larger than the wheels of most cars in this class. This allowed extremely high cross-country ability to be achieved without the use of heavy, complex and expensive independent suspension. The armored vehicle can be equipped with ballistic protection corresponding to STANAG Level 2 or 3; the latest models received additional ceramic armor that can withstand a 12.7 mm bullet and does not increase the load on the vehicle. The anti-mine protection of the RAM MkIII armored car corresponds to Level 2A / B, fiberglass shields allow you to deflect the blast wave when a mine is detonated under the wheel.
The combat weight of the RAM MkIII is 6.5 tons for the base variant, but with a set of additional armor, it grows to 7.2 tons. The car accommodates the driver and seven passengers; it develops a maximum speed on the highway up to 100 km / h, the cruising range is 800 km. The machine is offered with an open or closed cab, in a short or long version. The following options were developed: armored personnel carrier, commander, reconnaissance, armament platform, anti-aircraft gun, mortar and special forces vehicle. The RAM armored car has been tested in real combat operations and serves in dozens of different military, paramilitary and police formations in Asia, Africa and Latin America.
With the acquisition of Seymar, Elbit Systems also entered the vehicle business, inheriting the Musketeer 4x4 light armored vehicle, which is primarily intended for border security and patrolling. After several years of improvements, Elbit has finally found its starting customer for this machine. In March 2016, it was reported that the Musketeer armored car was purchased for the presidential guard of Cameroon. These vehicles are equipped with a remotely controlled weapon station with a 7, 62-mm machine gun. The number of cars sold has not been reported.
Reservation and protection of cars
IMI has developed additional light armor L-VAS in order to increase the level of protection of light vehicles against RPGs and IEDs
The need for constant modernization of vehicle protection systems is forcing Israeli companies to develop modern technologies and solutions to cope with the growing threats. Today, some of these companies are known worldwide for their active, passive and reactive protection solutions
PLASAN SASA
More than 200 engineers at Plasan Sasa are working to improve the protection systems. She is a major player in the passive defense industry and has focused on creating new grades of composite armor in order to reduce the weight and cost of its solutions. The company not only develops new technologies to help deal with growing threats, but also directly participates in the production of machines in order to minimize labor and cost. The technical details of the passive armor kits used in bestsellers such as the Oshkosh M-ATV remain largely classified. These kits, in particular, are designed to protect against cumulative, armor-piercing ammunition, as well as IEDs.
Passive protection kits are also available for offshore platforms and aircraft protection, mainly in the cockpit. They are modular and easy to install, while weight is a priority in personnel and aircraft solutions. The company, whose products have been well known for many years, is rapidly adapting to new realities.
Given the need to reduce the mass of armor systems, Plasan has various composite solutions in its portfolio, not least thanks to its Plasan US Defense Composite Structures division. While information on compositional solutions for land vehicles is extremely limited, then a little more is available on marine applications. Composite sandwich panels from Plasan US DCS offer design and cost advantages, flammability protection and electrical shielding compatibility. They are ideal for the next generation of tall rectangular superstructures with a small effective reflection area. Composite technologies, such as pultrusion, are also used to manufacture structural components for ships and missile launchers, reducing weight and cost by 50%. Plasan Sasa looks confidently to the future with its TorTech division, which specializes in carbon nanotubes, which are used to improve the quality of the composite armor of vehicles. Q-Flo carbon nanotubes have the potential to revolutionize the defense sector by introducing new grades of lightweight, stretchable and extremely durable protective materials. It is believed that TorTech is producing nanotube-based fiber from which the strongest man-made material can be made.
IRON WALL - IMI
Israel Military Industries supplies all ballistic protection kits for Merkava and Namer armored vehicles. Unlike many Western countries, Israel has always considered reactive armor (in our terminology, dynamic protection) as a very important means of dealing with cumulative anti-tank shells, while constantly developing solutions aimed at reducing the risk to nearby infantry. With the advent of IEDs, especially of the “impact core” type or self-forming submunitions, IMI developed the Iron Wall, whose composite-metal hybrid structure saves weight compared to traditional homogeneous armor. The system used as an add-on, depending on the level of protection, weighs 200-230 kg / m2 and adds 110 to 150 mm to the original armor. The heavier Breakwater hybrid passive-reactive composite material, designed to combat RPGs, adds roughly 450kg / m2 and 350-400mm thickness. At the other end of the family can be noted the L-VAS protection system, designed for light vehicles, such as wheeled armored personnel carriers, which increases the level of protection against RPGs and IEDs. This is another system based on passive and energy materials, fully qualified by the Israeli army for the M113 APC. Able to withstand multiple hits from RPG-7, 14, 5-mm armor-piercing bullets or IEDs, the system guarantees the absence of a detonating wave between adjacent dynamic protection units, hull damage and minimal impact on people in the immediate vicinity of the vehicle.
The Bright Arrow complex combines a remotely controlled weapon station and an Iron Fist anti-projectile
Iron Fist primary sensor is a compact hemispherical RPS-10 radar developed by Rada
IMI calls Iron Fist a second generation active protection complex; it consists of a component of optical-electronic countermeasures and a component of direct destruction of attacking means
IRON FIST - IMI
In the field of active protection, IMI has developed an active protection and optoelectronic countermeasures system, designated Iron Fist. The idea is to drown out all suppressable threats, leaving counter-projectiles for what cannot be damped. Anti-tank missiles are counteracted by an optoelectronic jammer capable of shooting down a missile at a distance of one kilometer, launched from a distance of three kilometers. The muffler was developed by the Israeli company Ariel Photonics, while the muffler technology was developed by IMI. If the threat cannot be damped, a counter-projectile is fired from the rotating twin-tube launcher. The meeting point is calculated using input signals from several sensors: a bolometric camera, a day camera and a Rada RPS-10 radar. The latter weighs 17 kg, covers the 120 ° sector; thus three radars are needed for 360 ° all-round coverage. The counter-projectile flies fast enough and burns up, while destroying the attacking projectile. The existing warhead contains a certain amount of metal, which will be replaced by composite materials, which will further reduce indirect losses.
The technology developed for the Iron Fist was also used in the development of the Bright Arrow active protection complex. It combines a DBM and an Iron Fist anti-projectile launcher on one pivot support; it also includes a radio frequency sensor, a thermal imager and a CCD camera. The complex is easily and easily installed on light armored vehicles due to its low weight of 250 kg. IMI is also developing a stationary system to protect camps and bases from artillery shells, unguided rockets and mortar rounds.
TROPHY - RAFAEL
Currently, the only active system in service with the Israeli army is the Trophy-HV complex from Rafael, installed on Merkava Mk4 tanks. The complex demonstrated its usefulness in combat in March 2011, when the 1A tank from the 9th tank battalion hit an attacking shell. Threat detection and tracking is performed by IAI / ELTA's ELM-2133 WindGuard AFAR Doppler radar (with active phased antenna array) with four antennas installed at four corners of the vehicle to provide 360 ° coverage of the upper hemisphere. The radar complex provides the on-board computer with the necessary data, including the classification of threats. Maximum accuracy of calculations is necessary in order to activate one of the two launchers with the best position and launch an anti-projectile with ready-made striking elements in the direction of the attacking projectile. These submunitions target specific zones of the attacking projectile and therefore the classification of the target by the radar is a key issue. Each counter-projectile generates a "certain number" of non-aerodynamic elements, the number of which is very limited, which allows you to destroy the threat without exploding.
When visiting the Rafael test site, where the Merkava tank with the Trophy complex was tested, it seems like a full box of rocket-propelled grenade warheads, which are hit by the complex's anti-missiles in the same place, which serves as proof of the stability and accuracy of the entire system. Over 2,000 RPG attacks on a tank in real conditions were carried out in Haifa, in addition, anti-tank missiles were fired at a training ground in southern Israel. According to Rafael, over 90% of RPGs are destroyed without charge initiation. In the case of anti-tank missiles, their detonation occurs at large distances from the vehicle. Threat classification also means that if an attacking threat flies past, the system is not activated, which saves the counter-projectile and avoids the detonation of the projectile. The ELM-2133 radar is also used as a situational awareness tool, as it can determine the position of the shooter; With the push of a single button, the tank commander can move the turret and direct the weaponry directly to the source of fire. Rafael received a second major order from the Israeli army, and since 2012, all three armored battalions have received Merkava Mk4 tanks equipped with a Trophy complex. Since the first publicized defeat, the Trophy complex has worked at least five more times, and the shooter has been identified by the radar.
For the export market, Rafael has developed the Trophy-MV complex, which has a lower weight compared to the HV version (450 kg versus 850 kg), while retaining the characteristics and also adding opto-electronic countermeasures. The miniaturization process helped to reduce the mass of the new version. The system, which is at the prototype stage, is awaiting the launch customer to complete its qualifications. A third variant of the Trophy-LV is also offered, designed for light vehicles. Threat detection is based on optoelectronic sensors; its executive elements in the form of modules, mounted on the roof of the vehicle, create at a minimum distance from the vehicle's armor an “energy blade” directed downward, which “cuts off” the attacking warhead. If the HV and MV complexes are effective against missiles and armor-piercing shells, then the Trophy-LV complex with a mass of 200 kg (for the Humvee armored car) is designed to combat RPGs. Rafael is also looking forward to a launch customer.
Three tank battalions are armed with Merkava Mk4 tanks equipped with the Rafael Trophy complex. These systems have been successfully tested in battle.
A key component of the Rafael Trophy complex is the ELM 2133 Winguard radar from IAI-Elta, which provides the data required to launch the final element.
ASPRO - RAFAEL
Rafael is also a major player in passive (traditional) and reactive (reactive) armor. Its systems are installed on the machines of many armies of the world, for example, eight different additional reservation systems of this company were operated in Iraq and Afghanistan by the coalition forces. The company currently offers two armoring families, Aspro-P and Aspro-H, in the designation of which the "P" index stands for passive and the "H" index for hybrid.
The fully passive Aspro-P system is designed to absorb energy and prevent penetration of the main armor; it enhances the ballistic protection of the vehicle to Level 3, 4 or 5, meeting the NATO STANAG 4569 standard. This easy-to-install, fully modular system has been field proven. While the composition of the chemical armor remains classified, it is clear that Rafael has leveraged its expertise in ceramics, metals and other materials, as well as their joining and research into the mutual influence of these multi-layer structures. Rafael's ammunition and protection division, along with the floating bottom, has developed a multi-layer mine protection with superior energy absorption characteristics.
The lightweight Enhanced Applique Armor Kit was developed specifically to increase the level of protection of the AAV7 amphibious assault vehicles of the US Marine Corps while maintaining their amphibious characteristics. Using its experience in the field of dynamic protection, the Rafael company has developed blocks installed on the American Army Bradley BMP. The company has created the Aspro-H hybrid system, which uses low-sensitivity energy materials with a low burning rate. They do not detonate or burn when hit by bullets, projectiles or shrapnel, and only react when hit by a cumulative projectile, generating energy that destroys the cumulative jet. The passive elements of the Aspro-H system provide ballistic protection in accordance with NATO Level 5 STANAG 4569.
The Trophy-LV complex, designed for installation on light patrol vehicles, is based on a completely different actuator. In the photo, the complex is installed on an HMMWV armored car.
Rafael has developed a hybrid protection, giving it the designation Apsro-H. To destroy the cumulative jet, it uses insensitive energetic materials with a low burning rate
ORAN SAFETY GLASS
We reviewed the solutions of Israeli companies in the field of opaque and active protection. But we cannot fail to mention the solutions in the field of transparent protection. Oran Safety Glass (OSG) specializes in the design and manufacture of flat and curved laminated tempered glass and armored glass for military and civilian applications. The company has sold its products to over 35 countries; it works in partnership with numerous vehicle manufacturers from the United States, France, Germany, Italy and others. Its most advanced solutions save up to 30% weight. Taking into account the changes in the types of threats, OSG has built a proving ground, where now not only ballistic tests are carried out, but also explosive, fragmentation, rocket-propelled grenades and shock core charges. This made it possible to expand the assortment due to flat and curved glass, resistant to explosion and splinters. OSG also manufactures glass based on ceramics, which allows for weight savings of around 50%. It provides protection levels from 1 to 4 in accordance with the STANAG standard (the company's conventional STANAG Level 2 glass has a basis weight of 125 kg / m2, while the ceramic solution has a basis weight of 71 kg / m2).
OSG glass products can be found on most American MRAPs, trucks and general purpose vehicles, PVP vehicles from Renault Trucks Defense, Zetros and Actros from Daimler, German MAN trucks and Italian Astra trucks.
Oran Safety Glass's ScreenX digital window system integrates the digital display into the windshield (pictured above for night driving). It displays the map and GPS coordinates (in the center). Visualization of the Silk Light function; built-in system allows you to project various types of programmed messages (below)
Well aware of the risks of urban combat scenarios, OSG has developed an innovative RockStrike solution - a layer that protects armored glass from damage by stones, even launched at relatively high speeds, such as with a sling. This solution saves costs because the bulletproof glass does not need to be replaced unless it has been hit by bullets. It also provides better visibility compared to metal mesh solutions. Another new product is called Adi (Hebrew gemstone). This technology avoids the formation of splinters inside the vehicle without using the typical plastic coating that attaches to the inside of the glass and often delaminates and breaks, thereby shortening the life of the armored glass.
RockStrike outer cover protects against any solid objects launched by muscular force
In terms of situational awareness, another OSG innovation is the so-called Digital Visual Window (recently designated ScreenX). The liquid crystal display is integrated into the windshield, allowing the driver and commander to receive information simply by looking forward through the glass. The screen can be installed anywhere and is capable of displaying high definition video, text and graphics. Another OSG solution for providing information on the windshield is called Silk Light. It is a built-in light-controlled electronic system that outputs information directly onto transparent bulletproof glass. It provides predefined specific information such as machine location, rollover hazard, engine or cab overheating, emergency exit and exit warnings, etc.
Another key element in the vehicle safety system is the protection of the fuel tanks. Magam Safety, part of the Star Defense System Group, has designed and manufactured flexible, self-sealing fuel tanks for Merkava tanks. She recently developed an external solution that converts a standard tank into a self-sealing tank with a weight gain of only 14 kg / m2. Adopted by the Israeli army in several secret projects, this decision showed during tests a fuel leak of only 7, 7 grams when a fuel tank was pierced by a 7.62 mm bullet.
