Physics-Based Approaches for Sizing Thermal Management Systems for Battery-Electric Regional Aircraft

Dissipating the waste heat produced by electrical losses is pertinent for achieving optimal performance of electromechanical systems, particularly for electric aircraft that operate at megawatt power levels. This paper presents a comprehensive design methodology for battery thermal management systems (BTMS) tailored to the unique demands of electric aircraft. The approach utilizes physics-based modeling to size the heat acquisition system, heat exchanger system, and auxiliary components. For the heat acquisition system, a conjugate cooling strategy is deployed within each battery pack module to extract heat efficiently. This heat is then ejected into the atmosphere via a fuselage-integrated heat exchanger. This study aims to quantify the power requirements of individual components of the BTMS across the different flight stages. Moreover, by determining the upper bounds of the achievable range for this 19-seater aircraft, which stands among the largest vehicles that fall under the Title 14 Code of Federal Regulations Part 23 jurisdiction, we are able to provide realistic estimates of regional air mobility within metropolitan areas. This study enables exploration into BTMS controller design to optimize its utilization to prolong battery life during nominal flight operations, as well as demonstrate safe thermal management during emergency engine failure scenarios. It therefore marks a pivotal stride in the ongoing advancement of thermal management systems tailored for the unique challenges posed by electric aviation.