This thesis outlines the mechanical design and integration of a P0/P4 Parallel Through-the-Road Hybrid Electric Vehicle. The vehicle is McMaster University’s entrant into the EcoCAR Mobility Challenge, the current offering of the long running Advanced Vehicle Technology Competition series. The competition challenges students to electrify a 2019 Chevrolet Blazer, while meeting the needs of a car sharing platform. The design of the McMaster vehicle will be explored, starting with a walkthrough of the architecture selection process performed in the first year of competition. The design process of both powertrains will be examined, starting with component selection and working up to assembly integration. Particular attention will be paid to the rear electrified powertrain, which has been designed from the ground up for this purpose, including custom single speed gear reduction. The current integration status of the vehicle will be shown. Timeline delays due to the COVID-19 pandemic will be discussed, as well as next steps to move towards complete vehicle integration. A vehicle testing plan will be put forward, using the cutting edge systems available at the McMaster Automotive Resource Center. / Thesis / Master of Applied Science (MASc) / As Hybrid Electric Vehicles continue to grow in market share, the Advanced Vehicle Technology Competition series seeks to challenge and train students in this booming industry. The current competition in this series is the EcoCAR Mobility Challenge, where students must re-engineer a 2019 Chevrolet Blazer into a hybrid vehicle over four years. The vehicle is to incorporate new autonomous technologies, as well as be targeted at a car sharing application. The McMaster University Engineering EcoCAR team has entered into this competition. This thesis describes the detailed mechanical design of the new vehicle. This begins by examining the selected hybrid layout, or architecture. Then the design process of individual systems is shown, with emphasis on how each system meets the McMaster team goals. Then the current state of the vehicle is shown, and delays due to COVID-19 are discussed. Finally, a testing plan is proposed, to ensure all systems can meet their design goals.

The rise in overall powertrain complexity and the stringent performance requirements of a hybrid electric vehicle (HEV) have elevated the role of its powertrain control strategy to considerable importance. Iterative modeling and simulation form an integral part of the control strategy design process and industry engineers rely on proprietary ?legacy? models to rapidly develop and implement control strategies. However, others must initiate new algorithms and models in order to develop production-capable control systems. This thesis demonstrates the development and validation of a charge-sustaining control algorithm for a through-the-road (TTR) parallel hybrid (diesel-electric) powertrain. Some unique approaches used in powertrain-level control of other commercial and prototype vehicles have been adopted to incrementally develop this control strategy. The real-time performance of the control strategy has been analyzed through on-road and chassis dynamometer tests over several standard drive cycles. Substantial quantitative improvements in the overall HEV performance over the stock configuration, including better acceleration and fuel-economy have been achieved.