Tethered Drone Power Supply Cable Requirements

2025-11-08 09:28:31

　　The Tethered Drone Power Supply cable is one of the critical components of a Tethered Drone system, enabling the drone to stay in the air for extended periods by providing a continuous power source from the ground. The cable also typically carries data signals, depending on the system’s configuration, such as live video feeds, telemetry data, or communication signals.

　　The requirements for the tethered Drone Power Supply cable depend on several factors, including the power needs of the drone, the type of mission, the environment, and the distance/altitude the drone is expected to operate at. Here's a detailed breakdown of the key requirements for the tethered drone power supply cable:

　　1. Power Transmission Capability

　　The primary function of the tether cable is to transmit power from the ground station to the drone. The power requirements depend on the type of drone, its payload, and the mission.

　　Voltage and Current Requirements:The cable must be able to handle the drone’s voltage (e.g., 12V, 24V, 48V, or higher) and the current required by the drone’s motors, sensors, and communication systems. For drones with heavy payloads or high-performance requirements (e.g., industrial, surveillance, telecom), the power demands can be substantial.

　　For light-to-medium drones, typical power requirements might range from 300W to 1kW.For larger or industrial drones, power demands could be much higher, ranging from 2kW to 10kW or more, depending on the payload and power usage.

　　Cable Gauge:The gauge of the wire (thickness of the cable) is a critical factor in power transmission. Higher current demands require thicker wires to prevent overheating, voltage drops, and signal degradation.

　　For high power demands, cables may use AWG 12 - AWG 8 for transmitting higher currents.For lower power requirements, AWG 18 - AWG 12 may suffice.

　　2. Data Transmission

　　In addition to power, the tether cable often carries data signals such as video feeds, telemetry, or communication signals. This is especially important for drones used in telecommunications, aerial surveillance, or environmental monitoring.

　　Fiber Optic Cables:If high-bandwidth communication (e.g., HD video streaming, real-time data) is required, fiber optic cables are commonly integrated into the tether. Fiber optics allow high-speed data transmission over long distances with minimal signal loss and interference.

　　Fiber optic cables are particularly useful for high-data-rate communication, such as live video from cameras or sensors mounted on the drone.Single-mode fiber (for long-distance transmission) or multi-mode fiber (for shorter distances and higher bandwidth) can be used depending on the application.

　　Copper Wire (Coaxial, Twisted-Pair):For lower-bandwidth needs, coaxial cables or twisted-pair copper cables can carry data signals. These are typically more affordable but can have limitations in range and data speed.

　　3. Weight Considerations

　　The cable should be lightweight but strong enough to handle the mechanical stress of being suspended from the drone. The heavier the tether, the more it will affect the drone’s flight characteristics, including stability and maneuverability.

　　Cable Weight:Lightweight cables are preferred for most applications to reduce the drag on the drone and minimize the power needed to lift the tether.

　　Cables for typical drone applications can weigh around 1 to 4 kg per 100 meters of cable.The length and weight of the cable will also affect the drone’s ability to fly at high altitudes or distances.

　　Strength and Durability:The cable must be durable and resistant to wear and tear. For aerial systems, the cable will be exposed to wind, sun, rain, and potential abrasion. High-strength materials such as Kevlar, aramid fibers, or carbon fibers are often used to reinforce the tether cable, making it resistant to breaking or fraying under tension.

　　4. Environmental Protection

　　The tether cable must be weatherproof and able to function in harsh environmental conditions. Drones are often deployed in outdoor settings, where they may face extreme weather conditions such as high winds, rain, snow, or even saltwater exposure (in maritime operations).

　　Waterproofing:The cable must be water-resistant to prevent damage from rain, humidity, or even submersion. Waterproofing is achieved through coatings or jackets made from polyurethane, PVC, or rubber.

　　UV Resistance:Cables used for outdoor applications need to be UV-resistant to avoid degradation from prolonged sun exposure.

　　Temperature Resistance:Depending on the operating environment, the cable should be capable of withstanding temperature extremes, from -40°C to 80°C or more.

　　Low-temperature flexibility: In cold climates, cables must remain flexible to prevent cracking and damage.

　　5. Mechanical Strength & Flexibility

　　Tensile Strength:The cable must be strong enough to support its own weight, along with any additional stress from wind or movement. The tensile strength should be high enough to prevent snapping or stretching under load. Kevlar or other high-strength fibers are often used to reinforce the cable.

　　Flexibility:The cable must also be flexible enough to withstand dynamic movement without breaking or kinking. This is especially important for drones that require mobility and for cables that will be reeled in and out frequently.

　　Flex Life:Cables used in tethered drone applications need to have a high flex life, meaning they must be able to bend and twist repeatedly without degrading. This is particularly critical when the tether is reeled in and out, and the drone moves in various directions.

　　6. Length of the Cable

　　The length of the tether will determine how far the drone can fly, as well as how much power it can draw from the ground station.

　　Standard Lengths:Typical tether lengths for most commercial drones range from 50 meters to 200 meters, though some specialized systems may require cables as long as 500 meters or more.

　　Voltage Drop:For longer tether cables, voltage drop can become an issue. The longer the tether, the more resistance it introduces, which can result in less power being delivered to the drone. To minimize voltage drop, higher voltage systems (e.g., 48V or 72V) are often used, as they can maintain a more consistent voltage over longer distances.

　　7. Reeling and Deployment Mechanism

　　Most tethered drone systems come with a reel or winch system to manage the tether cable. This is important to ensure the cable is deployed smoothly and efficiently while avoiding tangles or damage.

　　Automatic Reel Mechanism:High-quality systems often have motorized reels that can deploy or retract the cable automatically. This helps in managing the tether efficiently while maintaining the drone’s stability and minimizing manual labor.

　　Cable Storage and Protection:The reel or storage system should be able to protect the cable from kinking or unnecessary wear, which can affect its performance.

　　8. Safety Features

　　Breakaway Mechanism:Some tethered systems include a breakaway mechanism that allows the tether to detach automatically in case of an emergency (e.g., if the drone is at risk of crashing or the cable is under excessive strain).

　　Overload Protection:Cables can include overload protection features to ensure they don't overheat or fail if the drone’s power needs exceed what the tether can provide. This might include fuses or circuit breakers integrated into the power delivery system.

　　Conclusion

　　The tethered drone power supply cable is a critical component for ensuring the success of tethered drone operations, particularly for applications like telecommunications, surveillance, and infrastructure inspection. By balancing the need for power, data transmission, flexibility, and durability, the right cable design can enable efficient, long-duration drone flights while minimizing risks of failure or performance degradation.