SEARCH · Search NASA

Results for “Automation & control systems”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records

All sources NASA NTRS DOE OSTI

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)↗

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↗

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)↗

DOE OSTI2025

Microreactor Program Technology Maturation MACS system reports

This submission contains several reports associated with the DOE Microreactor Program Technology Maturation MACS system. These include milestone reports: M3AT-24IN0804031-Optimized MACS architecture M3AT-24IN0804033-Light and temp sensor integration M4AT-23IN0804055-Update Microreactor Automated Control System (MACS) hardware based on input from demonstration M2AT-23IN0804054-Demonstrate actuation of control system using Microreactor Automated Control System (MACS)

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2020

Systems and methods for monitoring traffic on industrial control and building automation system networks

Technologies relating to monitoring communications traffic to detect potential attacks on industrial control system networks and building automation system networks are described herein. In an embodiment, a monitoring device receives a plurality of communications from a control network. The monitoring device transmits the communications to a computing device. Based on the communications, the computing device generates a listing of devices that communicated by way of the control network over a period of time, and computes a volume of traffic between each pair of devices in the listing of devices. The computing device then outputs a graphical user interface (GUI) by way of display, the GUI comprising data indicative of the computed volumes of traffic, which may be indicative of a potential attack on the control network.

Jenkins, Chris↗

DOE OSTI2022

Combining diagnostics, modeling, and control systems for automated alignment of the TES beamline

X-ray beamlines are essential components of all synchrotron light sources. Practical operations involve frequent variation in beamline component positions and orientation, particularly when photon beam parameters shift due to experimental needs, or due to variations in the incoming photon beam. The alignment process can be time consuming and takes away from valuable beam time for experimental data collection. We describe progress in the automation of certain alignment tasks on the tender-energy X-ray spectroscopy (TES) beamline at the National Synchrotron Light Source II (NSLS-II). The beamline is controlled using the BlueSky software in which high level experimental plans guide the beamline components during an experiment. Numerous software packages exist for beamline modeling, and they may be tied to the beamline control system using a package we are continuing to develop called Sirepo-Bluesky. The photon beam distribution may be measured with fluorescent screens, and a relation between beam and machine state can be found by varying the mirror and aperture settings over a multi-dimensional range. We describe the results of such parameter varying measurements and how we are combining Sirepo-Bluesky with machine learning methods and reduced models to automate mirror alignment on the TES beamline.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A Framework to Design Consumer-Centric Operational Strategies for Resilience Enhancement

Extreme temperature-related events like heat waves or cold snaps can significantly stress the power distribution grid as electricity demand spikes leading to brownouts or blackouts if not managed properly. In addition, such extreme events can exacerbate inequity, with vulnerable populations (for example, houses with poor insulation, located in non-critical zones, and lack of local resources) at greater risk. There is a growing deployment of distribution systems automation technologies such as advanced metering infrastructure, sensors, and automated control systems to enhance the visibility of the entire distribution grid while meeting resilience objectives. Here, this paper proposes a framework for investigating how automation can improve the distribution system's resilience and ensure customers' health and safety during such extremes. The proposed framework's efficacy will be demonstrated for the Electricity Reliability Council of Texas (ERCOT) during winter storm Uri with varying levels of distribution automation technologies such as feeder isolation using smart switches, remote outage signals using advanced meters, and comfort-aware outage using advanced analytics and communication. Simulation results show that an outage strategy involving advanced grid technology and communication can reduce the occupant exposure to severe cold by 93% and, simultaneously, reduce expected energy not served by 73.2% when compared against feeder isolation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

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

2025 Intern Poster

The Hot Fuel Examination Facility (HFEF) at the Materials and Fuels Complex (MFC) houses the largest U.S. inert atmosphere hot cell for nuclear material research. Key features include the precision gamma scanning (PGS), Fuel Accident Condition Simulator (FACS), Neutron Radiography Reactor (NRAD), and the focus of this project, the Metallograph Loading Cell (MET Cell). The MET Cell performs tests on spent nuclear fuel, such as microhardness testing, microscopy, and neutron radiography. However, the MET Cell’s existing pressure and lighting control systems are outdated and inefficient, with inadequate documentation for system changes over time. This project aims to design a new automated control system for the MET Cell, ensuring longevity (minimum ten years), ease of troubleshooting/repair, and integration into the building monitoring system. The design process addressed challenges such as space restrictions, varied voltages within enclosures, sourcing new components, and security limitations. Compliance with NFPA 70, UL508A, MFC Physical Security, and INL Engineering standards was essential. The project involves repurposing an existing PLC to manage lighting and pressure control using digital and analog signals, simplifying wiring, and ensuring thorough documentation for future reference.

42 - ENGINEERING↗

DOE OSTI2025

Real-time process monitoring and automated control for direct ink write 3D printing of frontally polymerizing thermosets

Additive manufacturing (AM) enables the fabrication of complex geometries, yet its application to thermosets remains limited by post-processing requirements. Frontal ring-opening metathesis polymerization (FROMP) offers a promising alternative, enabling energy-efficient, in situ curing of freestanding thermoset structures. This study presents a real-time process monitoring and automated control system for direct ink writing (DIW) of FROMP thermosets. By integrating thermochromic leuco dyes and computer vision, we enable real-time polymerization front tracking, allowing autonomous printing parameter adjustments for consistent geometries across resin formulations. The system’s accuracy was validated against manual tracking, demonstrating precise front velocity detection. Its adaptability was confirmed by printing freestanding mechanical springs with different resins, achieving consistent geometries and mechanical properties despite front velocity variations. These findings highlight the potential of automated DIW control for scalable, repeatable, and material-agnostic 3D printing of thermosets.

Mejia, Edgar Brian [Sandia National Laboratories (↗

DOE OSTI2024

LLM integration into EPICS

The utilization of large language models (LLMs) such as ChatGPT has seen a remarkable increase in various fields over the past few years. These models have demonstrated their versatility and capability in understanding and generating human-like text, making them invaluable tools in numerous applications. In this project, we explore the integration of a LLM into the Experimental Physics and Industrial Control System (EPICS). The primary focus of this integration is to employ the LLM for advanced image processing and spatial analysis on images obtained from the beamlines. By leveraging the capabilities of the LLM, we aim to enhance the accuracy and efficiency of image interpretation, enabling more precise data analysis and decision-making within the EPICS framework. This integration not only showcases the potential of LLMs in scientific and industrial applications but also sets the stage for future advancements in automated control systems.

Adams, Ethan↗

DOE OSTI2026

Autonomous Hydrogen Fueling Station

This project “Autonomous Hydrogen Fueling Station” covered the autonomous refueling with both gaseous hydrogen and liquid hydrogen. The part on gaseous hydrogen focused on the development of an autonomous robotic fueling arm that would couple to a fuel cell engine for hydrogen refueling without guidance from the forklift operator and budget period. Research was also covered for the robotic fueling with a commercial vehicle. The second phase of the project created the baseline for an autonomous liquid hydrogen transfer system that would minimize boil off losses by operating at thermodynamically efficient state points. For the development of the robotic fueling arm, testing was conducted to establish a baseline measurement of the accuracy and repeatability of a human operator positioning a lift truck in front of a dispenser. The goal was to establish the range of motion required for an autonomous fueling mechanism to mate a hydrogen nozzle with a receptacle on a fuel cell system installed in a forklift. The final design comprised a selective compliance articulated robot arm (SCARA)-type mechanism with two arms for horizontal motion and a ball screw for vertical movement and color and LIDAR cameras were used for marker identification and proximity awareness to guide the robotic arm to its target receptacle. Initial tests resulted in 199 out of 200 successful attempts at autonomous coupling of the dispensing coupler and a fuel cell engine, without hydrogen. The dispenser prototype was modified to include tubing for both hydrogen fuel and air purge lines, but subsequent tests were confounded by the shoulder motor over current errors which limited the robot from getting to the fully inserted position to achieve a positive latch. Robotic hydrogen refueling was successfully demonstrated over 1.5 hours of testing, Plug completed 29 successful latches with an average number of 4 sequential latches before failure. However, a robot capable of placing the nozzle with more force is required for higher reliability. For budget period two, a small scale (10 kg / transfer) automated control system was designed that would operate valves to control pressure and flow of liquid nitrogen between a source and receiving tank with an aim to minimize boil off losses by operating at the most thermodynamically efficient state points. Control system logic flow and a P&ID were developed prior to system safety characterization via HAZOP. A control narrative and system state points were defined. Delays in approval for a change of project objective and procurement issues precluded the construction and test of the final prototype system.

08 HYDROGEN↗

DOE OSTI2023

Creating a Simulation Platform for Research and Development of Advanced Control Methods

Advanced nuclear reactors are essential to meet the changing energy requirements throughout both the United States and the rest of world. In addition to other features, they are designed to enable deployment in remote locations and operate in a fully (or near-fully) autonomous manner, which will require a new control paradigm. To realize autonomously operating reactors, the U.S. Department of Energy’s Nuclear Energy Enabling Technologies Advanced Sensors and Instrumentation (NEET ASI) program conducts research and development into the enabling technologies and methods needed, including digital twins, machine learning, and risk modeling, in addition to various types of control methods. These technologies and methods are the key foundations needed to achieve fully autonomous systems. To develop and evaluate the technologies and methods necessary for achieving autonomous operations, it is critical to identify a software tool capable of integrating all the required elements. In surveying the available solutions, no software platforms were identified that could accomplish what was needed without introducing drawbacks. This challenge was the motivation for the current effort: to develop a software platform that can seamlessly integrate autonomouscontrol-enabling technologies and methods, allowing for accelerated research and development and transfer of ideas. The resulting platform, known as the Control and Optimization Modular Modeling Application for Nuclear Deployment (COMMAND), is Python-based, and leverages open-source tools to provide flexibility and facilitate building upon prior research. It is designed to enable advanced reactor developers to deploy and test advanced control technologies and methods coupled with their own models, solutions, and hardware. Given the substantial undertaking of developing such a platform, the current effort focused on laying down scalable, flexible software foundations and infrastructure, then demonstrating the platform via a use case. These foundations included developing generic modules, which contain the base variable and system blocks (the information and functional building blocks, respectively, that can be used to design a simulation) and the data handling and storage blocks needed to exchange information between the various blocks; as well as enablingtechnology-specific modules. This platform was evaluated via a use case, which was to simulate and control a process for the Microreactor Automated Control System (MACS) test bed. While MACS is not currently directly coupled to any specific microreactor physics, it was initially developed in concert with the Microreactor Applications Research Validation and Evaluation (MARVEL) microreactor, and so the MARVEL physics are used here. As part of this use case, several enabling-technology-specific blocks within COMMAND were integrated, including a proportional integral derivative (PID) control block, a Reactor Excursion and Leak Analysis Program (RELAP5-3D) block, and an anomaly detection block. The COMMAND software platform was successfully demonstrated to achieve the scalability and flexibility objectives of this effort and will be leveraged by the program’s research efforts to advance state of the art control methodologies towards autonomous operations of advanced reactors. As new use cases are created and implemented, it is anticipated that COMMAND will continue to grow and evolve to meet new requirements.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗