Design and feasibility analysis of small aircraft electrification with battery modeling

Abstract

The aviation industry plays a fundamental role in modern society by enabling global transportation, economic development, and social connectivity. However, the sector also faces significant environmental, economic, and technical challenges. These challenges include growing concerns such as increasing dependence on fossil fuels, rising fuel prices, stringent emissions regulations, and noise pollution. This situation has intensified the search for sustainable aviation solutions. Aviation currently accounts for a significant portion of global greenhouse gas emissions. If current operational trends continue, this contribution is expected to increase significantly by 2050. As a result, decarbonizing aviation and developing alternative propulsion technologies have become strategic priorities. In this context, the All Electric Aircraft concept has emerged as a promising solution to reduce environmental impact and operational costs. Advances in battery technologies, electric propulsion systems, and power electronics have significantly accelerated research and development activities in this field. Several pioneering projects, such as the Pipistrel Velis Electro, Eviation Alice, and NASA's X-57 Maxwell, have demonstrated the technical feasibility of electric flight. In addition, they have provided the industry with valuable experimental data and operational experience. These developments indicate that electric aviation technologies are maturing, especially for short-range and light aircraft applications. This study presents a comprehensive technical, environmental, and economic feasibility assessment of converting the Tecnam P2008 JC, a small single-engine aircraft, to a fully electric propulsion configuration. The primary objective is to evaluate the applicability of electric propulsion systems while preserving the aircraft's original structural architecture and certification constraints. The conversion process involves replacing the traditional internal combustion engine and fuel system with an electric motor, a lithium-ion battery pack, and appropriate power electronics units. The aircraft's system-level design constraints and maximum take-off weight (MTOW) are carefully evaluated to ensure compliance with flight safety requirements. A lithium-ion battery pack with a nominal capacity of approximately 45 kWh has been designed and integrated into the aircraft. Battery selection and sizing were based on the energy requirements of the designed flight profile, discharge characteristics, and safety considerations. Current lithium-ion battery technologies have lower specific energy values compared to traditional aviation fuels. This creates significant performance and weight constraints in electric aircraft design. In particular, the design trade-offs between range, payload capacity, and total system weight must be carefully evaluated. In this context, the relationships between these parameters have been analyzed in detail. The final configuration maintains operational feasibility while limiting payload capacity within acceptable safety limits. Performance and energy consumption analyses are performed through detailed MATLAB/Simulink-based system-level simulations. Battery behavior is modeled using the Shepherd mathematical model. This ensures accurate prediction of voltage, current, and state of charge (SOC) dynamics throughout the flight mission.The selected flight route is between Istanbul Sabiha Gökçen and Bursa Yenisehir airports. Simulation results show that the converted aircraft can safely complete the mission with sufficient energy reserves. Environmental and economic assessments highlight the significant advantages of electric propulsion. Direct operational carbon dioxide emissions and energy costs per flight have been significantly reduced compared to the traditional configuration. Furthermore, reduced maintenance requirements due to fewer mechanical components further enhance economic feasibility. However, battery investment costs, limited cycle life, and charging infrastructure requirements remain critical challenges. Overall, the results confirm that fully electric propulsion is technically and economically feasible for short-range, small aircraft missions under current technological constraints. Significant limitations remain in terms of energy density and charging time. On the other hand, continuous advancements in battery chemistry, power electronics, and sustainable energy infrastructure are expected to enable the broader adoption of electric aviation in the near future.