Optimization of Power Chain for High-End Urban Delivery eVTOLs: A Precise MOSFET Selection Scheme Based on Propulsion Inverter, High-Density Auxiliary Power Management, and Critical System Interfaces

Preface: Architecting the "Power Core" for Urban Aerial Mobility – A Systems Approach to Power Device Selection in eVTOLs

In the emergent field of urban aerial logistics, high-performance delivery eVTOLs (Electric Vertical Take-Off and Landing aircraft) represent the pinnacle of integrated electromechanical design. The power system is not merely an energy provider but the definitive enabler of safety, payload capacity, range, and operational reliability. Under extreme constraints of power density, weight, and thermal management, the selection of power semiconductors becomes a critical determinant of overall system performance.

This analysis adopts a holistic, mission-profile-driven mindset to address the core challenges within a 50kg-payload delivery eVTOL's power chain. It focuses on selecting the optimal MOSFETs for three pivotal nodes: the high-current propulsion inverter, the intelligent and dense auxiliary power distribution, and the high-voltage interface or secondary power conversion, balancing the demands of peak efficiency, robust transient handling, unparalleled reliability, and minimal weight/volume.

I. In-Depth Analysis of the Selected Device Combination and Application Roles

1. The Propulsion Powerhouse: VBGL71203 (120V, 190A, SGT, TO-263-7L) – Main Propulsion Inverter Phase Leg Switch

Core Positioning & Topology Deep Dive: As the core switch in a multi-phase propulsion motor inverter bridge, its exceptionally low Rds(on) of 2.8mΩ @10V is paramount. The 120V rating is optimal for battery packs in the 48V to 96V range, common in eVTOLs, providing ample margin for voltage transients. The SGT (Shielded Gate Trench) technology offers an outstanding balance of low on-resistance, low gate charge, and high avalanche ruggedness.

Key Technical Parameter Analysis:

Ultra-Low Conduction Loss: The milliohm-level Rds(on) minimizes I²R losses during high-thrust phases like takeoff and climb, directly translating to extended range or reduced battery weight for the same mission.

High Current Capability & Package: The 190A rating and TO-263-7L package with an exposed pad are designed for extreme current density and efficient heat dissipation into a cold plate or heatsink, which is critical for the compact, liquid-cooled motor drives in eVTOLs.

 

 

图1: 高端城市即时配送 eVTOL（载重 50kg）方案与适用功率器件型号分析推荐VBA4225与VBGL71203与VBE15R10S产品应用拓扑图_en_01_total

 

Switching Performance: SGT technology typically yields fast switching speeds, reducing switching losses at high PWM frequencies (e.g., 30-80kHz), which is essential for high-speed motor control and minimizing filter magnetics size and weight.

2. The Intelligent Power Distributor: VBA4225 (Dual -20V, -8.5A, SOP8) – Low-Voltage Avionics & Auxiliary System Power Switch

Core Positioning & System Integration Advantage: This dual P-Channel MOSFET in a compact SOP8 package is the ideal solution for intelligent, high-density power distribution within the eVTOL's low-voltage (typically 12V/24V) system. It manages critical loads such as Flight Control Computers (FCC), sensors, communication radios, gimbal controllers, and landing gear actuators.

Application Example: Enables sequenced power-up/down of subsystems, load shedding based on flight mode or fault conditions, and provides robust over-current protection for sensitive avionics.

PCB Design & Control Simplicity: The dual integration drastically saves space on densely packed avionics boards. Using P-MOS as a high-side switch allows direct control via low-voltage logic from the Vehicle Management Computer (VMC), eliminating charge pumps and simplifying the gate drive circuit—a key advantage for reliability and noise-sensitive environments.

Key Parameter: With Rds(on) of 19mΩ @10V, it offers low voltage drop even at several amps, ensuring stable voltage rails for sensitive electronics.

3. The High-Voltage Interface Specialist: VBE15R10S (500V, 10A, SJ-Multi-EPI, TO-252) – High-Voltage DC Link Interface or High-Step-Up Converter Switch

Core Positioning & System Benefit: This 500V Super Junction MOSFET serves a critical role in interfacing with high-voltage charging systems (e.g., 400V DC fast charging) or as the main switch in a high-step-up DC-DC converter that generates a high-voltage bus from the main battery for potential high-power ancillary systems.

Key Technical Parameter Analysis:

High Voltage Robustness: The 500V rating provides a strong safety margin for 400V-class systems, handling voltage spikes from long cable harnesses or inductive switching events.

Balanced Performance: The SJ-Multi-EPI technology offers a good compromise between low switching loss (crucial for efficiency in converters) and cost-effectiveness compared to SiC solutions at this power/voltage level.

Compact Power Handling: In a TO-252 package, it can handle up to 10A, suitable for managing the interface current or converter power levels necessary for ancillary systems in this eVTOL class.

II. System Integration Design and Expanded Key Considerations

 

 

图2: 高端城市即时配送 eVTOL（载重 50kg）方案与适用功率器件型号分析推荐VBA4225与VBGL71203与VBE15R10S产品应用拓扑图_en_02_propulsion

 

1. Propulsion, Control, and Health Monitoring

High-Fidelity Motor Control: The VBGL71203, as part of the inverter, must be driven by high-speed, low-propagation-delay isolated gate drivers synchronized with the motor controller's FOC algorithm. Consistency in switching is vital for smooth torque and acoustic performance.

Digital Power Management: The VBA4225's gates should be controlled by the VMC or a dedicated Power Distribution Unit (PDU) with telemetry feedback (current sensing), enabling smart load management and predictive health monitoring.

High-Voltage Safety & Control: The VBE15R10S drive must include reinforced isolation where necessary and be integrated into the high-voltage interlock and pre-charge control loops.

2. Hierarchical and Aggressive Thermal Management Strategy

Primary Heat Source (Liquid Cold Plate): The VBGL71203 in the propulsion inverter is the dominant heat source. It must be mounted directly onto a liquid-cooled cold plate, with thermal interface material (TIM) optimized for minimal junction-to-coolant thermal resistance.

Secondary Heat Source (PCB Conduction & Forced Air): The VBE15R10S may require a small attached heatsink or rely on thermal vias to conduct heat to an internal forced-air-cooled board or chassis wall.

Tertiary Heat Source (PCB Conduction & Ambient): The VBA4225, given its lower power dissipation, can rely on optimized PCB copper pours and the vehicle's internal ambient airflow.

3. Engineering for Extreme Reliability and Airworthiness

Electrical Stress Protection:

 

 

图3: 高端城市即时配送 eVTOL（载重 50kg）方案与适用功率器件型号分析推荐VBA4225与VBGL71203与VBE15R10S产品应用拓扑图_en_03_auxiliary

 

VBGL71203: Requires careful layout to minimize DC-link loop inductance. Snubber networks may be necessary to clamp voltage spikes from motor winding inductance.

VBA4225: Loads like servos and solenoids require freewheeling diodes. Input transients should be filtered with TVS and capacitors.

VBE15R10S: In converter topologies, snubbers are essential to manage leakage inductance spikes from transformers or inductors.

Enhanced Gate Protection: All gate drives should feature TVS or Zener diodes for overvoltage clamp, series resistors for damping, and strong pull-downs. Redundant or monitoring circuits for gate health are advisable for critical propulsion paths.

Conservative Derating Practice:

Voltage Derating: Operational VDS/VDC should be ≤ 80% of rated BVDSS (e.g., VBE15R10S operating ≤400V).

Current & Thermal Derating: Maximum junction temperature (Tjmax) should be derated for mission profile (e.g., target Tj < 110°C for high reliability). Continuous and pulsed current ratings must be validated against worst-case thermal impedances.

III. Quantifiable Perspective on Scheme Advantages

Quantifiable Efficiency & Weight Saving: Utilizing VBGL71203 with its ultra-low Rds(on) can reduce inverter conduction losses by >25% compared to standard 100V MOSFETs, directly increasing hover time or allowing for a smaller, lighter battery pack for the same flight duration.

Quantifiable Integration & Reliability: The dual P-MOS VBA4225 consolidates two power switches into one SOP8 footprint, saving >60% board area compared to discrete solutions and reducing interconnection points, thereby improving the PDU's power density and MTBF.

System-Level Safety & Manageability: The clear separation of roles—high-current propulsion, intelligent low-voltage distribution, and specialized high-voltage handling—creates a modular, fault-isolated architecture that simplifies certification, testing, and in-field diagnostics.

IV. Summary and Forward Look

This scheme presents a cohesive, optimized power device strategy for a high-end urban delivery eVTOL, addressing the triumvirate of high-thrust propulsion, intelligent auxiliary management, and high-voltage interfacing.

Propulsion Level – Focus on "Ultimate Current Density & Efficiency": Leverage the most advanced SGT MOSFETs to minimize weight and loss in the highest power path.

Power Management Level – Focus on "Intelligent Integration & Control": Employ highly integrated multi-chip packages to achieve complex, software-defined power distribution with minimal hardware footprint.

System Interface Level – Focus on "Specialized Robustness": Select devices with specific voltage and technology attributes to safely and efficiently handle unique system interfaces.

 

 

图4: 高端城市即时配送 eVTOL（载重 50kg）方案与适用功率器件型号分析推荐VBA4225与VBGL71203与VBE15R10S产品应用拓扑图_en_04_hv_interface

 

Future Evolution Directions:

Full Wide-Bandgap Adoption: Transitioning the propulsion inverter to GaN HEMTs could enable even higher switching frequencies (>500kHz), drastically reducing motor harmonic losses and the size/weight of output filters.

Fully Integrated Intelligent Power Modules (IPMs): For the auxiliary system, moving towards IPMs that integrate MOSFETs, drivers, protection, and diagnostics in a single package would further enhance reliability and simplify design.

Health-Aware Predictive Operation: Integrating real-time junction temperature and on-resistance monitoring for critical switches like VBGL71203 can enable predictive maintenance and adaptive control for maximizing component life.

Engineers can refine this selection based on specific eVTOL parameters: exact battery voltage, peak/propulsion power requirements, detailed auxiliary load profiles, and the chosen thermal management architecture, paving the way for high-performance, safe, and reliable urban aerial delivery platforms.