Work

A Novel Multi-Core Parallel Current Differential Sensing Approach for Tethered UAV Power Cable Break Detection

Year: 2025

Type: article

Abstract: Tethered unmanned aerial vehicles (UAVs) operating in terrestrial environments face critical safety challenges from power cable breaks, yet existing solutions—including fiber optic sensing (cost > USD 20,000) and impedance analysis (35% payload increase)—suffer from high cost or heavy weight. This study proposes a dual innovation: a real-time break detection method and a low-cost multi-core parallel sensing system design based on ACS712 Hall sensors, achieving high detection accuracy (100% with zero false positives in tests). Unlike conventional techniques, the approach leverages current differential (ΔI) monitoring across parallel cores, triggering alarms when ΔI exceeds Irate/2 (e.g., 0.3 A for 0.6 A rated current), corresponding to a voltage deviation ≥ 110 mV (normal baseline ≤ 3 mV). The core innovation lies in the integrated sensing system design: by optimizing the parallel deployment of ACS712 sensors and LMV324-based differential circuits, the solution reduces hardware cost to USD 3 (99.99% lower than fiber optic systems), payload by 18%, and power consumption by 23% compared to traditional methods. Post-fault cable temperatures remain ≤56 °C, ensuring safety margins. The 4-core architecture enhances mean time between failures (MTBF) by 83% over traditional systems, establishing a new paradigm for low-cost, high-reliability sensing systems in terrestrial tethered UAV cable health monitoring. Preliminary theoretical analysis suggests potential extensibility to underwater scenarios with further environmental hardening.

Source: Sensors

DOI: 10.3390/s25165112