Long-endurance electric wired drone electric load-bearing drone

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Long-endurance electric load-bearing wired UAV solution

In power engineering construction and operation and maintenance scenarios, power wiring drones not only need to meet the needs of long-distance cruising, but also need to have strong load-bearing capacity to handle tasks such as towing heavy cables and transporting wiring tools. Based on the long-cruise design, this solution deeply integrates large-load technology and optimizes it from multiple dimensions such as power, structure, and function to provide an efficient and reliable solution for power operations.

1. Super power and energy system enhancement

(1) Power system upgrade

  1. Hybrid system enhancements : Based on the intelligent series gasoline-electric hybrid architecture, the aviation heavy oil engine is upgraded to a 6-stroke turbocharged model, with the maximum power increased to 220kW and the torque increased by 30%, ensuring that it can still output strong power stably under heavy load conditions. The lithium battery pack uses a new type of lithium metal polymer battery with an energy density of 450Wh/kg and an expanded capacity of 300Ah, providing instant high current support for short-term high-load operations. The intelligent energy management system has a new load dynamic adjustment algorithm, which can optimize the collaborative working mode of the engine and battery in real time according to load changes, improving energy utilization efficiency.

  1. Strengthened power unit : Customized ultra-high-power external rotor brushless motor, the stator diameter is expanded to 220mm, the rated power is increased to 15kW, and the power density reaches 3.2kW/kg. It adopts dual-rotor structure design to enhance torque output capability. Equipped with 2.2-meter-diameter high-strength carbon fiber composite propellers, the maximum lift is increased by 40% by optimizing the airfoil and pitch-changing system to meet the needs of heavy-load flight. The intelligent ESC system has been upgraded to a multi-core processor architecture, and the response speed has been increased to 0.03 seconds. It can accurately control multiple groups of motors to work together at the same time to ensure stable power output.

(2) Energy life optimization

  1. Fuel system expansion : Adopting a three-fuel tank design, the main fuel tank has a capacity of 150L, ​​and the two auxiliary fuel tanks are 80L each, with a total oil storage capacity of 310L. The fuel tank is made of new high-strength lightweight alloy material, which only increases the weight by 15%. The fuel supply system is optimized and equipped with a high-pressure fuel injection pump and an intelligent oil distribution valve to ensure a stable and efficient supply of fuel. Together with efficient combustion technology, the cruising range can still reach 600 kilometers under full load.

  1. Improved battery performance : The lithium metal polymer battery pack is equipped with an intelligent two-way fast charging system, supporting two modes of on-board fast charging and wireless charging, and can charge to 80% power in 1 hour. The battery management system has been upgraded to a distributed architecture. Each battery module is independently monitored and equipped with multiple protection functions such as overcharge, over-discharge, over-current, and short-circuit. At the same time, the battery output power can be dynamically adjusted according to the flight status to extend the battery life and endurance.

2. Overload structure design optimization

(1) Strengthening of fuselage structure

  1. high strength frame : The fuselage frame adopts a hybrid structure of titanium alloy and carbon nanotube composite materials. Through topology optimization design, titanium alloy one-piece molding technology is used in key load-bearing parts such as mounting points, motor brackets, etc., and carbon nanotube composite materials are used in non-load-bearing parts to reduce weight. The overall structural strength is increased by 50%, while the weight is only increased by 20%, effectively improving the load-to-load ratio.

  1. Reinforced landing gear : The landing gear adopts a hydraulic shock-absorbing high-strength alloy steel structure and is equipped with large-size run-proof tires, which can withstand a vertical load of more than 200kg. The landing gear has an automatic adjustment function. When taking off and landing with heavy loads, the hydraulic system automatically increases damping to ensure the drone lands smoothly. ； It can be completely folded and stowed during flight to reduce air resistance.

(2) Design of load-carrying system

  1. Intelligent mounting platform : The design of a modular intelligent mounting platform supports a variety of mounting methods, such as hook type, tray type, clamp type, etc., and can quickly replace different mounting devices to adapt to various operational needs such as cable traction and tool transportation. The mounting platform is equipped with a high-precision load cell and a 6-axis force sensor to monitor the load weight and center of gravity deviation in real time, with the error range controlled within ±1kg and ±2°.

  1. Anti-sway stabilization device : In order to solve the problem of heavy-load transportation prone to shaking, an active anti-sway stabilizing device is installed under the mounting platform. The gyroscope and acceleration sensor sense the swaying posture of the cargo in real time, and drive the hydraulic damper and motor to adjust the angle and tension of the stabilizer bar to control the swaying amplitude of the cargo to a very small range to ensure flight safety and operational accuracy.

3. Complete professional functions for electric power operations

(1) Precision wiring function upgrade

  1. Heavy duty cable pulling system : Equipped with a high-power cable pulling machine, the maximum pulling force can reach 3000N, and can pull heavy power cables with a diameter of more than 20mm. The tractor adopts variable frequency speed control, which can automatically adjust the traction speed according to the flight speed and cable tension to ensure smooth cable traction. Equipped with a high-precision pay-off device, the cable can be placed and recovered accurately, with an error range of ±0.3 meters.

  1. Pole and tower positioning and docking system : Equipped with a laser radar and visual recognition composite positioning device, it can quickly identify the location and structural features of power pole towers. Through the AI ​​image recognition algorithm, the optimal towing path and docking point are automatically planned, and the flight attitude is adjusted in real time during the flight to achieve precise docking of the towing rope and the pole tower, greatly improving the efficiency and accuracy of wiring operations.

(2) Operation assistance and safety system

  1. Environmental perception and obstacle avoidance : Based on the original 360° obstacle avoidance system, millimeter wave radar and ultrasonic sensors are added to form a multi-sensor fusion all-round sensing network with a detection range of up to 200 meters. For common obstacles such as transmission lines and towers in power operations, the obstacle avoidance algorithm is optimized to achieve intelligent obstacle avoidance and path planning in complex environments to ensure the safety of heavy-load flights.

  1. Emergency support function : Equipped with dual redundant flight control systems and backup power systems, when the main system fails, it can seamlessly switch to the backup system within 0.2 seconds. An emergency throwing device is set up to quickly release the mounted cargo when encountering extreme circumstances, reducing the load on the drone and ensuring the drone's safe return. At the same time, the drone supports emergency operation functions such as one-click hovering and one-click return to improve operational safety.