Expertise Called on for MoD Upgrade

02 May 2008

Working for BAE Systems, Airchannels’ knowledge and assistance was called upon when the airend on the Army’s Challenger 2 Tank support vehicle became obsolete and they needed a rethink of the design and tolerances required. 

The British Challenger 2 is the main battle tank currently in service with the Army, during operations it must be able to move rapidly through minefields, cross barriers and overcome natural dry and wet obstacles.  

The Challenger Armoured Repair and Recovery Vehicle (CRARRV) is a highly evolved armoured vehicle designed to recover and repair damaged tanks. Based on Challenger components, the CRARRV carries a crew of three plus two Royal Electrical and Mechanical Engineers (REME) fitters in a separate compartment. 

Inside CRARRV a small airend, running off hydraulics, powers the airtools and ratchet drills needed to keep the tanks mobile. As part of upgrade program BAE Systems went to Airchannel subsidiary Woodside Pneumatics. 

As the airend was originally put on early 1980’s, there was no chance of getting a like for like replacement, so Airchannel had to design a completely new one. This took one and a half years to create from old drawings, and was cast by Hydrovane who got the new castings manufactured using original drawings.  BAE Systems had to correct the design of all the compressors fabricated mounting feet in order to install the new compressor. 

The air end is the heart of every rotary vane compressor package. Rebuilding the 'heart' is a precision job, requiring workmanship to work to specified tolerances, this requires expertise and the correct tools. Engineering skills were critical as the airend had to fit into the same space, with the same bolt holes, studding and drives as the old model. 

The low noise operation of the Hydrovane airend means that they can be installed right alongside original equipment. Most models are available either as open units or fitted with enclosure panels which further reduce noise levels. 

Once completed, the new model was retrofitted onto CRARRV. The validation fit was carried out at Newcastle, the remainder of the work was carried out by offsite retrofit activity.     

Note: A ‘Type 58’ tank Challenger 2 Regiment has 5 x CRARRV, one with each Sabre squadron and one with the REME Light Aid Detachment (LAD). The vehicle is fitted with two winches (main and auxiliary) plus an Atlas hydraulically operated crane capable of lifting a complete Challenger 2 powerpack. The front dozer blade can be used as a stabiliser blade for the crane or as a simple earth anchor.