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At least 289 records · Page 16

Using Hardware-In-The-Loop Methodology to Develop Test Systems

Hardware in the Loop (HIL) testing methodologies have become widespread in industry. Typically, they focus on developing control algorithms for systems such as autonomous vehicles or aircraft. An oft overlooked aspect of product development is the design and fabrication of a test system for validating that the product meets requirements. Abstractly, a test system differs little from a control system—testers provide signals to the unit, monitor feedback, and base decisions on the results. While the time scales may differ, the functionalities are conceptually similar. Viewed in this light, it becomes natural to extend HIL approaches to tester development. By replacing a physical unit with a proxy model deployed to a real-time or pseudo real-time target, test systems can be developed in parallel with the design and fabrication of a first production unit. This saves considerable time in the life cycle from conceptual design to realized product. This manuscript demonstrates the process flow using a capacitive discharge unit as an exemplar.

42 ENGINEERING↗

Even Higher-Level Synthesis: An Exploration of AI Hardware Accelerators using HLS4ML

With the rise of artificial intelligence, the popularization of deep learning, and a constantly evolving industry, the demand for flexible and efficient tools has never been greater. As algorithms grow more complex, their runtime and energy consumption increase exponentially. Customized hardware accelerators, long used for specific mathematical operations, remain essential for managing modern applications' computational and power demands. Hardware accelerators can speed up complex computations by orders of magnitude, but their manual design and verification processes are often challenging and time-consuming. High-Level Synthesis (HLS) provides a solution by transforming high-level algorithm descriptions, typically written in C++ or SystemC, into synthesizable RTL suitable for hardware implementation. This approach reduces development time for RTL engineers while offering flexibility beyond what traditional handwritten RTL can provide. We extended this capability to the machine-learning domain with the open-source framework hls4ml, which allows neural networks trained in Python frameworks like Tensorflow or PyTorch to be synthesized into efficient hardware representations for the traditional FPGA and ASIC flows. This breakthrough addresses the growing need for reduced design turnaround and easy verification of ML hardware accelerators with low latency and power efficiency constraints. During this tutorial, we will demonstrate how Python complements HLS by simplifying the ML design process, bridging the gap between software and hardware development. Attendees will explore how we translate neural networks modeled in Python into fixed-point C++ models suitable for HLS workflows. We will dive into strategies like Value-Range Analysis and Quantization-Aware Training, which optimize these designs for deployment and evaluate their accuracy, power consumption, and energy efficiency. To exemplify these concepts, experts from Fermilab will share their experiences applying this technology to high-energy physics experiments, where real-time, low-latency processing is critical. Over the years, Fermilab engineers have demonstrated how deep neural networks, optimized for hardware using hls4ml, can meet the stringent requirements of trigger systems at the CERN Large Hadron Collider. These systems rely on rapid decision-making to process immense data volumes while retaining only the most relevant events for further analysis. The application of hls4ml has also been extended to innovative technologies like smart pixel arrays. These smart pixels integrate ML inference capabilities directly into sensor devices, enabling localized data processing at the pixel level. This approach drastically reduces the need to transmit raw data to external processing units, significantly decreasing power consumption and latency. By embedding neural networks within the pixel architecture, the smart pixels can identify and prioritize relevant data in real time, providing a highly efficient solution for edge computing in scenarios such as particle detectors and imaging systems. Fermilab's work highlights the potential of hardware-accelerated ML in scenarios where both speed and power efficiency are mission-critical. Through this tutorial, attendees will gain valuable insights into the challenges and solutions of deploying ML in hardware. Understanding how HLS and hls4ml streamline the development of neural network-based hardware accelerators is fundamental for the industry's future. Participants will learn how these technologies are shaping the future of AI and scientific computing.

Di Guglielmo, Giuseppe [Fermilab]↗

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗

Uncertainty-Guided Prediction Horizon of Phase-Resolved Ocean Wave Forecasting Under Data Sparsity: Experimental and Numerical Evaluation

Accurate short-term wave forecasting is critical for the safe and efficient operation of marine structures that rely on real-time, phase-resolved ocean wave information for control and monitoring purposes (e.g., digital twins). These systems often depend on environmental sensors (e.g., waverider buoys, wave-sensing LIDAR). Challenges arise when upstream sensor data are missing, sparse, or phase-shifted due to drift. This study investigates the performance of two machine learning models, time-series dense encoder (TiDE) and long short-term memory (LSTM), for forecasting phase-resolved ocean surface elevations under varying degrees of data degradation. We introduce the τ-trimming algorithm, which adapts the prediction horizon based on uncertainty thresholds derived from historical forecasts. Numerical wave tank (NWT) and wave basin experiments are used to benchmark model performance under short- and long-term data masking, spatially coarse sensor grids, and upstream phase shifts. Results show under a 50% probability of upstream data loss, the τ-trimmed TiDE model achieves a 46% reduction in error at the most upstream target, compared to 22% for LSTM. Furthermore, phase misalignment in upstream data introduces a near-linear increase in forecast error. Under moderate model settings, a ±3 s misalignment increases the mean absolute error by approximately 0.5 m, while the same error is accumulated at ±4 s using the more conservative approach. These findings inform the design of resilient, uncertainty-aware wave forecasting systems suited for realistic offshore sensing environments.

42 ENGINEERING↗

Procedure for estimating stability and control parameters from flight test data by using maximum likelihood methods employing a real-time digital system

A maximum likelihood parameter estimation procedure and program were developed for the extraction of the stability and control derivatives of aircraft from flight test data. Nonlinear six-degree-of-freedom equations describing aircraft dynamics were used to derive sensitivity equations for quasilinearization. The maximum likelihood function with quasilinearization was used to derive the parameter change equations, the covariance matrices for the parameters and measurement noise, and the performance index function. The maximum likelihood estimator was mechanized into an iterative estimation procedure utilizing a real time digital computer and graphic display system. This program was developed for 8 measured state variables and 40 parameters. Test cases were conducted with simulated data for validation of the estimation procedure and program. The program was applied to a V/STOL tilt wing aircraft, a military fighter airplane, and a light single engine airplane. The particular nonlinear equations of motion, derivation of the sensitivity equations, addition of accelerations into the algorithm, operational features of the real time digital system, and test cases are described.

Grove, R. D.↗

Mariner 9 - Image processing and products.

The purpose of this paper is to describe the system for the display, processing, and production of image data products created to support the Mariner 9 Television Experiment. Of necessity, the system was large in order to respond to the needs of a large team of scientists with a broad scope of experimental objectives. The desire to generate processed data products as rapidly as possible to take advantage of adaptive planning during the mission, coupled with the complexities introduced by the nature of the vidicon camera, greatly increased the scale of the ground image processing effort. This paper describes the systems that carried out the processes and delivered the products necessary for real-time and near-real-time analyses. References are made to the computer algorithms used for the different levels of decalibration and analysis.

Levinthal, E. C.↗

Mariner 9 - Image processing and products.

The purpose of this paper is to describe the system for the display, processing, and production of image-data products created to support the Mariner 9 Television Experiment. Of necessity, the system was large in order to respond to the needs of a large team of scientists with a broad scope of experimental objectives. The desire to generate processed data products as rapidly as possible, coupled with the complexities introduced by the nature of the vidicon camera, greatly increased the scale of the ground-image processing effort. This paper describes the systems that carried out the processes and delivered the products necessary for real-time and near-real-time analyses. References are made to the computer algorithms used for the different levels of decalibration and analysis.

Levinthal, E. C.↗

Comparison of seven performance measures in a time-delayed manipulation task

Real-time performance data was collected during a pick-up task carried out with a Rancho master-slave manipulator using a minicomputer-based data taker. In addition to the usual task-time measurements, computer algorithms to integrate the energy consumed and to count and time the number of moves were implemented. In addition to these measures, several derived measures such as the fraction of time moving (MRATIO) and mean time per move (MBAR) were obtained in an off-line analysis. Preliminary results of the time delay experiment indicate that two new measures, MRATIO and MBAR, are almost an order of magnitude more sensitive than task time, the conventional measure, in determining performance changes with transmission delays in the range from 0.0 to 1.0s.

Hill, J. W.↗

Real-time onboard geometric image correction

A system to perform real time onboard geometric connection of LANDSAT D resolution satellite imagery is described. System requirements, algorithms, sensors, and other hardware components are defined. Feasibility of implementing the correction process is demonstrated using Kalman filter techniques to incorporate information from onboard ephemeris, attitude control, and ground control points. Random access sensor systems, such as charge injected devices and charge coupled devices are used to obtain pixel values at desired ground location, thus greatly reducing the data processing requirements.

Discenza, W.↗

Low-level processing for real-time image analysis

A system that detects object outlines in television images in real time is described. A high-speed pipeline processor transforms the raw image into an edge map and a microprocessor, which is integrated into the system, clusters the edges, and represents them as chain codes. Image statistics, useful for higher level tasks such as pattern recognition, are computed by the microprocessor. Peak intensity and peak gradient values are extracted within a programmable window and are used for iris and focus control. The algorithms implemented in hardware and the pipeline processor architecture are described. The strategy for partitioning functions in the pipeline was chosen to make the implementation modular. The microprocessor interface allows flexible and adaptive control of the feature extraction process. The software algorithms for clustering edge segments, creating chain codes, and computing image statistics are also discussed. A strategy for real time image analysis that uses this system is given.

Eskenazi, R.↗

Real-time data reduction capabilities at the Langley 7 by 10 foot high speed tunnel

The 7 by 10 foot high speed tunnel performs a wide range of tests employing a variety of model installation methods. To support the reduction of static data from this facility, a generalized wind tunnel data reduction program had been developed for use on the Langley central computer complex. The capabilities of a version of this generalized program adapted for real time use on a dedicated on-site computer are discussed. The input specifications, instructions for the console operator, and full descriptions of the algorithms are included.

Fox, C. H., Jr.↗

Application of a ground based minicomputer system for real time, closed loop control of remotely piloted aircraft models used in stall/spin research

The paper describes a minicomputer-based, real-time closed loop remote control system at NASA Langley outdoor facility which is used to determine the stall/departure/spin characteristics of high-performance aircraft. The experiments are conducted with 15% dynamically scaled, unpowered models that are dropped from 3000 m and ground controlled. The effects of time delays and sampling rates on the stability of the control system and the selection of digital algorithms to meet frequency response and real time constraints are examined. Also described is the implementation of the modular software for the flexible programming of multi-axis control laws.

Montoya, R. J.↗

Real-time pilot guidance system for improved flight test maneuvers

The Dryden Flight Research Facility of the NASA Ames Research Center has developed a pilot trajectory guidance system that increases the accuracy of flight-test data and decreases the time required to achieve and maintain desired test conditions. The system usually presented to the pilot computed differences between reference or desired and actual flight state conditions. The pilot then used a cockpit display as an aid to acquire and hold desired test conditions. This paper discusses various flight-test maneuvers and the quality of data obtained using the guidance system. Some comparisons are made between the quality of maneuvers obtained with and without the system. Limited details of the guidance system and algorithms used are included. In general, the guidance system improved the quality of the maneuvers and trajectories flown, as well as allowing trajectories to be flown that would not have been possible without the system. This system has moved from the developmental stage to full operational use in various Dryden research and test aircraft.

Meyer, R. R., Jr.↗

Real-time MST radar signal processing using a microcomputer running under FORTH

Data on power, correlation time, and velocity were obtained at the Urbana radar using microcomputer and a single floppy disk drive. This system includes the following features: (1) measurement of the real and imaginary components of the received signal at 20 altitudes spaced by 1.5 km; (2) coherent integration of these components over a 1/8-s time period; (3) continuous real time display of the height profiles of the two coherently integrated components; (4) real time calculation of the 1 minute averages of the power and autocovariance function up to 6 lags; (5) output of these data to floppy disk once every 2 minutes; (6) display of the 1 minute power profiles while the data are stored to the disk; (7) visual prompting for the operator to change disks when required at the end of each hour of data; and (8) continuous audible indication of the status of the interrupt service routine. Accomplishments were enabled by two developments: the use of a new correlation algorithm and the use of the FORTH language to manage the various low level and high level procedures involved.

Bowhill, S. A.↗

Real-time pilot guidance system for improved flight-test maneuvers

The Dryden Flight Research Facility has developed a pilot trajectory guidance system that is intended to increase the accuracy of flight-test data and decrease the time required to achieve and maintain desired test conditions, or both. The system usually presented to the pilot computed differences between reference or desired and actual flight state conditions. The pilot then used a cockpit display as an aid to acquire and hold desired test conditions. This paper discusses various flight-test maneuvers and the quality of data obtained using the guidance system. Some comparisons are made between the quality of maneuvers obtained with and without the system. Limited details of the guidance system and algorithms used are included. In general, the guidance system improved the quality of the maneuvers and trajectories flown, as well as allowing trajectories to be flown that would not have been possible without the system. This system has moved from the developmental stage to full operational use in various Dryden research and test aircraft.

Meyer, R. R., Jr.↗

A unified method for evaluating real-time computer controllers: A case study

A real time control system consists of a synergistic pair, that is, a controlled process and a controller computer. Performance measures for real time controller computers are defined on the basis of the nature of this synergistic pair. A case study of a typical critical controlled process is presented in the context of new performance measures that express the performance of both controlled processes and real time controllers (taken as a unit) on the basis of a single variable: controller response time. Controller response time is a function of current system state, system failure rate, electrical and/or magnetic interference, etc., and is therefore a random variable. Control overhead is expressed as a monotonically nondecreasing function of the response time and the system suffers catastrophic failure, or dynamic failure, if the response time for a control task exceeds the corresponding system hard deadline, if any. A rigorous probabilistic approach is used to estimate the performance measures. The controlled process chosen for study is an aircraft in the final stages of descent, just prior to landing. First, the performance measures for the controller are presented. Secondly, control algorithms for solving the landing problem are discussed and finally the impact of the performance measures on the problem is analyzed.

Shin, K. G.↗

Synchronization and fault-masking in redundant real-time systems

A real time computer may fail because of massive component failures or not responding quickly enough to satisfy real time requirements. An increase in redundancy - a conventional means of improving reliability - can improve the former but can - in some cases - degrade the latter considerably due to the overhead associated with redundancy management, namely the time delay resulting from synchronization and voting/interactive consistency techniques. The implications of synchronization and voting/interactive consistency algorithms in N-modular clusters on reliability are considered. All these studies were carried out in the context of real time applications. As a demonstrative example, we have analyzed results from experiments conducted at the NASA Airlab on the Software Implemented Fault Tolerance (SIFT) computer. This analysis has indeed indicated that in most real time applications, it is better to employ hardware synchronization instead of software synchronization and not allow reconfiguration.

Krishna, C. M.↗

Evaluation of a real-time predictive guidance law for landing VTOL aircraft at sea

A piloted simulation evaluation was conducted to assess the merits of a predictive lull/swell guidance law for landing a vertical takeoff and landing aircraft at sea. Two cases were evaluated. The first was performed by the pilot without the aid of the lull/swell guidance indicator, which indicates a landing opportunity. The second was performed in a similar manner with the aid of the guidance indicator. The pilot was instructed to use the guidance indicator only as a landing aid. The results indicated the pilots were able to visually determine ship lulls and swells prior to landing. However, use of the lull/swell guidance resulted in increased pilot confidence in the existence of a landing opportunity, which resulted in significantly shorter hover waiting times prior to landing. The performance of the lull/swell guidance was conservative, in that it forecast the onset of deck lulls and swells later than the pilot could detect them, but with greater reliability and therefore greater pilot confidence. In no instances did the guidance algorithm predict a false ship lull with which the pilot did not agree.

Paulk, C. H., Jr.↗