Vroom, Vroom: The 2010 Army Vehicle Programs
By Scott Clay, Bishop & Associates Inc.

During the February AUSA Winter Meeting in Fort Lauderdale, the Army released a Request for Proposal for the technology development phase of the new infantry fighting vehicle that the Army wants developed through the Ground Combat Vehicle Group. This program is an outgrowth from the cancellation of the Future Combat Vehicle systems, which entailed a series of various mission vehicles. This program was cancelled last year by Defense Secretary Robert M. Gates, as it was over budget, seriously delayed, and far too costly to complete, especially with the costs of the Iraq and Afghanistan wars exceeding $150 billion every year.

Rather than continue developing these FCS vehicles, the Army and civilian leaders within the Defense Department have created a new series of requirements for a vehicle that will replace some legacy vehicles now in service, and augment some new systems that are planned as part of the new Army rapid deployment brigades, such as the MRAP (Mine Resistant Ambush Protection) trucks, smaller M-ATVs built by Oshkosh Truck, and an updated eight-wheeled vehicle, the Stryker, built by General Dynamics. The first version of this new fighting vehicle will be the infantry version, with the mission of delivering a nine- or 10-man infantry squad safely to the battlefield. This new vehicle will be designed from the ground up to protect these troops from the danger of IED (Improvised Explosive Devices), mines, RPGs, small weapons fire, and other hazards. Using technology developed from combat experience, the specifications also could require other technologies, such as remote weapon stations, which keep the troops protected while still able to fire the vehicle’s gun systems; the newest application of specialized armor on the vehicle chassis, and even the latest in “electronic incoming round protection systems,” similar to systems being installed by the Israelis.

The Army is asking a lot from bidders. They want the vehicle to have the protection of the 65,000 pound MRAP, better armament and ballistic protection than a Bradley (the current tracked fighting vehicle, which has been in service for almost 30 years), and the cross-country ability of the Abrams Main Battle Tank. Issues such as weight, propulsion, even tracked or wheeled, are still to be determined. The Army wants to follow their example of the Joint Light Tactical Vehicle, in which they awarded three technology contracts to different companies, and are now evaluating the prototypes at various Army test locations. The JLTV is another of the largest new programs, as it is intended to replace the HUMVEE, and the total needed will exceed 100,000.

Proposals are expected from the usual players in the military vehicle market—General Dynamics, AM General, BAE Land Systems, Oshkosh Truck, Lockheed Martin Land Systems, Textron Land and Marine, and others, including foreign manufacturers, and undoubtedly some of these companies will join together to share their expertise and the cost of development. The numbers of these vehicles are still to be determined, but as there are over 4,000 Bradleys in service, and at least 1,500 of the British “Warrior” versions, the numbers could be very large. Also, this new vehicle is intended as a “first” version, with other variants to be determined.

Obviously, this means some connector development for these new vehicles, and high current products are going to be very much in need, as high power is going to be needed in almost every system in these new platforms. The other real opportunity is going to be in the upgrading and refurbishing of current vehicles in the Army force, as their useful lives are going to be extended due to this new course in vehicle development. Here is a list of the current systems and the upgrade plans and dollars that are already allocated: 

These are dollars already budgeted for 2011. That means the depots and build sites for companies like BAE, Textron, GD, and the Army depots where rebuilding takes place, will be very busy places next year. The wire and cable shops that supply places like York, Tobyhanna, Anniston, Red River, and Fort Knox are going to be good markets indeed. And, this first year will only start the process for getting these systems ready for years of future service. There will be even more dollars for 2012 and 2013.

Both of these platforms will be upgraded with better electronics, more power within the vehicle, and better engines, transmissions, suspensions, and protection. The Army intends for these vehicles to continue on in service for another 20 years, or more.

JLTV Concept, which will replace the HUMVEEs in service over the next 10 years. Teams from General Dynamics and AM General; BAE Systems and Navistar; and Lockheed Martin and BAE Systems have all submitted three prototypes currently undergoing testing and evaluation by the Army. This testing will eliminate at least one of the teams, and the remaining two will compete for the orders, which could start as early as 2011. The JLTV is not a single vehicle, but a family of platforms, with three different payload capacities, all of them targeted to be light enough to be carried from a CH-53, Ch-47, or a V-22.

Another sector that continues to develop is the military truck market, with trucks of various sizes and capacities. Large cabs and trailers, which will be used to transport tanks and other vehicles, have been ordered by the Defense Department from Freightliner and Oshkosh. Another large contract was granted to Oshkosh Truck for their version of the FMTV (Family of Medium Tactical Vehicles), but the GAO reversed the award. It will allow new bids based on a complaint from BAE Systems in Sealy Texas, (formerly Stewart Stevenson), who up until now had provided this level of truck to the Army and Marines. So, the potential of another 20,000 trucks is to be determined. While these are extra heavy duty in nature, the manufacturer of them runs very much like any of the big truck makers in existence. They use typical truck harnesses, connectors, and controllers, most of them waterproofed or sealed to allow fording of small rivers and streams.

Another key sector will be the rebuilding and upgrading of so-called “legacy” Army platforms, such as the Main Battle Tanks, existing Bradley Fighting Vehicles, and large amounts of Strykers, and even the 40-year-old M-113s still being used in a reserve and support role. The Army has issued requests to BAE Systems for upgrading the current Bradleys, and have ordered an upgraded version of the Stryker eight-wheeled Armored Personnel Carrier from General Dynamic’s plant in Canada. This new version will have better electronics, improved armor, and base-plate protection, and a more powerful engine and drivetrain to handle the additional weight.

The harness and system makers will keep busy for the next several years making changes to these systems. Many will be done in the U. S., with the vehicles shipped back from the Mideast war zones, but many sets of upgraded equipment will be kitted into full systems and sent to the depots in theatre, where they can be installed in place, rather than withdrawing the vehicles from the areas of use. Here is some idea of the scope of this project. These quantities of equipment have already been upgraded: 2,702 aircraft, 3,819 trailers, 4,622 tracked vehicles, 6,550 trucks, 20,170 generators, 33,721 HUMVEEs, and 214,484 weapons and small arms. Since 2006, Congress has authorized nearly $75 billion for reset and upgrades of equipment, with well over half of it going to the Army.

Scott Clay
Director Military and Aerospace, Bishop & Associates Inc.
Scott Clay has worked for more than 25 years in the connector and wiring systems markets. He has held various positions in field applications and marketing for Molex, Tyco, Methode, and ITT. For the past 15 years, Clay has focused on the military/aerospace sector, and five years ago formed his own company for consulting and application engineering. He has worked on design-in and electronics on F/A-18E/F, F-22, F-35, C-130J, C-5M, C-27, P-8, A-10, and numerous other aircraft. Some of the Navy programs Clay has participated in are SSN-774 Virginia class subs, CVX, DDG-1000, and the Littoral Combat Ship class. He has extensive expertise in land vehicle systems, and has worked closely with the worldwide locations of GD, BAE, AM General, and other key manufacturers. He is currently working on variations of MRAP, JLTV, upgrades for the Bradley fighting vehicle, M-88 recovery vehicle, FMTV, and other platforms in the wiring and systems areas, plus portions of the future combat systems.