Numerical Investigation of Stepped Ram-Air Inlets for Air Capture and Thermal Management in a UAV Power Cabin

Unmanned aerial vehicles (UAVs) used in low-altitude mobility and electric aviation are increasingly required to carry higher payloads, operate for longer durations and maintain reliable performance under constrained installation conditions. In compact power cabins, batteries, controllers, power distribution units and auxiliary actuators are densely arranged, making cabin thermal management a critical design issue. In this study, a full-scale conjugate flow and heat transfer model is developed for the power cabin of a UAV and validated against thermal management experiments. The validated model is then used to examine how a conventional rectangular ram-air inlet and a proposed stepped ram-air inlet affect air capture, internal flow organization and temperature distribution. The inlet area of the rectangular configuration is first varied to establish a baseline, after which the transition arc ratio, spacing ratio and area ratio of the stepped inlet are parametrically investigated. The results show that increasing the rectangular inlet area from 0.002 to 0.008 m2 increases the total captured mass flow rate from 0.258 to 1.084 kg/s, whereas the cabin average temperature decreases by 0.34 °C. By contrast, the cabin maximum temperature decreases nonlinearly, with a 27.2% reduction when the area increases from 0.004 to 0.006 m2. These results indicate that air capture and the cabin average temperature alone are insufficient to evaluate cooling effectiveness in a compact multi-source cabin. For the stepped inlet, the transition arc ratio controls the turning of the incoming flow, the spacing ratio governs shielding and backflow between adjacent inlet sections, and the area ratio redistributes the dominant inlet sections. The best-performing stepped-inlet configuration among the tested cases increases the captured mass flow rate by 32.8% compared with the rectangular baseline under the same opening constraint and improves the utilization of cooling air around high heat load components. This study demonstrates that ram-air inlet design for UAV power cabins should be treated as a coupled problem of the mass flow capture, internal flow path and component-level thermal response.