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All sources NASA NTRS DOE OSTI

NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗

NASA NTRS2008

Thermal Vacuum Control Systems Options for Test Facilities

This presentation suggests several Thermal Vacuum System (TVAC) control design approach methods for TVAC facilities. Over the past several years many aerospace companies have or are currently upgrading their TVAC testing facilities whether it be by upgrading old equipment or purchasing new. In doing so they are updating vacuum pumping and thermal capabilities of their chambers as well as their control systems. Although control systems are sometimes are considered second to the vacuum or thermal system upgrade process, they should not be taken lightly and must be planned and implemented with the equipment it is to control. Also, emphasis should be placed on how the operators will use the system as well as the requirements of "their" customers. Presented will be various successful methods of TVAC control systems from Programmable Logic Controller (PLC) based to personal computer (PC) based control.

Marchetti, John↗

NASA NTRS2007

My Rewarding Summer Research Experience at NASA

My summer research experience at the Kennedy Space Center has been a truly rewarding one. As an electrical engineering student at the University of South Florida, I was blessed with a beneficial opportunity to gain valuable knowledge in my career, and also apply it through working at NASA. One of my inspirations in becoming an engineer is to work at NASA someday, and I was very excited and honored to have this opportunity. My goal in this internship was to strengthen my preparation in becoming an engineer by learning new material, acquiring skills by practicing what I learned, and discovering the expectations of engineering work at NASA. Through this summer research, I was able to learn new computer programs and perform various tasks that gave me experience and skills as an engineer. My primary job was to conduct work on the Constellation Test article, which is a simulation model of the Crew Launch Vehicle (CLV) tanking system. This is a prototype of a launch facility and an Ares I Vehicle, which God willing will transport astronauts to the moon. Construction of the CLV is in progress and a test launch is anticipated for 2010. Moreover, the Test Article serves as a demonstration too, training test bed, and may be expanded for new simulation of launch system elements, which could be applied to real life operations. The test article is operated and run by a Programmable Logic Controller (PLC), which is a digital computer that is used to control all forms of machinery such as those in manufacturing buildings and other industries. PLCs are different than other computers because of the physical protection they have against damaging environmental conditions that would destroy other computers. Also, PLCs are equipped with lots of input and output connections that allow extensive amounts of commands to be executed, which would normally require many computers to do. Therefore, PLCs are small, rugged, and extremely powerful tools that may continue to be employed at NASA. Furthermore, in order to conduct productive work on the Test Article, I needed to learn the computer program called RS Logics 5000.

Aviles, Andres↗

NASA NTRS2012

Modernization of B-2 Data, Video, and Control Systems Infrastructure

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) Plum Brook Station (PBS) Spacecraft Propulsion Research Facility, commonly referred to as B-2, is NASA s third largest thermal-vacuum facility with propellant systems capability. B-2 has completed a modernization effort of its facility legacy data, video and control systems infrastructure to accommodate modern integrated testing and Information Technology (IT) Security requirements. Integrated systems tests have been conducted to demonstrate the new data, video and control systems functionality and capability. Discrete analog signal conditioners have been replaced by new programmable, signal processing hardware that is integrated with the data system. This integration supports automated calibration and verification of the analog subsystem. Modern measurement systems analysis (MSA) tools are being developed to help verify system health and measurement integrity. Legacy hard wired digital data systems have been replaced by distributed Fibre Channel (FC) network connected digitizers where high speed sampling rates have increased to 256,000 samples per second. Several analog video cameras have been replaced by digital image and storage systems. Hard-wired analog control systems have been replaced by Programmable Logic Controllers (PLC), fiber optic networks (FON) infrastructure and human machine interface (HMI) operator screens. New modern IT Security procedures and schemes have been employed to control data access and process control flows. Due to the nature of testing possible at B-2, flexibility and configurability of systems has been central to the architecture during modernization.

Cmar, Mark D.↗

NASA NTRS2012

Modernization of B-2 Data, Video, and Control Systems Infrastructure

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) Plum Brook Station (PBS) Spacecraft Propulsion Research Facility, commonly referred to as B-2, is NASA's third largest thermal-vacuum facility with propellant systems capability. B-2 has completed a modernization effort of its facility legacy data, video and control systems infrastructure to accommodate modern integrated testing and Information Technology (IT) Security requirements. Integrated systems tests have been conducted to demonstrate the new data, video and control systems functionality and capability. Discrete analog signal conditioners have been replaced by new programmable, signal processing hardware that is integrated with the data system. This integration supports automated calibration and verification of the analog subsystem. Modern measurement systems analysis (MSA) tools are being developed to help verify system health and measurement integrity. Legacy hard wired digital data systems have been replaced by distributed Fibre Channel (FC) network connected digitizers where high speed sampling rates have increased to 256,000 samples per second. Several analog video cameras have been replaced by digital image and storage systems. Hard-wired analog control systems have been replaced by Programmable Logic Controllers (PLC), fiber optic networks (FON) infrastructure and human machine interface (HMI) operator screens. New modern IT Security procedures and schemes have been employed to control data access and process control flows. Due to the nature of testing possible at B-2, flexibility and configurability of systems has been central to the architecture during modernization.

Cmar, Mark D.↗

NASA NTRS2013

Human Machine Interface Programming and Testing

Human Machine Interface (HMI) Programming and Testing is about creating graphical displays to mimic mission critical ground control systems in order to provide NASA engineers with the ability to monitor the health management of these systems in real time. The Health Management System (HMS) is an online interactive human machine interface system that monitors all Kennedy Ground Control Subsystem (KGCS) hardware in the field. The Health Management System is essential to NASA engineers because it allows remote control and monitoring of the health management systems of all the Programmable Logic Controllers (PLC) and associated field devices. KGCS will have equipment installed at the launch pad, Vehicle Assembly Building, Mobile Launcher, as well as the Multi-Purpose Processing Facility. I am designing graphical displays to monitor and control new modules that will be integrated into the HMS. The design of the display screen will closely mimic the appearance and functionality of the actual modules. There are many different field devices used to monitor health management and each device has its own unique set of health management related data, therefore each display must also have its own unique way to display this data. Once the displays are created, the RSLogix5000 application is used to write software that maps all the required data read from the hardware to the graphical display. Once this data is mapped to its corresponding display item, the graphical display and hardware device will be connected through the same network in order to test all possible scenarios and types of data the graphical display was designed to receive. Test Procedures will be written to thoroughly test out the displays and ensure that they are working correctly before being deployed to the field. Additionally, the Kennedy Ground Controls Subsystem's user manual will be updated to explain to the NASA engineers how to use the new module displays.

Foster, Thomas Garrison↗

NASA NTRS2016

Integrated System for Health Management and Autonomous Control (ISHM-AC): Development and Application

Autonomous control systems represent a technological barrier from manual and automated operated control systems in an industry wide application. An increase in energy-efficient storage, transfer and use of cryogens and cryogenic propellants on Earth and in space has been observed in space related industries between NASA, government and commercial programs. An increase in efficiency of cryogenic systems demands an increase in the capabilities of the control and monitoring system that manages them. As new technologies are developed for cryogenic systems, complexity and capability increases. The increase in complexities are a natural drive to develop better and more capable health monitoring and control system management. Current research and development efforts lead the Cryogenics Test Laboratory at the Kennedy Space Center to improve its automated control and health monitoring system from a Programmable Logic Control (PLC) based-only system to a fully Integrated System for Health Management (ISHM) - Autonomous Control (AC) capable of performing autonomous operations on a cryogenic propellant transfer system. This ISHM-AC system has been developed and tested by controlling a complete simulated propellant transfer operation. The capabilities and test results of this fully integrated autonomous system for cryogenics propellant transfer operation will be presented in this paper.

Toro, Jaime A.↗

NASA NTRS2016

Integrated System for Health Management and Autonomous Control (ISHM-AC) for Cryogenic Operations on the Simulated Propellant Loading System

Toro Medina, Jaime A.↗

NASA NTRS2016

Environmental Testing of Flight Hardware in the 25 ft. Space Simulator at JPL in a Manual Mode

After receiving global admiration for the Mars Science Laboratory (MSL) Curiosity rover, the Jet Propulsion Laboratory (JPL) is planning to embark upon another mobile mission to the red planet in the year 2020. Currently, the working name given to this sophisticated next-generation rover is Mars 2020. Mars 2020 will boast a multitude of newly developed instruments to aid in the scientific study of Mars. This paper will describe the process of testing one of the Mars 2020 instruments in the 25 ft. Space Simulator. The testing was performed at Mars CO2 atmospheric pressure of 7 Torr and consisted of multiple chamber evacuations and backfills. The Programmable Logic Control (PLC) system for the chamber was in the middle of a major overhaul that resulted in utilizing the manual Hand/Off/Auto switches to operate the chamber. Accomplishing this challenging task required the meticulous development of new operating procedures and thorough training of the chamber’s operators.

Ovcharenko, Anton↗

DOE OSTI2025

Poster: Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Autonomous thermal regulation in nuclear reactors remains crucial for maintaining stable operation and ensuring the integrity of fuel. To alleviate public skepticism of the safety of nuclear reactors, demonstrating control over this key factor is pivotal. Utilizing electric heat pads to simulate the heat released in a reactor core, thermocouples for temperature monitoring, and an Arduino micro programmable logic controller (PLC) with an embedded proportional-integral-derivative (PID) algorithm for control, a hardware-based demonstration of a reactor heating system will validate the efficacy of reactor control over this key parameter.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2025

IOTA Pre-Bake Test Development

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

Seagrave, Kayla [DuPage Coll.; Fermilab]↗

DOE OSTI2025

From Obsolete to Optimal (ATR Demineralized Water System)

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

47 - OTHER INSTRUMENTATION↗

DOE OSTI2025

Control System Upgrade for Battery State-of-Charge Indications

The Advanced Test Reactor (ATR) Complex at Idaho National Laboratory (INL) relies on Battery Backed Power (BBP) systems and Uninterruptible Power Supplies (UPS) to ensure continuous power supply to critical components. This project aims to enhance the reliability and functionality of the battery monitoring and control systems by updating the State-of-Charge (SOC) system, Programmable Logic Controller (PLC), and Human-Machine Interface (HMI) for the nuclear safety-related battery banks. The current system, while functional, has areas for improvement, particularly in recharging calculations and alarm functions. The project objectives include developing flow charts, programming the new PLC and HMI, conducting bench tests, and updating design documentation. Additionally, the project ensures compliance with safety standards, develops training materials, creates comprehensive documentation, and integrates seamlessly with existing ATR infrastructure. The new SOC system is designed to be scalable for future upgrades, improve efficiency, enhance data accuracy, implement redundancy features, and achieve project goals within budget constraints while considering environmental impact. The methodology involved familiarizing with BBP and UPS systems, collecting current readings, rescaling signals, learning ladder logic, and updating the HMI. The transition from SLC 5/03 PLC using RS Logix 500 to CompactLogix 5380 using Studio 5000 was a key step. Despite challenges in transferring outdated PLC ladder logic and HMI code, starting from scratch led to a more accurate and efficient monitoring system, contributing to improved safety and operational efficiency. The project is currently awaiting approval of the Engineering Calculation and Analysis Report (ECAR) before implementation.

42 - ENGINEERING↗

DOE OSTI2025

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

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

42 ENGINEERING↗

DOE OSTI2026

A New Era for Modern Bubble Chamber Technology: Cooling and Real-Time Control for the MAMBA Neutrino Bubble Chamber∗

Future neutrino experiments such as DUNE will be limited less by statistics than by how well neutrino--nucleus interactions are understood, and the cleanest way to improve that understanding is to measure interactions with light nuclei such as hydrogen or deuterium. The detector best suited to the job, the bubble chamber, has not been built for a neutrino beam in about fifty years. MAMBA (Modern Adaptive Modular Bubble chamber Archetype) is a small prototype at Fermilab intended to bring the technology back with modern cryogenics and automation, cycling continuously at 1~Hz. This paper summarizes my work on two of its subsystems during a summer internship. A new solid copper thermal link brought the coldhead to 21.3~K in a commissioning cooldown, near the 20~K operating target. An Industrial Shields Raspberry Pi programmable logic controller (PLC) running OpenPLC was characterized at a median round-trip response of 0.64~ms over 20,000 trials, with 0.66\% of trials exceeding 1~ms. Both results support continuous cycling.

Williams, Nicholas [Fermilab; DuPage Coll.]↗

NASA NTRS2019

Hardware and Software Engineering

The Launch Control System (LCS) is a part of the system used to launch the Space Launch System (SLS). It monitors and control of both vehicle and ground systems for SLS. My internship this spring was focused both on the hardware and software aspects of the command and control system. During my internship I worked in two groups, the Record and Playback Subsystem (RPS) and Kennedy Ground Control Subsystems (KGCS). During my time on RPS, I worked on automating the updating of displays and engineering reports. While on KGCS I worked on creating a power distribution diagram of the Control System Development Lab (CDL) and a new trainer for new interns or employees to gain an understanding of Programmable Logic Controllers (PLCs).

Hardware↗

DOE OSTI2025

Innovative PLC Design for Optimized Potable Water Managment

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

47 - OTHER INSTRUMENTATION↗

DOE OSTI2024

PLC Vulnerabilities and Mitigations

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

42 ENGINEERING↗