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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Industry 4.0 and Intelligent Manufacturing Processes: A Review of Modern Sensing Technologies

Digital Manufacturing technologies have quickly become ubiquitous in the manufacturing industry. The transformation commonly referred to as the fourth industrial revolution, or Industry 4.0, has ushered in a wide range of communication technologies, connection mechanisms, and data analysis capabilities. These technologies provide powerful tools to create a more lean, profitable, and data-driven manufacturing processes. In this paper, we review modern communication technologies and connection architectures for Digital Manufacturing and Industry 4.0 applications. An introduction to Cyber-Physical Systems and a review of digital manufacturing trends is followed by an overview of data acquisition methods for manufacturing processes. Numerous communication protocols are presented and discussed for connecting disparate machines and processes. Flexible data architectures are discussed and examples of machine monitoring implementations are provided. Finally, select implementations of these communication protocols and architectures are surveyed with recommendations for future architecture implementations.

42 ENGINEERING↗
DOE OSTI2020

Remote Hardware-in-the-Loop Approach for Microgrid Controller Evaluation

Utilities have been installing microgrids because of the increased resilience and reliability advantages they may provide to the distribution system. A microgrid controller is a critical component in microgrids. It is of great benefit to derisk the installation of microgrid controllers before field deployment. Hardware-in-the-loop (HIL) testing is used by controller developers and utilities to evaluate the controllers under stressful conditions. In this work, a microgrid control function developed by the Synchrophasor Grid Monitoring and Automation (SyGMA) laboratory at the University of California, San Diego is tested in a remote HIL (RHIL) setup. The digital real-time simulation of the detailed microgrid system was operated at the National Renewable Energy Laboratory's Energy Systems Integration Facility. Under such RHIL setup, successful controller operation is contingent on understanding and characterizing the communications channel and in particular network latencies. The novelty of this paper is the proposed use of a RHIL setup that leverages existing power system communications protocols to evaluate the controller in conjunction with the simulation capabilities of a remote facility. The work presented here will provide the complete setup of the HIL evaluation platform, the details of the communications protocols used by the setup for data transfer between the two organizations, test cases developed to evaluate the controller, and the results from the experiments.

controller hardware-in-the-loop↗
DOE OSTI2021

Icypaw

The Intermode Communication Protocol Wrapper, or Icypaw, structures and facilitates communication between endpoints in a network. It is used to connect various independent software and hardware components into one loosely organized system controllable from one or more locations. The code uses the MQTT protocol to communicate and enhances it with a useful framework. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-8293 O

Van Der Wall, JayW.↗
DOE OSTI2021

Securing Environmental IoT Data Using Masked Authentication Messaging Protocol in a DAG-Based Blockchain: IOTA Tangle

The demand for the digital monitoring of environmental ecosystems is high and growing rapidly as a means of protecting the public and managing the environment. However, before data, algorithms, and models can be mobilized at scale, there are considerable concerns associated with privacy and security that can negatively affect the adoption of technology within this domain. In this paper, we propose the advancement of electronic environmental monitoring through the capability provided by the blockchain. The blockchain’s use of a distributed ledger as its underlying infrastructure is an attractive approach to counter these privacy and security issues, although its performance and ability to manage sensor data must be assessed. We focus on a new distributed ledger technology for the IoT, called IOTA, that is based on a directed acyclic graph. IOTA overcomes the current limitations of the blockchain and offers a data communication protocol called masked authenticated messaging for secure data sharing among Internet of Things (IoT) devices. We show how the application layer employing the data communication protocol, MAM, can support the secure transmission, storage, and retrieval of encrypted environmental sensor data by using an immutable distributed ledger such as that shown in IOTA. Finally, we evaluate, compare, and analyze the performance of the MAM protocol against a non-protocol approach.

Gangwani, Pranav (ORCID:0000000159226002)↗
DOE OSTI2022

Microgrid Communications Using the Open-Source Open Field Message Bus (OpenFMB) Framework Applied to a 480V, 100kW Laboratory Microgrid

Microgrids require an extensive communication infrastructure to allow interoperability between the microgrid controller and assets. However, the lack of standardization of data structures combined with the variety of communication protocols poses several challenges to the implementation of a communication network. This paper presents an application of the open-source Open Field Message Bus (OpenFMB) framework to simplify the communication layer in microgrids. This work leverages the OpenFMB protocol translation and data model extensions to reduce the complexity in the microgrid communications. Conducted in a laboratory microgrid, the case study demonstrates how the OpenFMB provides predefined data models and simplifies the communication layer by providing information exchange between multiple legacy communication protocols.

Ferrari Maglia, Max↗
DOE OSTI2022

Incentivizing Distributed Energy Resource Participation in Grid Services

The bulk power system is experiencing a dramatic shift as renewable generation growth continues to accelerate. Large-scale renewables adoption will help societies transition to a low-carbon, low-cost, and environmentally friendly electrical power system. However, the transition from a paradigm of generation following load to one where load follows generation will require large-scale interconnection and coordinated operation of Distributed Energy Resources (DERs), supported by open communication protocols. In this future grid scenario, DER aggregations will provide critical grid services that enable high penetration levels of renewable generation. This position paper presents an Energy Service Interface (ESI) that defines scope for ensuring secure, trustworthy information exchange between grid service providers and DERs. The goal of the ESI is to encourage large-scale participation of DERs in order to provide grid services through dispatch of DER aggregations. This position paper also presents an open smart energy communications protocol that allows DERs to advertise their characteristics and participate in grid services, within constraints established by the ESI. The paper presents several monetization incentives that grid service providers could use to encourage large-scale DER participation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Modeling Grid Data Flows for Transmission and Distribution Operations: Review, Design, Next Steps

Operational scenarios of the power grids grow multifold to accommodate the diverse needs of both the utilities and end consumers, and the various other stakeholders in-between. To comprehensively model and apply analytics to support objectives and business functions of grid sectors, a reliable approach to characterize and design data flows is crucial. The flows bridge business functions with communications protocols, stakeholders such as the grid actors, and data interfaces comprising different data objects. Additionally, constraints applied to the flow such as cybersecurity, trust, privacy, and ownership among others intersect these entities, requiring the delineation of their interactions under different scenarios. This paper aims to not only highlight relevant research in the space of grid data flows, but also proposes, for the transmission-distribution sector, a novel modeling approach that marries the aforementioned entities: objectives, business functions, data interfaces, communication protocols, data stakeholders, and flow constraints. It elaborates on the design philosophy and the significance of each entity within the model and applies it to an example function of fault location, isolation and service restoration (FLISR). Finally, the next steps to extend the application of this data flow model for other practical operational scenarios are discussed.

Sundararajan, Aditya [ORNL] (ORCID:000000033577854↗
DOE OSTI2021

EMS and DMS Integration of the Coordinative Real-time Sub-Transmission Volt-Var Control Tool under High DER Penetration

This paper proposes an applicable approach to deploy the Coordinative Real-time Sub-Transmission Volt-Var Control Tool (CReST-VCT), and a holistic system integration framework considering both the energy management system (EMS) and distribution system management system (DMS). This provides an architectural basis and can serve as the implementation guideline of CReST-VCT and other advanced grid support tools, to co-optimize the operation benefits of DERs and assets in both transmission and distribution networks. Potential communication protocols for different physical domains of a real application is included. Performance and security issues are also discussed, along with specific considerations for field deployment. Finally, the paper presents a viable pathway for CReST-VCT and other advanced grid support tools, which could be integrated in an open-source standardized-based platform that supports distribution utilities.

Nguyen, Quan H.↗
DOE OSTI2023

Towards 5G-Enabled Operational Technology for Process Monitoring and Network Slicing

Cyber-Physical Systems (CPS) are deployed to monitor physical processes in critical cyber-enabled services like power generation. However, CPS ecosystems are typically designed without robust security. While it is important to ensure optimal performance of the Operational Technology (OT) environments, security cannot be overlooked. To modernize traditional OT services, 5G technology is being integrated. 5G technology offers low latency and high availability, making it a suitable infrastructure for managing and monitoring physical processes. How-ever, integrating 5G mechanisms into large-scale OT networks introduces new implementation and performance challenges. Therefore, this paper presents a 5G-enabled CPS architecture (5G-CPS) that describes the necessary components, services, and communication protocols and conducts feasibility study to integrate 5G technology in industrial control system networks to understand the performance merits. The 5G-CPS architecture aims to minimize implementation and operational challenges associated with integrating 5G technology into constrained OT.

Aguayo, Jared M.↗
DOE OSTI2023

Barriers and Alternatives to Encryption in Critical Nuclear Systems

Over the past decade, cybersecurity researchers have released multiple studies highlighting the insecure nature of I&C system communication protocols. In response, standards bodies have addressed the issue by adding the ability to encrypt communications to some protocols in some cases, while control system engineers have argued that encryption within these kinds of high consequence systems is in fact dangerous. Certainly, control system information between systems should be protected. But encrypting the information may not be the best way to do so. In fact, while in IT systems vendors are concerned with confidentiality, integrity, and availability, frequently in that order, in OT systems engineers are much more concerned with availability and integrity that confidentiality. In this paper, we will counter specific arguments against encrypting control system traffic, and present potential alternatives to encryption that support nuclear OT system needs more strongly that commodity IT system needs while still providing robust integrity and availability guarantees.

42 ENGINEERING↗
DOE OSTI2022

Sample-Efficient Adaptive Calibration of Quantum Networks Using Bayesian Optimization

All physical systems employed for quantum information tasks must act as unbiased carriers of encoded quantum states. Ensuring such indistinguishability of information carriers is a major challenge in many quantum information applications, including advanced quantum communication protocols. For photons, the workhorses of quantum communication networks, it is difficult to obtain and maintain their indistinguishability because of environment-induced transformations and loss imparted by communication channels, especially in noisy scenarios. Conventional strategies to mitigate these transformations often require hardware or software overhead that is restrictive (e.g., adding noise), infeasible (e.g., on a satellite), or time-consuming for deployed networks. In this work we propose and develop resource-efficient Bayesian optimization techniques to rapidly and adaptively calibrate the indistinguishability of individual photons for quantum networks using only information derived from their measurement. To experimentally validate our approach, we demonstrate the optimization of Hong-Ou-Mandel interference between two photons-a central task in quantum networking- finding rapid, efficient, and reliable convergence towards maximal photon indistinguishability in the presence of high loss and shot noise. We expect our resource-optimized and experimentally friendly methodology will allow fast and reliable calibration of indistinguishable quanta, a necessary task in distributed quantum computing, communications, and sensing, as well as for fundamental investigations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Implementation of ISO 15118-202 messages within Everest EV Charging Open Source Framework [SWR-25-56]

This software implements the messages defined in the ISO 15118-202 standard within the Everest EV Charging open source framework. The protocol and messages defined in the ISO 15118-202 standard enable the exchange of additional information which is not available for exchange within the currently deployed EV/EVSE communications protocols. This information includes co-identification parameters, error message exchange and more. This fork of the everest-core repository adds a prototype of the Extensible Supply Equipment Communication Controller (SECC) Discovery Protocol (ESDP) implemented based on a draft of the ISO 15118-202 standard. This is achieved through additions and modifications to the EvseV2G module. The implementation provides a demonstration of the ESDP messages, encoding and decoding but does not include a full integration within the Everest framework. Much of the information being sent over ESDP in this implementation is set statically for the sake of demonstrating the protocol itself. This fork of the ext-switchev-iso15118 repository adds a prototype of the Extensible Supply Equipment Communication Controller (SECC) Discovery Protocol (ESDP) implemented based on a draft of the ISO 15118-202 standard. The implementation provides a demonstration of the ESDP messages, encoding and decoding but does not include a full integration within the Everest framework. Much of the information being sent over ESDP in this implementation is set statically for the sake of demonstrating the protocol itself. This fork adds the ESDP features for only the EVCC controller because that is the only portion that is utilized in the everest Software-in-the-Loop.

Watt, Ed [National Renewable Energy Laboratory (NR↗
DOE OSTI2022

Cyber–physical vulnerability and resiliency analysis for DER integration: A review, challenges and research needs

High penetration of renewable and sustainable Distributed Energy Resources (DER) into the traditional distribution system requires a well-coordinated control strategy for the improvement of system-wide reliability and resiliency. Implementation of such a holistic control architecture requires a flexible, near real-time, and bi-directional communication framework for facilitating the participation of various agents in a multi-vendor heterogeneous smart grid. While the sustainability of energy generation is ensured, this exposes the smart grid to extrinsic cyber threats, and appropriate defense mechanism(s) must be deployed to guarantee continued reliability and resiliency of the power grid. Further, the comprehensive literature review presented in this paper discusses the latest trends in the DER control schemes with fast communication requirements and their accompanying cyber–physical vulnerabilities. These control schemes are compared and contrasted for various traits. A three-level DER system architecture has been depicted, facilitating the deployment of these control schemes. The current developments of standard communication protocols, key security mechanisms, and best practices along major standards and guidelines are explored. The impacts of different attack types with miscellaneous DER functions based on various control schemes and associated mitigation solutions are also provided. Finally, challenges and future research directions for limiting cyber-power susceptibility to enhance resiliency are summarized. The work presented here will help us enabling a cyber-resilient and sustainable smart electric grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Review of Design Elements within Power Infrastructure Cyber–Physical Test Beds as Threat Analysis Environments

Cyber–physical systems (CPSs) are an integral part of modern society; thus, enhancing these systems’ reliability and resilience is paramount. Cyber–physical testbeds (CPTs) are a safe way to test and explore the interplay between the cyber and physical domains and to cost-effectively enhance the reliability and resilience of CPSs. Here a review of CPT elements, broken down into physical components (simulators, emulators, and physical hardware), soft components (communication protocols, network timing protocols), and user interfaces (visualization-dashboard design considerations) is presented. Various methods used to validate CPS performance are reviewed and evaluated for potential applications in CPT performance validation. Last, initial simulated results for a CPT design, based on the IEEE 33 bus system, are presented, along with a brief discussion on how model-based testing and fault–injection-based testing (using scaling and ramp-type attacks) may be used to help validate CPT performance.

14 SOLAR ENERGY↗
DOE OSTI2026

FERC order 2222 & DER policy and implementation report - January 2026

The January 2026 FERC 2222 Tracker Report provides an overview of the progress and challenges in the implementation of FERC Order 2222, emphasizing the critical need for state-level action to address gaps in DERA/EDC communication protocols. The report highlights the importance of reliable communication between electric distribution companies (EDCs) and DER aggregators (DERAs) for seamless market operations, noting the absence of specific directives from FERC and RTO/ISO compliance filings. Key discussions include the operational coordination required to manage DER operations within aggregated markets, the potential use of tools like DER Registries for efficient data exchange, and the implications of non-performance due to communication issues. While steps are being taken at the state level, such as ongoing policy development and bi-monthly webinars for stakeholder education, no states have fully developed coordination frameworks as of early 2026. The report underscores the growing role of states and local regulators in defining these protocols and ensuring effective coordination amidst the complex dynamics of distributed energy resources (DERs) integration into wholesale markets.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

A Systems Engineering Analysis of National Ignition Facility Industrial Controls Systems and Safety Interlock Systems Remote Input/Output Networking Migration from ControlNet to EtherNet/IP

The ControlNet industrial communications protocol and modules used in the Industrial Control System (ICS) and Safety Interlock System (SIS) at the National Ignition Facility (NIF) are no longer necessary and the ICS and SIS would be better served by migrating the communications structure to use EtherNet/Industrial Protocol (IP) and EtherNet bridge modules instead. By the admission of the vendor of ControlNet hardware, Rockwell Automation, in literature by Bill Petro [1], “Moving forward, customers will be able to optimize their asset utilization better using EtherNet/IP protocol than with ControlNet.” The NIF is one of the key elements of the Inertial Confinement Fusion (ICF) program at Lawrence Livermore National Laboratory (LLNL), a federally funded research and development center (FFRDC). The NIF contains the systems and provides the operational capacity to perform ICF, high energy density (HED), and discovery science experiments utilizing 192 individual beamlines, a host of diagnostics, and all the industrial systems required to facilitate these beamlines and diagnostics. The industrial systems are governed by the ICS and SIS, with the ICS providing control and the SIS providing monitoring and permissives. Construction on the NIF began in 1997 and was certified complete in 2009 and, as a result, the ICS and SIS were developed during this time using the tools that were available then. This includes the communications structure and protocols for these systems, much of which was, and still is, ControlNet. ControlNet, particularly during the time that the ICS and SIS were being built, has several attractive features. ControlNet hardware is exclusive to Rockwell Automation, which was the automation hardware chosen for the ICS and SIS. One feature that could be considered an advantage or a disadvantage depending on the communication needs of the system is that ControlNet also utilizes no active network components, excluding repeaters which are not always necessary. According to the architect of the ICS system at the NIF, Gordon Lau, one of the most attractive features of the ControlNet protocol during development of the ICS and SIS was that it is deterministic, providing timing of data transfer that is executed exactly as it is defined by the developer.

42 ENGINEERING↗
DOE OSTI2023

Incremental Threshold Scheme Enabled IoT Group Key Management

Cyber landscape evolves rapidly. Internet of Things (IoT) and Edge Computing (EC) have rapidly become an integral part of the modern computing infrastructure. It is expected that there will be more than 50 billion active and connected IoT devices by 2025 [1]. Pervasive IoT/EC creates unprecedented opportunities bridging the gap between previously segregated cyber and physical spaces. However, this progress also brings along new security challenges. IoT devices typically have limited computation, communication, and storage resources. This leads to security architecture designs such as using symmetric keys for group communication. While secure and efficient in stable network settings, symmetric key solutions are ill-adapted for IoT's highly dynamic device mobility behavior and frequent group membership turnover. Whenever IoT members leave a group, the known symmetric keys cannot be made forgotten, posing a serious vulnerability. This leads to frequent re-groupings that require expensive re-authentication, key regeneration, and key redistribution in order to maintain IoT/EC security. We present a novel symmetric key management framework that integrate an Incremental Threshold Scheme (ITS) cryptographical function into communication protocol's key rotation mechanism to allow for secure and efficient symmetric key communication group member node revocation. This ITS-enabled key management framework alleviates the need of frequent and expensive re-grouping and re-keying needed by today's large and dynamic IoT/EC operations. We further applied this ITS-enabled key management framework to a distributed IoT/EC-integrated publish and subscribe framework for applicability validation.

Li, Mingyan↗