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In order to reduce engine control strategy development time and cost, the Hardware-In-the-Loop (HIL) simulation technology is developed. This paper establishes a simulation model and control platform based on the HIL structure for studying control strategy development and verification. A 125c.c. engine model verified by the experimental data is established in Matlab/Simulink, which is used as a virtual engine and then implemented in the xPC real-time system. The Motorola MC 68376 controller chip provides control signals included injection duration/timing and ignition timing for the virtual engine. A PCI-6024E input/output board is used as an interface between the controller and the virtual engine. A simulation model, which consists of engine, powertrain, tire, and pitch plane dynamics, is used to evaluate the response of engine dynamics and longitudinal dynamics via HIL simulation.

This paper develops an engine model for the model-in-the-loop (MIL) and hardware-in-the-loop (HIL) application to shorten the time duration and reduce the costs of developing and verifying the engine management system (EMS). The target engine is a 1.0L V-type two cylinder water-cooled spark-ignition engine. The engine model is developed using a so-called modulization method, which includes to: (1) separate the sub-models according to the different physical phenomena; (2) collect the sub-models to establish a library; (3) execute the component modules based on a pre-determined sequence by a more flexible way. The engine model is then applied in MIL structure for testing and verifying the control strategies in the developed EMS. After all strategies are verified, the HIL structure is constructed by a hardware controller and a virtual engine in the xPC target. The execution time-step of engine model is analyzed to keep enough accuracy and numeric stability for real-time simulation.

This paper established a hardware-in-the-loop (HIL) system for developing the engine management system (EMS) of a motorcycle, which combines xPC target real-time simulator and PC based controller. An engine model of 125cc four-stroke gasoline engine that included the calculation of cylinder pressure is employed to be a control plant. A proposed control strategy developed with application of this HIL is verified to be superior to the conventional EMS of motorcycles. The proposed controller can send fuel injection and spark ignition control signals every two revolutions accurately via stroke identification method. During the engine running period, perhaps the ignition coil or other electronic equipment will conduct noise that interfere crankshaft tooth signal. Therefore, a Kalman filter is designed to improve the robustness of controller. Under interference, the performance of proposed controller is more satisfied than that without Kalman filter.