Special Tasks Company. PONAR Wadowice and Its Defence Projects [INTERVIEW]

Sponsored Article Article Partner: PONAR Wadowice S.A.

Today, PONAR Wadowice is a key supplier of components for Polish military equipment. We discuss with Mr. Dariusz Nalepa, Special Production Director at the Małopolska-based company, how the P-18PL radar was hardened against hurricane conditions, the prospects for the development of hydropneumatic suspension for the Borsuk infantry fighting vehicle, and the fruitful cooperation with PGZ.

Antoni Walkowski, Defence24: In which defense projects is PONAR Wadowice currently involved?

Dariusz Nalepa, Special Production Director at PONAR Wadowice: Regarding current defence industry projects we are implementing with Huta Stalowa Wola, they include primarily: the Krab self-propelled howitzer, the Borsuk infantry fighting vehicle, as well as the command vehicle and command-staff vehicle. We cooperate with PIT-RADWAR on most radar stations, both deployable ones and long-range units. Most radars produced in Poland operate on power hydraulics components supplied by PONAR Wadowice.

I understand that work for these projects is carried out in both PONAR plants, that is in Wadowice and in Łaziska Górne.

Exactly. We manufacture the hydraulic components and apparatus in our Wadowice plant, while the assembly of sub-assemblies and units is carried out at the branch in Łaziska Górne. In many cases, the installation of the hydraulics on the finished vehicle supplied by our customers is conducted in Łaziska Górne.

I had the pleasure of familiarizing myself with the measurement equipment you developed yourselves for defence projects, to test your products before handing them over to the end user.

Due to the strict requirements that these systems must meet, we have built test stations and purchased such measurement equipment and cabins that enable us to simulate the operation of our systems under extreme conditions.

This would not be the first instance of using your own testing equipment in your company. Moreover, PONAR also supplies such equipment to other entities.

Many institutions, after visiting our plants, have stated that they want to have this type of equipment so that they can test hydraulic, pneumatic, and electrical systems themselves.

Let’s move on to discussing specific examples. In what capacity does PONAR Wadowice participate in the P-18PL program? Which components do you supply for this project? 

The P-18PL 3D radar is a modernized version of the prototype that was developed between 2014-17 with the involvement of our components. The radar successfully passed all qualification tests. The new radar variant is somewhat different from the prototype, taking into account the experience from trials and operation. Several significant, functional changes were introduced, for example, those facilitating maintenance and servicing.

In 2024, we signed a contract for the supply and installation of hydraulic systems for the P-18PL station. The assembly will take place in Łaziska Górne on a Jelcz chassis with 10x10 drive.  

This very expensive, complicated, and yet delicate equipment is based on a massive 10x10 drive truck. What challenges does such a project pose? I assume the requirements concerning power hydraulics in such a radar are specific. 

All military products, including the P-18PL radar station, must meet defence industry standards, especially those concerning resistance to environmental factors (i.e., climate-related and mechanical). We are talking about the ability to operate in temperatures from -40 to +65º C, resistance to salt fog, atmospheric deposits such as frost or dew, dust, and mechanical impacts. These aspects must be thoroughly tested to ensure that our products meet these often very strict requirements.

One of the bigger challenges was that the P-18PL, when deployed and operating, must withstand a storm wind pressure of 110 km/h. When the deployed radar is not operating, this requirement increases to 180 km/h. Additionally, it is required to level it on uneven terrain with an accuracy of 3º on the longitudinal axis and 4º on the transverse axis of the vehicle. Proper leveling of such a large object, while ensuring it withstands powerful forces, was a huge challenge for us. We encountered this when designing the systems for both the prototype and the series produced units.

So, the P-18PL radar is capable of withstanding a hurricane, among other things, thanks to your components. 

All our activities aimed at preparing the equipment for operation under such extreme conditions were carried out with significant assistance from the radar manufacturer, that is, PIT-RADWAR, more specifically, the designers from that plant.

So, one could say that the P-18PL is the culmination of many years of development by PONAR Wadowice in the area of power hydraulics for mobile radars.

We gathered experience from various radars, including the P-18PL prototype. The final results will be revealed in the coming years. As I mentioned, in 2024 we signed a contract for the delivery of this equipment. 

Will PONAR Wadowice expand its range of products and services for this segment of military equipment in the coming years?

Yes indeed! Exactly. Our systems are used in the Soła radar stations, the deployable Bystra radar station (the successor of Soła), in which our hydraulic systems are assembled in the Łaziska Górne plant, as well as in the long-range Warta radars. Of course, we are ready to meet the requirements set by our customers and hope to develop in this sector.

Since you are developing, I must ask about the hydropneumatic suspension modules. The WHP35 modules were developed for the NBPWP Borsuk. Do you plan further development of these solutions and expansion of the catalogue? 

We are continuously working on improving and extending the service life of hydropneumatic control arms, as well as increasing their resistance to environmental factors. This work is ongoing. We gather feedback and experience because this product evolves. Every product, even one already implemented, must continuously develop. In this regard, we are working on that control arm, as well as developing semi-active and active systems for these modules.

Once I asked you about the most challenging aspect of developing semi-active and active systems. You replied that the biggest obstacle is the control system.

Yes, the biggest problem appears to be the method of controlling the suspension module. Unlike the passive version, where each control arm is an independent unit, in active suspensions all twelve control arms must be controlled simultaneously (the BWP Borsuk has six pairs of road wheels and twelve WHP35 control arms – ed.). This is a very challenging task. There are such solutions in the world (for tracked vehicles – ed.), but the specifics of their operation and technical-dynamic parameters remain shrouded in mystery.  

Can the WHP35 module used in the Borsuk be reinforced so that the IFV can support additional armor?

We are working on it. From the very beginning of the conceptual work, we were aware that there might be a need to build a control arm with unchanged external dimensions but capable of operating in a vehicle of higher mass than originally assumed. Such a version of the hydropneumatic control arm is also under consideration. I believe that we are capable of designing, producing, testing, and implementing such a module in cooperation with our customers.  

May I ask, purely hypothetically in the context of the Heavy Infantry Fighting Vehicle – is it possible that PONAR Wadowice could develop a system that, in terms of dimensions and mass, corresponds to that of the Borsuk, while at the same time having a load capacity similar to the modules from the Krab?

There are many ways to approach this. One could consider increasing the number of control arms from 6 to 7 per side of the vehicle, as well as introducing minor changes in the internal construction of the control arm. The mass of such a module may be slightly higher. It should be taken into account that the Heavy Infantry Fighting Vehicle will not be amphibious. In that case, the focus will be on ballistic protection as well as mine protection.   

I had the pleasure of speaking with Vice President Rafał Worek about hydropneumatic suspensions for wheeled vehicles, even for heavy-duty Jelcz trucks. Are you conducting such work?

As the president mentioned, for some time now we have been conducting conceptual work to create a hydropneumatic suspension for wheeled vehicles. This project has been initiated, and we are at the stage of building a prototype system designed for heavy vehicles. We are also developing test stations that will allow the prototype to be evaluated under semi-laboratory conditions and implemented on the chassis of a truck, not necessarily a Jelcz. We have employed vibration dampers and hydraulic shock absorbers, which will enable the stabilization of a heavy wheeled vehicle on curves, modification of ground clearance, as well as the transportation of heavy loads both in the vehicle’s cargo space and on a tow or trailer. Of course, this will improve driving comfort, safety, and off-road capability.

So, you are essentially transplanting the characteristics of a classic Citroën suspension – which, on a bumpy road, moves like a flying carpet – into a military vehicle weighing several tens of tonnes.

In a broad sense, that is one way to describe it. The experiences we have gained while designing hydropneumatic control arms for tracked vehicles, particularly regarding damping theory, are also being utilized in the project for modules for wheeled vehicles.  

There are really many modernization programs in the Polish Army. Could you perhaps reveal a little bit about which ones PONAR Wadowice is participating in?

We are involved in many projects. We operate in the programs for short and medium-range air defense, namely Narwew and Wisła. The aforementioned P-18PL radar will support both of these systems. We are involved in the artillery modernization program, of course supplying components for the Krab, as well as suspension for the WD and WDSz (WHP25 modules – ed.), which in the Squadron-level Fire Modules accompany both the Krab and K9 howitzers. Of course, we are also active in the Borsuk program.  

Naturally, we want to join as many modernization programs as possible. We have the capabilities, knowledge, and an excellent team of engineers. We are ready to take on the toughest tasks. With the help of our partners, mainly the plants of the Polish Armaments Group, which provide us with significant support, we are capable of taking on any challenge.  

Sponsored Article Article Partner: PONAR Wadowice S.A.