Migration of fine materials such as soil from the roadbed and the ground will gradually pollute the aggregate in the arrester bed of truck escape ramps. However, there are few studies on the impact of aggregate pollution of the arrester bed on the stopping distance of runaway vehicles. This paper uses the discrete element method to study the influence of aggregates with different degrees of pollution on stopping distance by taking silty cohesive soil as a typical pollutant. In this paper, the stopping process of the uncontrolled vehicle on the arrester bed with different pollution levels was numerically simulated. The simulation results show that the uncontrolled vehicle’s stopping distance increases with the contaminated aggregate’s soil content. The simulation results show that when the soil content in the contaminated aggregate is less than 15%, the increase in the stopping distance of the uncontrol vehicle is less than 5%; when the soil content is 20–25%, the stopping distance of the uncontrolled vehicle increases by more than 20%; and when the soil content is 30–35%, the stopping distance of uncontrol vehicle increases by more than 50%. Different maintenance measures should be taken according to the increase in stopping distance.

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.

Lightweight design and crashworthiness of protective structures are critical for battery safety in electric vehicles (EVs). This study addresses the limited research on cross-sectional shape design of high-strength steel double-cell roll-formed tubes (DCRFTs), widely used in EV bumper beams, battery boxes, and electric bus frames. A parametric design method is proposed based on three parameters: middle flange offset (o), upper deflection angle (α), and lower deflection angle (β). Under the constraints of constant cross-sectional height and enclosed area, this method systematically generates diverse shapes, including square, trapezoid, hexagon, re-entrant hexagon, and various hybrid shapes. Validated finite element models were employed to analyze the deformation modes and crashworthiness of DP980 steel DCRFTs under idealized lateral three-point bending with simple supports. The results indicated that the re-entrant hexagon section reduced maximum deformation (Disp) by 2.95%, peak crushing force (PCF) by 9.53%, and improved crushing force efficiency (CFE) by 13.88% compared to the baseline square section. The parametric study and sensitivity analysis confirmed that the offset (o) was the most critical parameter, contributing over 80% of the variance in Disp, PCF, and CFE. Multi-objective optimization using an RBF surrogate model and the NSGA-II algorithm yielded Pareto optimal solutions. Compared to the baseline, three representative solutions achieved Disp reductions of 11.83–25.10% and CFE improvements of 15.63–22.26%, each with distinct trade-offs among objectives. This work establishes a methodological framework for parametric cross-section design of roll-formed profiles; its extension to realistic boundary conditions will further facilitate practical EV protective structure design.

To address the significant degradation of steering performance in dual-motor steer-by-wire (DMSBW) systems caused by the coupling of communication delays and motor faults, a robust fault-tolerant control strategy is proposed under the dual-motor collaborative driving mode. First, a matrix polytopic model is employed to describe the nonlinearities introduced by delays, establishing a delay-dependent DMSBW system dynamics model. Second, for electrical faults such as internal motor short circuits that cause a sudden drop in rotational speed, an adaptive motor-switching fault-tolerant mechanism is designed based on a smooth monitoring function to achieve rapid fault detection and steering function reconstruction. Furthermore, considering the coupled impact of delays and faults, a robust linear quadratic regulator (LQR) controller with feedforward compensation is designed to enhance system fault tolerance and robustness. Simulation results demonstrate that under steering wheel angle step input with delays, the proposed strategy achieves a rapid response without significant overshoot, and the steady-state tracking error is significantly reduced. In variable-speed single lane change maneuvers with coupled delays and severe motor faults, the peak and root mean square (RMS) errors of the front wheel angle are reduced to 0.0112 rad and 0.0031 rad, respectively. Compared to the delay-compensated nonlinear model predictive control (NMPC) and sliding mode control (SMC) strategies that do not account for delays, the peak error is reduced by 15.79% and 45.37%, while the RMS error decreases by 27.91% and 35.42%, respectively. Additionally, the peak and RMS errors of the sideslip angle and yaw rate are substantially reduced, validating the strategy’s excellent steering fault tolerance, robustness, and vehicle handling stability.