Ram air–based thermal management systems (TMS) are investigated herein for the cooling of future hybrid-electric aircraft. The developed TMS model consists of all components required to estimate the impacts of mass, drag, and fuel burn on the aircraft, including heat exchangers, coldplates, ducts, pumps, and fans. To gain a better understanding of the TMS, one- and multi-dimensional system sensitivity analyses were conducted. The observations were used to aid with the numerical optimization of a ram air–based TMS towards the minimum fuel burn of a 180-passenger short-range partial-turboelectric aircraft with a power split of up to 30% electric power. The TMS was designed for the conditions at the top of the climb. For an aircraft with the maximum power split, the additional fuel burn caused by the TMS is 0.19%. Conditions occurring at a hot-day takeoff represent the most challenging off-design conditions for TMS. Steady-state cooling of all electric components with the designed TMS is possible during a hot-day takeoff if a small puller fan is utilized. Omitting the puller fan and instead oversizing the TMS is an alternative, but the fuel burn increase on aircraft level grows to 0.29%.

A battery thermal management system (BTMS) for a hybrid electric aircraft is designed. Hot-day takeoff conditions are assumed, resulting in an ambient temperature higher than the allowed battery te...

Providing sufficient cooling power for an aircraft will become increasingly challenging with the introduction of (hybrid-) electric propulsion. To avoid excessive drag from heat exchangers, the heat sink potential of the aircraft surface is evaluated in this study. Semi-empirical correlations are used to estimate aircraft surface area and heat transfer. The impact of surface heating on aircraft drag is qualitatively assessed. Locating surface heat exchangers where fully turbulent flow is present promises a decrease in aircraft drag. Surface cooling potential is investigated over a range from small regional aircraft to large wide body jets and a range of surface temperatures. Four mission points are considered: Take-off, hot day take-off, climb and cruise. The results show that surface heat exchangers can provide cooling power in the same order of magnitude as the waste heat expected from (hybrid-) electric drive trains for all sizes of considered aircraft. Also, a clear trend favouring smaller aircraft with regards to the ratio of available to required cooling power is visible.

Batteries are the lynchpin of electric vertical takeoff and landing (eVTOL) aircraft, and the high discharge rates pose a critical challenge to the battery thermal management system (BTMS). This work presents a channeled liquid cooling technology-based BTMS for eVTOL aircraft. During the flight, the heat generated from the batteries is partly extracted by circulating liquid coolant within a wavy channel (WC) attached firmly to the battery cells. The heat is then transported into a plate-fin compact heat exchanger (HEX), where all the heat is dissipated into the atmosphere. We report sensitivity analyses of the HEX model to shed light on the impact of the relevant design parameters on the BTMS size, weight, and power. We also examine critical parameters of the coupled WC-HEX BTMS in a one-dimensional off-design analysis. We demonstrate that the liquid cooling system can maintain the battery operating temperature within acceptable levels with a mass of less than 20% of the battery pack mass. Battery degradation using the liquid cooling system is reduced by over three times compared to an air-cooled system for both tilt-wing and lift+cruise eVTOL aircraft.

Hybrid-Electric Propulsion (HEP) could be part of the solution to decrease emissions associated with regional commercial aviation. This study presents results for the aircraft level fuel reduction potential of a regional turboprop concept with an HEP architecture and Entry-Into-Service (EIS) in 2035+. The configuration specifically tackles the elaborated challenges of introducing an additional electrical energy source to the configuration by employing a twofold electrical assistance to a turboshaft engine in combination with an innovative thermal management concept. Relevant components and disciplines were modeled and incorporated into an integrated aircraft design environment. The behavior and interaction of the HEP architecture with the aircraft was thoroughly investigated. A best-performing configuration was derived and compared with a conventional reference configuration following a State-of-the-Art (SoA) reference aircraft approach. For a typical mission with 200 nmi range, a block fuel reduction of 9.6% was found. However, the assumed battery performance characteristics limited the reduction potential and led to a fuel burn increase for the 600 nmi design mission. Furthermore, sourcing the non-propulsive subsystems directly from the on-board battery was detrimental. The innovative Thermal Management System (TMS) located in the propeller slipstream showed a synergistic effect with the investigated configuration.