Cell-to-Body (CTB) and Cell-to-Chassis (CTC) technologies enhance body performance through integration. This article proposes a novel hybrid cellular automata (HCA)-based multi-case topology optimization method for CTB-specific battery pack system (BPS) design, uniquely integrating linear (bending/torsional stiffness) and nonlinear (crash) loads. Simulation-derived weights guide BPS optimization under multi-constraints. Results demonstrate 41.3% reduction in equivalent plastic strain (EPS) under frontal crash, 38.9% under mid-column crash and 6.7%/5.7% gains in bending/torsional stiffness. Optimized structures exhibit efficient force transfer, evidenced by uniform stress distributions and reduced von Mises stress. This work advances integrated BPS design for CTB/CTC architectures, improving vehicle safety and NVH performance.
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