Hybrid electric vehicle technology has become a preferred method for the automotive industry to reduce environmental impact and fuel consumption of their vehicles. Hybrid electric vehicles accomplish these reductions through the use of multiple propulsion systems, namely an electric motor and internal combustion engine, which allow the elimination of idling, operation of the internal combustion engine in a more efficient manner and the use of regenerative braking. However, the added cost of the hybrid electric system has hindered the sales of these vehicles. A more cost effective design of an electro-hydraulic braking system is presented. The system electro-mechanically controlled the boost force created by the brake booster independently of the driver braking force and with adequate time response. The system allowed for the blending of the mechanical and regenerative braking torques in a manner transparent to the driver and allowed for regenerative braking to be conducted efficiently. A systematic design process was followed, with emphasis placed on demonstrating conceptual design feasibility and preliminary design functionality using virtual and physical prototyping. The virtual and physical prototypes were then used in combination as a powerful tool to validate and develop the system. The role of prototyping in the design process is presented and discussed. Through the experiences gained by the author during the design process, it is recommended that students create physical prototypes to enhance their educational experience. These experiences are evident throughout the thesis presented.

Hybrid electric vehicle technology has become a preferred method for the automotive industry to reduce environmental impact and fuel consumption of their vehicles. Hybrid electric vehicles accomplish these reductions through the use of multiple propulsion systems, namely an electric motor and internal combustion engine, which allow the elimination of idling, operation of the internal combustion engine in a more efficient manner and the use of regenerative braking. However, the added cost of the hybrid electric system has hindered the sales of these vehicles. A more cost effective design of an electro-hydraulic braking system is presented. The system electro-mechanically controlled the boost force created by the brake booster independently of the driver braking force and with adequate time response. The system allowed for the blending of the mechanical and regenerative braking torques in a manner transparent to the driver and allowed for regenerative braking to be conducted efficiently. A systematic design process was followed, with emphasis placed on demonstrating conceptual design feasibility and preliminary design functionality using virtual and physical prototyping. The virtual and physical prototypes were then used in combination as a powerful tool to validate and develop the system. The role of prototyping in the design process is presented and discussed. Through the experiences gained by the author during the design process, it is recommended that students create physical prototypes to enhance their educational experience. These experiences are evident throughout the thesis presented.

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