Electric unmanned aerial vehicles (E-UAVs) represent a promising vehicle platform with applications spanning medical services, agriculture, disaster relief, and geological surveys, among others. Within E-UAVs, power electronics play a pivotal role in transferring electrical energy from the battery to the electric motors as the driving force. However, the energy losses inherent in switching power semiconductor devices make these components major heat generators, necessitating the need for effective thermal management. Direct air cooling, due to its simplicity for weight-restricted platforms like E-UAVs, is a preferred method for managing these thermal challenges. In this study, we present a numerical analysis of a direct air-cooling system designed for a MOSFET-based motor control system embedded within an E-UAV's airfoil with 82 W loss per module. Through our parametric numerical studies, we design a low drag force heat sink by heuristically optimizing the fin shape, configuration, and height of a commercial benchmark under various E-UAV operating conditions, including altitude climbing and full-speed flight. Results indicate an optimal and machinable heat sink design featuring a configuration of elliptical pin fins with a functionally graded fin density that is exposed to external air flow. A further primary goal in the heat sink design is to achieve low thermal resistance at low flight speeds while also minimizing drag at higher speeds; these are objectives that are traditionally at odds with each other. Thus, to overcome this, we introduce innovative strategies such as a prepositioned, moveable front panel, and it is found that the optimal inclined angle of the front panel is similar to 15 degrees. While computational insights offer promising leads, experimental validation via wind tunnel tests is left as future work. In summary, the study provides guidance on power electronics thermal management for future E-UAV platforms.
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