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NASA NTRSDate not supplied

SUbsonic Single Aft eNgine (SUSAN) Power/Propulsion System Hardware-in-the-Loop Test Results

Electrified Aircraft Propulsion (EAP) technology offers a promising path forward for reducing greenhouse gas emissions and other negative environmental effects from the commercial aviation sector. EAP systems can reduce fuel burn and improve performance over state-of the-art designs, however the increased complexity and highly coupled nature of these systems present challenges that require new control approaches. The SUbsonic Single Aft eNgine (SUSAN) Electrofan is a concept aircraft developed by NASA as a reference design for a commercial transport aircraft with a highly integrated hybrid-electric powertrain. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test of a control architecture developed for the SUSAN power/propulsion system (PPS). The test was performed in the Hybrid Propulsion Emulation Rig (HyPER) facility at the NASA Glenn Research Center (GRC) and involved a real-time reference model of the SUSAN PPS and control system running with a sub-scale electro-mechanical system replacing one of the PPS subsystems. A side-by-side comparison of the simulated and real systems in the HIL test results shows that the control architecture functions well in both the simulation and the real-time HIL environment. In both cases the controller is able to simultaneously deliver the required thrust response and balance power levels between the electrical and turbomachinery subsystems.

Jonah J Sachs-Wetstone↗

NASA NTRSDate not supplied

SUbsonic Single Aft eNgine (SUSAN) Power/Propulsion System Hardware-in-the-Loop Test Results

EAP↗

DOE OSTI2025

Evaluating Thermostats’ Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies

Thermostats play a crucial role in energy consumption, user control, and occupant comfort by serving as the interface between the heating, ventilation, and air conditioning (HVAC) system and the building's occupants. The deadband, also referred to as temperature differential, is defined as the temperature difference between the desired setpoint and upper threshold or lower threshold for the HVAC equipment to turn on or off. It is a key factor influencing energy efficiency and user satisfaction. This paper presents a comparative analysis of the deadbands of five different thermostats, tested with a residential heat pump, aiming to identify variations in their deadband settings and implications for energy usage and management. The experimental study was conducted using a HVAC hardware-in-the-loop (HIL) system that allows thermostats to be connected with physical HVAC equipment, driven by conditions in a simulated residential building. The study explores the trade-offs between energy efficiency and occupant comfort and highlights how different thermostats cycle differently based on their deadband settings. The findings offer valuable insights into how thermostat deadband affects comfort and energy use, as well as the cycling frequency of a heat pump.

Ramaraj, Sugirdhalakshmi [National Renewable Energ↗

NASA NTRS2010

Demonstration of an Aerocapture GN and C System Through Hardware-in-the-Loop Simulations

Aerocapture is an orbit insertion maneuver in which a spacecraft flies through a planetary atmosphere one time using drag force to decelerate and effect a hyperbolic to elliptical orbit change. Aerocapture employs a feedback Guidance, Navigation, and Control (GN&C) system to deliver the spacecraft into a precise postatmospheric orbit despite the uncertainties inherent in planetary atmosphere knowledge, entry targeting and aerodynamic predictions. Only small amounts of propellant are required for attitude control and orbit adjustments, thereby providing mass savings of hundreds to thousands of kilograms over conventional all-propulsive techniques. The Analytic Predictor Corrector (APC) guidance algorithm has been developed to steer the vehicle through the aerocapture maneuver using bank angle control. Through funding provided by NASA's In-Space Propulsion Technology Program, the operation of an aerocapture GN&C system has been demonstrated in high-fidelity simulations that include real-time hardware in the loop, thus increasing the Technology Readiness Level (TRL) of aerocapture GN&C. First, a non-real-time (NRT), 6-DOF trajectory simulation was developed for the aerocapture trajectory. The simulation included vehicle dynamics, gravity model, atmosphere model, aerodynamics model, inertial measurement unit (IMU) model, attitude control thruster torque models, and GN&C algorithms (including the APC aerocapture guidance). The simulation used the vehicle and mission parameters from the ST-9 mission. A 2000 case Monte Carlo simulation was performed and results show an aerocapture success rate of greater than 99.7%, greater than 95% of total delta-V required for orbit insertion is provided by aerodynamic drag, and post-aerocapture orbit plane wedge angle error is less than 0.5 deg (3-sigma). Then a real-time (RT), 6-DOF simulation for the aerocapture trajectory was developed which demonstrated the guidance software executing on a flight-like computer, interfacing with a simulated IMU and simulated thrusters, with vehicle dynamics provided by an external simulator. Five cases from the NRT simulations were run in the RT simulation environment. The results compare well to those of the NRT simulation thus verifying the RT simulation configuration. The results of the above described simulations show the aerocapture maneuver using the APC algorithm can be accomplished reliably and the algorithm is now at TRL-6. Flight validation is the next step for aerocapture technology development.

Masciarelli, James↗

DOE OSTI2025

Optimal Network Reconfiguration and Scheduling With Hardware-in-the-Loop Validation for Improved Microgrid Resilience

With the increased occurrence of various major extreme weather events, power outages and prompt power system restorations have recently drawn more attention to the resilience and recovery of power systems. From the perspective of a more resilient power delivery at the distribution grid, system restoration using network topology reconfiguration together with optimal scheduling of distributed energy resources are adopted in this paper. The proposed optimization model aims at minimizing the total load shedding cost and other operational costs, in which linearized topological constraints borrowed from graph theory and linearized DistFlow models are respectively used to maintain the radial network topology and power flow balance after system contingencies. To demonstrate the applicability of the proposed strategy, a real-world case study of a networked three-microgrid system in Adjuntas, Puerto Rico, is used with the consideration of different independent/interconnected microgrid scenarios, contingencies, and fairness settings. Furthermore, hardware-in-the-loop testing is conducted for the same three-microgrid network, where the closely matched results with the simulated ones have validated the effectiveness of the proposed restoration strategy, which is now ready to move one step forward towards field deployment. Finally, to test the proposed restoration strategy in a larger networked system, the modified IEEE-33 bus test distribution system is considered, and the results show a more resilient power delivery for critical loads under three and four line outages.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Solid State Power Substation DC Node Optimization and Controller Hardware-In-The-Loop Demonstration

A solid state power substation (SSPS) node is a microgrid that integrates distributed energy resources and loads and injects/absorbs power to/from the SSPS distribution network. It is an essential building block of a futuristic distribution grid network. This paper presents the development and demonstration of optimization use cases of a SSPS DC node. By adopting multi-layer hierarchical control architecture and developing automatic device identification and dynamic optimization formulation algorithms, the SSPS DC node can perform plug-and-play resource integration and seamless transition of the optimized node operation under on and off grid condition without sophisticated algorithms, control mode changes, and user interactions. Four optimization use cases including economic dispatches with price signal changes, a sudden PV power drop, and a single directional meter and its associated costs with sending power back to the grid, and resiliency under a grid inverter trip condition were demonstrated through the real-time controller hardware-in-the-loop simulation.

Kim, Namwon↗

DOE OSTI2024

Verification of Adaptive Protection in Hardware in the Loop for Coordination with Solar Variability

As inverter-based resources continue to be installed at all levels of the electric grid, the fixed protection schemes used at the distribution level will continue to be stressed until they no longer ensure the protection of the grid. Adaptive protection has been proposed as a solution with the ability to update the protection schemes in near real-time to ensure reliability and increase the resilience of the grid. However, weather variability poses a significant challenge to the ability of these methods to keep the selectivity and reliability of these schemes coordinated. If the ramp rates, due to solar variability, of the inverter-based resources change faster than the adaptive protection can issue new settings, the protection system could be uncoordinated, with the wrong device responding to a system fault. The proposed adaptive protection method ensures that due to solar variability, communication, and protection calculation latency, it can issu e coordinated protection settings promptly, in one minute or less. The hardware-in-the-loop results show the protection settings being issued and maintaining system coordination in under a minute.

Summers, Adam↗

DOE OSTI2025

Employing a Hardware-in-the-Loop Approach to Realize a Fully Homomorphic Controller for a Small Modular Advanced High Temperature Reactor

This paper addresses the cybersecurity challenges of advanced nuclear reactors by integrating fully homomorphic encryption (FHE) into their control systems, enabling encrypted processing of control signals without compromising functionality. Advanced nuclear reactors, including Small Modular Reactors (SMRs) and microreactors, aim to achieve autonomous and remote operations, reducing costs and enhancing competitiveness. However, these advancements expand the attack surface for cyberattacks, particularly in autonomous and remote operation scenarios. Cyberattacks can exploit vulnerabilities to manipulate physical processes, causing shutdowns, asset damage, or public harm. Such attacks begin with passive reconnaissance, where adversaries intercept communications or observe behaviors to gather information, which is then leveraged to execute cyber-physical attacks by injecting malicious commands. Nuclear power must adopt cybersecurity protection measures to secure the integrity and availability of their digital control systems. This paper demonstrates the application of FHE to secure operations by enabling encrypted processing of sensitive signals and parameters -- ensuring privacy without exposing data. FHE supports secure mathematical operations on encrypted data without requiring decryption. Using a hardware-in-the-loop (HIL) approach, this paper implements an FHE-integrated controller on a BeagleBone Black (BBB) controlling a simulation of the Small Modular Advanced High Temperature Reactor (SmAHTR). By doing so, the encrypted controller protects the integrity of critical set points and control signals during transmission and processing. Thus, FHE-integrated controllers enhance secure operations of advanced nuclear reactors while maintaining functionality.

control systems↗

NASA NTRS2011

Performance of the Extravehicular Mobility Unit (EMU) Airlock Coolant Loop Remediation (A/L CLR) Hardware - Final

An EMU water processing kit (Airlock Coolant Loop Recovery -- A/L CLR) was developed as a corrective action to Extravehicular Mobility Unit (EMU) coolant flow disruptions experienced on the International Space Station (ISS) in May of 2004 and thereafter. A conservative duty cycle and set of use parameters for A/L CLR use and component life were initially developed and implemented based on prior analysis results and analytical modeling. Several initiatives were undertaken to optimize the duty cycle and use parameters of the hardware. Examination of post-flight samples and EMU Coolant Loop hardware provided invaluable information on the performance of the A/L CLR and has allowed for an optimization of the process. The intent of this paper is to detail the evolution of the A/L CLR hardware, efforts to optimize the duty cycle and use parameters, and the final recommendations for implementation in the post-Shuttle retirement era.

Steele, John W.↗

DOE OSTI2026

Balance of Plant Modeling and Real-Time Hardware-in-the-Loop Integration with the Microreactor Automated Control System

The advent of novel microreactor technology has driven a focused effort to explore safety and efficiency improvements that can be achieved through the use of automated system control. Development of control strategies, especially for initial demonstration, requires an adequate surrogate environment to safely research failure modes and control integration with realistic hardware delay. However, efficiency gains from control strategies are improved when the scope of controller action is expanded to include system-level dynamics such as downstream heat extraction and mass flow. For this reason, a balance-of-plant (BOP) model of a representative microreactor system has been developed using the TRANsient Simulation Framework of Reconfigurable Models library in Modelica. This model captures a reactor and primary NaK coolant loop that represent corresponding system components of the Microreactor Applications Research Validation and EvaLuation (MARVEL) design as well as a secondary coolant loop and heat extraction representative of the Microreactor Agile Non-Nuclear Experimental Test Bed (MAGNET). This model configuration allows for hardware-in-the-loop (HIL) integration with microreactor automated control system (MACS) hardware in real time through a Python-based gRPC client. Real-time simulation of model performance with emulated hardware and communication delay suggests that under independent proportional-integral-derivative control of BOP model drum dynamics and downstream heat extraction, stable power load following is achievable. A slight delay in load following, filtering of high-frequency dynamics, and localized temperature fluctation suggest room for improvement through the development of higher-level control strategies. The simulated coupling of the MAGNET facility lays the groundwork for future digital twin analysis with a coupled MACS-MAGNET HIL demonstration.

McConnell, Jono [ORNL] (ORCID:0000000238984741)↗

NASA NTRSDate not supplied

Tutorial: Electrified Aircraft Propulsion Approaches for Modeling and Electrical Hardware-in-the-Loop Testing

This tutorial session outlines capabilities made available by the National Aeronautics and Space Administration for testing electrified aircraft propulsion (EAP) hardware and software prior to using turbomachinery. Removing these components from the experimentation process until necessary significantly reduces the development and testing costs and safety risks. Three facilities, the NASA Electric Aircraft Testbed (NEAT) and the Hybrid Propulsion Emulation Rig (HyPER) are unique facilities that provide the following capabilities: (i) the verification of megawatt-scale electrical and electromechanical system components at altitude, (ii) the verification of EAP control systems on sub-scale representative electromechanical architectures. The importance, operation, and specifications of each facility is described with detail. Provided examples of past testing showcase the abilities of each facility. Simple and complex methods for replicating the steady state and dynamical mechanical loading on the electrical power system are discussed

Electrified Aircraft Propulsion↗

DOE OSTI2025

Evaluating Thermostats' Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies

Smart thermostats have gained significant popularity due to their potential for optimizing energy consumption and enhanced user control while ensuring occupants' comfort. The deadband, also referred to as temperature differential, is defined as the temperature difference between the desired setpoint and upper threshold or lower threshold for the HVAC equipment to turn on. It is a key factor influencing energy efficiency and user satisfaction. This paper presents a comparative analysis of the deadbands of five different smart thermostats, tested with a heat pump, aiming to identify variations in their deadband settings and implications for energy management. The experimental study was conducted using a HVAC hardware-in-theloop (HIL) system that integrates smart thermostats with physical HVAC equipment in a simulated house environment. The study explores the trade-offs between energy efficiency and occupant comfort and highlights how different thermostats participating in demand response event cycle differently based on their deadband settings. The findings offer valuable insights into how selecting the right thermostat or configuring smart thermostat with appropriate deadband settings can be leveraged to enhance demand response capabilities, shift loads effectively and improve operational flexibility in HVAC systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Evaluating Thermostats' Deadbands Using HVAC Hardware-In-the-Loop Experiment for Advanced Control Strategies: Preprint

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential

SuperLab 2.0 (5-Lab Demo) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, PV, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactor (SMR), control centers, and gas turbines, across five DOE national laboratories-NLR, INL, NETL, LBNL, and SNL. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance U.S. Department of Energy's (DOE) network, and controlled via a centralized energy controller hosted at NLR's ARIES facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility. SuperLab 2.0 (5-Lab Demo) showcased a major advancement in federated national laboratory collaboration, enabling real-time, cross-laboratory experimentation to coordinate geographically dispersed distributed energy resources (DERs) using various communication protocols and networks. SuperLab 2.0 (5-Lab Demo) built on previous demonstrations conducted between NLR-PNNL and NLR-INL connecting diverse assets including distant protection devices, a SMR simulator, and a high temperature electrolyzer (HTE). Previous demos were based on a single connection between two labs with minimal coordination challenges. The 5-Lab demo with a centralized controller, distributed testbeds across different geographical locations, and use of protocols-based communication represents a scenario closer to real-world grid operations that coordinate resources across a region to meet system needs. This experiment studied how local DER controllers interact with a centralized energy controller during normal and abnormal events to maintain reliability. The SuperLab team across the five labs implemented a notional power system model equivalent of transmission and distribution lines, represented by the data networks interconnecting the labs. Each lab continuously exchanged local parameters (such as P and Q) from its Hardware-In-Loop (CHIL) and Power Hardware-In-Loop (PHIL) assets through centralized energy controller at NLR, enabling real-time interaction and coordination across sites. By leveraging ESnet as the communication backbone, the team successfully operated the distributed assets as a unified power system, with each bus represented by a different laboratory. This setup mirrors how assets interact in real-world power systems across dispersed locations with various protocols and latencies. At each lab site, assets were operated using their own local controllers which were coordinated through an overarching operation and control layer of centralized energy controller, equivalent to how an energy management system (EMS) orchestrates assets across a regional or national grid. SuperLab's federated connectivity utilized a Digital Real-Time Simulators (DRTS)-type gateway to connect Controller Hardware-In-Loop (CHIL) and PHIL assets between labs. To enable this federated connection through ESnet, a deterministic network was established where latency variations were consistent. This consistency allowed the development of digital filters for the power system assets across CHIL and PHIL interfaces to avoid unstable and unreliable grid conditions. This report provides an overview of the cross-laboratory configuration and offers insights into interconnecting geographically distributed research assets to test them as if they were co-located. This experiment represents a step toward linking nine DOE national laboratories, enabling nation-wide simulations that can address utility-driven challenges with grid resilience, flexibility, and modernization.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

A Hardware-in-the-Loop Experimental Testbed Using Air Conditioners for Grid Balancing

Driven by the need to offset the variability of renewable generation on the grid, development of load control is a highly active field of research. However, practical use of residential loads for grid balancing remains rare, in part due to the cost of communicating with large numbers of small loads and also the limited experimentation done so far to demonstrate reliable operation. To establish a basis for the safe and reliable use of fleets of compressor loads as distributed energy resources, we constructed an experimental testbed in a laboratory, so that load coordination schemes could be tested at extreme conditions. Here, this experimental testbed was used to tune a simulation testbed to which it was then linked, thereby augmenting the effective size of the fleet. Modeling of the system was done both to demonstrate the experimental testbed's behavior and also to understand how to tune the behavior of each load. Implementing this testbed has enabled rapid turnaround of experiments on various load control algorithms, and year-round testing without the constraints and limitations arising in seasonal field tests with real houses. Experimental results show the practical feasibility of an ensemble of small loads contributing to grid balancing.

Air Conditioners↗

NASA NTRS2001

A Hardware-in-the-Loop Testbed for Spacecraft Formation Flying Applications

The Formation Flying Test Bed (FFTB) at NASA Goddard Space Flight Center (GSFC) is being developed as a modular, hybrid dynamic simulation facility employed for end-to-end guidance, navigation, and control (GN&C) analysis and design for formation flying clusters and constellations of satellites. The FFTB will support critical hardware and software technology development to enable current and future missions for NASA, other government agencies, and external customers for a wide range of missions, particularly those involving distributed spacecraft operations. The initial capabilities of the FFTB are based upon an integration of high fidelity hardware and software simulation, emulation, and test platforms developed at GSFC in recent years; including a high-fidelity GPS simulator which has been a fundamental component of the Guidance, Navigation, and Control Center's GPS Test Facility. The FFTB will be continuously evolving over the next several years from a too[ with initial capabilities in GPS navigation hardware/software- in-the- loop analysis and closed loop GPS-based orbit control algorithm assessment to one with cross-link communications and relative navigation analysis and simulation capability. Eventually the FFT13 will provide full capability to support all aspects of multi-sensor, absolute and relative position determination and control, in all (attitude and orbit) degrees of freedom, as well as information management for satellite clusters and constellations. In this paper we focus on the architecture for the FFT13 as a general GN&C analysis environment for the spacecraft formation flying community inside and outside of NASA GSFC and we briefly reference some current and future activities which will drive the requirements and development.

Leitner, Jesse↗

NASA NTRS2023

Real-Time Hardware-in-the-Loop Evaluation of A Partially Turboelectric Propulsion Control Design

In support of aviation fuel burn and emission reduction goals, NASA is pursuing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP). Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes addressing challenges related to propulsion controls, which will be vital for ensuring efficient coordinated operation of EAP subsystems. This paper presents results from real-time hardware-in-theloop (HIL) testing of a control design for a single aisle partially-turboelectric aircraft propulsion concept conducted at the NASA Electric Aircraft Testbed (NEAT) facility. The control system under test is designed for a propulsion concept consisting of two wing-mounted turbofan engines that produce thrust and generate electrical power to drive a boundary layer ingesting tailfan propulsor via an electrical motor. An integrated control strategy is applied to ensure coordinated operation of the turbofan and tailfan subsystems during steady-state and transient operation throughout the flight envelope. The NEAT test of this integrated control design consists of a partially HIL, partially simulated configuration. A subscale representation of the electrical system design is implemented in hardware and mechanically coupled to electric machines that emulate turbomachinery and propulsor shaft dynamics. The hardware configuration is then operated under the control of a real-time computer application that runs a simulation of the propulsion system and the developed control logic. The NEAT facility test campaign includes a series of experiments that subject the control design to throttle transients conducted throughout the flight envelope and full-flight mission profiles. Testing under simulated performance degradation is also conducted to evaluate control design robustness. This includes constant and abrupt changes in degradation levels. Results from the HIL test are presented and shown to be in good agreement with pretest simulation predictions demonstrating the efficacy of the integrated control design approach.

Electrified Aircraft Propulsion↗

DOE OSTI2024

Hardware In the Loop for Demand Flexibility (HIL4DF) v1.0

The software package in question is a collection of simulation models in the Modelica language, representing a variety of mechanical system designs and envelope conditions related to LBL's FLEXLAB facility. The collection of models also features multiple controls sequences that can be simulated with the FLEXLAB model to simulate different demand flexibility scenarios. Additionally, this package will feature datasets from 3 experimental tests, used for calibration, validation and comparison against the Modelica models, this includes weather data that can be used to replicate different scenarios in simulation across the same weather conditions experienced in real experiments. Given FLEXLAB high level of instrumentation and available data, the models are calibrated across multiple measurement points, and thus results from the extension of this model to other climate zones or control sequences, would provide high level of confidence.

Huang, Weiping↗