Unmanned aerial vehicle tether system
UAV tether systems are provided that reliably deploy and retract cables capable of high-power and high-bandwidth data transmission. The tether system spools cables in a single layer to promote heat dissipation thereby allowing the use of lower-diameter cables. The tether systems further utilize a lightweight converter that achieves a high-voltage power transmission across a cable that is stepped down to a plurality of lower-voltage outputs usable by a UAV and accompanying payloads. The converter is constructed in a manner that promotes heat dissipation through the use of multi-layer PCBs and separate power modules PCBs mounted above main PCBs to create a cavity where forced air can reach heat sinks affixed to the power modules that extend into the cavity.
1. A UAV tether system power supply comprising:
a first converter unit comprising
a first main printed circuit board,
a first power module printed circuit board comprising a plurality of conductor layers,
first support pin and a second support pin each having a first end coupled to the first main printed circuit board a second end coupled to the first power module printed circuit board and a first converter unit support pin length between the first end and the second end, wherein the first converter unit support pin length defines a first space between the first main printed circuit board and the first power module printed circuit board;
a first converter module mechanically and electrically coupled to the first power module printed circuit board; and
a second converter unit comprising
a second main printed circuit board,
a second power module printed circuit board comprising a plurality of conductor layers,
third support pin and a fourth support pin each having a third end coupled to the second main printed circuit board, a fourth end coupled to the second power module printed circuit board, and a second converter unit support pin length between the third end and the fourth end, wherein the second converter unit support pin length defines a second space between the second main printed circuit board and the second power module printed circuit board, and
a second converter module mechanically and electrically coupled to the second power module printed circuit board; and
a housing configured to accommodate the first converter unit and the second converter unit, wherein
the first converter unit and the second converter unit are at least partially enclosed within the housing unit and separated by third space, and
the first converter unit and the second converter unit are arranged such that the second converter unit is a mirror image of the first converter unit about the third space.
2. The UAV tether system power supply of claim 1 wherein the first power module printed circuit board comprises eight or more conductive layers and the second power module printed circuit board comprises eight or more conductive layers.
3. The UAV tether system power supply of claim 1 wherein the first support pin, the second support pin, the third support pint, and the fourth support pin are each electrically and thermally conductive.
4. The UAV tether system power supply of claim 1 further comprising device that blows air across the first converter unit into the first space.
5. The UAV tether system power supply of claim 1 wherein the first converter module is a direct current to direct current module.
6. The UAV tether system power supply of claim 4 further comprising device that blows air across the second converter unit into the second space.
7. The UAV tether system power supply of claim 5 wherein the second converter module is a direct current to direct current module.
8. The UAV tether system power supply of claim 1 further comprising:
a plurality of first converter unit converter modules mechanically and electrically coupled to the first power module printed circuit board, wherein the plurality of first converter unit converter modules
are connected in series,
each have a first voltage output connection point and a second voltage output connection point, and wherein
the second voltage output connection point has a lower voltage than the first voltage output connection point;
a first transistor comprising
a first terminal electrically coupled to the first voltage output connection point, and
a second terminal;
a second transistor comprising
a third terminal electrically coupled to the second voltage output connection point, and
a fourth terminal; and
a first battery backup comprising
a positive terminal electrically coupled to the second terminal through a first diode, and
a negative terminal electrically coupled to the fourth terminal through the second diode.
9. The UAV tether system power supply of claim 8 further comprising:
a plurality of second converter unit converter modules mechanically and electrically coupled to the second power module printed circuit board, wherein the plurality of second converter unit converter modules
are connected in series,
each have a third voltage output connection point and a fourth voltage output connection point, and wherein
the fourth voltage output connection point has a lower voltage than the third juhhhhvoltage output connection point;
a third transistor comprising
a fifth terminal electrically coupled to the third voltage output connection point, and
a sixth terminal;
a fourth transistor comprising
a seventh terminal electrically coupled to the fourth voltage output connection point, and
an eighth terminal;
a second battery backup comprising
a positive terminal electrically coupled to the sixth terminal through a third diode, and
a negative terminal electrically coupled to the eighth terminal through the fourth diode.