Manufacturability-Constrained Multi-Objective Optimization of an EV Battery Pack Enclosure for Side-Pole Impact
摘要整理
This work minimizes battery pack enclosure mass (kg) and peak deformation (mm) under a side-pole impact condition and validates the results by finite-element reruns complemented by coupon-level material tests. A 64-run optimal Latin hypercube dataset trained ARD Matérn-5/2 Gaussian-process surrogates, and NSGA-II performed a multi-objective search on a manufacturability grid (Δt = 0.5 mm). Decision-making processes used knee-region filtering and TOPSIS in the normalized objective space with robustness checks (uncertainty inflation, weight perturbation, and cross-kernel audit). The representative optimum reduced mass from 149.40 kg to 115.20 kg (−22.89%) while keeping peak deformation essentially unchanged (66.17 → 66.25 mm) in independent reruns. To examine material dependence, an orthotropic CFRP cross-check was performed by substituting the upper cover and side walls: the iso-thickness mapping yields 90.40 kg with 68.67 mm (+3.65% vs. aluminum x⋆), whereas a constrained iso-mass setting (H1 = 7.0 mm, H2 = 7.0 mm) gives 111.70 kg with 80.85 mm (+22.04%). The observed trends are consistent with the laminate’s lower transverse-shear moduli and shear-sensitive load paths; damage evolution and lay-up optimization are outside the present scope. The workflow provides a reproducible route to balance lightweighting and deformation control for battery pack enclosures.