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In recent years the fuel injection technology has taken a great leap in two-wheeler industries both in terms of having lean emissions and in terms of improving efficiency. Especially in a market like India where fuel efficiency is given, as prime importance and fuel contamination duly exists, it becomes all the more a bigger challenge to address to these kinds of problems by some means. The main function of the fuel system is to make sure right amount of fuel is injected into the intake manifold at right time with the help of Electronic Control Unit. Variation from the right quantity and quality of fuel leads to partial burning and finally to more emissions and poor performance. So monitoring fuel pressure, there by the quantity and fuel quality is very much important to reduce emissions and to achieve desired performance.

In today's automotive power train control, the usage of model based control system is getting more focused because of the advantages associated with this approach. The model-based system can be implemented to predict and control different control parameters associated with Power train control. As a part of this work a multivariable control oriented model is developed to control the inlet manifold airflow of a small S.I. engine running on Gas. A stepper motor-based actuator is placed on the gas flow control path. A model based controller approach is adopted to control the actuator, which is placed on the low-pressure tube with inlet manifold to control the gas flow. In the initial phase of work, a state based non-linear model is developed for the actuator. This model captures the total dynamics of a permanent magnet stepper motor-based flow control device in a state space model. Different parameters for the model are calculated using system identification methodology.

The growing challenges being met by the automotive industry are raising the needs and expectations for detailed simulation with in short time. Today there is more pressure to get products to market faster and reduce design cycle times. This has led to a need for dynamic testing, where components are tested while in use with the entire system, either real or simulated, unlike in static testing where only typical functional testing is done. This dynamic testing is defined as Hardware-in-Loop (HIL) testing where it includes sensors to send signals to the control system, actuators to receive signals, a controller to process data, a Human-Machine Interface (HMI) and a development post simulation analysis platform. The engine simulator, which is proposed in this paper, has been developed by TVS-M using a high speed embedded controller with a FPGA based I/O module. In the background a complex plant model of engine is running in a dedicated operating system platform.