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DOE OSTI2025

Engineering Out Industry 4.0 Cyber Risk

The increasing complexity and business requirements of operational technology (OT) devices is beginning to break the normal segmentation between information technology (IT) and OT networks. The introduction of industry 4.0 devices such as industrial internet of things (IIoT) and other intelligent industrial devices (IID), virtualized OT systems, OT cloud integration, and artificial intelligence (AI)-driven industrial control systems (ICS) has challenged traditional IT/OT cybersecurity strategies. Industry 4.0 devices are analyzed through the lens of well-regarded models such as the PERA model and confidentiality, integrity, and availability (CIA) security objectives, showing the division between what is needed and traditional cybersecurity countermeasures. In this paper, the practice of Cyber-Informed Engineering (CIE) is proposed to bridge the gap between IT/OT security, enhance the practice of cybersecurity in this modern age, and reduce the impacts of consequential events in OT.

42 - ENGINEERING↗

DOE OSTI2025

Time-Varying Output Delay Compensation-A Model-Free Approach and its Application on Cooperative On-Ramp Merging

This paper presents a model-free approach to compensate for time-varying output delay in networked control systems. The proposed architecture combines a model-free observer and the Smith predictor. The model-free observer estimates the current state while handling modeling errors and uncertainties of the system. The Smith predictor moves the effect of time delay outside the control closed-loop using the estimated delayed output and the actual output of the plant. The proposed method is applied to a cooperative on-ramp merging problem. First, an ultra-local model predictive control is implemented to provide a computationally efficient online speed planner agnostic to the vehicle dynamics. After that, a model-free observer is designed to estimate the current state. Finally, the proposed architecture is tested against a time-varying output delay with an upper bound of 200 milliseconds. The results demonstrate the effectiveness of the proposed method with improved tracking of intervehicle distance.

Waleed khan, Muhammad [The University of Texas at ↗

DOE OSTI2024

Rattlesnake User's Manual (V.3)

Rattlesnake is a combined-environments, multiple input/multiple output control system for dynamic excitation of structures under test. It provides capabilities to control multiple responses on the part using multiple exciters using various control strategies. Rattlesnake is written in the Python programming language to facilitate multiple input/multiple output vibration research by allowing users to prescribe custom control laws to the controller. Rattlesnake can target multiple hardware devices, or even perform synthetic control to simulate a test virtually. Rattlesnake has been used to execute control problems with up to 200 response channels and 24 shaker drives. This document describes the functionality, architecture, and usage of the Rattlesnake controller to perform combined environments testing.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Initial PIP-II Beam Current Monitor Fault Case Analyses & Beam Position Monitor Linearity Studies in CST Studio Suite

The use of non-invasive sensors & systems to measure particle beam characteristics is a crucial part of modern accelerator control systems due to their ability to return real time beam data while minimizing negative effects on beam quality. To ensure that one can be reasonably confident these sensors will behave as desired upon be-ing implemented within the beamline, simulations pre-dicting the performance of these sensors under beamline conditions can be used as a valuable tool for checking sensor functionality without a physical test bench. This paper details the design, testing, and results of two sensor models developed using CST Studio Suite soft-ware designed to mimic two sensors to be implemented within the PIP-III beamline: an elliptical, large-aperture beam position monitor (BPM) for which vertical & hori-zontal position signal linearity was analyzed, and an AC current transformer (ACCT) beam current monitor (BCM) used to search for potential fault cases within the BCM and beam pipe flange gaps. Special focus is given to the discovery of linearity variations within the BPM and the use of frequency domain techniques in the BCM fault case analyses.

Rouzky, A. R.↗

DOE OSTI2025

Adapting Traditional Hazards Analysis Methods to Address Cyber Risks

Traditional hazards analysis (HA) methods, originally developed to address physical and operational risks, often fall short when it comes to identifying and mitigating cyber threats. These cyber threats pose unique and evolving risks to critical infrastructure and industrial control systems (ICS). This report explores the integration of Cyber-Informed Engineering (CIE) principles into existing HA methods to enhance their ability to address cyber-induced risks. CIE provides organizations with a practical, cost-effective approach to closing the gap between traditional HA methods and the need for cyber risk mitigation. By leveraging existing safety processes and controls, CIE allows users to examine and mitigate cyber vulnerabilities without overhauling existing HA methods. This report identifies areas where HA and CIE naturally align and where their approaches diverge. It emphasizes how CIE principles can be used to adapt HA methods, broadening their scope to include cyber risks and enabling the mitigation of cyber- induced impacts alongside traditional hazards and failure scenarios. This report examines how CIE can be applied across various HA methods—such as Hazard and Operability Studies (HAZOP), Probabilistic Risk Assessment (PRA), Failure Modes and Effects Analysis (FMEA), Systems-Theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), and Layers of Protection Analysis (LOPA). It provides strategies for integrating CIE to strengthen the identification, assessment, and mitigation of cyber-induced risks. The findings offer a structured entry point for organizations to embed CIE concepts into hazards and safety analyses, as well as broader engineering processes, ultimately supporting the design and operation of a more resilient infrastructure.

42 ENGINEERING↗

DOE OSTI2025

Adapting Traditional Hazards Analysis Methods to Address Cyber Risks

42 - ENGINEERING↗

DOE OSTI2025

Hardware-in-Loop Modules for Testing Automated Ventilator Controllers

Automated ventilator controllers have the potential to simplify oxygen and carbon dioxide management for trauma. In the pre-hospital or military medicine environment, trauma care can be required for prolonged periods by personnel with limited ventilator management training. As such, there is a need for closed-loop control systems that can adapt ventilator management to a complex, ever-changing medical environment. Here, we present a novel hardware-in-loop test platform for the independent troubleshooting and evaluation of oxygen and carbon dioxide automated ventilator management capabilities. The oxygen management system provides an analogue blood oxygen signal that is responsive to the fraction of inspired oxygen and the peak inspiratory pressure ventilator settings. A tested oxygenation controller successfully reached the target oxygen saturation within 5 min. The carbon dioxide removal system integrates with commercial ventilator technology and mimics carbon dioxide generation, lung compliance, and airway resistance while providing an end-tidal carbon dioxide level that is responsive to changes in the tidal volume and respiratory rate settings. A test mechanical ventilator controller was able to regulate EtCO2 regardless of the starting value within 10 min. This highlights the system’s functionality and provides proof-of-concept demonstrations for how the hardware-in-loop test platforms can be used for evaluating closed-loop controller technologies.

Berard, David (ORCID:0000000322863846)↗

DOE OSTI2025

Xopt and Badger: a machine learning ecosystem for real-time accelerator control and optimization

Machine learning (ML)-based black-box optimization algorithms have demonstrated significant improvements in accelerator optimization speed, often by orders of magnitude. However, deploying these algorithms in real-time facility control remains challenging due to the specialized expertise and infrastructure required. To bridge this gap, we introduce the Xopt ecosystem, a versatile suite of tools designed to make advanced ML-based optimization accessible to the broader accelerator community. This ecosystem includes Xopt, a modular Python framework that facilitates the integration of ML-based optimization algorithms with arbitrary control problems, and Badger, a graphical user interface built on top of Xopt, which enables seamless deployment of ML algorithms in real-time control systems. The Xopt ecosystem has been successfully applied towards solving challenging real-time control problems at leading international accelerator facilities, including SLAC, LBNL, Argonne, Fermilab, BNL, DESY, and ESRF, demonstrating its effectiveness in real-world optimization tasks. In this presentation, we provide an overview of Xopt’s capabilities and illustrate its impact through case studies from SLAC accelerator facilities including LCLS, LCLS-II, and FACET-II.

Roussel, Ryan [SLAC]↗

DOE OSTI2026

APOLLO: a facility-scale differentiable virtual accelerator for Fermilab

As the design complexity of modern accelerators grows, there is more interest in using advanced simulations that have fast execution time or yield additional insights like gradients. The FAST/IOTA facility has been working on implementing and experimentally validating an end-to-end digital twin that is both fast and gradient-aware, allowing for rapid prototyping of new software and experiments with minimal beam time costs. Our framework integrates physics and ML codes for linac and ring simulation through a set of generic interfaces between surrogate and physics-based sections. To reproduce device inputs and outputs, system state is exposed as a deterministic discrete event simulator. Because Fermilab is undergoing control system transition, both EPICS and ACNET frontends are supported. Recently, we have begun transitioning to a new community lattice standard, PALS, as well as developing standardized infrastructure for data ingest and normalization to prepare for model calibration during FAST proton injector commissioning. We discuss implementation details as well as challenges, and future plans to extend modelling to main complex proton accelerators like PIPII and Booster.

Kuklev, Nikita [Fermilab]↗

DOE OSTI2024

Convergence Analysis for an Online Data-Driven Feedback Control Algorithm

This paper presents convergence analysis of a novel data-driven feedback control algorithm designed for generating online controls based on partial noisy observational data. The algorithm comprises a particle filter-enabled state estimation component, estimating the controlled system’s state via indirect observations, alongside an efficient stochastic maximum principle-type optimal control solver. By integrating weak convergence techniques for the particle filter with convergence analysis for the stochastic maximum principle control solver, we derive a weak convergence result for the optimization procedure in search of optimal data-driven feedback control. Numerical experiments are performed to validate the theoretical findings.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Proof-of-Concept for Sensor Modeling in MOOSE for the Design of Autonomous Nuclear Reactor Control

Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this paper, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Proof-of-Concept for Sensor Modeling in MOOSE for the Design of Autonomous Nuclear Reactor Control

Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. For this reason, recent studies have investigated autonomous control by using adaptive model predictive control and multi-objective optimization for heat pipe–cooled microreactors under normal and heat pipe failure conditions. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this poster, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

A Portable Wave Tank and Wave Energy Converter for Engineering Dissemination and Outreach

Wave energy converters are a nascent energy generation technology that harnesses the power in ocean waves. To assist in communicating both fundamental and complex concepts of wave energy, a small-scale portable wave tank and wave energy converter have been developed. The system has been designed using commercial off-the-shelf components, and all design hardware and software are openly available for replication. This project builds on prior research conducted at Sandia National Laboratories, particularly in the areas of WEC device design and control systems. By showcasing the principles of causal feedback control and innovative device design, SIWEED not only serves as a practical demonstration tool but also enhances the educational experience for users. This paper presents the detailed system design of this tool. Furthermore, via testing and analysis, we demonstrate the basic functionality of the system.

educational↗

DOE OSTI2025

Unified Model of Current-Limiting Grid-Forming Inverters for Large-Signal Analysis

Grid-forming (GFM) inverters can hardly withstand any overloading. As such, GFM inverters need a current limiter in their control system to avoid hardware damage during overloading or grid disturbances. When the current limiter is engaged for inverter protection, however, it dynamically changes the inverter output impedance, which can significantly affect the system behavior against large disturbances. For example, when the current limiter curtails the output power, the primary controller of the GFM inverter-which generates the voltage and angle reference-is prone to losing synchronization with the grid. This can cause large-signal instability in the network. This paper presents a unified GFM current-limiter model to gain a deeper understanding of the impact of the GFM inverter current limiting on large-signal instability and other system behaviors. The unified model captures several well-known current limiters for GFM inverters, and it reveals their large-signal equivalence characterized by the limiter angle. We use the unified model to present in-depth insights into the driving forces that cause large-signal instability in GFM inverter-driven grids. Further, this paper illustrates that the unified model can be used as a tool for assessing the system-level impacts of various GFM current-limiter designs during grid disturbances. Using numerical, analytical, electromagnetic transient models, and a hardware setup, the validity of the unified model is evaluated.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes

Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Intelligent Experiments Through Real-time AI: Fast Data Processing and Autonomous Detector Control for sPHENIX and Future EIC Detectors (Final Report)

The overall vision of this project was to integrate real-time artificial intelligence (AI) directly into the data acquisition and detector-control systems of nuclear physics experiments, including both fast online event selection and an autonomous detector-control feedback loop. The work carried out under the award focused on the fast online event-selection half of that vision: the efficient recording of low-momentum heavy-flavor (HF) hadron decays in proton-proton collisions at the sPHENIX experiment at the Relativistic Heavy Ion Collider (RHIC)—an observable that requires fast tracking and topological trigger selection not previously demonstrated at RHIC, and that is essential for QCD studies at future facilities such as the Electron-Ion Collider (EIC). The autonomous detector-control (GPU-based feedback) component named in the project title remained a design concept and was not implemented under this award. The Massachusetts Institute of Technology (MIT) group led the offline simulation and data processing needed to train the machine-learning (ML) models, the translation of trained models to Field-Programmable Gate Array (FPGA) firmware using the hls4ml framework, and the physics validation of heavy-flavor reconstruction. Over the award period, the team developed and hardware-tested the principal components of an AI-based heavy-flavor trigger on simulated and recorded sPHENIX tracker data: a software Bipartite Graph Attention Network (BiGAT) trigger model reaching > 95% signal efficiency at 99% background rejection; an FPGA-native hit clusterizer matching the offline clustering; smaller networks synthesized to FPGA within the required sub-10 µs latency; and an assembled decoder–clusterizer–inference firmware chain exercised on the FELIX readout board. A complete, fully integrated hardware demonstrator was not finished within the award period. This report documents the project goals, the MIT group’s contributions, the technical accomplishments, and the outlook toward applications at the future EIC ePIC detector.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2026

Automation of Nanoparticle Synthesis Processes in a Plasma Environment Using LabVIEW

This work presents an automated control system for the synthesis of nanomaterials by plasma-enhanced chemical vapor deposition (PECVD), implemented using the LabVIEW software environment. The main objective of the study is to develop an integrated hardware-software platform that enables sequential control of the key stages of the PECVD process, including vacuum chamber preparation, pressure monitoring, working gas supply, plasma ignition, power matching, cyclic nanomaterial growth, and optical monitoring of nanoparticles in the plasma environment. The use of LabVIEW made it possible to integrate actuator control, experimental parameter acquisition, and realtime process visualization within a single automated system. The automated cycle begins with evacuation of the reaction chamber to a predefined base pressure. Transition to the next stage is permitted only after the specified pressure threshold has been reached, ensuring reproducible initial conditions for each experiment. The program then controls the supply of the working gas through mass flow controllers (MFCs). In this work, two gas-flow control modes were considered: analog control using a 0-5 V voltage signal and digital communication via RS-232 interface. It was shown that the analog approach requires accurate scaling of the control voltage, since applying 5 V corresponds to full-scale opening of the controller and results in the maximum gas flow. In contrast, the RS232 interface enables the gas flow rate to be specified directly in sccm, improving the accuracy, flexibility, and convenience of gas-environment control. After pressure stabilization, LabVIEW initiates RF plasma ignition and executes the RF matching algorithm aimed at minimizing reflected power and improving the stability of the plasma process. A separate software module implements the cyclic nanomaterial growth mode, in which the plasma-on time, plasma duration, and total number of synthesis cycles are predefined. This approach makes it possible to control material accumulation on the substrate and to correlate the process parameters with the morphological characteristics of the resulting nanostructures. The final module of the system is designed for optical monitoring of the nanoparticle cloud density in dusty plasma. For this purpose, the change in the intensity of laser radiation passing through the plasma region is recorded using a photodetector and a Keithley 2401 measuring unit connected to LabVIEW via RS-232 interface. The difference between the initial and modified optical signal intensity is used as a diagnostic parameter characterizing the formation and temporal evolution of nanoparticles. The developed system demonstrates that LabVIEW can be effectively applied not only for the automation of individual instruments, but also for the implementation of a complete digital control cycle for PECVD-based nanomaterial synthesis.

PECVD↗

DOE OSTI2025

Tracking and Positioning System for Floating Solar (CRADA Abstract)

The project goal is to develop a floating solar photovoltaics (FPV) tracking & position system that: (1) increases annual energy production of FPV projects by >10%, (2) lowers levelized cost of energy (LCOE) for FPV by >10%, and (3) leverages U.S. contract supply chain & manufacturing. The outcome of the project will be a certified tracking product that has undergone extensive field testing and is ready for commercial sales. The primary objectives for each budget period are: • BP1: Define product requirements, develop initial controls architecture and design other sub-components, complete small-scale pilot testing, install a larger-scale pilot, secure sites for commercial pilots, and develop the beta-version of a user portal. • BP2: complete control system and sub-component design, successful demonstration and testing at a commercial pilot, certification & bankability, finalize user portal, and complete various commercialization activities related to supply chain, customer acquisition, and sales. PNNL will provide support during both project phases for prototype development and testing of the controls architecture, software, and hardware components of the tracking and positioning system. PNNL will provide support during both project phases for prototype development and testing of the controls architecture, software, and hardware components of the tracking and positioning system. This effort represents PNNL’s first opportunity to support the floating solar photovoltaics (FPV) industry with capabilities, facilities, and personnel developed to contribute to the marine energy (e.g., wave and tidal energy) sector. This portfolio expansion leverages internal and DOE EERE investments and the growing visibility of PNNL-Sequim’s Marine and Coastal Research Laboratory (MCRL) and our marine research capabilities, in general. The development of effective and low-cost FPV platforms is a potential way to increase the nation’s set of tools for providing emission-free electricity without utilizing valuable terrestrial resources. Successful commercialization of such a project may lead to economic benefits through job creation, supply chain creation, and access to a cheaper source of electricity.

14 SOLAR ENERGY↗