Design and simulation of eVTOL aircraft Thermal Management System

Vertical Take-off and Landing (VTOL) aircraft with hybrid or fully-electric propulsion systems are becoming popular for Urban Air Mobility (UAM) applications. However, they face challenges such as limited power and energy density, stringent operating temperature constraints, and the generation of low-grade waste heat. These issues emphasize the need for effective Thermal Management Systems (TMS) design. In light of the above, this paper aims to design the TMS for a parallel hybrid electric XV-15 aircraft, a widely known civil tiltrotor concept. The TMS is integrated into the aircraft system to assess its impact on energy efficiency and emissions at both aircraft and mission levels. This study considers current state of the art technology and expected advancements over the next two decades to identify the benefits of electrification. In the designed TMS, liquid cooling cold plates serve as the main heat acquisition and cooling system for each electric component. An air-coolant heat exchanger is also incorporated to dissipate the accumulated heat load. The study conducts a comparative analysis to determine the optimal TMS design point. It involves a comparison between two design scenarios: one focused on the cruise condition, which constitutes a significant portion of the flight mission, and another designed specifically for peak heat load conditions. This ensures a holistic evaluation of the TMS's performance across various flight phases, balancing efficiency and resilience to peak demands. Finally, the energy efficiency and emission penalty associated with the TMS integration are quantified and discussed in the study.