Tether management systems face significant friction challenges, with standard spooling mechanisms experiencing up to 25% energy losses during deployment and retrieval operations. Field tests demonstrate that tether friction generates localized heating exceeding 60°C at contact points, accelerates wear on guide components, and introduces variable tension that can destabilize tethered systems during critical operations. These effects become particularly pronounced in aerial applications where dynamic loading can vary by factors of 3-5x during flight maneuvers.

The engineering challenge lies in balancing mechanical simplicity against the need for precise tension control across widely varying operational conditions.

This page brings together solutions from recent research—including adaptive tether mechanisms with dynamic spool positioning, low-friction guide systems with integrated rollers, passive swing arm configurations, and tension-sensing closed-loop control systems. These and other approaches focus on practical implementation strategies that minimize energy losses while maintaining reliable operation across deployment scenarios ranging from payload delivery to long-duration tethered flight.

1. Autonomous Tether Management System with Slack Control and Reference Length Model for UAVs Tethered to Moving Vehicles

USA AS REPRESENTED BY THE SECRETARY OF THE NAVY, 2024

Autonomous tether management system for unmanned aerial vehicles (UAVs) tethered to moving vehicles like boats or ground vehicles. The system allows the UAV to fly at a slack tether length rather than taut, enabling decoupling of the UAV and vehicle motion. A reference tether length model is used based on relative position between the UAV and vehicle. A controller adjusts the tether length to match the model. The controller uses measurements like GPS, IMU, and tether length to estimate relative motion and calculate the reference length. A low-pass filter with speed-based gain schedules is applied. This improves performance in varying vehicle speeds.

US2024400236A1-patent-drawing

2. Control Device for Unmanned Aircraft with Dynamic Wire Payout Based on Real-Time Wind Strength Measurements

RAKUTEN GROUP INC, 2024

Control device for unmanned aircraft that reduces wind influence during article lowering by dynamically adjusting wire payout based on real-time wind strength measurements. The device acquires wind strength data and controls the wire payout to compensate for wind forces, enabling precise article placement even in windy conditions.

3. Unmanned Aerial Vehicle System with Controlled Winch Assembly Featuring Selective Brake Mechanism and Motorized Spool Rotation

WORKHORSE GROUP INC, 2023

An unmanned aerial vehicle (UAV) system for parcel delivery, comprising a winch assembly with a spool, motor, and brake mechanism. The winch assembly includes a mounting assembly, a spool rotatably mounted to the mounting assembly, a line with a wound portion wound about the spool and a free portion, and an attachment device attached to the free portion. The brake mechanism selectively prevents rotation of the spool in the unwinding direction, and is operable to transition between a locked state and an unlocked state under control of the control system. The control system is configured to selectively unlock the brake mechanism, and to operate the motor to rotate the spool in the winding direction, thereby facilitating unlocking of the brake mechanism.

4. Tethered UAV System with Adaptive Tether Mechanism Control and Dynamic Spool Position Adjustment

EASY AERIAL INC, 2022

A tethered UAV system with adaptive control of the tether mechanism, enabling continuous flight within a predefined area. The system employs a motorized spool that dynamically adjusts its position based on the UAV's flight characteristics, including altitude, wind, and power status. The spool's control is synchronized with the UAV's flight commands, ensuring seamless transition between tethered and free-flight modes. The system incorporates a tension sensor to continuously monitor the tether's state, automatically activating the spool when slack develops during descent or when the UAV activates a quick release mechanism. This closed-loop control enables precise tether management, preventing tether entanglement and ensuring reliable operation.

5. Unmanned Aerial Vehicle Payload Delivery System with Passive Swing Arm and Spool Mechanism

WING AVIATION LLC, 2022

A payload delivery system for unmanned aerial vehicles (UAVs) that lowers payloads using a simple mechanism that reduces cost and weight compared to powered systems. The system uses a support structure with a swing arm and shaft that allows upward movement and restricts downward movement. A spool rests on the shaft when raised. During delivery, the UAV unwinds the tether from the spool and rotation of the spool also turns a fan to control descent rate. When done, the swing arm moves the shaft upward to remove the empty spool and replaces it with a new spool loaded with the next payload. This passive loading mechanism eliminates powered components.

US11214371B2-patent-drawing

6. Unmanned Aerial Vehicle System with Winch-Controlled Payload Delivery and Line Severing Mechanism

WORKHORSE GROUP INC, 2021

An unmanned aerial vehicle (UAV) system that enables controlled delivery of payloads to a target surface. The system includes a winch with a reel that winds and unwinds a line, a motor that controls the reel's rotation, and a severing mechanism that can cut the line in case of a fault. The system also includes a ranging-and-detection device that determines the distance between the UAV and the target surface, and a control system that operates the winch to lower the payload at a controlled speed. The control system accelerates the payload as it approaches the target surface and decelerates it as it reaches the surface, ensuring a controlled and safe delivery.

7. Winding Device with Detachable Reel Units and Electric Motor-Driven Reel Drives for Multi-Line Systems

HEESCHEN STEFFEN, 2021

Winding device for stunt kites, paragliders, and parachutes with multiple reels, comprising a device housing with detachable reel units, a fastening mechanism for attachment to a handlebar or component, and electric motor-driven reel drives with separate or common control units. The device enables automated winding and unwinding of multiple lines, with features such as line stripping and tensioning, and manual override capabilities.

8. Reefing Grommet with Integrated Roller and Low-Friction Line Guides

Henry Sanders, 2021

A sail reefing grommet with reduced friction and snagging, comprising a ring with a roller and low-friction guides that channel the reefing line through the grommet, facilitating rapid and smooth sail reefing.

9. Unmanned Tethered Aircraft with Integrated Winch and Cable Management System

NACT ENGINEERING PTE LTD, 2021

An unmanned tethered aircraft configured with a cable management system for effective operation. The system includes a ground station, an unmanned robot with a robotic controller module, and a winch and cable unit mounted on the aircraft. The winch and cable unit includes a spool for accommodating a tether cable with an extendable end that can be released during flight. The system enables stable and controlled operation of the tethered aircraft by managing cable tension and preventing entanglement or friction.

10. Aerial Boom System with Tethered UAVs and Autonomous Length Adjustment for Material Dispensing

AGCO CORP, 2021

Aerial boom system for agricultural sprayers and crop extractors that enables dynamic, autonomous boom adjustment and efficient material dispensing through unmanned aerial vehicles (UAVs). The system incorporates a reel with a tether that unwinds to release UAVs, which then autonomously adjust their length and deploy through fans. The UAVs carry nozzles for liquid material delivery, and the reel's flow dispersion mechanism optimizes atomization. This configuration enables the boom to cover irregular fields and terrain while maintaining precision control over material application.

US2021147074A1-patent-drawing

11. Tether Management System with Rotatable Spool and Pivoting Angle Arm for Unmanned Aerial Vehicles

UNITED STATES GOVERNMENT AS REPRESENTED BY THE SECRETARY OF THE NAVY, 2021

A tether management system for unmanned aerial vehicles (UAVs) that enables extended flight times while maintaining a stable tether connection. The system features a rotatable spool with a slip ring, an angle arm that pivots around the spool axis, and an encoder that measures the arm's offset angle. The angle arm guides the tether while maintaining a center of mass aligned with the spool axis, ensuring stable operation even in dynamic environments such as ships at sea.

12. Drone Elevator System with Looped Cable and Tethered Extension Arms

FORD GLOBAL TECHNOLOGIES LLC, 2020

A drone elevator system that lifts one or more drones to a desired height before allowing them to take flight on their own power. The system includes a looped cable with pulleys, a lifting mechanism, and a motor to move the cable. Drones are attached to tethers with extension arms that prevent contact with the cable during lifting, allowing them to be launched at a desired height.

US2020361631A1-patent-drawing

13. Retractable Line Buffer Structure for Tethered Unmanned Aerial Vehicle with Fixed Pulley and Slide Rail Integration

SHENZHEN SUNWIN INTELLIGENT CO LTD, 2020

Tethered unmanned aerial vehicle (UAV) retractable line buffer structure and working method thereof. The buffer structure includes a bottom plate, a fixed pulley attached to the bottom plate, and a slide rail connected to the bottom plate. The pulley and slide rail work together to prevent entanglement or knotting during the ascending pay-off or descending take-up process, maintaining an even arrangement of the entire winding drum.

Get Full Report

Access our comprehensive collection of 13 documents related to this technology