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In order to continue the effort of converting traditional internal combustion engine (ICE)-based vehicles into hybrid-electric vehicles (HEV), it is important to consider a variety of design architectures in which hybrid-electric operation is achieved. Such architectures include power split, parallel, and series. Of the previously stated architectures, the Purdue EcoMakers of the EcoCar 2 international Advanced Vehicle Technology Competition (AVTC) have chosen a parallel-through-the-road architecture for their 2013 Chevrolet Malibu provided by General Motors. From this, the Purdue EcoMaker vehicle design will be used as a case study for the design challenges and optimization strategies that are experienced when choosing this specific architecture for a light-duty passenger vehicle. This paper will focus on the design procedure and structural analysis of the custom rear suspension cradle created by the Purdue EcoMakers.

A parallel-through-the-road (PTTR) plug-in hybrid electric vehicle is being created by modifying a 2013 Chevrolet Malibu. This is being accomplished by replacing the stock 2.4L gasoline engine which powers the front wheels of the vehicle with a 1.7L diesel engine and by placing a high voltage electric motor in the rear of the vehicle to power the rear wheels. In order to meet the high voltage needs of the vehicle created by the PTTR hybrid architecture, an energy storage system (ESS) will need to be created. This paper explains considerations, such as location, structure integrity, and cooling, which are needed in order to properly design an ESS.