Advanced Vehicle Powertrain Design, Validation, and Integration for the EcoCAR 2 Advanced Vehicle Technology Competition 2014-01-1926

For the EcoCAR 2 collegiate engineering competition, The University of Tennessee is modifying a 2013 Chevrolet Malibu Eco from a mild hybrid into a series-parallel plug-in hybrid electric vehicle. For this design, the team is exchanging the engine for one that is E85 compatible, slightly separating the engine and transmission, and coupling an electric generator to the engine. In the rear of the vehicle, a modified all-wheel drive subframe will be implemented. This subframe will house a traction motor and a single gear electric drive transmission. A custom fuel tank and fuel system will be constructed for the vehicle, in order to use E85 fuel. Furthermore, an energy storage system will be placed in the rear of the vehicle, in the trunk and spare tire space. Modifications for the packaging must be made and analysis must be performed to validate the structural integrity of all modifications.

Tennessee's engineering team is made up of five specific groups: mechanical, thermal, electrical, controls, and center stack teams. This report details the work that was done strictly by the mechanical team in Year Two. This paper outlines the general design of the powertrain, the changes made to the architecture and vehicle components during Year Two of the competition, the analysis performed on modified and replacement components, and the actual implementation of the components into the Malibu.