05/02/2007
 

Gefas – A new dimension in armoured vehicle design

Optimum protection combined with extreme flexibility

Confronted with an increasingly complex array of tasks, today's armed forces need a highly mobile, universally deployable vehicle that combines excellent survivability with maximum flexibility.

Based on a groundbreaking vehicle concept, Rheinmetall's Gefas meets this requirement in compelling fashion. Unveiled for the first time at the Eurosatory fair in Paris in June 2006, the vehicle's innovative approach to crew protection makes it the safest, most future-proof system of its kind anywhere.
 

Currently under development, the Gefas protected vehicle system is a pioneering new tactical vehicle concept. Its extreme modularity already makes it stand out from the crowd, greatly facilitating logistics and guaranteeing maximum operational flexibility. Moreover, the vehicle successfully combines superb crew protection with excellent strategic and tactical mobility.

The Gefas, which stands for 'Geschütztes Fahrzeug System', or "protected vehicle system", offers a level of protection never attained before in a vehicle of its weight class. It is thus ideally suited for patrol and convoy escort duties. But its modular design and ability to accommodate a wide variety of tactical retrofit kits mean that the Gefas can serve just as easily in a command, reconnaissance or air defence role.
 

Chief characteristics

A classic example of cutting edge German engineering, the Gefas is the best-protected vehicle in its weight class. The basic structural principle incorporates a suspended safety cell coupled with high-grade armour protection for the crew compartment. Its modular design means that the vehicle can be quickly reconfigured to meet specific mission requirements, including integration of the necessary subsystems. The vehicle can be airlifted in transport aircraft such as the C-130 or A400M. At 2.55 metres, it is no wider than a standard truck, readily qualifying it for roadworthiness certification. Moreover, its conventional width makes it ideal for convoy operations, since the Gefas can follow in the tracks of other vehicles.

Its modular layout, coupled with the possibility of integrating a multiplicity of retrofit units, makes the Gefas the perfect platform for a wide variety of vehicle configurations. For the first time, it is now possible to put together different vehicle platforms using the same modules. Encompassing 4x4, 6x6 and 8x8 vehicles, the weight spectrum is huge, ranging from 12.5 to 20 tons – or 25 tons with a trailer.
 

A joint development project

The Gefas is the outcome of a joint development effort by Rheinmetall Landsysteme GmbH, MTU Motoren- und Turbinen-Union Friedrichshafen GmbH, ESW GmbH and STW Sensor-Technik Wiedemann GmbH. Also taking part in the project are companies such as IBD Ingenieurbüro Deisenroth of Lohmar, Germany and Ireland's Timoney Technology Ltd.
 

Gefas convoy protection vehicle

The 1:1 mock-up of the Gefas on display at Eurosatory 2006 in Paris – the first ever seen by the international public – was configured for convoy protection operations. Networked in an intelligent command and weapon engagement system, a string of variously configured vehicles ensures excellent protection throughout the entire length of a convoy.

Mounted on escort vehicles, high-power electromagnetic systems (HPEM) can prevent insurgents from detonating improvised explosive devices by mobile phone or radio; or they can be used to induce premature detonation of roadside IEDs at a safe standoff: a highly effective means of thwarting one of the commonest threats to military convoys in contested areas. In situations where lethal force is the only answer, an automated weapons station enables precision engagement of hostile targets, controlled from the safety of the vehicle's fighting compartment.

Electro-optical sensor systems with downstream image processing for detecting and tracking moving targets assure early recognition of threats in the form of vehicles or dismounted persons. Laser-optical sensors for detecting enemy optics (coupled with instantaneously activated smoke/obscurant effectors) reduce the threat from snipers even before a shot is fired.
 

The vehicle system

The modular design means that various elements can be mixed and matched to form a multitude of different vehicles. In its basic configuration, the vehicle consists of a main module, a power module and two axel modules. Front and rear modules carry the headlights and tail lights. If the power pack module is placed behind the main unit, a roomy cargo area or platform space results, where a wide variety of weapons or sensor systems can be installed. If required, future weapons can be mounted on additional new modules.

The mechanical and functional interfaces between the modules are standardized, making it possible to rearrange and reconfigure the modules in very short order. An additional battery pack provides a redundant power source, assuring residual mobility if the power pack module is knocked out. As a basic force protection measure, the Gefas is designed to ensure minimum mobility even if only one axel module is functioning. The use of identical axel modules in each vehicle results in an extremely high degree of redundancy in all of the subassemblies. This in turn leads to major logistical advantages with regard to maintenance, spare parts and life cycle costs. By employing standard off-the-shelf components, the vehicle's makers have succeeded in achieving outstanding reliability as well as significant cost savings.

These factors combine to make Gefas the world's most future-proof vehicle system.
 

Mobile antiaircraft missile platform

Configured as a guided missile platform, the Gefas vehicle consists of two axel modules, a 2-man main module and a power pack module integrated at the rear; a special module forms the interface to the mobile launcher.
 

Radar vehicle

The Gefas radar version is a 6x6 vehicle comprising three axel modules. Powered by a rear-integrated power pack module, the vehicle offers sufficient space to integrate a 12-metre tactical radar mast for detecting small, fast, steeply ascending targets.
 

Mass launcher platform vehicle

Likewise made by Rheinmetall Defence, the Multi Ammunition Softkill System Mass requires a platform vehicle with high electrical output. Providing a globally unique level of protection against sensor-guided projectiles, Mass can now be deployed on a wheeled tactical vehicle: the Gefas, here consisting of two axel modules, one 2-man main module and a power pack arrayed at the rear; to save space, the Mass control unit is located above the power pack.
 

Air defence platform vehicle

This variant represents the 8x8 configuration of the Gefas, consisting of a 4x4 basic vehicle with an additional 4x4 rear vehicle / trailor. The latter carries an air defence turret, e.g. the Skyranger system made by Oerlikon Contraves, which can be used for engaging air and ground targets alike. As an option, the vehicle can also be armed with guided missiles.
 

The Gefas modules

The axel modules

Located in the interior of the axel module is the drive unit, consisting of two STW electro-motors, as well as the necessary control electronics. The decision to place the electric drive unit inside the axel module was no coincidence, the aim being to avoid vulnerable exposed coolant hoses and cables leading to the wheels.

Here, too, it proved possible to use standard double wishbone axels from Timoney for the single wheel suspension. The wheels are equipped with run-flat elements. Coupled with a central tyre inflation system, this feature gives the Gefas an excellent all-terrain capability. The axel modules can be used either as front or rear axels. Moreover, thanks to all-wheel steering, the turning radius is small.
 

The power module

The power pack module contains all of the assemblies necessary for powering the vehicle. Coupled to other modules via the standardized interface, it is able to operate independently. Modules can be easily swapped in the event of a defect. The elaborate process of exchanging power packs thus becomes superfluous for the first time. Cooling air and combustion air are channelled so as to provide optimum protection from combustive agents. At the same time, a variety of measures minimize its IR signature.

MTU is responsible for developing the power pack, whose chief feature is the 4R890 diesel engine, a 10-cylinder version of which is already installed in Germany's new Puma infantry fighting vehicle. Specially developed for military applications, the 890 series features high performance density with extreme compactness. The drive unit contains the engine, an electrically powered cooling unit, an air filter system and an electric power generator. The latter, developed and manufactured by ESW, consists of a starter generator, generator power converter, the vehicle circuitry and the power management system.
 

Main module

The main module consists of a carrier structure containing a suspended safety cell. The latter is attached exclusively to the vehicle's roof, creating a large zone of free space in the floor area. This ensures that the safety cell remains undamaged if a landmine explodes under the vehicle. Moreover, the vehicle's flanks and undercarriage – consisting of large slanting surfaces – are excellent at deflecting the shockwaves caused by blast mines and roadside IEDs. Additional armour plating on the carrier structure and safety cell provide added protection from ballistic threats and explosively formed projectiles. Rheinmetall is developing appliqué armour modules in cooperation with the IBD company. Reactive and active armour versions are also planned as options.

The forward area of the vehicle is fitted with ballistic glass, as are the side doors. The vehicle is entered and exited through a wide, well-protected door at the rear of the vehicle, or through the roof and side hatches. The main module is roomy enough to carry a six-man crew with their complete equipment. Large lateral storage bins at the side and in the rear section of the vehicle increase the amount of useful space.

Additional configurations for four- and two-man crews are planned.