Multi-Objective Lightweight Optimization and Decision for CTB Battery Box Under Multi-Condition Performance

To address the conflicts among objectives and the decision-making challenges in the multi-condition adaptive design of battery boxes for new energy vehicles, this study proposes a multi-objective collaborative optimization method based on an improved relaxation factor, aiming to achieve a comprehensive enhancement in both structural lightweighting and mechanical performance. A finite element model of the CTB high-strength steel roll-formed battery box was established and validated through modal testing. According to the Chinese National Standard GB 38031-2025, the mechanical responses of the battery box under random vibration, extreme operating conditions, and impact loads were analyzed to identify performance weaknesses. Sensitivity analysis was conducted to screen the design variables, and an improved relaxation factor strategy based on weight distribution difference information was introduced to construct a multi-objective collaborative optimization model. Furthermore, the entropy-weighted TOPSIS method was employed to enable intelligent decision-making on the Pareto solution set. The results demonstrate that the proposed method outperforms conventional approaches in both convergence speed and solution distribution uniformity. After optimization, the mass of the battery box was reduced by 12.38%, while multiple mechanical performance indicators were simultaneously improved, providing valuable theoretical and engineering guidance for the structural design of power battery systems.