Diseño e implementación de un sistema automático de despliegue controlado de 50 metros de cable para un vehículo aéreo no tripulado

Abstract

This paper presents the design and implementation of an automated, controlled deployment system for a 50 meter cable for a tethered unmanned aerial vehicle, with the aim of improving cable portability, operational stability, and energy efficiency. To achieve this, a process of analysis, design, and controlled testing was followed. First, the mechanical and electrical requirements of the system were defined based on the weight and characteristics of the cable and the drone. Then, the parts were modeled using CAD software, and kinematic simulations were performed to verify that the components did not fail under the previously analyzed loads. Using these models, the main parts were manufactured via 3D printing in ABS plastic, and the main components were assembled: a motorized reel, a DIN less screw and crown gear transmission assembly, a Scotch yoke that serves as a guide to control cable winding, a slip ring to maintain the electrical connection, and an electronic controller with a stepper motor and driver. The assembled prototype underwent field testing, where winding speed, motor response, and reel stability were measured during cable unwinding and winding. The system successfully wound 50 meters of cable in approximately 4 minutes, demonstrating rapid and controlled deployment and retrieval. Additionally, the selected motor delivers 1.2 N·m, providing a safety margin for operations. The estimated cost of the prototype is USD 565.95. Ultimately, a functional and affordable prototype was obtained that successfully deploys 50 meters of cable in a stable and safe manner. This project validates the combination of simulation based design and 3D printing as a profitable alternative for developing functional cable winding system prototypes for drones.