The evaluation of propulsion systems used in UAVs is of paramount importance to enhance the flight endurance, increase the flight control performance, and minimize the power consumption. This evaluation, however, is typically performed experimentally after the preliminary hardware design of the UAV is completed, which tends to be expensive and time-consuming. In this paper, a comprehensive theoretical UAV propulsion system assessment is proposed to assess both static and dynamic performance characteristics via an integrated simulation model. The approach encompasses the electromechanical dynamics of both the motor and its controller. The proposed analytical model estimates the propeller and motor combination performance with the overarching goal of enhancing the overall efficiency of the aircraft propulsion system before expensive costs are incurred. The model embraces an advanced blade element momentum theory underpinned by the development of a novel mechanism to predict the propeller performance under low Reynolds number conditions. The propeller model utilizes XFOIL and various factors, including post-stall effects, 3D correction, Reynolds number fluctuations, and tip loss corrections to predict the corresponding aerodynamic loads. Computational fluid dynamics are used to corroborate the dynamic formulations followed by extensive experimental tests to validate the proposed estimation methodology.
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