Technical Insight for Covert, High-Mass Vehicle Applications
The optimal brake system design varies significantly depending on vehicle type and operational requirements. For Civilian Armoured Vehicles (CAVs), braking systems must address a unique combination of increased mass, security considerations, and real-world operational risks.
This requires a fundamentally different engineering approach compared to standard passenger or performance vehicles.
Civilian armoured vehicles are typically based on production SUVs or passenger vehicles that have been significantly modified through the addition of ballistic protection.
These modifications introduce:
– Increased vehicle mass
– Altered weight distribution
– Higher braking torque requirements
– Security and covert operation considerations
As a result, brake system design must prioritise strength, reliability, and discretion over purely performance-driven characteristics.
Key Considerations
– Vehicles are often required to remain visually indistinguishable from standard models
– Visible performance components may compromise security
– Brake systems must avoid drawing attention
Design Approach
– Calipers should closely resemble OE components
– Zinc-plated finishes preferred over painted or branded designs
In civilian armoured applications, visual discretion is a security requirement—not a styling preference. Brake components must not reveal that a vehicle is armoured.
Key Considerations
– Vehicles may be exposed to deliberate tampering
– External brake components can be easily accessed
Design Risks
– External bridge pipes can be loosened or damaged
– Outboard bleed screws are vulnerable to interference
– Open wheel designs increase exposure
Design Approach
– Eliminate external bridge pipes
– Use internal fluid transfer within the caliper
– Position bleed screws on the inboard side only
Brake system security is critical. Poorly designed external features can be intentionally compromised, leading to brake failure.
Aluminium
– Lower weight
– Reduced stiffness under high loads
– More susceptible to fatigue in high-temperature environments
Cast Iron (SG Iron)
– Higher strength and stiffness
– Better suited to high torque and pressure
– Improved fatigue life, particularly at elevated temperatures
Design Considerations
– Installation space is often limited due to wheel and tyre constraints
– Armoured vehicles generate significantly higher brake loads than standard vehicles
For armoured vehicles, stiffness and durability are more critical than weight. Cast iron calipers provide superior performance within constrained packaging envelopes.
Opposed Piston Calipers
– Higher structural stiffness
– More even load distribution across pads
– Preferred for armoured brake upgrades
Single-Sided (Sliding) Calipers
– Simpler design
– Less suitable for high-load applications
Two-Piece vs Monobloc
– Two-piece calipers offer increased stiffness through high-tensile bridge bolts
– Monobloc designs may be lighter but less rigid in high-load scenarios
In high-mass applications, caliper stiffness is a primary performance driver. Two-piece opposed piston designs provide the structural integrity required for armoured vehicles.
Iron Calipers
– May show surface rust over time
– Internal components remain protected and functional
Aluminium Calipers
– More susceptible to corrosion-related degradation
– Risk of galvanic corrosion due to mixed materials
Surface appearance does not reflect performance. Iron calipers often provide superior long-term reliability in real-world operating environments.
Iron Calipers
– Lower material and manufacturing cost
– More cost-effective for large-scale or fleet applications
Aluminium Calipers
– Higher cost due to material and production complexity
For civilian armoured vehicles, cost must be balanced with durability and performance. Iron calipers provide a robust and economical solution.
Brake system design for civilian armoured vehicles is driven by:
– Increased vehicle mass and braking loads
– Need for covert operation
– Resistance to tampering and environmental damage
– Long-term durability and serviceability
This results in a clear engineering preference for:
– Cast iron caliper housings
– Opposed piston designs
– Internalised, tamper-resistant configurations
– OE-style appearance for discretion
MSW Engineering Perspective
At MSW, brake systems for civilian armoured vehicles are engineered with a clear focus on real-world operational requirements, not automotive trends.
Key principles include:
– Security-first design to prevent tampering and maintain covert capability
– High-stiffness caliper structures to manage increased braking loads
– Material selection based on durability, not weight alone
– Application-specific solutions tailored to each vehicle configuration
This approach ensures:
– Maximum safety under extreme loads
– Reliable performance in demanding environments
– Long-term operational integrity