Workshop Overview and Introduction

Dr. Roger Schäfer

Bolzano Italy

December, 2019
Contains confidential proprietary and trade secrets information of CNH Industrial. Any use of this work without express written consent is strictly prohibited.
Workshop Overview
Structure

 Week 1:
Overview and basics of threats, armor technologies and related physics
Place: IVECO, Bolzano, Italy

 Week 2:
Armor materials & application
Place: IVECO, Vittorio Veneto, Italy

 Week 3:
Experimental approach for design and qualification of armored vehicles
Place: IABG, Lichtenau, Germany

 Week 4:
Design of armored vehicles
Place: IVECO, Bolzano, Italy

December, 2019 Introduction 2

CV

December, 2019 Introduction 3

Introduction to Workshop
Overview on week 1

 Overview on
• Threat classification from scenarios
• Technical threats
• Definition of surrogates
• International standards
 Introduction to protection technologies
• ballistic science and terminology
• survivability onion
• armour performance criteria
• armour system design principles & hystorical notes
 Penetration mechanics
 Blast phenomena
• RoadSide & mine blast treats
• Hints of mine explosion physics
• Explosion – military platform interaction for different weight classes
• Explosion crew & mission kit interaction
 Visit of IVECO
December, 2019 Introduction 4
Introduction to Workshop
Overview on week 1

 The aim of the first week is to

• give an overview on different subjects related to requirement specifications of
tenders
• get a deep understanding of your expectations

 Subjects / topics worth deepening will be considered in the following weeks

 Most important:
Your comments and questions are very much welcome at any time!

December, 2019 Introduction 5

AUTOMOTIVE DIGITAL ASSURANCE MOBILITY, ENERGY & AERONAUTICS SPACE DEFENCE & SECURITY
ENVIRONMENT

Competence Center Protection, Impact & High Risk Testing

Technologies, Simulation, Research Projects, Processes and Tests

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IABG is a leading European technology enterprise
with the core competencies of analysis, simulation & testing
as well as plant operation (safety & security)

87.4 % 12.6 % IABG

SCHWARZ Holding GmbH Mitarbeiterbeteiligungs AG

IABG
Total operating performance: about € 157 million* - Staff: approx. 1000

Mobility, Energy Defence &

Automotive InfoCom Aeronautics Space Security
& Environment

Development and Development and Environmental Fatigue strength Operation of ESA Operation of
operation of operation of solutions, tests for complete coordinated military simulation
mechatronic test secure ICT protection, airframes and Space Test & test systems
electro-mobility components Centres in for analyses and
systems for systems
Ottobrunn and
OEM & suppliers and change in conceptions
Noordwijk
energy policy.

* Business year 2016

© IABG 2015 7
Milestones

2014 Establishment of the Safety business field

2012 Development of new energy solutions (electro-mobility, wind energy, energy storage, etc.)

2011 New mobile infrastructure for large-scale aircraft tests in Erding (Airbus A350)

2011 IABG’s 50-year anniversary

2010 Security management for German digital radio
2009 Take-over of management responsibility on part of the SCHWARZ Holding GmbH
2008 New test infrastructure A400M
2007 Inauguration of the Geodata Factory in Dresden
2006 New defence & security simulation and test centre in Ottobrunn
2004 New infrastructure for large-scale aircraft tests in Dresden

1999 Development of the satellite communications sector (teleport)

1997 Takeover of ESA’s space test centre (NL)

1993 Privatisation of enterprise

1982 Commencement of operation of the Transrapid Test Facility
1973 First large-scale aircraft test with Airbus A300
1965 Foundation of the Space Test Centre (ESA-coordinated since 1979)
Company foundation on part of the German government as central test facility for tests of
1961 the aviation industry and security and defence analyses

© IABG 2015 8
Business approach

Customer-specific solutions

HRText, 1.Ebene18
Qualification pt Functional expertise
Text, 2.Ebene 16 pt
 Engineering
 Text,3.Ebene
sciences 14 pt  Simulation & test (safety & security)

 IT - Text, 4.Ebene 12 pt (nur in Ausnahmefällen)  Qualification & certification

Analysis
 Mathematics &  Life cycle optimisation of
Text, 1.Ebene 18 pt conception
 Physics complex products & systems
Text, 2.Ebene 16 pt
 System analysis Implementation  Development
13 cm of product
 Text, 3.Ebene 14 pt & system
 Economic sciences & process standards
- Text, 4.Ebene 12 pt integration
(nur in Ausnahmefällen)
 Psychology  Technology development /
innovation management
Operation of
22,57 cm

complex  Software systems &

plants & systems applications

Core competency: simulation & testing

IABG • Company Presentation © IABG 9

Automotive

Analysis & conception

Experimental investigations
CAE services
Mechatronics system analyses

Implementation
Customer-specific test facilities
Long-term performance stands
System test facilities with
hardware-in-the-loop option

Operation
IABG test centre in Ottobrunn
On-site test facilities with customers
Customer-specific investment and operator
models (chassis / bodywork / drive)

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Aeronautics

Analysis & conception

Structural integrity / fatigue testing including
test concepts for structural tests
Aircraft construction, design and certification
Contribution to the aviation research project
management

Implementation
Test facilities for structural and fatigue
tests of complete airframes or components
Innovative automation solutions for test
systems

Operation
Test facilities for static and dynamic testing
of complete airframes, assemblies and
components in Ottobrunn / Dresden / Erding

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Space

Analysis & conception

Studies and system analyses
Test specification, planning and
implementation
Quality management systems

Implementation
Development, qualification and
acceptance tests
Testing facilities and plants
Quality assurance systems

Operation
IABG’s National Space Test Centre
in Ottobrunn
ETS (Test facilities ESA) in Noordwijk (NL)
as Joint Venture with Intespace (F)

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Defence

Analysis & conception

Military and mission doctrines
Analysis of weapon systems
Mission support
Training / exercises

Implementation
Integrated modelling and simulation
systems (TexNet-SimSys)
Test facilities, in particular in the
competence field “protection”
Experimental laboratories and test beds
for analysis and training

Operation
Modelling & simulation-supported
experimental laboratories (CD&E)
Test facilities for land systems /
overall protection (Lichtenau)
Exercise and training centres
(GÜZ, Wildflecken)

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Center of Competence Safety

Consulting and support of safety

Functional safety
Operational safety
Mechanical, electronic and software-related
safety aspects

Services
Process consulting
Safety engineering
Audits and assessments
Partner for outsourcing development services
Safety academy

Expertise regarding industry standards

Automotive: ISO 26262
Defence: MIL-STD-882, IEC EN 61508
Aeronautics: RTCA/DO-178, RTCA/DO-254
Railway: EN 50128/9

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 IABG Sites
Engineering Services,
e-Mobility

Training Support
Competence Centre
Protection
Hamburg
Lathen
Berlin
Hannover
Noordwijk
Huntsville Letzlingen
Lichtenau
Space Tests Dresden
Air Defence Bonn
Systems
Koblenz
ICT Systems
Aircraft Tests
Geodata Factory
Project Management Karlsruhe
Support Oberpfaffenhofen Erding
Ottobrunn

Headquarters and
Technology Centre

Flight Tests

DS-FM06/0616
15 © IABG
IABG Sites

Erding Meppen
Oberpfaffenhofen

Koblenz Dresden

Lichtenau Dresden
Leipzig

Lathen Noordwijk (NL)

IABG Headquarters in Ottobrunn

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Overview of Competence Center Protection & Weapon Effects

Presently Lichtenau has a highly experienced

and specialized workforce of 40 employees

Active since 50 years

Range of Services
Feasibility Studies for Armored Vehicles
Development of Protection Technologies
Impact Testing
Vulnerability & Lethality
Test rig design and operation

Most modern test equipment, e.g.

State of the art measurement techniques
for short time physics
Occupant safety analysis
IABG site (Area of 180ha)

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Milestones of IABG in Lichtenau

2015 New Infrastructure

Competence Center
2011
Protection & Weapon effects
2011 50 Years IABG

2009 SCHWARZ Holding GmbH

2007 Protection investigation of national military platforms

2006 Impact-Testing

2004 Qualification MBT Leo 2 A6M

2003 Protection against explosive assassinations, C-IED

2000 Technical Tactical Center-concept / Application NGP

1996 Basic research of mine protection, IFV Marder

1993 Privatization of company

1983 Camouflage/ stealth EGS

1980 KPz 90 /Char 90 (GE, FR), digital fire control

1975 Combat tests GVT

1969 Foundation of IABG Lichtenau, Protection and mobility

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Main Competences

Mine and IED threats Ballistics R&D Studies

Impact Testing High Risk Tests Measurement Techniques

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Testing and Qualification of Protected Civil and Military Vehicles

Short project description: (1) Ballistics

IABG tests either at the customer or on its own proving
ground the effectiveness of protection solutions against
ballistic and Improvised Explosive Device (IED) threats as
well as mines according to international standards like
STANAG 4569.

Background:
National and international need of protected civil or (2) Mine
military vehicles with best occupant safety and
survivability

Services:
 ballistic, mine-, and IED-testing according to national and
international standards
 analysis of loads on occupants
 analysis and assessment of overall survivability
(3) IED

Results:
Analysis and assessment of the effectiveness of
protection solutions and the overall survivability of
occupants, qualification and certification of civil and
military vehicles

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Testing and Qualification of Protected Civil and Military Vehicles

Short project description: (1) Ballistics

IABG tests either at the customer or on its own proving
ground the effectiveness of protection solutions against
ballistic and Improvised Explosive Device (IED) threats as
well as mines according to international standards like
STANAG 4569, VPAM.

Background: (2) Mine

National and international need of protected civil or
military vehicles with best occupant safety and
survivability

Services:
 ballistic, mine-, and IED-testing according to national and
international standards
 analysis of loads on occupants (3) IED
 analysis and assessment of overall survivability
Pic. 3
Results:
Analysis and assessment of the effectiveness of
protection solutions and the overall survivability of
occupants, qualification and certification of civil and
military vehicles

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STANAG 4569 / 4686 activities and National Working Groups

Support of the national authority for the work within

ToE (Team of Experts) of STANAG 4569 and 4686 for
AEP (Allied Engineering Publication) 55 (Vol. 1 to 4)
AEP 62 (Vol.1 to 7)

Threat characterization und classification

Basic research of loads and effects on occupants
Assessment of structural loads and effects due to the influence of IEDs

 Assuring the ability of the national authority to assess protection systems and
effects on vehicles and occupants.

Long-term member of national working groups like

GE R&D national working group
IED-Warheads
Overmatch assessment

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STANAG 4569: Protection levels for vehicles

A NATO standard to classify the protection

levels of military vehicles

Used to evaluate and to qualify protected

vehicles

Test and Qualification given in the AEP 55

documents
Volume 1: KE threat
Volume 2: Mine threat
Volume 3: IED threat
Volume 4: CE threat (under preparation)

Qualification of mine/IED protection based

on injury criteria developed by Human
Factors and Medicine panel working group

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Testing and Qualification of Protected Military Vehicles

Test set-up and performance for

assessment of protection against
Improvised Explosive Devices
Mines under belly
Road side Blast
Multi Fragments
Explosively Formed Projectiles (EFP)
Ballistics

According to international
standards like STANAG 4569

Data measurement and acquisition

Analysis and Documentation

Development support

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Testing and Qualification of Protected Non-Military Vehicles

Experimental and numerical assessment of

protection against
Mines under belly
Road side blast
Fragmentation charge (e.g. DM51, HG85, DM31)

According to international
standards like VPAM

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Methodology for Mine Protection Analysis and Design

IABG‘s coupled approach of experimental and numerical analysis of mine

protection technology

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Testing and Qualification of Protected Military Vehicles

National References

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Customers/ References

Achleitner, ACS, ASC, Aurum Security, Autoflug, Benteler, Daimler Trucks,

Farmingtons Automotive, FFG, General Dynamics – European Land Systems,
German Federal Armed Forces, Hyundai Rotem, IAG, Iveco, Jankel, KMW,
Mowag, Nexter, Plasan, Raba, Renault Trucks, Rheinmetall, RUAG, Samyang
Comtech, Schroth, Schüco, Soframe, Stoof, STREIT, SVOS, Tencate,
Thyssenkrupp, TPS, etc.

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Methodology for Road Side Protection Analysis and Design

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Methodology for Road Side Protection Analysis and Design

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Methodology for Road Side Protection Analysis and Design

Simulation Experiment

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Main Competences

Mine and IED threats Ballistics R&D Studies

Impact Testing High Risk Tests Measurement Techniques

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Measurement and data acquisition

Data measurement and acquisition

Fully instrumented crash test dummies
High-speed video
Acceleration, pressure and strain
measurement

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Main Competences

Mine and IED threats Ballistics R&D Studies

Impact Testing High Risk Tests Measurement Techniques

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Ballistic testing 1/2

IABG provides full service for ballistic Available ammunition:

testing and qualification of: Calibre from .357 Mag to 25 mm
Materials FSG 12/70 shotgun
Components FSP artillery fragment from
5.56 mm to 20 mm
Transparent armour
Velocity up to 1500 m/s depending
Armoured vehicles on ammunition e.g. FSP 20 mm
Spall liner Tailoring of required projectile
Body armour velocity

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Ballistic testing 2/2

Diagnostic capabilities:
Measuring of impact velocity
Measuring of yaw angle
Measuring of residual velocity
Analysis of structural behaviour during impact e.g.behind armour debris
Further diagnostics on customers demand

top view
2,41°

2,43°

Δt = 50 µs
0,54°
0,13°

side view

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Main Competences

Mine and IED threats Ballistics R&D Studies

Impact Testing High Risk Tests Measurement Techniques

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R&D-Studies – Influence of IED Threats on Vehicles and Occupants

Short project description:

IABG supports the national authority with basic research of the

influence of IED (Improvised Explosive Device ) threats on
vehicles and occupants. IABG helps the national authority to
keep the ability of assessing protection systems and to work
within international committees like STANAG 4569 and TV28

Background: (1) fragmentation charge (2) blast test with IFV MARDER
Need for the national authority to keep the ability of
assessing protection systems

Services:

Threat characterisation and classification

Assessment of structural loads and effects due to the influence of
IEDs
Basic research of loads and effects on occupants
Support of the national authority for the work within ToE of
STANAG 4569 (3) blast test with IED-TROSS (4) test rig TROSS
Collaboration within national working groups like IED-Taskforce

Results:
Assuring the ability of the national authority to assess protection
systems and effects on vehicles and occupants.

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R&D-Studies – threat characterisation und classification

Reproducible test charges for various protection levels against

IEDs (Improvised Explosive Devices)

Transparent armour HS-Camera

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R&D-Studies – Protection against RPGs

Short project description:

IABG studies the feasibility, the effectiveness, the possibility

of integration, and the robustness of cutting edge protection
systems against antitank weaponry (i.e. shape charge).

Background:
Due to current and future threats there is the need of
powerful and lightweight protection systems against antitank
weaponry for protected vehicles of different weight classes

Services:
 experimental testing of protection effectiveness and
polyvalence of components and the whole system
 collaboration within international committees
(i.e. STANAG 4686)
 support of international measurement campaigns
 screening of technology and market

Results:
Assuring the ability of the national authority to assess
the effectiveness of protection systems and to work
within international standardisation committees.

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R&D-Studies –Protection against RPGs

Assessment of Statistical Armor

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R&D-Studies –Protection against RPGs

Assessment of Active Protection – Demonstrator of Active Protection System

EFA “Explosively Formed Axe”

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Main Competences

Mine and IED threats Ballistics R&D Studies

Impact Testing High Risk Tests Measurement Techniques

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Impact Testing

Design and operation of several

Impact Devices

Analysis of impact phenomena

Bird strike
Hail and Tire Impact
FOD (Foreign Object Damage)
Military warhead surrogates

National/international standards
(e.g., ASTM F330-94, DIN EN
12975-2:2006, FAR CS 25.631,
CS 25.571, CS 25.775, CS
29.631)

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Impact Testing – A400M Fin Tip

Source:
AIRBUS

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Impact Testing – Non-Destructive Testing
Experienced personnel qualified to
EN 4179 and EN 473 (level 3)
covering all relevant methods (UT,
ET, MT, PT, RT, VT)

Calibrated equipment convenient

to inspect metallic and CFRP
structures

Planning and performance of

extensive inspections including up
to 15 inspectors about several
days

Development and validation of

inspection procedures for fleet
maintenance based on customer
requirements

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Impact Testing – Customers

Aerospace
Rail

Components Special Applications

(Automotive, Space, Defense)

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Any Questions?

December, 2019 Introduction 49