Advanced Thermal Analysis Methodologies to Support eVTOL Propulsion System Optimization

eVTOL vehicles have seen rapid advancements in electric propulsion technologies supported by complex high-fidelity simulations that allow subsystem performance to be maximized. Optimizing subsystem performance can improve propulsion system power density, especially through improved cooling. However, current work on holistic system level approach to eVTOL propulsion system designs [1,2] can benefit from earlier consideration of the interactions between inverter, motor, transmission, and thermal management systems. This can give a better understanding of the trade-offs between increasing power density and more complex, active cooling systems. These trade-offs must be understood as active cooling elements can lead to additional redundancy and certification requirements, which can increase the time-to-market in a highly competitive environment. This paper proposes an approach that quantifies these trade-offs early in the design process, so that the right propulsion system can be brought to market in the right timeframe.