Introduction: Customization decisions for industrial UAV payloads depend on the fixed power chain, tether construction, fiber option, and payload interface that the system can support.
Custom tethered power systems start with a fixed power chain and cable format. System integrators, OEM procurement teams, and drone manufacturers often begin with a payload, then need to know which parts of the power, tether, fiber, and interface package can be adjusted before they quote a job. A customer may need a thermal camera holding station above a construction site, a radio relay over a disaster zone, or a follow-along camera tracking a patrol boat. The practical questions come next: can the tethered platform lift that payload, power it continuously, and return its data over a reliable link? The answer depends on four things: the AC220V to DC375V/DC400V power chain, the 120m composite tether, the optional 10Gb/s single-mode fiber, and the payload interface. With those four points clear, an integrator can organize a requirement package for engineering review instead of trading messages for weeks.
How the AC220V to Onboard 3000W Power Chain Defines Custom Scope
The power chain sets the first boundary. On the Tinko LZZ-THOR-100, the ground station accepts AC 220V ±10% at 50Hz and draws 3000W. It converts that input to DC375V or DC400V, ±5V, with output power 3000W, then sends it up the tether. Onboard, a 3000W regulator steps the high voltage down to the voltages used by the aircraft and payload. The high-voltage DC link keeps current lower than a low-voltage link would for the same power, which aligns with the tether’s 7A ampacity and 2.2Ω per 100m resistance. MIT OpenCourseWare covers the DC-DC step-down and regulation principles behind this kind of architecture. Continuous high-voltage DC conduction also creates a magnetic field environment around the cable, and ICNIRP publishes static magnetic field reference material useful for planning conductor layout and shielding. That chain limits customization in three ways. Ground power is capped below 3000W, so aircraft systems and payload share one budget. The onboard 3000W regulator has its own thermal behavior, so a payload with high continuous current makes the module work harder; engineers therefore need both continuous and peak draw. The output rails are set for the aircraft, so a payload that needs a different voltage usually gets its own converter rather than a change to the tether voltage. If a payload needs 24V at 4A continuous, state that plainly. It tells the team whether the standard architecture covers it or whether a separate regulator belongs in the build.
How Tether and Fiber Options Change Integration Choices
The tether is where electrical and mechanical decisions meet. One cable carries power, carries data if fiber is specified, and supports its own weight plus the aircraft’s movement. Two parts of the specification drive most integration work: the physical rating of the composite cable and the optional single-mode fiber inside it.
1. Tether Weight and Tensile Rating Limit Mobile Payload Options
The LZZ-THOR-100 tether is a 120m composite cable weighing 2 kg per 100m, so a full run puts roughly 2.4 kg in the air. That mass counts against the platform. Maximum takeoff weight is 10–12 kg and useful payload is 2.5 kg, so cable, airframe, and payload all sit inside the same envelope. The cable is rated above 100kg tensile with 2000V insulation, which gives mechanical headroom on an aircraft in this weight class. That rating also matters when the ground station moves, because the cable must handle its own load and the aircraft’s motion. On the electrical side, the 2.2Ω per 100m resistance keeps voltage drop predictable across the full run, while 7A ampacity sets how much current the cable can carry before heating becomes a concern. If a payload plan assumes more continuous power than the standard chain provides, it shows up here first.
2. Single-Mode Fiber Changes Video and Telemetry Integration Choices
The optional 10Gb/s single-mode fiber shifts the data planning. Instead of designing around RF links, antenna placement, and spectrum coordination, the tether carries the data path physically. IEEE 802.3 defines the physical layer background for 10Gb/s single-mode transmission, and the practical effect for an integrator is that bandwidth is less likely to be the limiting factor. Multiple 4K streams, high-rate sensor data, and telemetry can share the link without the usual wireless trade-offs. It also changes the parts list: fiber connectors at both ends, a compatible reel interface on the ground side, and an airborne media converter or switch that fits inside the payload allowance. Fiber is an option, not a default. The early question is whether the payload’s data rate genuinely needs it. A single compressed video stream may not; a multi-sensor pod with raw output is more likely to justify it.
How Payload Interfaces and Power Needs Reach an Engineering Review
The process lands in a written requirement that an engineer can act on. The 2.5 kg payload figure and the 10–12 kg maximum takeoff weight are starting constraints, but mass distribution matters just as much as total mass. A 2.5 kg gimbal mounted far forward shifts the center of gravity, changes how the flight controller trims, and reduces margin. The same 2.5 kg relay box mounted near the frame center is a different integration. A useful description therefore covers mass, mounting footprint, available attachment points, and distance from the aircraft’s center. Then comes the interface: what voltage the payload needs, what connector it uses, whether it requires a regulated rail or accepts a wide input range, how many watts it draws continuously versus at peak, and what data it produces. A drone manufacturer adding a tethered payload can use the same requirement list. A system integrator who sends a one-line message saying “we want to add a camera” gets a slow answer. One who sends a short specification sheet — payload mass, mounting pattern, input voltage, current, data rate, protocol, and operating environment — gives the team enough to say yes, no, or here is the trade-off. Customization is subject to engineering review, and not every voltage or connector can be changed, but a clear requirement makes that review faster.
Conclusion
Custom tethered power systems have a defined envelope. The AC220V input, DC375V/DC400V output, 3000W onboard regulator, 120m composite cable, and optional 10Gb/s single-mode fiber set the boundaries. Inside that envelope, integrators can plan payload mass, voltage, connector type, and data rate with reasonable confidence. Outside it, the next step is an engineering conversation rather than an assumption. The fastest route from a customer requirement to a workable configuration is a clear payload description sent to a team that can read it against real power and tether numbers. Tinko builds the LZZ-THOR-100 around that kind of integration work. Send your payload mass, interface needs, and data rate so the team can confirm what fits the standard build and what needs a custom answer.
FAQ
Q：Which parts of a tethered power system can be customized for industrial UAV payloads?
A：The practical customization points are the payload interface and its power rail, the tether configuration including whether the optional 10Gb/s single-mode fiber is fitted, and the connectors and data path at both ends. The AC220V input, DC375V/DC400V output, and 3000W onboard regulation set the fixed envelope those changes work inside. Whether a specific voltage, connector, or mounting arrangement can be changed depends on engineering review of the payload mass, power draw, and data rate you submit.
Q：Can the tether include a 10Gb/s single-mode fiber option for video and telemetry?
A：Yes. The LZZ-THOR-100 tether is available with an integrated 10Gb/s single-mode fiber option running alongside the power conductors. It carries video and telemetry over a physical optical link, which avoids RF spectrum planning and leaves more headroom for multiple high-rate streams. Specifying it changes the ground-side reel interface plus the airborne connector and media conversion hardware, so it belongs early in the integration plan. Fiber remains an option rather than a default choice.
Q：How should a system integrator describe payload power and interface needs for engineering review?
A：Lead with payload mass and mounting footprint, then the electrical picture: input voltage, connector type, whether a regulated rail is required, continuous and peak current draw, and total watts. Add the data side — protocol, data rate, and whether video, telemetry, or both travel over the tether — plus the operating environment and working height you need. Numbers move a review forward far faster than a general description, and they let the engineering team confirm what the standard 3000W chain and 2.5 kg payload allowance can support.
Sources / References
IEEE 802.3 Ethernet Standards
Power Electronics - MIT OpenCourseWare
ICNIRP - Static Magnetic Fields (0 Hz)
Related Examples
LZZ-THOR-100 Tethered UAV System
