Design and Development of the Toyota Land Cruiser 76-series Armored Vehicle BR 7

1. Introduction

Toyota Land Cruiser 76 Series Armored Vehicle; The essay is aimed at providing additional information about the development of the Toyota Land Cruiser 76-series Armored Vehicle BR 7. The assignment gives better insight into the background and significance of the project, outlines the purposes and scope of this extended essay, and introduces some of the important principles of ballistic protection and the Land Cruiser 76-series. The essay could serve as a guideline to develop and/or improve ballistic armored vehicles.

This project gives a representation of the development and modification within three months of the Toyota Land Cruiser 76-series armored vehicle BR 6 to an armored vehicle rated at a ballistic rating of BR7. The Toyota Land Cruiser 76-series was designed as an armored patrol vehicle with the purpose to protect the occupants from ballistic threats, mainly to protect the vehicle occupants from a 5.56×45 MJ (BR 6) (7.62×51 MJ) (BR7). The armored Toyota Land Cruiser 76-series had to be designed, manufactured, and tested to specific ballistic protection needs. This included design, manufacture, protection testing, and the final offering of a requested brand new passenger armored Toyota Land Cruiser 76-series for potential use by a high-profile government agency as a head of state, visiting VIP personnel, and the citizens of a country MOD.

The Toyota Land Cruiser 76-series was designed and developed to withstand the restricted requirements of being rated at a ballistic rating of BR6. The Toyota Land Cruiser was designed with the final specification in mind of the vehicle occupants and the type of mines and/or factory-manufactured items. This head of state bullet-resistant vehicle is built to specifications rather than for a price agreement with a known recommended price range. The responsibility of the final decision on the price rests on the client who must now determine all the options required before the final cost is declared. The purpose of compliance with the above regulation is to provide as close as practical bullet-resistant windows to protect the occupants from firearms. It is important to note that the above test is specified to protect the occupants and not the vehicle. The armoring is irrespective of the Land Cruiser 76-series used on mine protection vehicles.

1.1. Background and Significance

The first prototypes of the BR 7 armored vehicle based on the Toyota Land Cruiser 76-series chassis were assembled. This final project aims to show the design development of an armored vehicle based on the Toyota Land Cruiser 76-series, which can be successfully homologated. The dissertation also describes the relevant parts of the vehicle and its extension thereof. The dissertation further describes all the processes for the development of this extraordinary vehicle. Compatibility of the prototype signifies that the design and development are on the right track. Therefore, the construction of this prototype concludes this diploma thesis.

The fact that the development of each component requires at least several hours of theoretical work stresses the complexity and importance of this diploma thesis. Also, the diploma thesis is original in many aspects, primarily in the segment of Ford BR 7-homologation. It is also the first of its kind in the development of a premium SUV armored vehicle, which has a supporting structure built by one of only five manufacturers in the world. Therefore, the diploma thesis is also an integral part of the automotive technology and armored vehicles field. With the right market strategy, a flawlessly developed vehicle could be well placed on the world market.

1.2. Purpose and Scope

The aim of this work is to develop an armored personnel carrier based on a stock single-row.

The main purpose of the work is to provide information on the design and development of the Toyota Land Cruiser 76-series armored vehicle, equipped with a mine protection system and reinforced bullet-proof armor protection class 7. The final BTF (Built Test Fuel) vehicle is designed for use in police, anti-terrorist units, reconnaissance, patrol service, quick reaction teams, and special units. Proposed to combine frame body with mine protection modules. The aim of the research is to develop a patrol protection vehicle with a mine-resistant underframe and an anthropomax underframe based on the Extreme 4×4 Toyota Land Cruiser 76 with 4.5 TD engine, 8 kW power, and reinforced architecture.

Research question: Is it possible to reinforce the built-in protected patrol vehicle base regarding the increase of the vertical load from 1,050 to 1,200 kg (15% increase) in the chassis after the exploitation of the vehicle under Bulgarian conditions according to the methodology of the Bulgarian military standard inst Ch. 1761-80 “Protected Array Vehicles”? To provide additional protection for passengers and cargo compartment free of charge, in order to make serial production for domestic and international purposes.

2. Technical Specifications

Toyota Land Cruiser 76 Series Armored Vehicle; Toyota Land Cruiser 76-series Armored Vehicle BR 7 is a full-time 4×4 vehicle with high cross-country ability (including travel on country roads and off-road), wrapped in a reinforced body of a Japanese car and pledged in it additional armor protection which meets the requirements of class of protection – BR 7 (STANAG 4569), which fully protects people in the cabin located at the same time against the damaging factors of improvised explosive devices (IEDs), as well as 7.62x51mm caliber bullets for various bullet cartridges (cartridge NATO) and blanks 7N10, 57-N132IR cartridges of caliber 5.45x39mm and 7.62×39; 7N6, 7N10, 7N22 cartridges of caliber 5.45x39mm and 7.62×39; bullet 57-H-231-series ZO-v, ZP 5.45x39mm cartridge, 57-H-231-series PS, PB cartridges caliber 5.45x39mm; bullet 57-N-323-series FMJ cartridges caliber 7.62x54R; 7.62×51 mm cartridges of caliber 7.62 x 51mm. The vehicle can be used as a staff, reconnaissance, command and staff vehicle. Its potential use as a transport and evacuation vehicle.

Its rotational capacity is power 39.62 horsepower per ton with a fully loaded mass of 3.40 tons. This means the car has good road behavior on sloping terrain. The protection against underbody authenticity is such that when contented with the relevant configuration, equivalent to stratagem 8 of STANAG 4569 and provides an 8kg underbelly hat-shaped explosive plate. The vehicle can armor against fragmentation hand grenades without any failure – 33 lethal and 147 non-lethal (this data is confirmed after fulfillment of test report HRERA/2013/01 and confirmed that Toyota Land Cruiser 76-series Armored Vehicle BR 7 has the resistance against landmines and hand grenades equivalent to STANAG 4569 underbelly).

2.1. Engine and Performance

The modification of the new armored vehicle is based on the production of a passenger car Land Cruiser 76 (updated model) and was developed at the request of the customer. In its wheelbase and in the base of the performance characteristics, the car is original. At the same time, unlike the base car, the armored vehicle is designed as a monocoque body, inside of which a three-layer metal-ceramic armor is placed. The design of the armored vehicle provides for the preservation of the civilian appearance and protective characteristics of the base car. The cooling system for the base engine that allows the use of an air conditioner is installed in addition to the primary cooling system.

The car is equipped with a petrol engine 1VD-FTV of 4.5 liters displacement providing 235 kW of power at 3,400 rpm. An acceleration to 100 km/h of 13.0 s and a maximum speed of 160 km/h have been observed during road tests by the enterprise’s special equipment department providing armored vehicles tuning. The engine heat release is 80 kW, shaft torque related to the engine is M = 627 N during driving at maximum speed. In some cases, the vehicle can reach the maximum speed with the use of the special engine control system. The maximum speed in this case is limited to 130 km/h on downward grades. Engine resource without maintenance is 1,500 hours and the lubrication system provides a 50% reduction of this figure. The fuel tank is behind the rear seat and holds 130 liters. The fuel consumption is 32 l/100 km at the military power control.

2.2. Armor Protection

One of the most important parts in the construction of an armored vehicle is to ensure the protection of the crew from at least 7.62 × 51 mm bullets with an armor-piercing core. The cabin is covered by the armor-apron complex (BPK) composed of multilayer armor plates of different thickness. The roof and bonnet are additionally lined with armor. To protect from a shot from an armor-piercing bullet, as well as to protect delicate components of the car, add-on armor was employed. The windows are made of multi-layered composite glass-polycarbonate-glazing coatings, which ensure viewing under extreme conditions, protect against UV exposure, and provide maximum protection against prying eyes and chemical weapons.

Up to 100% of the fuel tank volume is covered with add-on armor. The mine-seat (mine-dissipation floor) dampens the shock wave from the mine, while a fixed layer of armor keeps the vehicle’s lower front end from collapsing at the point of mine explosion. An anti-splinter “main” (fixed) layer of deflection armor is also built into the deck in conjunction with arch and side armor, to isolate the passengers from the energy of the detonation and prevent pintle balls, mine components, etc. from entering the cabin. Armor is bolted to the metal trapezium, inserted and strengthened in a special way in the body of the car so that elements are inextricably connected to each other. The corners and joints are welded and reinforced with diaphragms. Only original (4.5″ x 5.5″) bolts are used.

2.3. Mobility and Handling

The concept of the Toyota Land Cruiser 76-series Armored Vehicle BR 7 is defined as multipurpose, expeditionary, and providing intense force mobility using heavy and unprepared terrain. For this purpose, it is equipped with a snorkel to overcome water obstacles. It also has significant agility and excellent maneuverability for driving on rugged terrain. The design of the vehicle’s chassis and performance capabilities was designed specifically for the implementation of the maneuver war. Also, this car has compliance with the world’s requirements for safe driving.

The developed car was based on the “Turnunities truck” concept, which was characterized by good maneuverability and off-road performance. Compliance with this concept has made it possible to offer consumers a high-performance and reliable car designed for everyday use in difficult off-road conditions. The targeting configuration project influenced the following distinct character of the armored car. A military armored vehicle should be able to move without ever maintaining, running off-road, and avoiding all types of obstacles while doing so. This vehicle is also primarily intended for duty in equatorial Africa. Military work will go mostly on dirt roads and, to be able to maintain the mission of peacekeeping, the carrying capacity must be reliable, which this vehicle provides. Its basic weight floor should be well suited for current road loads and softness such as sand and wet ground. The good agility of the Toyota Land Cruiser 76 series Armored Vehicle BR 7 distinguishes it.

3. Design Features

The armored vehicle has a well-defined crew compartment and engine compartment. The crew compartment offers enough head, leg, and elbow room for all crew, even with their body armor and additional combat swimmers’ equipment. The vehicle’s cabin offers seating for all crew with fold-down flexible attitude seating for some crew as well as additional inverted fold-down benches for additional passengers to be seated. The windshield is curved and laminated fit for purpose. The windshields and windows are V-protagonist shaped to match the specific steel add-on kit when viewed from the front. Hinges are down-proof. The doors are flexible and give ballistic protection up to BRV 200, plus have nice functional elements such as a simple-to-operate French window. These, along with the special rubber seals, offer increased protection against attacking gas and flash-bangs. There are blast-protected freshly designed six vision blocks. All of the vision block’s opening mechanisms are not locking to ensure that the vision is not compromised in case of a stuck locking mechanism.

The vision block offers an uninterrupted field of vision of greater than 110 degrees. The roof has been designed to bring out the operator’s flexibility for fitting of QD brackets. The vehicle is designed such that all four sides have the same level of ballistic protection (e.g. the disturbances of the doors for the integrated Step assist do not disturb the level of protection). The vehicle has a single flush-fit protected rectangular hatch on the roof. Special roof-mounted ring mounts allow two SF Scout surveillance port modular saddles to be fitted either to the left or right in front or in aft. The vehicles are fitted with a 2-part ammunition box and a water masher. The rear slant is protected by 4 comparatively longer Rubber Blocs, to ensure a more civilized design. All corners for the mine-protected floor are given a ball shape to reduce the risk for ejection injury when subjected to a vehicle analyzed stopping event. All the main systems are fully operational and can be changed on the chassis on the race, offer easy access through new design and unique locking levels while the other systems are protectively arranged that ensures comfort and non-obstructive functionality of the previous systems. All systems offer the best of BRE solutions when necessary and wherever necessary.

3.1. Exterior Design

The creation of any car, but especially an armored vehicle, begins with the external design, as a distinctive and dynamic look will always attract potential buyers. Moreover, it is important to remember that the external design is determined, first and foremost, by the type and shape of the armor that will further affect the entire appearance of the car. Therefore, the process of creating an armored car begins with models of the structural features and the visual silhouette of the car, as well as the stylistic features of the externally located elements, such as the radiator grille, lights, etc.

Foreign buyers of armored vehicles need a car in which they will feel comfortable in their immediate environment, and local inhabitants will perceive them more calmly. The customer asked for the development of a protected SUV with a distinctive appearance, which could be used on a daily basis both in urban environments and in the mountains. Based on the drawings, the cost of the complex of body styling and CFD testing is estimated at 450 euros. Studio Toyota Motor Corporation offers a more Spartan look of the classic Toyota Land Cruiser, which details hint at a bulletproof car. The lower part of the bumper – protection for the radiator system and engine compartment. The upper part of the bumper also acts as a structural item, protecting the high zone of the body and the bonnet from deformation during a head-on collision. A spoiler at the top of the windscreen was added for better aerodynamics, not only on the unpaved extra-urban scenario, but also on highways where the car will travel at a maximum speed of 155 km/h without an active maneuvering campaign. The Toyota Land Cruiser 76 series does not have a standard roof rail. Instead, the upper body of the car is equipped with roof parapets to strengthen the roof.

3.2. Interior Design

In addition to providing high body safety, it was necessary to develop such a project for an armored vehicle so as not to forget about the comfort and ergonomics in the final version. The interior of the car is unusual first of all, in that the driver and co-driver have very little space, and people sitting on the second and third rows of seats have a lot of space. The comfort of the front passengers is facilitated by comfortable armchairs that are adjusted as additional equipment. The design of the Toyota Land Cruiser 76-series Armored Vehicle BR 7 rear soft bench takes into account the fragile body of the passenger, the backrest is made taller and at a different angle. The rear and rear side windows of the vehicle’s body are made of standard unarmored glass with the ability to open electrically.

The manholes on the body have an emergency hatch that can be opened from the inside manually by swinging the handle. The front windows of the vehicle’s body were removed. This allows the Toyota Land Cruiser 76-series Armored Vehicle BR 7 driver to communicate with the driver of an unarmored vehicle. The interior and the panel of the armored vehicle are made in an individual design. Colored in the tone of the vehicle body. On request, the customer can offer any overall color that is not part of the protected kit or one of the special colors from the optional extras. The panel has a simple and functional shape. On request, the armored car Toyota Land Cruiser 76-series Armored Vehicle BR 7 can be provided with an Alcantara or wooden panel. The color scheme inside the car is free at the request of the customer. The side ceiling consoles are equipped with personal LED lighting for each passenger individually. The armored vehicle already includes a folding armrest, storage compartment, and ashtray.

4. Testing and Evaluation

Once fabrication was completed, testing and evaluation (T&E) of the Land Cruiser hard body was conducted. Ballistic testing was done in order to assess the true level of protection afforded by the vehicle. After successful testing of the burdened vehicle, field performance evaluations were done. An unarmored version of the LC 76 was then evaluated to determine performance characteristics of the production model.

Ballistic tolerance of the Land Cruiser was studied over a period of a year and in more than 30 shots. Ballistic testing was conducted in accordance with VNAM SC4 volume 2 using snipers of certain loads and muzzle velocity, AK 47 assault rifles of 7.62 x 39mm, G3 7.62mm battle rifles, along with heavy automatic weapons such as PK M-80s and 14.5mm Anti Tank Rifles to test the level of protection afforded to the crew by the armor system. Numerous configurations of spaced and non-spaced steels were used in testing, meaning the vehicle armor experienced several ballistic shots. At 180ka distance, the armor has shown an ability to sustain a minimum threat level of 7.62 x 39mm. Modeling of the vehicle attacks was conducted using the numerical code AUTODYN. Results showed that the ballistic tolerance of the vehicle would be consistent with the theoretical calculations. Countermeasures can be added to increase the blast strength of the vehicle at a minimum extra and insignificant weight. In addition, an arched layout can be designed to increase the blast resistance of the vehicle and the passengers.

4.1. Ballistic Testing

The ballistic tests consist of two major parts or groups. The first group combines tests in which armored windows on a light transmittance tester’s curtain were tested in terms of endurance (the requirements are not too restrictive) and response during destructive tests (can the windows withstand the mandatory 3 rounds). Both constructive and destructive tests showed similar results, and that’s why the destructive test in terms of windows can be omitted.

The other resistant tests should be proceeded with testing according to other norms, but the possibility of risk due to failure of windows resulting from the impact of a vast number of bullets during the test was anticipated, and it was not proceeded due to the potential risk of injury of observing personnel. For interview windows, only a constructive test is necessary for the requirement of resistance to 1-round FB6 (BR7) bullet impact according to EN1522 or EN1063. One window sample was produced and tested according to EN1063.

At the second group of ballistic tests, the representative armored cell (BR 7, equivalent to FB7) of Toyota Land Cruiser 76-series Armored Vehicle, 4-door passenger carrier monocoque body, doped with an additional crash box was subjected to resistance tests according to VPAM regulation PM 2007/9. The successful resistance test has proved that 3 and 4 round shots and 1 and 3 blast simulation shots at the following target objects are stopped and do not penetrate. It is a “B” front part of the cell construction + armored side door protection (as door impact beam) + PE element. It means the remaining side door and floor at B-posts with side window armored part towards C-posts was tested for resistance according to VPAM regulation PM 2007/9 as 5-impact shots with pressurized blasting. Only one reinforced armored sample was produced and tested for resistance according to VPAM. Standalone counterparts must resist target objects and shots as well as an integral version of the armored cell.

In the case of BR 7, the armored cell is a monocoque body and a door with ballistic protection tested for resistance according to the previously mentioned VPAM and requirements 2 and 1 of Table 3, respectively. The results are summarized in tables and figures that explicitly indicate target object designations and shots. And the final result of testing is either penetrated or not. The first presented table and the second corresponding figure summarize results of resistance and penetration tests according to standards EN1063-VR7 (B6 replacing the original norm designation; simulator of 3 shots) follows in Table 5 and Table 6. In the case of the door protection module, the results of the remaining shots are also presented in Table 5. The last table and corresponding figure summarize results of resistance and penetration tests according to standard FB7 – PM 2007/9 (simulator of 3 and 4 plus 3 shots). In the case of the remaining shots, the results are also presented in the aforementioned tables. A summary of the progress rate of penetration is shown in the following plate in units of percent.

4.2. Field Performance Testing

4.2.1 General Background

Field performance testing was planned in order to evaluate the operational effectiveness and real adaptability of the proposed vehicle in the field. The main role of the testing was to evaluate the performance of the unmodified Toyota Land Cruiser 76-series vehicle fitted with the BR 7 armored body kit and the armoring addition of a B6/Amor AK 47 armor kit, in various kinds of terrains in a typical South African terrain and other terrains, including mountains, valleys, muddy terrain, rocky terrain, grassy vegetation, sparse bush, Veld with thick bush and sour grasses, areas with rocks of various sizes, sand, and track climbing. The tests lasted from 20 November 2006 to 1 December 2006 and were performed.

All the tests were performed without any prior preparation on any part of the vehicle such as tuning wheel pressures, etc. Repetitive testing of the vehicle was performed to ensure the testing results were authentic. The following tests were performed on suitable tracks and terrains selected to simulate the proposed operating environment: – Gravel road testing: Tracks with various size corners were selected to determine the handling capability of the vehicle in various cornering situations for the acceleration and braking tests. These tests have a limited top speed of the vehicle. – High-speed dirt road testing: A suitable dirt road was selected for the high-speed test to determine the vehicle handling and braking capability. Tests were performed for top speed and constant speed, and a constant speed vehicle test was applied to brake with and without the brake test. – Real off-road testing: Various tracks were selected to simulate the proposed environment to see how the vehicle reacts to body and chassis twisting. These were tested for body mount, backlash, handling testing, and wheel articulation on sand and over mountains.

5. Conclusion and Future Developments

In conclusion to the essay, it can be highlighted that the result of this work, which consists of detailed design solutions to adapt an existing SUV to increase the level of protection against small arms, fragmentation, and anti-personnel landmines, should significantly reduce the time required to adapt a commercially available vehicle to an armored vehicle suitable for developing countries with a low budget. In parallel with this study, sponsorship is necessary to develop all ballistic testing and the manufacture and assembly of the prototype to validate compliance with the standard (BR 7 = former B6 FB6).

In the scope of modifying the Toyota design, several key points were raised. For the safety of the vehicle, it is recommended that the seats be changed to energy-absorbing seats, and that steering rods from the steering gear linkage be replaced with collapsible columns and spine-type pins or hydraulic nipple cylinders should be added to the existing T-bar gear in addition. In order to have a discreet vehicle, it is recommended to change the appearance of the vehicle using various coatings such as mudguards, wheel arches, power outlet casings, etc., which also contribute to changing the packaging design and are easily fixable in the event of an explosion. It was found to be appropriate to design it with the intention of being removed and replaced with a hand.

In the 63rd-year tests, it was concluded that in the new Toyota Land Cruiser 76-series vehicle developed for both the Turkish Land Forces Command and the General Directorate of Gendarmerie, the ladder frame should be reinforced and vibration tests to be carried out due to mass increase, traction, and dynamic service braking tests were performed. As a result of the test, it was decided to be strengthened by 2 bends and 1 cross-member steel profile. The reasons for the choice of this bend and cross-profile, as well as the additional reinforcements and combinations made for the body floor and diagonal upper tank support, have been shared. Craft techniques to perform an inappropriate design approach of purchasing as a resource, the headlights horizontal and vertical vehicle direction, protection rails, ball joint luminaire connection location, basket holder, a flexible structural view of the radiators that are filtering 154-layer in special brand coolant plate and the parking brakes for the parking brakes were discussed in a detailed way based on the need for someone to participate in various automotive exam competitions to choose a college.

The design and development of the vehicle, which was developed with the main design goal of not holding outbursts and shrapnels with a low budget, consist of the study of theoretical calculations in terms of lightness and application techniques to be implemented in the vehicle. Information on vehicle safety and safety for small and medium-sized families were made in relation to the design criteria used for the vehicle, in the form of custom armoring, which will not be blind to structural elements, on the proposals to be implemented in the design and manufacturing part of the vehicle. It is also included. In connection, the future of one of the new projection devices, the gimbal system with three axes carrying the device, is not a sufficiently mature field of technology.

Toyota Land Cruiser Armored Vehicle