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Specifications and performance parameters of unmanned aerial vehicle cables

Jun. 17, 2025

Conductor materials and structures


The conductor material and structure of unmanned aerial vehicle (UAV) cables are the key factors determining their electrical and mechanical properties. Based on existing research and industry standards, the following are the common materials and structures of drone cable conductors:


1-1. Conductor materials:


The conductors of unmanned aerial vehicle cables are usually copper-clad aluminum wires, oxygen-free copper wires or tin-plated copper wires. These materials not only have good electrical conductivity, but also possess high corrosion resistance and wear resistance. For instance, copper-clad aluminum wire is widely used in unmanned aerial vehicle cables due to its light weight and high strength, while oxygen-free copper wire is preferred because of its superior electrical conductivity.


1-2. Conductor structure:


The conductor structure of unmanned aerial vehicle cables usually adopts the method of twisting multiple strands of fine wires to enhance the flexibility and tensile strength of the cables. The multi-strand twisted structure can also reduce the risk of damage to the cable when it is repeatedly bent and twisted, and extend the service life of the cable.


1-3. Cross-sectional area:


The cross-sectional area of the conductor directly affects the current-carrying capacity of the cable. The cross-sectional area of the drone cable is usually determined based on the power requirements and flight time of the drone. A larger cross-sectional area can reduce resistance and improve the power transmission efficiency of the cable.


2. Insulating Materials and Properties


The selection of insulating materials is crucial for ensuring the safety and reliability of unmanned aerial vehicle cables. The following are the commonly used insulating materials for drone cables and their performance parameters:


2-1. Polyethylene (PE) :


As a common insulating material, PE is widely used due to its excellent electrical insulation performance, chemical stability and good wear resistance. Its operating temperature range is wide, which can adapt to the application requirements of unmanned aerial vehicles in different environments.


2-2. Polyetheretherketone (PEEK) :


PEEK is a high-performance engineering plastic with outstanding chemical and heat resistance, making it suitable for more demanding application scenarios. The operating temperature of PEEK can reach up to 200℃, making it suitable for unmanned aerial vehicle cables in high-temperature environments.


2-3. Withstand voltage performance:


The insulating material of the drone cable must be capable of withstanding high voltage to prevent electrical breakdown and leakage. The withstand voltage performance is usually measured by the breakdown voltage. The breakdown voltage of the drone cable should be more than twice its working voltage.


3. Shielding and sheath materials


Shielding and sheath materials play a significant role in protecting the cables of unmanned aerial vehicles from the influence of the external environment and electromagnetic interference. The following are the commonly used shielding and sheathing materials for drone cables:


3-1. Braided shielding layer:


The cables of unmanned aerial vehicles usually adopt metal braided materials as the shielding layer to effectively shield against external electromagnetic interference. The coverage rate and weaving Angle of the braided shielding layer have a direct impact on the shielding effect. High coverage and optimized weaving angles can provide better shielding effects.


3-2. Outer sheath material:


The outer sheath materials are usually made of PE or PUR, etc. These materials have excellent wear resistance, oil resistance and chemical resistance, and can protect the cable in various harsh environments. The hardness and thickness of the outer sheath will also affect the mechanical protection performance of the cable.


3-3. Wear resistance:


The cable of the unmanned aerial vehicle will rub against the ground or other objects during the winding and unwinding process. Therefore, the outer sheath material must have excellent wear resistance. The wear resistance can be evaluated through wear resistance tests. The outer sheath material of the unmanned aerial vehicle cable should be capable of withstanding high-intensity wear.


The model specifications and performance parameters of unmanned aerial vehicle (UAV) cables need to comprehensively consider multiple aspects such as conductor materials and structures, insulating materials and performance, as well as shielding and sheath materials, to ensure the safe, stable and efficient operation of UAVs.


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