Abhay IFV

Abhay (Sanskrit: अभय, "Fearless") was an Infantry Combat Vehicle created under a tech-demonstration program started in India by the Defence Research and Development Organisation or DRDO. It was designed to:


 * Provide experience in the construction of AFV components to DRDO as their first IFV project
 * Serve as a replacement to India's vast BMP fleet used in its Mechanised Infantry Regiments (changed later on)
 * Serve as a test bed for weapons and systems to be used on future vehicles, as well as to be a reference for the designs of future vehicles.

A majority of the systems on the vehicle were indigenously (locally) developed as projected, excluding 3/4 weapons systems and the engine.

The program began in the mid-1990's. By 2003, the development of the first Mild Steel prototype was completed and the development of the first armoured prototype was in progress. By 2004, various stages of the vehicle were in the advanced stages of development. By 2005, the first prototype was integrated and tested with indigenous components and the second one was either completed or undergoing testing. By 2008, the Abhay program was officially declared successfully completed by DRDO in the Ministry of Defence Annual Report of 2007–2008.

Allegedly, Mr. M Natarajan, at the time recently appointed Director General of DRDO, stated about the Abhay in 2004: "The Abhay is under development. We see it as the future infantry combat vehicle for the Army. It will be a replacement for the Russian made BMPs that the Army has. It should be ready in two years." This was not clarified later on for unknown reasons and the BMP fleet is yet to be replaced with the FICV program in progress.

History
In 1975, the Indian Government appointed an expert panel to undertake a long-term perspective plan for the army. The committee, also called the Krishna Rao Committee Report. was headed by Lieutenant General (later General) K.V Krishna Rao. It was mandated to present a perspective till 2000. It was required to evaluate national security threats, propose a strategy against it, visualise the future battlefield, determine the size of the army and suggest an incremental build-up of forces. 40 Wide-ranging discussions were carried out by the committee with a number of agencies.

The report followed-up on the limited mechanisation of the army that had begun in 1969 with the induction of TOPAS and SKOT armoured personnel carriers. As a result of the recommendations of the report, the Mechanised Infantry Regiment equipped with the BMP-I was raised 2 April 1979. The real impact of the recommendations was felt when Krishnaswamy Sundarji took over as Chief of the Army Staff in 1986. At the end of his tenure in 1988, over 23 Mechanised Infantry Regiments were raised equipped with at the time state-of-the-art BMP-2 ICVs. The offensive potential of Indian armour was augmented by the availability of world-class technology from the Soviet Union of the BMP-1/BMP-2 ICVs. The changes post-1975, which eventually gained pace in the 1980s, were supported by technological advances, especially related to the ICV platform.

Around a decade later most of the shortcomings of the BMP were known and experienced by the army. It possessed limited all-around protection only up to 12.7mm rounds at best, had not yet been reequipped for night operations, the autocannon had large spread and the default soviet armor piercing rounds were not able to reliably penetrate better armored modern ICVs, mine protection was not particularly good, etc.

Due to these issues with the currently deployed ICVs eventually needing to be fixed in some way, and the push for self-reliance following the dissolution of the soviet union, DRDO was handed the task of forwarding the aforementioned objectives sometime after 1993, initiating the development of the technology demonstrator that would be named Abhay. Development suffered delays from 1998 to 1999 due to the sanctions imposed on India by multiple countries in consequence of Pokhran-II nuclear tests conducted that year. According to Indian Ministry of Defence annual reports released from 2003 to 2008, development of the mild steel hull prototype was completed by 2003, and was being used for testing the automotive systems of the Abhay. The development of the armoured steel prototype was in progress at the same time. By 2004, various stages of the vehicle were in the advanced stages of development, and by 2005 the armoured prototype of the Abhay was complete, using indigenously developed automotive and weapon systems, and armour. In 2008, DRDO stated about the Abhay:

"The multi-disciplinary, multi-laboratory, Technology Demonstration Programme for development of Infantry Combat Vehicle (ICV) Abhay, has been successfully completed during the year having realized two prototypes. The successful development programme has imparted a boost to the self-reliance in defence technology. The technologies developed under this programme, such as fire control system, composite armour, hydro-pneumatic suspension and host of other automotive and armament sub-systems can be adopted for futuristic ICV and light tracked vehicle projects." Only two prototypes were made of the Abhay, a mild steel prototype and an armoured prototype.

As of 14 January 2024, DRDO has worked with L&T to develop and test the Zorawar light tank, the first batch of which is to be delivered to the army in April 2024. The tank uses some of the systems developed on the Abhay, such as an Integrated Fire Suppression System or IFSS.

Design
Because the development of the Abhay required several technologies in the fields of materials, electronics, instrumentation, armaments, etc. Multiple DRDO laboratories were involved in the development of this ICV. These were:


 * IRDE - Development of instruments (gunner and commander sights, periscopes)
 * ARDE - Development of the armament system
 * DMRL - Development of composite armour
 * HEMRL - Development of ammunition
 * CFEES - Development of the IFSS
 * DEBEL - Development of the Ergonomic layout
 * CVRDE - Consultancy on all aspects of development
 * DLJ - Development of electronic protection systems (Laser Warning System)

VRDE carried out the basic design and development of hull and turret envelopes, power pack, running gear, suspension, electronics, automotive systems, system integration, and testing.

Hull
The hull on both prototypes housed automotive, armament, and running gear systems as well as the turret basket. Out of two prototypes, the first prototype was made from mild steel, whereas the second prototype was made from locally-developed compound steel. The development of the hull helped DRDO in understanding how to create an armoured hull through edge preparation, specialised welding and armour bending techniques. DRDO laboratory Defence Bioengineering and Electromedical Laboratory (DEBEL) based in Bengaluru designed the ergonomical layout of Abhay.

Turret
The mild steel prototype used a polygonal shaped turret with sloped armor all around to increase protection by decreasing penetration. For the armoured prototype, a rounded turret was made with the same composite armor as the hull again to increase protection by decreasing penetration. The turret accommodated the gunner and commander housing the electronics and mechanics related to both roles i.e primary and secondary armament systems, sights and monitors, fire control system, etc. Both turrets had suspended light-weight turret baskets, and both the commander and gunner had adjustable seats. Bearing meshed with pinion gear helped in turret traverse and was driven by lightweight precision servo gear drives. Stabilization of the turret was provided through a turret lock when required.

Instrumentation
Multiple instruments were indigenously developed by IRDE for the Abhay, including but not limited to:


 * Gunners Main Sight

An integrated, stabilized day sight complemented by a thermal imager and laser range finder with a built-in fire control computer. All the technologies involved and the components used are critical in nature. A modular concept was adapted to realise complete the system.


 * Commanders Thermal Moniter

The thermal monitor, a multi-functional display, facilitates the commander to view targets through thermal imaging as the gunner would. This thermal moniter uses keys to change settings instead of a touch screen common in modern vehicles.


 * Commanders Day Periscope

Provides a secondary way of surveillance and target designation to the commander when the commanders hatch is closed.


 * Driver's passive night periscope.

Provides night driving capability to the driver when the usage of lights is unavailable. It is based on image intensification technology using a second-generation image intensifier tube, a fast optical system as OG(?), and a binocular eye piece for comfortable vision.


 * Fire Control Computer

The Fire Control Computer (FCC) provides ballistic offsets to the gun in azimuth and elevation for different ammunition types based upon the range and environmental conditions. The FCC console enables the gunner to key in ammunition type, range, meteorological parameters, mean point of impact, and bore sighting range, etc. before calculating precise offset.


 * Muzzle Bore Sight

Modified from the existing TXP-1-515 sight used for the BMP-2 to accurately perform the same function on the larger 40mm autocannon of the Abhay.

Protection
The protection rating of the Abhay was an essential topic, as compared to the BMP-2, its replacement (later on the FICV program) would need much better protection against mines, small arms fire, shell fragments, and other most probably threats it would face. Therefore, the protection of the Abhay was ensure through multiple layers and systems.


 * Armour

The second of two prototypes (the first one was only for testing automotive systems) had all around protection against small arms and frontal protection from medium caliber cannons. It was developed using compound steel, behind which lay a recently indigenously developed composite armor consisting of multi-ceramic armor, high-hardness steel armor, titanium armor, dual hardness spaced armor, and anti-fragment armor at various locations. This led to a weight reduction of more than 40% in comparison with steel for equivalent protection. More than 300 armour components were fabricated to specific shapes, sizes and configurations to be made and tested on the armoured prototypes.


 * ERA

A lighter impact version of Explosive Reactive Armor (ERA) with mounting fixtures was developed for the Abhay, which offered protection without any damage to the hull armour of the Abhay.


 * NBC Protection System

This NBC (Nuclear, Biological, Chemical) protection system is the same as the modernised one which was tested and developed for the BMP-2. It consists of a Radiation Detection Measurement and Control (RADMAC) Unit, Automatic Control Unit (ACU), Blower Control Unit (BCU) and is automated.


 * Integrated Fire Suppression System

An Integrated Fire Suppression System (IFSS) was developed for the Abhay to protect the ICV from fires in the engine and crew compartment. It comprises the Main Control Unit (MCU), IR Detection Units, Automatic Fire Extinguisher (AFE), Portable Fire Extinguisher (PFE), Electrical Pyro Cartridge, Linear Thermal Detection, Alarm Unit (AU), Emergency Switch Unit (ESU), Cable Harness, and IFSS System software.


 * Laser Warning System

The Abhay also features a Laser Warning System which reduces the ICVs vulnerability to laser guided weapons by providing visual and auditory of any laser guided threats to the crew for the timely initiation of countermeasures.

Firepower
The Abhay features vastly improved firepower over the BMP-2 to better fit the requirements of a modern ICV. It has anti-air as well as anti-armor capabilities and an indigenous FCS.

Armament
Primary Armament:

Two primary weapons, a 40 mm autocannon and a twin ATGM launcher.


 * Bofors 40 mm L/70 autocannon fire on closing, self-ejecting cartridge gun with a recoil-operated autoloader using a 40x365mmR cartridge with 3 rate of fire modes - 240 rounds/min, 300 rounds/min, 330 rounds/min. On the Abhay, the Bofors 40mm L/70 autocannon is fed rounds through a two column feed and ejection/replenishment system allowing for the gun to be use two types of rounds without the need to change any ammunition belts. It is capable of firing 40 mm APFSDS rounds for armored targets as well as HE rounds for soft targets and bunkers with the APFSDS rounds being able to penetrate 100mm RHA at a range of 1000m/1 km. The barrel is progressively rifled, indigeniously developed for the first time in the country for a low calibre gun.
 * Twin ATGM launcher capable of carrying and firing the BEL modified Milan ATGM with an improved range of 3000m/3 km (possibly up to 4000m). It has space for two missiles placed side by side over two guide rails, which in turn are mounted onto the right side of the turret roof.

Secondary Armament:

Two secondary weapons, an automatic grenade launcher 17 and a co-axial 7.62 mm machine gun.


 * Automatic Grenade Launcher 17 (Russian Designation AGS-17 "Plamya"), which uses a 30x29 mm cartridge for 30 mm grenades, with a standard rate of fire of 400 rounds/min with an effective firing range of 800 to 1,700 m. The feed system uses a 29 grenade belt.
 * 7.62 mm solenoid-fired co-axial PKT machine gun with a standard rate of fire of 100 rounds/min, and a 250-round magazine. The PKT has a higher muzzle velocity and higher cyclic rate of fire then other PK machine gun variants. It can fire 500 rounds in rapid fire scenarios before meltdown.

Fire Control System
Equipped with an all-electric FCS and stabilisation of the turret developed in association with private sector industry (possibly BEL), the purpose of the all-electric FCS is to position the 40 mm main gun on the ICV on target with the correct azimuth and elevation, and to provide twin-axis stabilisation to the weapon platform against external disturbances.

The whole system is an electromechanical system, using brush-less drives with backlash free elevation and traverse gearboxes coupled to turret ring for rotation in azimuth The system employs vector control technology implemented through digital controllers and insulated gate bipolar transistor based power amplifiers for control of the stabiliser. It uses state-of-the-art fibre optic gyros as feedback elements to receive input on vehicle speed to apply the correct amount of stabilisation. The system has an interface for live connection and interaction with the Fire Control System and Battlefield Management System, using a combined day and night sight integrated with a Laser Range Finder for the purpose of automatically ranging the distance to a target. The whole system has excellent accuracy levels comparable with contemporary systems.

The finished system was tested using both prototypes on cross-country terrain and successfully test fired all armaments on static targets. Being an indigenous development, the FCS can be configured as required to work on similar weapons/allied platforms.

Salient Features
Source:


 * Provides fire on move capability
 * Operates in various modes, viz., self-stab and sight-master mode
 * Inbuilt provision for equipment testing
 * Interlocks for safe operation
 * Dual control through gunner and commander joysticks with override facility to commander

Technical Specifications
Source:


 * Traverse and elevation rates
 * Max.: 40o/s
 * Min.: 0.04o/s
 * Stabilisation: 0.8 mil/s (1s)
 * Acceleration: >50o/s2
 * Drift Rate: <0.1mil/s

Mobility
All of the Abhay's automotive systems excluding the Engine are indigenous projects.

Engine
The engine used to power the Abhay is the Greaves Cotton TD2V8 550 horsepower turbocharged diesel engine with a power-to-weight ratio of 24 horsepower per tonne (24 hp/tonne), able to push the vehicle to an on-road speed of 70 km/h, cross-country speed of 35 km/h, and a cruising range of 400 km.

Power pack
Power Pack: Abhay ran on a 550 hp indigenous turbocharged diesel engine with Hydro Mechanical Power Transmission (HMPT)-500-3EC fully automatic cross-drive transmission of M/s David Brown, UK. It has six forward and two reverse speeds. A new cooling system comprising radiator core, after cooler core, transmission oil cooler, hydraulic oil cooler core, cooling fan, and hydraulic drives was indigenously designed and developed. The compact cooling system with hydraulic drives is capable of withstanding temperatures ranging from -10 degree Celsius to +55 degree Celsius. The steering and brake system integrated with automatic transmission were controlled through indigenously developed actuation system and linkage mechanism. An indigenous Power Distribution System (PDU) distributed power to the compressor, generator, cooling fan, etc. Lightweight final drives offset using aluminium casings were also developed indigenously.

Suspension system
The hydro strut suspension of Abhay utilised the proven advantages of a pneumatic spring. Abhay's hydro damper can be adapted to both tracked vehicles. The damper is inbuilt in this form of suspension. The hydro strut suspension offers better ride comfort and exceptional cross-country mobility. The static load capacity of each suspension is 1.4 ton to 1.9 ton with wheel travel up to 400 mm, and bounce and rebound of 300 mm and 100 mm, respectively.

The technologies used during the development of the hydro gas suspension system include surface finishing and surface coating techniques, sealing materials, manufacturing techniques for seals, test cycles, and testing procedure.

Running Gear System
The indigenously developed running gear system system of the Abhay comprises a double pin, and rubber track with a central horn.

The axle arms, sprockets, idler wheels, road wheels, and track tension mechanism have also been indigenously designed and developed.

Advance Automotive Dashboard
An indigenous advance automotive dashboard with various sensors was developed and integrated on the vehicle. The dashboard was interfaced with GPS system for navigation. It acquires inputs on various parameters from engine, transmission, and troops' compartments and displays it on the front panel. The front end display shows selectable vehicle parameters such as vehicle speed, engine speed, engine/gearbox oil pressure, temperature, etc. The system checks all vehicle parameters and generates appropriate messages. It also records the cumulative values of important parameters, and schedule of periodic maintenance. The system continuously compares sensors inputs of critical parameters with threshold limits and gives audio/visual warning whenever any parameter goes out of specified range.

Vehicles of Comparable role, size and era

 * K21
 * BMP-2
 * Mitsubishi Type 89 IFV