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A critical external interference that often appears to pose a safety issue in rechargeable energy storage systems (RESS) for electric vehicles (EV) is ground impact due to stone impingement. This study aims to propose the new concept of the sandwich for structural battery protection using a lattice structure configuration for electric vehicle applications. The protective geometry consists of two layers of a twisted-octet lattice structure. The appropriate lattice structure was selected through topology and material optimization using an artificial neural network (ANN), genetic algorithms (GA), and multi-objective optimization with technique for order of preference by similarity to ideal solution (TOPSIS) methods. The optimization variables are the lattice structure relative density, ρ¯, angle, θ, and strength of the materials, σy. Numerical simulations were used to model the dynamic impact loading on the structures due to a conical stone mass of 0.77 kg traveling at 162 km/h. The two-layer lattice structure configuration appears to be suitable for the purposes of RESS protection. The optimum configuration for battery protection is a lattice structure with an angle of 66°, relative density of 0.8, and yield strength of 41 MPa. This optimum configuration can satisfy the safety threshold of battery-shortening deformation. Therefore, the proposed lattice structure configuration can potentially be implemented for electric vehicle applications to protect the battery from ground impact.

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Structural Lattice Topology and Material Optimization for Battery Protection in Electric Vehicles Subjected to Ground Impact Using Artificial Neural Networks and Genetic Algorithms