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.