1. Background & Market Demand
With the rapid growth of tethered drone applications in fields such as high-rise cleaning, aerial spraying, emergency communications, and aerial lighting, customers are demanding long-duration, high-power, and highly reliable tethered UAV power systems.
Traditionally integrated tethered systems combine the ground power source and winch into a single cabinet, but this design faces bottlenecks such as:
· Limited cooling capacity
· Restricted power output
· Complicated maintenance
To overcome these challenges, Airfly Tethered (Nanjing) first proposed the split-type tethered UAV power solution in July 2022, and successfully built the first prototype. In August 2025, the concept was officially productized, bringing a new level of industrial application and market adoption.
2. Airfly Split-Type Tethered Drone Power System – Design Concept
The solution adopts an innovative split architecture, separating the traditional integrated tether box into two independent functional units:
(1) Ground Power Unit
· Converts external AC380V into DC1000/1500V high-voltage output
· Independent cooling system for stable 40–60kW power delivery
· Comprehensive protection mechanisms (over-voltage, under-voltage, over-current, short-circuit, over-temperature)
(2) Tethered Winch Unit
· Integrated intelligent winch control system with 200–300m automatic cable management
· Supports 25A high-current transmission for stable long-distance power delivery
· Functions include torque adjustment, passive pay-out, and active retraction, ensuring drone stability during hovering and landing
(3) Onboard Power Module (Model: WF-1000S60-24K)
· Mounted on the UAV, converting DC1000V high-voltage into DC60V (14S) for onboard equipment
· High efficiency ≥97%, lightweight design ≤9.5kg
· Built-in safety protection for secure flight operations
3. Key Advantages & Technological Innovations
· Cooling Performance: Independent design separates heat sources, eliminating thermal interference and enabling 40kW-class operation
· Power Transmission: 200m tether cable supports 25A current for stable 24kW continuous output
· Smart Control: Torque adjustment, automatic cable management, and tension control for enhanced UAV flight stability and safety
· System Reliability: Split units reduce cabinet complexity, improving overall system reliability and ease of maintenance
· Flexible Expansion: Supports both 1000V/1500V input and multiple output voltages (12S~24S), compatible with a wide range of drone platforms
4. System Components & Functions
Ground Power Unit
· Input: AC380V
· Output: DC1000V, max 40kW
· Features: High-efficiency conversion, independent cooling, intelligent protection
· Installation: Fixed ground deployment
Tethered Winch Unit
· Cable Length: 200m (expandable)
· Transmission Current: 25A
· Reel-in Speed: ≥2m/s
· Control: Torque adjustment + active retraction / passive pay-out
· Portable design with handles for easy transport & deployment
Onboard Power Module (WF-1000S60-24K)
· Input: DC800–1000V
· Output: DC60V / 400A, max 24kW
· Features: High efficiency, compact size, intelligent protection
· Installation: Drone-mounted
5. Application Scenarios
· High-Rise Cleaning: Building maintenance, firefighting, industrial structure cleaning
· Emergency Communication: Tethered drones carrying relay equipment to provide emergency coverage
· Scientific Research: Atmospheric monitoring, meteorological studies, payload testing (EO/IR sensors, communication pods)
· Public Safety & Disaster Relief: 24/7 surveillance, event monitoring, rescue missions
6. Technical Support & Service Guarantee
· Complete system integration solutions and customization services
· Professional technical team providing full-cycle support
· Compliance with GB, IEC, EN safety and EMC standards
· Remote diagnostics & firmware upgrades available
7. Conclusion
Through its innovative split-type tethered drone system design, Airfly has successfully overcome the bottlenecks of cooling, high-power output, and system reliability faced by traditional integrated systems.
This breakthrough enables:
· 40kW-class continuous power supply
· 200m long-distance high-current transmission
· Significantly improved system maintainability and stability
As a leading China tethered UAV supplier and power system manufacturer, Airfly provides safe, reliable, and efficient tethered drone solutions for industrial, emergency, and research applications worldwide.
Building an Air-Space Information Bridge to Empower Emergency Response and Communication Coverage
Target Customers
· Core Clients: Major mobile network operators such as China Mobile, China Unicom, and China Telecom.
· Typical End Users:
o Emergency response agencies (fire departments, police, armed police units)
o Large-scale event organizers (concerts, sports events)
o Mining and energy enterprises
o Border patrol and scientific exploration teams
Pain Points
Signal “Islands” in Critical Scenarios:
· Communication Loss in Emergencies: Natural disasters (earthquakes, floods, wildfires, etc.) or accident sites often destroy ground-based telecom infrastructure, leading to large-scale communication blackouts, severely impacting rescue coordination and disaster reporting.
· Network Congestion at Large Events: In densely populated areas during concerts or sports events, existing base stations reach capacity, resulting in poor user experience (no signal, dropped calls, slow data).
· Signal Blind Spots in Remote Areas: In regions like deserts, mines, forests, mountains, or offshore islands where no public network exists, conventional communication tools fail, making operations, monitoring, and exploration extremely difficult.
· Signal Obstruction in Complex Terrain: Mountains, urban canyons, or skyscraper clusters obstruct signals, limiting wide-area coverage.
Limitations of Traditional Solutions:
· Slow Deployment & High Costs: Emergency communication vehicles or temporary base stations rely on road access and are time-consuming to deploy; fixed base stations in remote areas are costly and time-intensive.
· Limited Coverage: Ground-based stations are restricted by height and terrain, limiting signal penetration and coverage range.
· Short Endurance: Battery-powered drones typically last High-performance droneHigh-power ground-based tethered power boxLightweight, highly integrated airborne relay module5G base stations (for all three major operators)Military HF/VHF radiosPrivate mesh radiosPolice trunking systems (TeL)Civilian Mesh networksTraditional walkie-talkie repeatersRestores communication in disaster zonesEnhances coverage at large eventsEnables connectivity in remote regionsSupports 3D surveillance networksValidated in real-world operationsEstablishes a new benchmark in emergency and telecom support solutions
Target Customers
· Core Clients:
o High-rise façade cleaning companies
o Large-scale property management groups
o Equipment maintenance departments of power and chemical plants
· Strategic Clients:
o Municipal landmark building administrators
o Bridge maintenance authorities
o Wind turbine tower cleaning service providers
Industry Pain Points
Fatal Flaws of Traditional High-Altitude Cleaning:
· Severe Safety Risks:Rope-access “spider-men” cleaning has an annual accident rate exceeding 0.8%; in 2024 alone, 584 fatalities from high-altitude falls in China.
· Inefficient and Costly:Cleaning a 300-meter skyscraper typically requires a 30-person crew over 15 days, with labor accounting for over 65% of the total cost.
· Operational Restrictions:Work halts during bad weather; complex façades (curved glass, hollow structures) are hard to reach; high-risk zones in power/chemical plants restrict manual access.
· Environmental and Social Disruptions:Scaffolding blocks traffic; chemical cleaners pollute building surfaces and surrounding environment.
Limitations of Conventional Drone Cleaning:
· Payload Flight time Water pressure
Target Clients
· Core Clients:Urban management enforcement agencies, public security bureaus, emergency response departments (fire/rescue/earthquake), traffic control authorities
· Extended Users:Maritime patrol fleets, border patrol units, industrial zone security teams, municipal facility maintenance groups
Key Pain Points
Bottlenecks of Traditional Drone Operations:
· Low Deployment Efficiency:Manual transport, assembly, and calibration cause delays in emergency response.
· Fragmented Endurance:≤30min flight time per battery; frequent battery swaps disrupt continuous missions (e.g., monitoring or lighting).
· High Operational Threshold:Reliance on professional pilots; operator exposure to risk during inclement weather.
· Poor Equipment Management:Drones stored in open conditions or subjected to vehicle vibration damage—leading to high failure rates.
Insufficient Coverage in Special Scenarios:
· Inadequate lighting for night enforcement
· Communication blind zones at disaster sites
· Visual dead zones over water bodies, mountains, or rugged terrain
Our Solution: AIRFLY Fully-Automated Tethered Drone Hangar System
A Tri-Core Smart Platform:
· High-Strength Protective Hangar: IP54-rated all-metal shell
· J3 Tethered Drone: For continuous aerial operations
· Vehicle/Marine-Mounted Integration: Deployable on land or sea platforms
Feature Module
Technical Implementation
User Value
Unmanned Operation
One-click remote control → Hangar opens → Drone auto takeoff → Auto recovery post-mission
Fully autonomous; eliminates manual risk
24/7 Continuous Ops
Direct DC24V tether power from hangar → Drone stays airborne 24/7
Solves all endurance constraints
Rapid Mobile Deployment
Vehicle/boat-mounted system → Deployed & airborne in 3 minutes
Seizes golden window in emergency response
Extreme Environment Adaptability
IP54 rated, operates from -20°C to +50°C, withstands Level 7 winds (15 m/s)
Performs reliably in rain, dust, extreme cold
Modular Payload Expansion
Built-in lighting & loudspeaker, optional relay, payload drop, gas detection, etc.
Enables multi-role missions: surveillance, comms, rescue
Breakthrough Functional Modules & Value
Proven Outcomes
Revolutionizing Urban Governance (Urban Mgmt / Police Use Case)
Mounted on law enforcement vehicle rooftops → 24/7 patrol of key zonesViolations detected → Auto-hover for video capture → Remote warning broadcast → Coordinated on-ground response✅ Results:
· Nighttime law enforcement efficiency ↑ 300%
· Labor costs ↓ 60%
Bridging the “Last Mile” in Emergency Response
Emergency response vehicles deploy drone hangar in disaster core zone within 10 minutesAirborne lighting + relay node built instantly
On-Site Capabilities:
· 50W high beam covers 5,000 m² search zone
· Loudspeaker guides survivors
· Mesh relay streams live video
✅ Results:
· During 2023 South China flood response, a single hangar system supported 72 hours of continuous comms and lighting
Setting a New Benchmark for Industrial O&M
Deployed at fixed locations in chemical plants for daily routines:
· 8 infrared inspections of hazardous tanks per day
· Gas leak detection + perimeter patrol
✅ Results:
· Replaced manual high-risk inspections
· Annual cost savings > CNY 2 million
System Reliability Validated
· 5,000+ hours of fault-free operation across environments: salt mist, high humidity, rugged terrain
· Mass deployment in 32 Chinese cities for municipal enforcement
Summary Highlights
Target Users
Emergency/government agencies, urban management, public security needing mobile & unmanned ops
Pain Points
Slow deployment, short endurance, operator burden, poor storage, limited environmental adaptability
Solution
Vehicle/boat-mounted tethered drone hangar: 3-min auto takeoff, 24h continuous ops, IP54, wind-resistant
Outcomes
300% enforcement efficiency ↑ | 72h emergency ops guaranteed | CNY 2M+ annual cost savings
Parameter
Parameter
Specification
Dimensions of J3 drone
600*600*300mm
Wheelbase between diagonal motors
735mm
Weight
2.75kg(including tethered battery)
Maximum load
3kg
Hovering accuracy
±0.1 m
RTK Location accuracy
1cm+1ppm(Horizontal)1.5cm+1ppm(Vertical)
Maximum wind speed tolerance
7级(Force 7),15m/s
UAV flight stability power
≤300W
Product dimensions
Closed:长Length 1175mm宽Width*1172mm高Height*900mm
Opened:长Length2295mm*宽Width1172mm*高Height 900mm
Product weight
100 kg
IP rating
IP54
Material
Full - metal sheet metal processing
Operating power
Standard operating conditions:≤150w
Peak operating conditions:≤350w
Power supply requirements
DC24V
Quantity of UAVs accommodated
1unit
Installation method
Roof, flat ground, car trunk, etc.
Operation mode
Fully automatic
Operation interval cycle
Continuously
Power supply methods for UAVs
Tethered power supply
Working life
≥5000 Hours