Custom Wiring Solutions for UAVs and Robotics

Cable assemblies and wiring harnesses connect different subsystems of UAVs and robotic vehicles together, including batteries, sensors, autopilots, propulsion systems and flight controls. They route power, signals and data from one place to another, and are designed to save space and weight compared to separate cables.

Cable Assembly Design

In addition to meeting size and weight constraints, the design of cable assemblies may have to take a variety of other factors into consideration. They may have to be integrated into UAV airframes and vehicle chassis with complex routing requirements, and may need to flex through significant angles without wear. Outer cable protection may also have to deal with the fact that shock and vibration can cause cables to rub against sharp corners and other surfaces, causing structural weaknesses.

Cable assemblies for unmanned systems may need to be resistant to a range of substances, such as gasoline, diesel and oil. IP (ingress protection) ratings for moisture and immersion resistance may be important, especially for maritime and submarine systems such as USVs (unmanned surface vessels), ROVs (remotely operated vehicles) and AUVs (autonomous underwater vehicles).

Cable assemblies are typically constructed with one or more conducting wires or optical fibres at the centre, with insulation around each wire or groups of wires. Copper is typically used for conductor wires, due to its power-to-volume ratio, corrosion resistance, and relatively low cost. Conducting wires may be a single solid core or multiple strands twisted together.