Optimization of thin-walled battery protector design for electric vehicles under ground impact conditions using genetic algorithm

Ensuring electric vehicle battery safety is critical, as impacts from road debris or ground collisions can cause short circuits and thermal runaway. This study optimizes a thin-walled battery protector to enhance impact resistance while maintaining a lightweight design. A genetic algorithm-based optimization method and finite element analysis were used to determine the ideal thickness for minimizing deformation and maximizing specific energy absorption. Compared to the bottom armor plate, the optimized thin-walled protector with a 0.8572 mm thickness reduces battery deformation by 8.23 %, achieving 2.23 mm, while increasing specific energy absorption by 55.2 %, reaching 2157.6 kJ/kg. These improvements enhance battery safety by reducing mechanical failure risks without excessive weight. The optimized structure provides superior crashworthiness and material efficiency, offering a more effective solution for battery protection. This study applies genetic algorithms to optimize thin-walled protectors, balancing structural integrity and energy absorption. Unlike previous research focused on conventional plates or composite materials, this work presents a systematic approach for thin-walled structures under impact conditions, advancing lightweight, highperformance battery protectors for electric vehicles.