Development of a Sensorless ISG-EFI System using U558G ECU

Ms. Sucheta Raut, Mr. Vipul Dhumal , Ms. Suhani Khandetod, Mr. Harsh Pandit, Mr. Akshad Gupta, Mr. Bhushan Bansod, Mr. Sammyak Shende, Mr. Rishiket Deshmukh
1 Assistant Professor, Department of Electronics & Telecommunication Engineering, G H Raisoni Collage of

Engineering & Management, Nagpur, Maharashtra

2Executive Engineer, Sedemac Mechatronics Pvt Ltd, Pune, Maharashtra

3,4,5,6,7Student, Department of Electronics & Telecommunication Engineering, G H Raisoni Collage of Engineering & Management, Nagpur, Maharashtra

Abstract -:This paper presents the design and implementation of a U558G ECU-based control system integrating a sensorless Integrated Starter Generator (ISG) with an Electronic Fuel Injection (EFI) system for BS-VI compliant three-wheeler applications. The proposed architecture eliminates the need for conventional rotor position sensors by employing sensorless commutation techniques, thereby reducing system complexity, cost, and failure points under harsh operating conditions. The ECU performs real-time coordination of engine starting, fuel injection control, battery charging, and emission management within a unified platform. The integration of ISG functionality enables efficient engine cranking and energy recovery, while the EFI system ensures precise air–fuel mixture control based on dynamic engine conditions. The system also supports advanced diagnostic and emission monitoring functions in compliance with BS-VI OBD requirements. The overall implementation demonstrates improved engine start performance, better fuel utilization, reduced emissions, and enhanced system reliability, making it suitable for modern small commercial vehicle applications.

Keywords: U558G ECU, Sensor less ISG, Electronic Fuel Injection, Three-Wheeler, BS-VI OBD Stage II-B, Emission Control.