• • • CABLING & CABLE MANAGEMENT • • • Cabling Considerations
in UAV Design Unmanned aerial vehicles (UAVs) can be found almost anywhere these days, having had a huge impact in a number of sectors, from agriculture to logistics and engineering to military and defence
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mprovements to UAV capabilities over the last decade have opened a wide range of doors. Today’s UAVs offer longer flight times and are capable of flying faster at higher altitudes. On top of this, they often boast additional technologies such as high-resolution sensors and imaging, providing greater autonomy and efficiency than ever before. Accommodating these technological enhancements, while retaining the lightweight manoeuvrability, durability and payload capacity expected of the modern UAV, has presented new challenges, which today’s manufacturers are tackling with relish. We spoke to Gavin Darling, Sales and Marketing Director at GTK UK Ltd, a UK-based manufacturer of cable assemblies, to find out more about the processes, design considerations and testing regimes in place when designing and manufacturing cables for use in UAVs.
What are the primary
considerations when designing cables for UAVs, and how might these differ from designing cabling for other aerospace applications?
One of the foremost concerns when working on cables for UAVs is weight. We typically need to keep the vehicle as light as possible, as excess weight will directly impact the vehicle’s flight, range and payload capacity. Additionally, there is often a need to mix power and signal cables alongside the same cable loom and often into a mixed layout connector. This differs from other aerospace systems, where weight is likely to be less critical. In many cases, these other systems will use heavier cables due to needing a larger power source and higher payload capabilities.
How do you address weight reduction in cable assemblies without compromising
performance? To reduce weight without compromising on quality standards, we’ll look to simplify the cable assemblies’ design wherever possible. Using fewer joints or splices typically means improved reliability, durability and the ability to accommodate longer cable lengths without requiring mid-production joints.
Minimising wire sizes also helps reduce weight.
We aim to keep these as small as possible without impacting the performance of individual wires in
the cable assembly. Similarly, using lightweight insulation, such as PVC (Polyvinyl Chloride) or PE (Polyethylene), rather than rubber, can keep overall weight to a minimum.
In most applications within a UAV build, we use shielded cables to reduce noise and crosstalk. However, for certain cables, noise reduction isn’t a critical concern. In this instance, we’d use twisted pair wires rather than shielded cables, to further reduce the UAV’s weight.
How do you ensure minimal signal loss and interference in
high-frequency UAV systems? Much of this is down to the design of the unit, which is typically dictated by the customer or design authority specifying the UAV. However, we typically work with the customer from start to finish on the project, to ensure that their design meets specific standards for signal loss and interference.
This might mean entirely customised cable assemblies designed to minimise interference or the use of RF (radio frequency) cables or connectors. Ultimately, however, the best way to reduce signal loss and interference is by using high-quality materials throughout the product’s build.
What support do you provide for customers looking for
UAV cables? At GTK, we offer extensive support to help our customers get cables that are optimised for use, and part of an overall product build that is as efficient as possible. We work closely with the customer to ensure that their cables are designed for manufacture in the most efficient way. This helps ensure that the manufacturing process is as streamlined as possible, reducing costs associated with the build process.
When working with a UAV manufacturer that has an existing product, we’ll also review their BOM (bill of materials) to identify areas for improvement. This might be in the form of unnecessary components that are contributing to excessive costs. One of the ways GTK is unique is our Core Materials Strategy, under which we stock large quantities of standardised components and their associated tooling. There may be opportunities for our customers to switch parts of their BOM to our core component stock, which shortens lead times and helps them reduce costs.
38 ELECTRICAL ENGINEERING • FEBRUARY 2025 Are cables used in UAVs subject
to any industry standards? UAV builds, like much of the aerospace sector, are subject to strict quality control processes. However, customer requirements can vary significantly, depending on the required purpose of the vehicle. After all, the term UAV can span an incredibly wide range of applications. Standards-wise, everything we do follows IPC 620, which prescribes a number of requirements for the manufacture of cable, wire and harness assemblies. Specifically for the aerospace sector, everything we manufacture must conform to AS9100, which is an international standard for quality management in the aerospace sphere.
Which specific tests do you conduct to ensure GTK is
meeting those standards? We’re able to carry out a wide range of testing regimes for specific products. For this style of product, our standard testing is hi-pot (high potential) testing, wherein a high voltage is applied to the device to ensure that its insulation can handle the voltage without breaking down. All of our cables are Cirris tested and are subject to an examination that includes continuity testing, open testing and short testing, to ascertain how the cable would perform when part of a complete path, when part of an open circuit, and when part of an unintended connection.
Our customers commonly request specific or custom testing regimes and we’re happy to oblige. These usually centre around application-specific tests for things like vibration or waterproofing if required.
What trends in cable and assembly design do you see shaping the UAV industry over the next 5-10 years?
There have already been some great advancements in the UAV space over the last decade or so, so the next 5-10 years will be pretty exciting in terms of what happens. I expect a shift in the materials used in manufacturing, which will help cables and assemblies become lighter and more compact. More widespread use of materials like advanced polymers, aluminium alloys and micro connectors will enable smaller UAV builds to become lighter than ever before, facilitating longer journeys and a wider range of application possibilities.
electricalengineeringmagazine.co.uk
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