Design, Fabrication, and In-Flight Demonstration of a 24S NCM Battery System for an eVTOL Aircraft

Reliable pack-level battery systems capable of safely handling instantaneous high-C-rate discharge above 10C during take-off, climb, and hovering are required for the commercialization of urban air mobility (UAM) aircraft. However, pack-level studies on wide-range C-rate characteristics of battery systems for UAM applications remain very limited, and most previous studies have been restricted to single-cell experiments or battery-pack simulations. In this study, a 24S1P test battery pack using nickel–cobalt–manganese (NCM) pouch cells, with a nominal voltage of 88.8 V and a capacity of 22 Ah, was designed and fabricated. A two-level battery management system (BMS) based on the LTC6803G-4 was also developed. To evaluate the charge–discharge characteristics of the battery system, constant-current discharge tests were conducted under five conditions ranging from 0.2C (4.4 A) to 10.68C (235 A), and charging tests were performed over the range of 0.2C–2C. The discharge test results showed that the capacity retention remained within 97.5–100.0% in the 1C–5C range, confirming excellent power capability. Continuous discharge operation was confirmed at 10.68C, the maximum discharge condition considered for vertical take-off and climb. Under this condition, the capacity decreased to 16.26 Ah, corresponding to 74.2% of the rated capacity, owing to internal-resistance-induced voltage drop, electrochemical polarization, and early attainment of the cut-off voltage. The Peukert exponent was estimated to be 1.113. An apparent pack-level direct-current internal resistance (DCIR) of approximately 40.3 mΩ was estimated from the initial voltage-drop analysis under different discharge-current conditions. In addition, the maximum temperature during 10.68C discharge was measured as 55.1 °C, providing a thermal margin of 4.9 °C relative to the operational temperature limit of 60 °C adopted in this study. Finally, a 24S4P battery system with a capacity of 88 Ah, consisting of four 24S1P battery packs connected in parallel, was installed in the VS-210, a 210 kg-class maximum take-off weight (MTOW) eVTOL aircraft. An in-flight test was conducted by repeating six take-off–hovering–landing cycles during a total test session of 15 min 20 s, and a stable propulsion power supply was maintained throughout all flight cycles. This study provides experimental baseline data for the design and preliminary safety assessment of high-power battery systems for UAM applications by presenting both the electrical and thermal characteristics of a 24S NCM battery pack over a wide discharge-rate range of 0.2C–10.68C and in-flight eVTOL data.