Component-wise analysis of thermal management systems for electric aircraft

The efficient removal of waste heat generated by electrical losses is essential to maximizing electromechanical system performance—particularly electric aircraft operating at megawatt power levels. This study explores how thermal management system design impacts battery performance and life in a 19-seat passenger regional electric aircraft. Using physics-based modeling, three key subsystems are sized: the heat acquisition network within each battery module, a fuselage-integrated heat exchanger that rejects heat to the atmosphere, and all associated auxiliary components. The power consumption of each thermal management system component throughout all flight phases is quantified and, by establishing the aircraft's maximum achievable range. Realistic projections for metropolitan air mobility are provided. Alternative thermal management system sizing strategies are expanded to highlight the repercussions of oversizing a thermal management system while maintaining cell temperatures within safe limits and mitigating performance fade. This analysis accounts for system-level interactions: thermal management system mass itself increases propulsion power demand, which in turn draws more current from the battery. By performing Latin Hypercube sampling across multiple configurations, variations in thermal and electrical profiles driving battery degradation are mapped. Sensitivity studies reveal that although reservoir volume primarily governs system weight, the integrated thermal management system has a significant, coupled effect on battery life. These findings offer clear guidance for designing thermal management architectures that optimally balance weight against heat-rejection capacity to extend pack life.

Name thesis:degree_name

M.S.

Level thesis:degree_level

Thesis

Discipline thesis:degree_discipline

Aerospace Engineering

Grantor

University of Illinois Urbana-Champaign

Year dc:date

2025

Author dc:creator

• Shekar, Sai Sankalp Sankalp

Contributors dc:contributor

• Clarke, Matthew

• Electic Aircraft
• Battery Thermal Management
• Heat Transfer
• Regional Air Mobility
• Battery Cycle Life
• Lithium Ion Battery
• Ectol
• Twin Otter

Statement dc:rights

• Copyright 2025 Sai Sankalp Shekar

Language dc:language

en, eng

Handle dc:identifier

https://hdl.handle.net/2142/129974

OAI record oai:identifier

https://www.ideals.illinois.edu/oai-pmh?verb=GetRecord&metadataPrefix=etdms&identifier=oai%3Awww.ideals.illinois.edu%3A2142%2F129974