What challenges do electric propulsion systems pose for aircraft design?

Electric propulsion systems offer many potential benefits for aircraft design, such as lower emissions, noise, and fuel consumption. However, they also pose significant challenges that require innovative solutions and trade-offs. In this article, you will learn about some of the main challenges that electric propulsion systems face and how they affect aircraft design.

1 Power density

One of the biggest challenges of electric propulsion systems is achieving high power density, which means delivering enough power per unit of mass or volume. Electric motors and batteries are typically much heavier and bulkier than conventional engines and fuel tanks, which limits the performance, range, and payload of electric aircraft. To overcome this challenge, designers need to optimize the weight, size, and efficiency of electric components, as well as the aerodynamics and structure of the aircraft.

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Ahmad M. Mandili

Director of MRO Operations Systems | Vision 2030 | Executive Management | Operations Technology | Digital Transformation | AMOS SME | Prosci® Certified Change Practitioner
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Electric propulsion systems introduce challenges for aircraft design, notably in power density. Batteries' lower energy-to-weight ratio compared to aviation fuel limits the amount of energy that can be stored onboard. This affects range and performance, demanding innovative designs for lightweight yet efficient components. Overcoming this challenge involves optimizing battery technology, developing lighter materials, and rethinking traditional aircraft structures to accommodate larger batteries without compromising safety or performance. Achieving higher power densities in batteries is crucial for electric aircraft to match the capabilities of conventional propulsion systems.

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Edimário Lima

Co-founder & Director of Innovation at Solugy Engineering
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Na minha percepção a energia nuclear pode contribuir para termos baterias mais compactas e potentes na aviação por propulsão elétrica.

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Manuel Alexander Cadena Centeno

Coordinador Senior de Proyectos con experiencia en energía y estrategia empresarial
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Dentro de los principales retos esta Optimizar la eficiencia de los sistemas eléctricos para maximizar el rendimiento y minimizar la pérdida de energía durante la conversión y la distribución. Algunas estrategias para lograrlo pueden ser: Mejora de la eficiencia de las baterías, Uso de algoritmos inteligentes para equilibrar la carga entre las celdas de la batería y optimizar la eficiencia del sistema, Empleo de convertidores de potencia de alta eficiencia en la conversión entre la energía almacenada en las baterías y la potencia utilizada por los motores eléctricos, Motores eléctricos eficientes adaptados específicamente para aplicaciones aeronáuticas, Desarrollo de sistemas de carga rápida en tierra. etc.

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2 Thermal management

Another challenge of electric propulsion systems is managing the heat generated by the electric components, especially the batteries and the power electronics. Excessive heat can reduce the efficiency, lifespan, and safety of these components, as well as affect the comfort of the passengers and crew. To cope with this challenge, designers need to implement effective cooling systems that can dissipate the heat without adding too much weight or drag to the aircraft.

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Edimário Lima

Co-founder & Director of Innovation at Solugy Engineering
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Percebo que ainda temos muito a evoluir com os sistemas de armazenamento de energia elétrica, principalmente as baterias. Elas devem ser confiáveis, duráveis e à prova de explosão.

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(Cafari) Carlos Alberto Farineli
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Novas tecnologias e novos materiais veem sendo testados e empregados no crescente mercado de carros elétricos. A necessidade de evolução de suas baterias no quesito autonomia e segurança vem alimentando de forma constante e promissora seu desenvolvimento e inovação. Mercados diferentes (aéreo e terrestre) porém interligados por algumas necessidades comuns. Inovações aplicadas nos veículos elétricos deverão achar espaço no mercado da aviação civil (e militar) ajudando a resolver, ou atenuar, problemas comuns.

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3 Safety and reliability

A third challenge of electric propulsion systems is ensuring the safety and reliability of the electric components and the power distribution network. Electric components are subject to various failure modes, such as short circuits, overloads, overheating, and fire. These failures can have serious consequences for the aircraft and its occupants, especially if they occur in flight. To prevent or mitigate these failures, designers need to adopt robust standards, regulations, and testing methods for electric components, as well as redundant and fault-tolerant systems that can isolate and manage faults.

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Edimário Lima

Co-founder & Director of Innovation at Solugy Engineering
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Os sistemas de controle moderno já estão avançados e maduros o suficiente para entregarem a performance requerida.Vejo possibilidades de controle remoto via nuvem.

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4 Integration and compatibility

A fourth challenge of electric propulsion systems is integrating and compatible them with the existing aircraft infrastructure and operations. Electric aircraft may have different requirements and specifications than conventional aircraft, such as charging stations, maintenance facilities, flight procedures, and certification processes. These differences may pose technical, logistical, and regulatory barriers for the adoption and deployment of electric aircraft. To overcome these barriers, designers need to collaborate with stakeholders, such as airports, airlines, regulators, and customers, to ensure the smooth integration and compatibility of electric aircraft.

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5 Cost and scalability

A fifth challenge of electric propulsion systems is reducing the cost and increasing the scalability of electric components and aircraft. Electric components are currently more expensive and less available than conventional components, which makes electric aircraft less competitive and attractive for the market. To reduce the cost and increase the scalability of electric components and aircraft, designers need to leverage economies of scale, mass production, innovation, and competition, as well as seek subsidies, incentives, and partnerships that can support the development and growth of electric aviation.

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Edimário Lima

Co-founder & Director of Innovation at Solugy Engineering
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A China pode ser um grande aliado para dar a escalabilidade e reduzir os custos de produção destes motores, viabilizando essas tecnologias emergentes e limpas.

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6 Future trends

A sixth challenge of electric propulsion systems is anticipating and adapting to the future trends and demands of electric aviation. Electric propulsion systems are constantly evolving and improving, thanks to advances in technology, research, and innovation. These advances may create new opportunities and challenges for electric aircraft design, such as hybrid systems, distributed propulsion, vertical take-off and landing, and autonomous flight. To keep up with these trends and demands, designers need to be flexible, creative, and visionary, as well as embrace feedback, learning, and collaboration.

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Manuel Alexander Cadena Centeno

Coordinador Senior de Proyectos con experiencia en energía y estrategia empresarial
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One of the challenges posed by electric propulsion systems is the integration with other energy sources. Currently, the possibility of using hydrogen energy systems in aircraft is being explored. Specifically, in relation to hydrogen-electric aircraft configurations, significant advancements are needed in key technologies, such as high-temperature fuel cell power plants, electric machines, power electronics, power transmission systems, aircraft structural designs, and propulsion system integration.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What challenges do electric propulsion systems pose for aircraft design?

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1 Power density

2 Thermal management

3 Safety and reliability

4 Integration and compatibility

5 Cost and scalability

6 Future trends

7 Here’s what else to consider

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