Bradley with extra armor removed
Although the Bradley family of combat vehicles was conceived for European combat scenarios, its development did not stop there. The upgraded vehicles have proven themselves well in desert combat and modern operations to stabilize the military-political situation around the world
The Bradley family of armored vehicles has not been all that successful in sales, with the exception of relatively small exports to Saudi Arabia, but few combat vehicles can match the rapidly changing combat environment better than the infantry (M2) and reconnaissance (M3) variants.
Originally designed and tested to fit the imaginary combat scenarios of the 1970s Cold War, today's models perform critical operational tasks in urban counterinsurgency and peacekeeping operations.
The first batch of 2,300 A0 models was first deployed in the US Army in March 1983 as an infantry fighting vehicle with a compartment for transporting 9 soldiers and a reconnaissance version of the CFV (Cavalry Fighting Vehicle) with a compartment for 5 people. The firepower of both options is the 25-mm M242 Bushmaster cannon from McDonnell Douglas (now ATK), the twin TOW ATGM installation from Hughes (now Raytheon) and the coaxial 7.62 mm machine gun installed in the turret.
The first of 1,371 improved and modernized A1 models began to enter service in May 1986. The modernization included: TOW II subsystem; getter filter with ventilated face mask; blocking the armament complex, stopping firing in order to avoid damage to the vehicle or firing at angles exceeding permissible; changes in the design of the CFV version; improvements in the ammo rack; protective covers for crew periscopes; modified fuel system; modified fire extinguishing system; and final drives taken from the M270 MLRS, a member of the growing Bradley family.
Since May 1988, these machines were followed by about 3,000 cars in the A2 variant with a new power plant with a capacity of 600 hp; armor protection against fire from a 30 mm cannon; new armor tiles; internal anti-splinter lining; and changed places of ammunition storage. These A2 vehicles fought in Operation Desert Storm, and the lessons learned in the deserts of Kuwait and Saudi Arabia led to the development of another upgrade kit, known as the A2 ODS (Operation Desert Storm), which includes various improvements ranging from the system GPS and up to the driver's video amplification unit.
BAE Systems US Combat Systems (today's successor to the original manufacturer, FMC Corporation)'s current structural change activities focus on reworking and upgrading the M2 / M3A2 variants to the current M2 / M3A3 configuration.
A3 adds two second-generation infrared cameras, a commander's independent thermal viewer (CITV) and an Improved Bradley Acquisition Sight (IBAS) sight; improved positioning and navigation system; basic electronic architecture; and a digital command and control system.
The IBAS sight, created by DRS Technologies, has a target acquisition subsystem for tracking and a missile control subsystem to increase lethality through automated ballistic solutions and a target tracking program. The IBAS sight uses SADA II (Standard Advanced Dewar Assembly) technology (provides a high signal-to-noise ratio and a high-quality, close to television infrared image). It includes a second generation Block 1 B-Kit infrared camera (as part of the advanced technology implementation program); direct vision optics; duplicate target tracking functions; eye-safe laser rangefinder; daytime TV camera; stabilized head of the block of mirrors stabilized along two axes. Most importantly, the IBAS provides improved firing performance on the move for the Bradley main gun.
In parallel with countless upgrade packages, the last two and a half decades have seen a significant change in the size of the M2 / M3 fleet, from the original 6,882 systems to the modern "modular and final" Bradley fleet, which includes a total of 4,561 vehicles in A3 and A2 ODS configurations. The latter includes some ODS-SA (Situational Awareness) models, partially upgraded, that is, with digital communication capabilities of the A3 version, but without CITV.
"Since the cars were first released, nothing has visually changed for most of Bradley," says Lt. Col. William Sheehy, program manager for Bradley in the US Army. “We developed the Bradley partly in response to the Soviet BMP and for the first time we got an assault transporter with“combat characteristics”. The Bradley was built to destroy tanks and infantry fighting vehicles, and since then the vehicle has become a reliable workhorse. However, with the passage of time and with the development, we have done a lot to modernize the machine and facilitate the implementation of new combat missions."
“The original car was analog, for example, but we made a big leap forward with the A3 to bring the digital backbone and data bus inside the car, which is MIL-STD-1553. This step forward brought forward infrared surveillance devices and those categories of equipment that actually propelled the machine far ahead, leaving our opponents behind. We were able to detect the target, clearly identify and destroy it in a way that had not yet been seen on the battlefield. So it was kind of the last big development - digitizing the machine, simplifying communication and increasing the efficiency of weapons systems,”he continued.
“As soon as we entered Operation Iraqi Freedom in 2003, the first battles were just like the scenarios for which it was created,” he said. “Then we moved on to urban combat and counterinsurgency operations, and as a result, during the next modernization of the vehicle, we added a number of changes in order to increase its survivability.”
Vitality issues
These items were added in subsequent packages in accordance with the Bradley Urban Survivability Kit (BUSK), which can be installed in the field.
“The first rule that we learned is that there is no magic cure,” Lt. Col. Sheehi admitted. "People may have remembered V-hulls or different types of armor, but there is no single solution that gives you all the protection you need from the threats you face."
Describing some of the work on the new protection, he noted that the car has always had underbody armor since the Cold War, since the threat of mines is not new, but the 19 mm thick sheet of high-strength steel has been extended to the full length of the car and to sponsors.
“We also found that we could have stowed some ammunition on the bottom of the Bradley, but while in the past we focused on hull rupture protection, we now find that the main threat is not hull destruction, but energy transferred to hull, causing the ammunition to detonate on the bottom and their devastating dispersal inside the car. Therefore, we placed them in a heat-insulated containment container, which prevents ammunition from scattering in the event of an explosion under the bottom."
According to Lieutenant Colonel Shikhi, the strapping of the insulated container is an integral part of the design, as it slowly spreads out when the bottom deforms, absorbing energy, and then goes into a stable break. Each ammunition is stored in a Kevlar bag that does not rip or rip as easily as when fastened with straps.
The vehicles were also equipped with explosion-proof seats complete with foot supports to prevent the energy of the explosion from spreading through the bottom to the feet of the people. Lieutenant Colonel Sheehi said: “We have some concerns about soldiers hitting the roof of the car and getting their cervical injuries, so we chalked the helmets on the dummies to see if there was a blow on the roof when we were doing combat training. They didn't move. Instead, the seat squeezed as the bottom went up, and then it returned back to its original position again. Of course, the mannequins were shaking, but the overloads were reminiscent of the usual shaking while the car was moving."
He defined protection as a concept of "nested" survivability, from armoring the bottom to reinforcing the turret roof.
However, he admitted that there are restrictions on the amount of booking that a car can take and the American army does not control the level of threat itself. “The enemy is limited only by how big a hole he can dig and how much explosives he can push there in order to try to blow us up. So we're also looking at what else could happen if he punched the car.”
One of the main concerns about the consequences of armor penetration is the burning of the fuel tanks under the turret. “What we have learned from the experience of combat operations: when an explosion occurs and the hull is deformed, but not destroyed (cracked), there can be a“fracture”of the fuel tanks, fuel spraying and the release of a fireball into the rear of the vehicle. Therefore, we contacted the aviation community - the guys who created Chinook and Black Hawk. They have not had a hard landing or crash fire in 10 years.” As a result, Bradley cars are now equipped with self-priming fuel tanks.
Bradley's Latest Standard Showcases BRAT Remote Sensing Kit and Other Innovations at AUSA 2013
Fight against the threat of RPGs
In addition to countering the threat of undermining under the hull, protection has also developed in the direction of countering anti-tank rocket grenades (RPGs) and charges such as "shock core" (directed landmines), which are regularly found in Iraq. As a result, General Dynamics and Rafael developed a complete set of BRAT (Bradley Reactive Armor Tiles - reactive armor units for Bradley). In May 2009, the US Army ordered a series of BRAT kits from General Dynamics Armament and Technical Products, which began shipping that year.
Lieutenant Colonel Shikhi noted that this is a defense complex with insensitive components, some areas are designed to counter RPGs, while others are both RPGs and “shock cores”. “You can shoot at this armor all day with 5, 56 mm or 7, 62 mm bullets and there will be no reaction. However, if you shoot with cumulative ammunition, then the ERA explodes and destroys the cumulative jet before it hits the side of the vehicle."
He added that “we conducted combat tests at the Aberdeen Proving Grounds, we filmed inside and outside the vehicles, watching the test dummies. When fired by testers from an RPG at the car, the target DZ block hit the projectile, but none of the neighboring blocks detonated. Inside the car, it felt like driving through the streets. The dummies were shaking, but compared to the “power frenzy” outside the car, none of the dummies really moved. All of this has been installed and is currently being installed along with the underbody armor kits on the A3 flagship car."
Bradley M2A3 is equipped with improved armor plates and everything that is provided for the flagship A3 variant.
The modernization process is carried out under a full rebuild program, according to which Bradley vehicles, which have been intensively used in the theater of operations (theater of operations), are restored and modernized to a common standard. As an example, BAE Systems received a major order from the Pentagon worth $ 601 million in May 2009 for the complete restoration of 606 Bradley BMPs, 346 Bradley A3 vehicles, 141 A2 ODS vehicles and 119 A2 ODS SA vehicles.
The Army is a full partner in this work, performing initial disassembly and repair of subsystems at its Red River Army Depot plant, before further disassembly and design changes and final assembly are performed at BAE Systems' Pennsylvania plant. The deliveries of the vehicles restored under this contract began in mid-2009 and were completed by March 2010.
According to Lt. Col. Sheeha, the BUSK program is currently in its third phase of upgrading the Bradley fleet. “For example, the BUSK I included underbody armor, heavy wire protection at the top and screens in front of our FLIR [forward-looking infrared] to protect against thrown stones,” he explained. "This is a consequence of the experience gained earlier in combat in urban conditions."
“BUSK II includes additional elements such as a thermally insulated ammunition container, new seats, driver's seat, turret roof. It also includes opening the ramp in case of an emergency, which we are truly proud of. In the previous design of cars, the only point from where the ramp could be lowered was the driver's seat. However, if you have an emergency when the driver may be damaged, these guys need to get out through the landing door in the ramp. But when the soldiers are fully equipped, it is very difficult to get through this door quickly, especially when something unimaginable is happening. The designers have designed a system that allows the landing party, when the driver is disabled, to lower the stern ramp itself. This scheme is not intended to be used in day-to-day operations, but it allows you to quickly leave the machine. It's great and it works on combat vehicles with the BUSK II kit."
In connection with the urgent requirement to "overcome threats in real conditions", the first two BUSK upgrade kits were sent to the forward units first, then the "next systems" followed. These kits are currently being installed on new machines.
“Every machine already has a BUSK II, or is currently receiving it,” said Sheehy. BUSK III passed live fire tests and work continues; the army plans to undergo a phased modernization.
The current planning has more to do with the mass gains from the upgrades to date, especially in the booking area, Sheeha said. The total weight of the Bradley machine has increased by about 5,400 kg over the original 30,000 kg, which clearly affects the mobility of the machine. In such a tight timeframe, little was done to reduce the weight of the machine, therefore, in order to solve the problem, the work was focused on increasing the power of the power unit and, accordingly, restoring the specific power.
Bradley weapons systems
Over the entire period of its operation, a variety of weapons systems were installed on the base Bradley vehicle with varying success.
Despite the fact that the crew was very pleased with the standard 25mm Bushmaster cannon, a variety of weapons were also constantly installed and tested on the vehicle in order to increase the level of lethality, including firing from the 35mm Bushmaster III Chain Gun, created by ATK. Gun Systems at their own expense. This process began in 1997, and the gun was already considered ready for installation, but the customer did not consider this proposal.
Two years later, Bradley was successfully tested with a 40mm CTAI telescopic ammunition system for the British Warrior Capability Sustainment Program (WCSP) and the General Dynamics UK Specialist Vehicle - Scout project, but the US has no plans to install these weapons on your Bradley vehicles.
Several years ago, a 30 mm Mk 44 cannon from ATK was installed on the M2A3 BMP variant with minimal modifications to the turret design. They are mainly related to the ammunition handling system required for larger projectiles. The latter include armor-piercing and high-explosive fragmentation types, as well as they have the potential for future upgrades, which consists in the ability to fire 40-mm Super Forty ammunition from the same gun. However, as far as other options are concerned, at the moment the American army has no plans to install the Mk 44.
In the report of the American army on the results of Operation Iraqi Freedom, it was concluded that the existing 25-mm Bradley cannon was effective, especially with regard to its reaction speed, stabilized accuracy and effectiveness of ammunition, high-explosive fragmentation for infantry and armor-piercing for light armored combat vehicles. As a result, it is likely to remain in service for the foreseeable future.
Two anti-aircraft variants were manufactured, the Bradley Stinger and the Bradley Linebacker, but both are currently decommissioned and redesigned for other missions. The Linebacker variant was appropriately redesigned for an air defense installation based on the M2A2 ODS standard, but was equipped with a four-tube launcher for Stinger surface-to-air missiles instead of a TOW installation. In the Stinger variant, instead of the standard infantry squad, a close air defense squad was placed to service the Stinger installation.
TOW upgrades are also being considered with one possible alternative - the widespread Javelin missile, which fires off in fire-and-forget mode. Its cost is comparable to that of a conventional strike warhead, but it can be diverted away from the target if the situation has changed after launch. Although work on this characteristic is still ongoing as part of the modernization of Javelin.
On one of the Bradley variants, the M7 FIST (Fire Integration Support Team), the TOW launcher is replaced by a target designation kit consisting of an AN / TVQ-2 laser pointer and an AN / TAS-4B TOW night sight. This allows the M7 FIST to hit targets more accurately than any other Bradley variant, since it combines a target designation complex with a full-fledged command, control and communications system, including the Advanced Field Artillery Tactical Data System, designed to call fire direct and indirect aiming.
Other modified Bradley variants include the M4 command vehicle and the Armored Treatment Vehicle, which was successfully tested but never went into production due to ongoing underfunding.
A Bradley A3 in an urban operation covers foot soldiers sweeping the streets of Baghdad. A completely different task in comparison with those that were originally planned for this family of machines.
A Bradley vehicle at an observation post in Iraq. Standard A3 includes bottom armor and a number of components that increase the level of survivability
One of the distinguishing characteristics of the Bradley compared to modern Western BMPs is the TOW twin launcher, which complements the 25mm Bushmaster cannon.
Internal volume restoration
Lieutenant Colonel Shikhi also said that in addition to restoring the specific power, he is trying to find ways to restore the internal volume of the machine, which has decreased due to modernization. “Right now we are considering two different options for solving this problem. One of them, for design dimensions, if we can combine some of the linear plug-in units into linear plug-in units, like a server with a set of cards in it, then we can reclaim a certain amount of lost space and maybe get some extra power."
A bolder option, addressing issues of space and weight, could include reworking the car's body. “The tower is the most complex component of the machine, it has all the computing power, it has the cannon, it has FLIR's advanced infrared optics. So if I take out the turret, make the hull larger and put the turret back in, I will remove a lot of problems as I can fit a larger engine with more power, plus I will have more interior space. We are considering several options for enlarging the case. Are we going to make it wider? Or in length? Or so and so?"
“We are conducting 'pre-stage' work. From this point of view, we carry out a large amount of analytical work on our further actions in order to try to find out which way to go. But the most important goal is, as far as possible, to maintain uniformity across the entire armored brigade combat group HBCT (Heavy Brigade Combat Team). For example, we have Paladin PIM [Paladin Integrated Management] on a Bradley chassis. Just like us, they want a double pin track, and the same goes for the balancers and track rollers. All this will simplify logistics and training."
While there is no direct impact on the Bradley program from the Army's Ground Combat Vehicle (GCV) initiative, the fact that the first variant of the GCV was designated an Infantry Fighting Vehicle definitely increases the likelihood of choosing one variant of Bradley. … Meanwhile, the Bradley family continues to grow with new options and future potential applications.
The newest variant of Bradley is the already mentioned M109A6 Paladin PIM howitzer, which is planned to remain in service until 2050. Ron Hayward, director of fire support programs at BAE Systems, said: “We take a 50-year-old platform and give it another 50 years of planned exploitation. PIM started out as a lifespan extension program due to the mass of retired hardware and obsolete parts that were no longer supported and became too expensive. In fact, the PIM program currently envisions a completely new Bradley chassis that is 90 percent similar to existing machines, but with a lower cost of ownership and less logistics.
An infantryman dismounts from the stern of the Bradley. One of the newest measures aimed at increasing survivability is additional control of the ramp from the troop compartment in the event that the driver is disabled.
Digital standards
“From a manufacturing standpoint, we will introduce [M109] 'Alpha 6' at the Anniston plant,” added Hayward. “They will remove the cabins from the chassis and use the components for the current Paladin fleet with the aim of extending the lifespan until it is replaced by the PIM variant. The cabins will also be disassembled and converted to the new digital standard, while the M284 cannon and its M182 gun mount will also undergo a major overhaul."
Meanwhile, BAE Systems will manufacture new chassis "boxes" in Pennsylvania and launch a power pack assembly line along with the finished chassis. At the new plant in Oklahoma, the refurbished cannons and cockpits will be installed on the complete chassis. All relevant firing tests will be conducted nearby at Fort Sill.
The PIM work has become something of a conceptual development process over the past year. PIM participants in both the military and industry defined it as a program to improve “reliability” rather than “modernization” work.
However, based on the procurement memorandum, which identified the components of a land-based manned vehicle, the program was chosen because of its modernization potential. For example, PIM features a new overall modular power system and, according to Hayward, “70 kW of power creates a lot of 'free space' for any 'grid-centric' implementation now or in the future."
“To work on a network-centric architecture, you need a lot of power, hardware, a digital backbone, and you need a clean electromagnetic space. In order to have a clean electromagnetic space, we had to get rid of the contact rotating device, since the brushes and the armature create strong electrical interference, after that we switched to a cable management system inside the cab."
Discussing many other possibilities, he added: “We are leveraging the investment that taxpayers once invested in NLOS-C / FCS and we have created a machine that will take more weight than we now have. This is what is needed for future growth. It's all about it."
In addition to work on PIM, which is a significant development of the overall Bradley platform, the company's other efforts are focused on potential fleet expansion, including considering an ongoing Army initiative to eliminate the current M113 fleet.
“One of the proposals we presented to the Army as part of the M113 elimination effort was the option of replacing the fleet with a Bradley without a turret,” explained Adam Zarfoss, head of Bradley's Combat Systems Department at BAE Systems.
For example, to replace the existing command post M577 [based on M113], “you can cut off the top plate at Bradley, raise the roof and get a movable command post. You can also make an ambulance, an ambulance car, and a mortar transporter. As a result, 77 percent of the vehicles in the HBCT teams will have a common chassis. Again, this box does not add to your costs. Since you have the same repairable components, the same powertrain, the same tracks, you will not only make life easier for your soldiers, but also save taxpayers' money."
“We're not going to go out with this in front of the army,” he says, “and the army will make its decision soon, but more than 1,000 Bradley A0s are still dangling in the Sierra Army Depot warehouse. They could serve as significant "seed" and help the army to decommission the M113 fleet and save their time and money."
