Multi-objective optimization design of power pack structures based on floating projection topology optimization

Battery packs are vital components for storing and releasing energy. However, during driving, the intensity of heat emission and mechanical performance of electric vehicles are interrelated but conflicting indicators. To address this problem, this study topologically optimizes the power pack support structure with multiple objectives of minimizing compliance and heat dissipation, aiming to achieve a comprehensive and integrated design scheme. A floating projection topology optimization (FPTO) method is proposed, which normalizes the objectives of structural compliance and heat dissipation and derives the sensitivity. FPTO demonstrates superior objective function values and smoother topology configuration compared to the solid isotropic material with penalization (SIMP) method. Finally, the proposed method is applied to the power pack support structure. The results demonstrate that the method obtains a design solution with excellent mechanical performance and high heat dissipation performance with a suitable trade-off. The lightweight design of the overall structure of the battery pack is achieved.