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DOE OSTI2023

Supply Chain Binary Program Assessment Annual Report

Secure environments face a steadily increasing threat from the introduction of scientific equipment that includes extensive software components. Devices such as powerful microscopes, 3d printers, programmable logic controllers, and many others, increase our capability and scientific output. Unfortunately, they now frequently include an entire computing stack with custom software bundled along with entire operating systems. Our ability to introspect and understand binary software is extremely limited, opening up the possibility of malicious third-parties including software that compromises our critical missions.

42 ENGINEERING↗

DOE OSTI2024

PLC Vulnerabilities and Mitigations

Programmable Logic Controllers (PLCs) are used extensively in many high-importance industrial and nonindustrial settings including controlling elevators, manufacturing machines, and utility facilities such as power and natural gas, however cybersecurity protection for them has been neglected. Within recent years, PLCs have been put under more security scrutiny and experts have advocated for changes from the addition of protocol encryption and network segmentation to intrusion detection systems on the PLCs themselves. While PLC security is critical, a large portion of the PLCs available today will never receive these changes due to being legacy or the difficulty of overhauling the security on existing systems. Due to the infeasibility of applying many recommended security measures towards currently available machines, we aim to provide realistic and affordable best practices for hardening PLCs. We will first conduct security analysis and consider attack vectors within our target PLC. Once we’ve analyzed the device’s security, we will evaluate a variety of mitigation methods and create guidelines to effectively reduce the threat posed by PLC attacks with minimal disruption to operations.

42 ENGINEERING↗

DOE OSTI2026

PLC Integration for the Horn A Magnetic Field Mapping Device

This presentation summarizes the integration of a programmable logic controller (PLC) into the Horn A magnetic field mapping device for the Long-Baseline Neutrino Facility (LBNF). The device is used to position magnetic field probes along the centerline of the Horn A inner conductor to verify that the magnetic field within this region is approximately zero. The presentation covers the PLC hardware and electrical integration, stepper motor and encoder control, ladder logic development, mechanical integration, and system testing. Results include successful bidirectional motion and encoder feedback for the translation and rotation axes, as well as characterization of translational motion for repeatable probe positioning.

Bitakis, Kayla [Unlisted, US, IL]↗

DOE OSTI2016

Sensor sentinel computing device

Technologies pertaining to authenticating data output by sensors in an industrial environment are described herein. A sensor sentinel computing device receives time-series data from a sensor by way of a wireline connection. The sensor sentinel computing device generates a validation signal that is a function of the time-series signal. The sensor sentinel computing device then transmits the validation signal to a programmable logic controller in the industrial environment.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements from Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to clean technologies. As part of ongoing research in REEs recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high grade REEs from coal sources. To accomplish process control, PLC systems design/deployment, overall operational design and the utilization of Six Sigma design methodology by the team will be presented. Furthermore, application of the controls design, both procedural and electronic, team’s utilization of data analysis and integration for database decision-making will be discussed.

Leaching↗

DOE OSTI2025

IOTA Pre-Bake Test Development

The IOTA (Integrable Optics Test Accelerator) Bakeout project is intended to improve the quality of the vacuum within the IOTA ring. Impurities consisting of hydrogen and oxygen that build within the beampipe are reduced through applying heat to the beampipe’s exterior. Two versions of the Bakeout project exist, one as a smaller scale test setup, and one five times larger located within the IOTA ring. During my internship, I worked together with a team to bring this project from an effectively dormant state to ready for testing, working together to create full documentation of the PLC (Programmable Logic Controller) programs, making multiple new hardware configurations of this test possible, as well as an additional safety system.

Seagrave, Kayla [DuPage Coll.; Fermilab]↗

DOE OSTI2025

Innovative PLC Design for Optimized Potable Water Managment

My project here at Idaho National Laboratory (INL) was to work on Potable Water PLC Design (Programmable Logic Controllers). I was tasked in making a new panel design for the PLC system that will be moved from TRA BLDG 696 to TRA BLDG 608. This design needed to be updated since the old PLC system being about 20 years old. The manufacturer of the MicroLogix 1200 life expectancy showed it to be 10-20 years, and the system was discontinued in 2017. The new system we implemented was called CompactLogix Controller 5380, along with a new 24 VDC/10 Amp Power Supply. I made a design using Microsoft Visio, with the new material. But we needed to add it onto an Aluminum Panel that the system will be mounted onto, we need Unistrut’s for the aluminum panel to be mounted to. Some of the material we will still be using, like the R1 Alarm Relay, will be moving with the PLC system. The rest of the material will be new supplies that need to be updated systems, which the site is waiting for to complete the PLC system.

47 - OTHER INSTRUMENTATION↗

DOE OSTI2025

From Obsolete to Optimal (ATR Demineralized Water System)

My project was migrating a Human-Machine Interface (HMI) and Programmable Logic Controller (PLC) program from legacy software to a modern platform, enhancing operational efficiency and eliminating unsupported, obsolete equipment. Initially, I used a migration tool to transfer the programs to the new software, then manually updated variables to align with the new PLC. I optimized the PLC code by leveraging new scaling features in the I/O cards, removing over 45 obsolete rungs, and enhancing clarity with functional tag aliases. Next, I modernized the HMI's visuals with an updated color scheme and 3D buttons. I developed multiple interface versions iteratively refining them based on operator feedback. I also designed and created a dedicated "Rounds" screen incorporating insights from a previous intern’s project to streamline daily rounds. To improve clarity, consistency, and efficiency I redesigned the entire interface. Adding visual indicators to enhance operational awareness: red is used for values outside normal specifications, green for normal operating modes, yellow for manual mode, and grey for offline units. Additionally, I added a dynamic visual representation of tank levels, creating PLC logic to show the level in inches as well as inches and feet. I then incorporated a navigation sidebar to facilitate efficient screen transitions. Risk of human error was mitigated by defining narrow input ranges for tank level shutoff and password protecting setpoint changes. I also fixed issues with datatypes that caused inaccuracies in the original code. Overall, this comprehensive upgrade significantly enhanced the HMI's functionality, user experience, and operational reliability.

47 - OTHER INSTRUMENTATION↗

DOE OSTI2025

ON THE EFFECTIVENESS OF LLMS IN UNIT TEST GENERATION FOR STRUCTURED TEXT PROGRAMS

The reliability of industrial automation systems heavily depends on the correctness of Programmable Logic Controller (PLC) programs, which are often written in Structured Text (ST). While Large Language Models (LLMs) have shown promise in automating test generation for mainstream programming languages, their effectiveness for the syntactically strict ST language remains underexplored. This thesis presents a systematic empirical evaluation of three state-of-the-art LLMs—GPT-4o, Gemini 2.5 Pro, and Claude Sonnet 4.5—for generating ST unit tests. We examine three prompting strategies: Natural Language (NL), Code Language (CL), and Chain-of-Thought (CoT), across a curated set of 11 ST function blocks. The quality of the generated tests is assessed using Compilation Success Rate (CSR), Statement Coverage (SC), and Branch Coverage (BC). In the zero-shot setting, Claude Sonnet 4.5 achieves the highest CSR, while Gemini 2.5 Pro consistently delivers the best statement and branch coverage, particularly under CL prompts. By incorporating a one-shot CL prompt, all models exhibit substantial improvements—most notably GPT-4o, whose CSR increases from 45.45% to 90.91%, with substantial gains in both SC and BC. To further contextualize these findings, we compare GPT-4o’s one-shot results with PLCAutoTester, a state-ofthe- art ST unit test generation tool, on an additional benchmark dataset. While LLMgenerated tests approach competitive coverage levels, PLCAutoTester maintains significantly higher and more stable coverage across programs. This study provides the first comprehensive benchmark of modern LLMs for ST unit testing, highlighting their strengths, limitations, and improvements through one-shot prompting, and positioning their performance relative to specialized automated testing tools in industrial automation.

42 ENGINEERING↗

DOE OSTI2022

Programmable soft valves for digital and analog control

In soft devices, complex actuation sequences and precise force control typically require hard electronic valves and microcontrollers. Existing designs for entirely soft pneumatic control systems are capable of either digital or analog operation, but not both, and are limited by speed of actuation, range of pressure, time required for fabrication, or loss of power through pull-down resistors. Using the nonlinear mechanics intrinsic to structures composed of soft materials—in this case, by leveraging membrane inversion and tube kinking—two modular soft components are developed: a piston actuator and a bistable pneumatic switch. These two components combine to create valves capable of analog pressure regulation, simplified digital logic, controlled oscillation, nonvolatile memory storage, linear actuation, and interfacing with human users in both digital and analog formats. Three demonstrations showcase the capabilities of systems constructed from these valves: 1) a wearable glove capable of analog control of a soft artificial robotic hand based on input from a human user’s fingers, 2) a human-controlled cushion matrix designed for use in medical care, and 3) an untethered robot which travels a distance dynamically programmed at the time of operation to retrieve an object. This work illustrates pathways for complementary digital and analog control of soft robots using a unified valve design.

42 ENGINEERING↗

DOE OSTI2023

Logical quantum processor based on reconfigurable atom arrays

Suppressing errors is the central challenge for useful quantum computing, requiring quantum error correction (QEC) for large-scale processing. However, the overhead in the realization of error-corrected ‘logical’ qubits, in which information is encoded across many physical qubits for redundancy, poses substantial challenges to large-scale logical quantum computing. Here we report the realization of a programmable quantum processor based on encoded logical qubits operating with up to 280 physical qubits. Using logical-level control and a zoned architecture in reconfigurable neutral-atom arrays, our system combines high two-qubit gate fidelities, arbitrary connectivity, as well as fully programmable single-qubit rotations and mid-circuit readout. Operating this logical processor with various types of encoding, we demonstrate improvement of a two-qubit logic gate by scaling surface-code distance from d = 3 to d = 7, preparation of colour-code qubits with break-even fidelities, fault-tolerant creation of logical Greenberger–Horne–Zeilinger (GHZ) states and feedforward entanglement teleportation, as well as operation of 40 colour-code qubits. Finally, using 3D [[8,3,2]] code blocks, we realize computationally complex sampling circuits with up to 48 logical qubits entangled with hypercube connectivity with 228 logical two-qubit gates and 48 logical CCZ gates. We find that this logical encoding substantially improves algorithmic performance with error detection, outperforming physical-qubit fidelities at both cross-entropy benchmarking and quantum simulations of fast scrambling. These results herald the advent of early error-corrected quantum computation and chart a path towards large-scale logical processors.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2021

Open Radiation Monitoring: Histogram Builder Module Design

The Open Radiation Monitoring Project seeks to develop and demonstrate a modular radiation detection architecture designed specifically for use in arms control treaty verification (ACTV) applications that will facilitate rapid development of trusted systems to meet the needs of potential future treaties. A modular architecture can be used to reduce more complex systems to a series of single purpose building blocks, thereby facilitating equipment inspection and in turn building trust in the equipment by all treaty parties. Furthermore, a modular architecture can be used to control data flow within the measurement system, reducing the risk of "hidden switches" and constraining the amount of sensitive information that could potentially be inadvertently leaked. This report details the first revision of a prototype circuit that will convert analog pulses directly into a histogrammed data set for further processing. The circuit was designed with both spectroscopy and multiplicity analysis in mind but can, in principle, be used to reduce any raw data stream into a histogram. The number of output channels is limited, and the histogram bin ranges are user configurable to allow for non-uniform and discontinuous bins, which makes it possible to restrict the information being passed down stream if desired. Pulse processing relies entirely on analog circuitry and non- programmable logic, which enables operation without the need for a central processor or other programmable control unit. The circuit remains untested under the Open Radiation Monitoring project due to the closure of the sponsoring program. However, further development and testing is scheduled to take place in support of a purpose-built trusted verification system development effort known as COGNIZANT, which demonstrates the potential benefit of developing a suite of modular trusted system components.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2017

Practical applications of model checking in the finnish nuclear industry - 281

Model checking is a powerful, formal, computer-assisted verification method that can be used to prove that a model of a (hardware or software) system fulfills stated properties. When used right, model checking can prove the correctness of instrumentation and control (I and C) system application logic, be it a software or a field-programmable gate array (FPGA) based design. The verified properties can also address unwanted functionality, making model checking a very effective method for analyzing spurious actuation. Despite the benefits, model checking is still not widely adopted in the verification of I and C systems, one exception being the Finnish nuclear industry. Since 2008, VTT has applied model checking in practical customer work related to the Olkiluoto 3 EPR, Loviisa 1 and 2 VVER-440, and Hanhikivi 1 AES-2006 nuclear power plants, on commission from either the regulator or the utilities. In this paper, we look at how the method has been used in each of these three projects. We also introduce a user-friendly, graphical modelling tool called MODCHK. We then present an overall view of the design issues detected during nine years of customer work, and one practical example. The 100% coverage means that the design errors that are found often relate to scenarios that are otherwise hard to account for (e.g., exact timing of events, or improper operator actions). (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2018

Programmable design of orthogonal protein heterodimers

Specificity of interactions between two DNA strands, or between protein and DNA, is often achieved by varying bases or side chains coming off the DNA or protein backbone—for example, the bases participating in Watson–Crick pairing in the double helix, or the side chains contacting DNA in TALEN–DNA complexes. By contrast, specificity of protein–protein interactions usually involves backbone shape complementarity1, which is less modular and hence harder to generalize. Coiled-coil heterodimers are an exception, but the restricted geometry of interactions across the heterodimer interface (primarily at the heptad a and d positions2) limits the number of orthogonal pairs that can be created simply by varying side-chain interactions3,4. Here we show that protein–protein interaction specificity can be achieved using extensive and modular side-chain hydrogen-bond networks. We used the Crick generating equations5 to produce millions of four-helix backbones with varying degrees of supercoiling around a central axis, identified those accommodating extensive hydrogen-bond networks, and used Rosetta to connect pairs of helices with short loops and to optimize the remainder of the sequence. Of 97 such designs expressed in Escherichia coli, 65 formed constitutive heterodimers, and the crystal structures of four designs were in close agreement with the computational models and confirmed the designed hydrogen-bond networks. In cells, six heterodimers were fully orthogonal, and in vitro—following mixing of 32 chains from 16 heterodimer designs, denaturation in 5 M guanidine hydrochloride and reannealing—almost all of the interactions observed by native mass spectrometry were between the designed cognate pairs. The ability to design orthogonal protein heterodimers should enable sophisticated protein-based control logic for synthetic biology, and illustrates that nature has not fully explored the possibilities for programmable biomolecular interaction modalities.

Chen, Zibo↗

DOE OSTI2021

Information Leakage Analysis using a Co-design-Based Fault Injection Technique on a RISC-V Microprocessor

The RISC-V instruction set architecture open licensing policy has spawned a hive of development activity, making a range of implementations publicly available. The environments in which RISC-V operates have expanded correspondingly, driving the need for a generalized approach to evaluating the reliability of RISC-V implementations under adverse operating conditions or after normal wear-out periods. Fault injection (FI) refers to the process of changing the state of registers or wires, either permanently or momentarily, and then observing execution behavior. The analysis provides insight into the development of countermeasures that protect against the leakage or corruption of sensitive information which might occur because of unexpected execution behavior. In this paper, we develop a hardware-software co-design architecture that enables fast, configurable fault emulation and utilize it for information leakage and data corruption analysis. Modern System-on-chip FPGAs enable building an evaluation platform where control elements run on a processor(s) (PS) simultaneously with the target design running in the programmable logic (PL). Software components of the FI system introduce faults and report execution behavior. A pair of RISC-V FI-instrumented implementations are created and configured to execute the Advanced Encryption Standard and Twister algorithms. Key and plaintext information leakage and degraded pseudo-random sequences are both observed in the output for a subset of the emulated faults.

42 ENGINEERING↗

DOE OSTI2017

Development of programmable logic in a rapid, automated, and repeatable fashion for safety-related applications - 385

Digital safety platform considerations for power plant modernization or new build efforts involve a burdensome task of implementing a large number of software-based functions onto a designated platform to match the plant's architecture. This problem is not unique to any particular safety-related platform solution, but is prevalent across the landscape of current Qualified and Licensed Safety-related Instrumentation and Control (I and C) Solutions. As an example when implementing a RG 1.97 compliant Post Accident Monitoring System (PAMS) solution with the Lockheed Martin Nuclear Protection and Control (NuPAC) safety platform, 72 unique software loads are needed to configure the Qualified Display System (QDS). Large scale development and customization efforts to upgrade existing plant functions or systems require the licensee to assume the cost and technical risk necessary to undergo a digital based upgrade. Often the cost, schedule, and technical risk outweighed the benefit of modernization efforts due to the unknown hurdles and past projects that overran cost and schedule projections. Lockheed Martin's Engineering Production Suite (EPS) minimizes the licensee risk and expense associated with modernization efforts through a developer's toolkit for rapid, automated, and repeatable development of Programmable Logic used to implement plant functions and architectures for use on the Lockheed Martin NuPAC platform. This paper describes a use case where by EPS can create system level representations, simulate system functions, partition logic designs to accommodate hardware constraints through logic partitioning, automate the assembly of Application Specific Programmable Logic (ASPL), generate system test cases, program the NuPAC hardware, and perform testing throughout the design workflow. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Injection locking and coupling dynamics in superconducting nanowire-based cryogenic oscillators

Oscillators designed to function at cryogenic temperatures play a critical role in superconducting electronics and quantum computing by providing stable, low-noise signals with minimal energy loss. Here, in this work, we present a comprehensive numerical study of injection locking and mutual coupling dynamics in superconducting nanowire (ScNW)-based cryogenic oscillators. Using the design space of a standalone ScNW-based oscillator, we investigate two critical mechanisms that govern frequency synchronization and signal coordination in cryogenic computing architectures: (1) injection locking induced by an external AC signal with a frequency near the oscillator's natural frequency, and (2) the mutual coupling dynamics between two ScNW oscillators under varying coupling strengths. We identify key design parameters—such as shunt resistance, nanowire inductance, and coupling strength—that govern the locking range. Additionally, we examine how the amplitude of the injected signal affects the amplitude of the locked oscillation, offering valuable insights for power-aware oscillator synchronization. Furthermore, we analyze mutual synchronization between coupled ScNW oscillators using capacitive and resistive coupling elements. Our results reveal that the phase difference between oscillators can be controlled by tuning the coupling strength, enabling programmable phase-encoded information processing. These findings could enable building ScNW-based oscillatory neural networks, synchronized cryogenic logic blocks, and on-chip cryogenic resonator arrays.

Artificial neural networks↗

DOE OSTI2016

Note: A versatile radio-frequency source for cold atom experiments

A radio-frequency (RF) source designed for cold atom experiments is presented. The source uses AD9858, a direct digital synthesizer, to generate the sine wave directly, up to 400 MHz, with sub-Hz resolution. An amplitude control circuit consisting of wideband variable gain amplifier and high speed digital to analog converter is integrated into the source, capable of 70 dB off isolation and 4 ns on-off keying. A field programmable gate array is used to implement a versatile frequency and amplitude co-sweep logic. Owing to modular design, the RF sources have been used on many cold atom experiments to generate various complicated RF sequences, enriching the operation schemes of cold atoms, which cannot be done by standard RF source instruments.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗