The safety and reliability of battery packs are crucial to the overall performance of electric vehicles, while their structural design is challenged by the complex coupling of flow, thermal, and mechanical fields. A global multiphysics coupling model was established, and strong-weak coupling relationships were simplified to enable efficient computation. Static-dynamic analyses under representative operating conditions were conducted, and regression models for weight and first-order natural frequency were constructed using Box-Behnken design combined with response surface methodology. An improved HSGNSGA-II algorithm, integrating hyperspherical sampling and Gaussian perturbation, was developed to achieve lightweight and high-stiffness optimization. In addition, a fatigue damage model incorporating temperature effects was proposed to evaluate the reliability life of the optimized battery pack under one- and two-dimensional load spectra. The optimized design achieved a 3.15% reduction in weight, maintained modal performance, and significantly improved fatigue reliability. The study provides a systematic framework for multiphysics-based optimization and reliability evaluation of battery packs, with transferable value for applications requiring high reliability under harsh conditions such as aerospace, energy storage, and industrial robotics.
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