Student proof of concept with Kongsberg Defence & Aerospace
Modular counter-UAV station with AI-based detection, real-time tracking, and non-lethal engagement.
Tags: Counter UAV MOSA Autonomous Systems Mechanical Engineering
- Role: Mechanical Engineer – Design & Integration
- Team: 7 students (mechanical, electronics, software)
- Duration: ~11 weeks
- TRL Level: Early lab demonstrator (approx. TRL 4–5)
- Status / Next / Learning: Working lab prototype → Hardening & field-like trials → CAD, multidisciplinary teamwork, prototyping
- Current status: Integrated laboratory prototype where detection, tracking, and engagement run end-to-end on the same platform.
- What we have learned: The MOSA architecture with four domains (Power, Mission, Actuation, Gunhouse) works in practice and supports parallel development and upgrades.
- TRL assessment: Functioning lab prototype with hardware and software integrated; concept proven in a controlled but relevant environment (TRL 4–5).
- What happens next: Harden the system (mechanics, electronics, software), introduce sensor fusion and CAN-based system bus, and move toward structured testing in more realistic environments (toward TRL 5–6).
Iron Iris responds to the need for flexible systems that can detect, track, and neutralize unauthorized drones in civilian and defense environments. The station is a compact, Euro pallet-sized turret integrating sensing, computation, and actuation in a modular platform.
The prototype is a technology demonstrator, not an operational weapon system. The focus is on validating the system architecture, control pipeline, and MOSA principles as a step toward higher TRL in future iterations.
- Electronics Integration: Custom mounting solutions for internal electronics (Jetson, Arduinos, DC-DC), improving space utilization, weight balance, and overall system layout.
- Structural Rigidity: Motor mount implemented as a load-bearing element; lid designed for tension-loading to increase torsional stiffness and pointing accuracy.
- Sensor Module Optimization: Generative design reduced the sensor holder’s mass and static torque; counterweight system added for rotational stability.
- Turret Platform Design: Rotational platform with chamfered-edge profile for efficient cable routing and functional alignment.
- Interface & Payload Optimization: Defined all mounting interfaces and optimized internal layout for sensor module and electronics suite.
- Cooperation: Contributed directly to building the base, including assembly of the Bosch Rexroth frame and installation of the main bearing-holder assembly.
| Power System | Mission System (Jetson) |
|---|---|
| Provides 24 V DC power for electronics and motors | NVIDIA Jetson Orin AGX (Ubuntu/JetPack) with YOLO-based drone detection, OpenCV video pipeline, and manual/semi-autonomous control modes |
| Actuation | Gunhouse |
|---|---|
| Pan/tilt turret on Bosch Rexroth T-slot aluminum frame, Euro pallet footprint (1200 × 800 mm), continuous 360° rotation via multi-circuit slip ring | Non-lethal engagement using low-impact projectiles or 450 nm laser concept to disrupt drone vision; prototype level demonstration |
Key System Details:
- Mission System: Jetson Orin AGX for real-time drone detection and tracking, manual and semi-autonomous operation modes.
- Sensing & Tracking: 4K RGB camera as primary sensor; prepared for LiDAR/acoustic modules; range 2–100 m, sub-degree angular accuracy, ~1 s response time.
- Actuation & Structure: Pan/tilt turret integrated into a modular frame; high torsional stiffness and stable rotation.
- Power & Control: 24 V DC with separate PSUs for compute and motors; clear separation of high-power and sensitive electronics.
- Engagement Concept: Prototype system uses non-lethal methods to disable or disrupt UAVs safely.
- Concept Development: Sketched multiple frame and pan architectures; down-selected using manufacturability, stiffness, and modularity criteria.
- CAD & Simulation: 3D models for interference checks, mounting patterns, and cable routing; basic hand calculations for torque and deflection.
- Prototype Manufacturing: Saw-cut profiles, 3D-printed brackets, and laser-cut plates accelerated iteration.
- Assembly Trials: Incremental builds verified fit, alignment, and service access before electronics integration.
- Design for Upgrade: Standardized hole patterns and spare mounting faces enable future actuators, covers, and high-data-rate slip rings.