ENGINEERING BOUNTY: Anti-Fiber Drone Cutwire System

Bounty Amount: 10,000 UAH
Status: OPEN
Organization: Kaizen Labs / Kaizen Apps
Location: Kaizen Labs facility (bench test), Field deployment (Ukraine)
Project Origin: Winner from Kaizen Anti-Drone Hackathon, Lviv

WHY THIS MATTERS

The Prince Vandal and similar fiber optic FPV drones represent a significant threat to Ukrainian defense positions. Traditional electronic countermeasures (jamming) are ineffective against wired drones.

This mechanical interdiction system exploits the fundamental vulnerability of fiber optic drones—their physical tether. It requires:

• No sophisticated electronics (simple 12V motor)
• No consumables (unlike ammunition-based systems)
• Minimal power (solar-powered capability)
• Field-maintainable with basic tools

One installation can protect 500m of perimeter 24/7. Combined with Kaizen’s acoustic detection network, this creates a complete detect-to-engage capability against fiber FPV threats.

Your mechanical design work directly contributes to Ukrainian defense technology.

MISSION OBJECTIVE

Design, build, and field-test a rotating cutting wire defense system to physically sever fiber optic cables of Russian FPV drones (Prince Vandal class). System must be deployable in pole-to-pole, tree-to-pole, and tree-to-tree configurations for rapid perimeter defense.

Focus: Mechanical system only. All networking, control systems, and integration with Drone Sentinel will be handled internally by Kaizen Labs.

TARGET THREAT

Primary Target: Fiber optic FPV drones (Prince Vandal, similar models)

• Trailing fiber optic communication cable
• Low-altitude approach (0.5-5m above ground)
• Terminal dive attack profile
• Cable is primary vulnerability

Engagement Concept: Rotating cutting wire severs fiber optic tether, disabling drone control and causing crash/abort.

SYSTEM REQUIREMENTS

Performance Specifications

Deployment Scale:

• Bench test: 50-75m span
• Production deployment: 500m continuous run
• Engagement altitude: 0.5-1.5m above ground (accounting for wire sag)
• Wire speed: 1.0-2.0 m/s linear velocity
• Operational uptime: >95% over 30-day period

Environmental:

• Operating temperature: -20°C to +40°C (Ukrainian climate)
• Weather: All-weather operation (rain, snow, wind up to 60 km/h)
• Power: 12V DC input (battery/solar provided by Kaizen)
• Runtime: 24/7 operation capability

Reliability:

• Wire lifespan: >400 hours continuous operation
• MTBF (Mean Time Between Failures): >200 hours
• Field-maintainable with basic tools

SYSTEM ARCHITECTURE

Configuration (Triangulated Wire Loop)

[ANCHOR POINT 1] ←──── wire ────→ [ANCHOR POINT 3]
     (solid)                           (solid)
        ↓                                 ↓
        └──→ [MOTOR/SWIVEL] ──────────────┘
                  ↓
            [TENSIONER/HOIST]
                  ↓
         [Power Input - 12V DC]

Three-Point Design:

1. Top Anchor Points (solid, triangulated): U-loop tree mounts or pole-mounted eye bolts
2. Motor/Swivel Point: Rotating arm assembly drives wire around perimeter
3. Bottom Tensioner: Manual hoist maintains 50 kg wire tension

Wire Path: Continuous loop from Anchor 1 → Motor swivel → Anchor 3 → Down to hoist → Back to motor base

TECHNICAL SPECIFICATIONS

1. Motor & Gearbox Assembly

Motor (provided from parts list):

• Model: NeveRest Orbital 20 (am-2971a) OR equivalent from AndyMark FTC catalog
• Voltage: 12V DC
• No-load RPM: 340
• Stall current: 11.5A
• Continuous current: 2-4A

Gearbox (provided from parts list):

• Source: https://andymark.com/collections/motors-and-gearboxes-for-ftc
• Ratio: 12:1 integrated OR AndyMark Sport Gearbox
• Output: 28.3 RPM final
• Output shaft: 1/2″ hex or 14mm round
• Torque: 2.04 N⋅m minimum at output

Mounting Requirements:

• Motor/gearbox bolted to steel mounting plate
• Plate designed to attach to pole at 2-2.5m height
• Weatherproof if possible (motor housing)
• Accessible mounting hardware for field installation

Power Interface:

• Input: 12V DC via terminal block or Anderson PowerPole connector
• Wiring: Provide 12″ wire leads from motor (10 AWG minimum)
• Note: Kaizen will handle all control electronics, emergency stop, and power distribution

2. Rotating Arm Assembly

Arm Construction:

• Material: 25mm × 25mm steel square tube OR 1″ aluminum box section
• Length: 400mm from shaft center to wire guide roller
• Mount: Hub adapter for gearbox output shaft (1/2″ hex bore)
• Balance: Counterweight opposite wire guide (reduces bearing load, extends motor life)

Wire Guide Roller:

• Diameter: 50mm
• Type: V-groove pulley with sealed bearings
• Material: Steel or aluminum (corrosion-resistant)
• Mounting: Through-bolt at arm end, free-spinning
• Function: Guides moving wire with minimal friction

Calculated Performance:

• Arm radius: 400mm
• Gearbox output: 28.3 RPM
• Wire speed: 1.19 m/s ✓ (meets 1-2 m/s requirement)

Safety Features:

• Protective shroud/guard around rotating arm (recommended)
• Clear rotation zone (no obstructions within 500mm radius)
• Balance arm to minimize vibration

3. Cutting Wire (Provided for Bench Test)

Wire Specification:

• Type: 1.8mm diameter braided stainless steel cable
• Construction: 7×19 strand (flexible, cut-resistant)
• Breaking strength: 270 kg minimum
• Surface: Bare steel (uncoated) for maximum cutting action
• Length provided:
  • Bench test: 100-150m
  • Production deployment: 1000m (1 km) spool

Wire Terminations (required at 4 points):

• Method 1: Thimble + 3× wire rope clips per connection point
• Method 2: Swage ferrules (if hydraulic swage tool available)
• Attach to shackles at anchor points and hoist
• Critical: All terminations must be rated >270 kg breaking strength

4. Anchor Points (Tree or Pole Mounts)

Option A: U-Loop Tree Mount (for tree deployments)

U-Loop Fabrication:

• Material: 10-12mm steel rod or rebar
• Length: Custom-sized per tree diameter (typically 1.0-1.5m rod)
• Shape: Bent to U-shape, wraps around tree trunk
• Threading: Both ends threaded M10 or M12, 70mm thread length minimum
• Bend radius: 150-200mm at apex (forms the U)

Backing Plate:

• Dimensions: 200mm × 150mm × 6mm steel plate
• Holes: 2× holes for U-loop legs (10-12mm diameter)
• Hole spacing: Match U-loop leg spacing (varies by tree diameter)
• Finish: Painted or galvanized (rust prevention)
• Function: Distributes clamping load across tree bark

Tree Protection:

• Material: 10mm rubber padding (conveyor belt or horse stall mat)
• Size: 250mm × 200mm
• Placement: Between U-loop and tree bark
• Function: Prevents girdling and bark damage

Hardware per U-Loop:

• 4× nuts (M10 or M12, matching U-loop threads)
• 4× flat washers (30mm OD minimum)
• 2× lock washers or nylock nuts (anti-vibration)
• Torque specification: 40-50 N⋅m

Wire Connection:

• Shackle: 12mm screw-pin shackle (1000 kg WLL minimum)
• Attachment: Wraps around U-loop apex OR through hole in backing plate center
• Optional: Swivel shackle (prevents wire twist accumulation)

Option B: Pole-Mounted Eye Bolt (for pole deployments)

Eye Bolt Specification:

• Size: M16 or 5/8″ diameter
• Thread length: 100mm minimum
• Eye: 25mm minimum ID (fits shackle)
• Rated load: 1000 kg minimum (WLL)
• Material: Galvanized or stainless steel

Mounting Options:

1. Through-bolt: Drill pole, insert eye bolt, add backing plate inside, torque to 80-100 N⋅m
2. Welded: Weld eye bolt base plate directly to pole exterior (strongest)

Backing Plate (if through-bolted):

• 150mm × 100mm × 6mm steel plate
• Placed inside pole
• Distributes load across pole wall

5. Manual Hoist Tensioning System (Provided)

Hoist Specification:

• Type: Lever hoist (come-along style) OR hand-crank winch
• Capacity: 1-ton (1000 kg) working load limit
• Travel: 500mm minimum stroke
• Brake: Automatic load-holding (no drift under tension)
• Mount location: Base of pole, accessible from ground level

Recommended Models:

• CM Series 602 lever hoist (1-ton)
• Coffing LSB-style lever hoist (1-ton)
• Equivalent industrial-grade lever hoist

TIMELINE

Delivery: 2 weeks from acceptance date

Suggested Milestones:

• Week 1: Component sourcing, U-loop/arm fabrication
• Week 2: Assembly, initial motor testing, bench test installation (50m span), endurance testing, cutting demonstrations, video documentation, technical documentation completion, and final review

Total Duration: 2 weeks from start to bounty completion

Scope Note: Bounty details are flexible and open to adjustment. The core device represents the final deliverable. The system must be operational for 50-meter spans (requiring 100m of cutting wire total) – this serves as a 10% scale prototype. The same components will be used for the full-scale 500-meter version or whatever final length is determined for field deployment. Primary deployment will be between two trees, though a sturdy pole can serve as an alternative mounting point.

Document Version: 1.0
Last Updated: October 28, 2025
Bounty Status: OPEN
Focus: Mechanical system only (networking/controls handled by Kaizen)