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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1975

Apollo experience report: Guidance and control systems: Automated control system for unmanned mission AS-201

The Apollo command module heat shield and Apollo command and service module/Saturn launch vehicle structural integrity were evaluated in an unmanned test flight. An automated control system was developed to provide the mission event sequencing, the real-time ground control interface, and the backup attitude reference system for the unmanned flight. The required mission events, the design logic, the redundancy concept, and the ground-support-equipment concept are described and some development problem areas are discussed. The mission event time line and the real-time ground command list are included to provide an outline of the control system capabilities and requirements. The mission was accomplished with the automated control system, which functioned without flight anomalies.

Holloway, G. F.↗

DOE OSTI2025

Microreactor Automated Control System - Digital Twin Models and Advanced Control Systems Updates

Automation of control systems is expected to be important in the economic and safe operation of microreactors. Therefore, there is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a nonnuclear microreactor automated control system (MACS)—a real-time, hardware-in-the-loop testbed for non-nuclear testing of microreactor control system automation. A real-time hardware-in-the-loop testbed incorporates the realistic dynamics of physical systems into control system development and testing. The collaborative effort between Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL) resulted in the development of a prototypic microreactor plant-level digital twin that includes the reactor and a balance of plant system. Advanced control strategies were incorporated to demonstrate testing of control automation solutions. The gRPC communication protocol, which was implemented in the hardware-in-the-loop testbed by INL, was coupled to a digital twin model developed using the TRANsient Simulation Framework of Reconfigurable Models (TRANSFORM) library in Modelica. This digital twin simulation was tested with the ViBRANT hardware for realistic feedback and visual representation of control action in real time. A modular Python client structure was developed to manage functional mock-up unit-based simulation and real-time gRPC communication. Hardware-in-the-loop testing indicated that the modeled reactor—a natural-convection, molten-salt coolant loop configuration—responds well to control of drum positioning for modulation of reactor core power, as well as system-level control and downstream demand changes. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

An Update on Microreactor Automated Control System (MACS)

Automation of control systems is expected to be important in the economic and safe operation of microreactors. There is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a microreactor automated control system (MACS) testbed developed to test control system automation. While a future goal is to demonstrate this system using a prototypic microreactor such as MARVEL, the present focus is on developing and testing within a non-nuclear testbed. The testbed, developed in collaboration with Idaho National Laboratory, includes hardware-in-the-loop simulation and uses a Modelica-based model of a prototypic microreactor for use in testing control automation. Research to date at Oak Ridge National Laboratory has focused on the development of prototypic software for automating plant-level control under selected scenarios. Empirical testing on the integrated MACS testbed was performed to quantify key characteristics of the integrated testbed and to demonstrate the use of the software for automating the calculation and use of actuation setpoints for selected load-following scenarios. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

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 NTRS2017

Spaceport Command and Control System Automated Testing

The Spaceport Command and Control System (SCCS) is the National Aeronautics and Space Administrations (NASA) launch control system for the Orion capsule and Space Launch System, the next generation manned rocket currently in development. This large system requires high quality testing that will properly measure the capabilities of the system. Automating the test procedures would save the project time and money. Therefore, the Electrical Engineering Division at Kennedy Space Center (KSC) has recruited interns for the past two years to work alongside full-time engineers to develop these automated tests, as well as innovate upon the current automation process.

LCS↗

NASA NTRS2017

Spaceport Command and Control System Automation Testing

Testing↗

NASA NTRS1991

Thermal Control System Automation Project (TCSAP)

Information is given in viewgraph form on the Space Station Freedom (SSF) Thermal Control System Automation Project (TCSAP). Topics covered include the assembly of the External Thermal Control System (ETCS); the ETCS functional schematic; the baseline Fault Detection, Isolation, and Recovery (FDIR), including the development of a knowledge based system (KBS) for application of rule based reasoning to the SSF ETCS; TCSAP software architecture; the High Fidelity Simulator architecture; the TCSAP Runtime Object Database (RODB) data flow; KBS functional architecture and logic flow; TCSAP growth and evolution; and TCSAP relationships.

Boyer, Roger L.↗

DOE OSTI2022

Evaluating an Eco-Cooperative Automated Control System

The paper evaluates an Eco-Cooperative Automated Control (Eco-CAC) system on a large-scale network considering a combination of internal combustion engine vehicles (ICEVs), hybrid electric vehicles (HEVs), and battery-only electric vehicles (BEVs) in a microscopic traffic simulation environment. We used a novel integrated control system that: (1) routes ICEVs, HEVs, and BEVs in a fuel/energy-efficient manner; (2) selects vehicle speeds based on anticipated traffic network evolution; (3) minimizes vehicle fuel/energy consumption near signalized intersections; and (4) intelligently modulates the longitudinal motion of vehicles along freeways within a cooperative platoon to minimize fuel/energy consumption. The study tested the system using the INTEGRATION software on the Los Angeles (LA), U.S., downtown network for three different demand levels: no congestion, mild congestion, and heavy congestion. The results demonstrated that the Eco-CAC system effectively reduces vehicle fuel and energy consumption, travel time, total delay, and stopped delay in heavily congested conditions. However, different vehicle compositions produced different results. In particular, the maximum energy consumption savings for BEVs (36.9%) for a current vehicle composition occurred at a 10% market penetration rate (MPR) of connected automated vehicles (CAVs) in mild congestion, while the maximum savings for a future vehicle composition (35.5%) occurred at a 50% CAV MPR in no congestion. The system reduced fuel consumption for ICEVs and HEVs by up to 5.4% and 6.3% at a 25% CAV MPR in heavy congestion for current and future vehicle compositions, respectively. However, the system increased total fuel consumption by up to 4.6% at a 50% CAV MPR in no congestion for a current vehicle composition. The study demonstrates that the effectiveness of the Eco-CAC system depends on traffic conditions, including congestion level, network configuration, CAV MPR, and vehicle composition.

Engineering↗

DOE OSTI2021

Developing an Eco-Cooperative Automated Control System (Eco-CAC)

The goal of the project was to develop a novel Eco-Cooperative Automated Control (Eco-CAC) system that integrates vehicle dynamics (VD) control with connected and automated vehicle (CAV) applications. In particular, the team developed a novel integrated control system that (1) routes vehicles in a fuel/energy-efficient manner for internal combustion engine vehicles (ICEVs), battery-only electric vehicles (BEVs), and hybrid electric vehicles (HEVs); (2) selects vehicle speeds based on anticipated traffic network evolution; (3) minimizes vehicle fuel/energy consumption near signalized intersections; and (4) intelligently modulates the longitudinal motion of vehicles within a cooperative platoon to minimize its fuel/energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Development of Microreactor Automated Control System (MACS): Surrogate Plant-level Modeling and Control Algorithms Integration

This report discusses progress on the modeling and integration task as part of the development of Microreactor Automated Control System (MACS). What follows is a discussion of the software tools used to develop a surrogate microreactor plant-level model, MACS module development, and a summary of the findings from integration with a hardware-in-the-loop (HIL) setup at Idaho National Laboratory (INL). Oak Ridge National Laboratory worked with INL to understand available hardware at INL (such as existing control platforms). With this information and using a preliminary framework for MACS with software interfaces defined, surrogate models and initial automated control algorithms were created for integration into the hardware to provide a HIL demonstration platform for MACS. Available reduced order reactor models that leverage existing microreactor neutronics and thermal hydraulics models have been integrated in the surrogate plant-level model. The surrogate model has been evaluated for sensitivity of all parameters and the MACS software modules (including the surrogate model) have been demonstrated to interact with the hardware. The integration, however, pointed to the need for further improvements to the framework—and specifically improvements to the interfaces to ensure that the HIL simulator is capable of longer-term stable operation with MACS in the loop. These improvements will be the focus of future research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Comparing Control Performance Between Simulation and Experiment using the Microreactor Automated Control System Testbed

In the advanced reactor domain, a flexible and scalable software/hardware infrastructure is crucial for integrating and validating various control technologies. This study used the Microreactor Automated Control System (MACS) hardware platform as a testbed. MACS was originally designed to mirror Idaho National Laboratory (INL)'s Microreactor Applications Research Validation and Evaluation (MARVEL), a 85-kW thermal fission microreactor. It features control drums for simulated reactivity control; lights that function as a surrogate reactor core, with the brightness being proportional to the reactor power; and light sensors that emulate neutron detectors. To transform MACS into a physical twin of MARVEL for evaluating control methods, the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND) software was employed. This software integrated the hardware with two models of the MARVEL core, based on Reactor Excursion and Leak Analysis Program (RELAP5-3D) and Monte Carlo N-Particle (MCNP) models. The study aimed to demonstrate the gap between control theory and actual practice—a gap that often necessitates empirical adjustments such as control gain retuning, filters, time discretization, and integrator anti-windup measures. Controllers were developed based on increasingly complex simulations without hardware, starting from the base MARVEL model and then introducing actuator saturation constraints and sensor noise. The final control strategy was then tested using MACS, and a comparative performance analysis was conducted.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

NASA NTRS2019

Command and Control System Automated Testing

The Kennedy Space Center (KSC) has developed its own Command and Control System for the launch of the Space Launch System (SLS) and Orion capsule. The Command and Control System (CCS) is used by console engineers for the launch and system checkout of aerospace vehicles. The CCS allows console engineers to read data from the flight hardware on the launch pad and from the ground control systems and allows console engineers to issue commands, like opening a valve, to the flight hardware and ground control systems. The CCS needs to interact with thousands of devices and hardware controllers for the spacecraft and ground systems, receive data from these devices, distribute the data to console engineers in real-time, and allow console engineers to issue commands to manipulate hardware on the launch pad. The system needs to be robust, fault tolerant, responsive, and fast. In order to keep up with the pace of development of the CCS, a Test Automation System (TAS) is needed to validate the integrity of the system as a whole along with its individual components. Automated tests allow for faster development time, since tests can be ran through a Continuous Integration system and allow developers to check their code faster. Currently, the different modules, classes, and functions that make up the CCS are tested at the unit level, and the system level, with all the modules working together. My project was to implement a system for the data protocol layer of the Command Control System to be tested as a complete functional unit, with all of its classes and functions working together, but independent of the other modules of the CCS.

Automated TestingTest Automation↗

NASA NTRS2017

Spaceport Command and Control System Automated Verification Software Development

For as long as we have walked the Earth, humans have always been explorers. We have visited our nearest celestial body and sent Voyager 1 beyond our solar system1 out into interstellar space. Now it is finally time for us to step beyond our home and onto another planet. The Spaceport Command and Control System (SCCS) is being developed along with the Space Launch System (SLS) to take us on a journey further than ever attempted. Within SCCS are separate subsystems and system level software, each of which have to be tested and verified. Testing is a long and tedious process, so automating it will be much more efficient and also helps to remove the possibility of human error from mission operations. I was part of a team of interns and full-time engineers who automated tests for the requirements on SCCS, and with that was able to help verify that the software systems are performing as expected.

Automation↗

NASA NTRS2017

Spaceport Command and Control System Automation Testing

The goal of automated testing is to create and maintain a cohesive infrastructure of robust tests that could be run independently on a software package in its entirety. To that end, the Spaceport Command and Control System (SCCS) project at the National Aeronautics and Space Administration's (NASA) Kennedy Space Center (KSC) has brought in a large group of interns to work side-by-side with full time employees to do just this work. Thus, our job is to implement the tests that will put SCCS through its paces.

Plano, Tom↗

NASA NTRS2020

Command and Control System Automated Testing

To support the National Aeronautics and Space Administration’s (NASA) Space Launch System (SLS) rocket, Kennedy Space Center (KSC) has developed the Spaceport Command and Control System (SCCS) to monitor and control the pre-launch and launch operations. Within SCCS, the Launch Control System (LCS) is designed to allow console engineers to control and monitor the status of the launch and flight hardware, as well as issue commands to ground control systems and launch vehicles. The display software of the LCS is responsible for visualizing the various data that can be received from the hardware and software components of the LCS. Since this system is providing critical information to engineers in the firing room, the visualization of data across the system must be easy to understand, but also reliable and accurate.

Software↗

NASA NTRS2020

Command and Control System Automated Testing

To support the National Aeronautics and Space Administration’s (NASA) Space Launch System (SLS) rocket and the Orion capsule, designed to take humans back to the moon in 2024, Kennedy Space Center (KSC) has developed the Spaceport Command and Control System (SCCS) to monitor and control the launch. Within SCCS, the Launch Control System (LCS) is designed to allow console engineers to control and monitor the status of the launch and flight hardware, as well as issue commands to ground control systems and launch vehicles. The messaging software of LCS is responsible for handling the various data types that can be sent between the hardware and software components of the LCS. Since this system is interacting with numerous devices, controllers, and viewports in real time, the distribution of data across the system must be fast, but also reliable and accurate. To verify the accuracy and reliability of the system, developers on the project have created a set of tests to be performed that covers all operations allowed by the system. Given the extensive Application Programming Interface(API) provided by the messaging software, these unit tests are rather time-consuming and costly (in terms of man-hours) to perform. Therefore, an automated testing framework is used to perform supplemental tests automatically when updates are made to the code base.

Rebecca McFadden↗

DOE OSTI2025

Microreactor Automated Control System Test Bed Digital Architecture for Real-Time, Hardware-in-the-Loop Simulation

This work describes progress made towards the development of a real-time hardware-in-the-loop (HIL) test bed for non-nuclear testing of microreactor control schemes and failure modes. Non-nuclear testing is a crucial step in developing robust control algorithms for managing microreactor dynamics. The creation of an HIL simulation harnesses the realistic dynamics of physical analogue systems while additionally considering the challenges of variable communication delay. This collaborative effort between Oak Ridge National Laboratory and Idaho National Laboratory has resulted in a LabVIEW-based gRPC communication protocol which couples a TRANSFORM Modelica simulation of nuclear components to the ViBRANT physical hardware for realistic feedback and visual representation of control action in real time. A modular python client structure is developed to manage FMU-based Modelica simulation and real-time gRPC communication. HIL testing suggests that the modeled reactor with natural convection molten salt loop coolant configuration responds well to PID control of drum positioning for modulation of reactor core power, however, future efforts will be made to explore the added thermal inertial delay of system level control and downstream demand changes. Development of this platform with a generalized methodology provides a foundation for exploring a variety of reactor configurations and failure modes in rapid order to provide insight into the most effective avenues of study for further research and development.

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

NASA NTRS1985

Space infrared telescope pointing control system. Automated star pattern recognition

The Space Infrared Telescope Facility (SIRTF) is a free flying spacecraft carrying a 1 meter class cryogenically cooled infrared telescope nearly three oders of magnitude most sensitive than the current generation of infrared telescopes. Three automatic target acquisition methods will be presented that are based on the use of an imaging star tracker. The methods are distinguished by the number of guidestars that are required per target, the amount of computational capability necessary, and the time required for the complete acquisition process. Each method is described in detail.

Powell, J. D.↗