Results for “Hardware in the Loop” — Page 3

DOE OSTI2025

Real-Time Lifetime Prediction of Semiconductor Devices Using Hardware-in-the-Loop

This paper presents a unique approach to enable real-time lifespan prediction of semiconductor power modules using a Hardware-in-the-Loop (HIL) system. By integrating the module's overall loss characteristics-specifically switching and conduction losses-with a thermoelectric model of the thermal management system, this research demonstrates that the model can dynamically estimates the junction temperature profile of the semiconductor devices in response to a changing torque demand profile for the motor drive system. This capability enables continuous monitoring of the module's operational time and cumulative stress induced on the devices to compute accumulated remaining lifetime or time-to-failure (TTF). This study provides an architectural framework for the HIL system with high-fidelity component models of multiple physical domains, allowing simulation of dynamic behaviors of a closely-coupled motor drive system. The advanced real-time computation and measurement functionalities of the HIL system allow for both dynamic lifetime calculations based on simulated data and aggregate lifetime predictions utilizing historical data. Moreover, this paper details an algorithm that not only computes cumulative damage but also synthesizes these data into a comprehensive aggregated lifetime metric. This methodology can enhance the maintenance scheduling strategies and operational reliability of semiconductor devices in critical applications, ultimately extending their service life while optimizing performance.

hardware-in-the-loop (HIL)↗

NASA NTRSDate not supplied

Real-time Hardware-in-the-Loop Evaluation of a Partially Turboelectric Propulsion Control Design

In support of aviation fuel burn and emission reduction goals, NASA is pursuing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP). Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes addressing challenges related to propulsion controls, which will be vital for ensuring efficient coordinated operation of EAP subsystems. This paper presents results from real-time hardware-in-the-loop testing of a control design for a single aisle partially-turboelectric aircraft propulsion concept conducted at the NASA Electric Aircraft Testbed (NEAT) facility. The control system under test is designed for a propulsion concept consisting of two wing-mounted turbofan engines that produce thrust and generate electrical power to drive a boundary layer ingesting tailfan propulsor via an electrical motor. An integrated control strategy is applied to ensure coordinated operation of the turbofan and tailfan subsystems during steady-state and transient operation throughout the flight envelope. The NEAT test of this integrated control design consists of a partially hardware-in-the-loop, partially simulated configuration. A subscale representation of the electrical system design is implemented in hardware and mechanically coupled to electric machines that emulate turbomachinery and propulsor shaft dynamics. The hardware configuration is then operated under the control of a real-time computer application that runs a simulation of the propulsion system and the developed control logic. The NEAT facility test campaign includes a series of experiments that subject the control design to throttle transients conducted throughout the flight envelope and full-flight mission profiles. Testing under simulated performance degradation is also conducted to evaluate control design robustness. This includes constant and abrupt changes in degradation levels. Results from the hardware-in-the-loop test are presented and shown to be in good agreement with pre-test simulation predictions demonstrating the efficacy of the integrated control design approach.

Electrified Aircraft Propulsion↗

NASA NTRSDate not supplied

Real-time Hardware-in-the-Loop Evaluation of a Partially Turboelectric Propulsion Control Design

In support of aviation fuel burn and emission reduction goals, NASA is pursuing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP). Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes addressing challenges related to propulsion controls, which will be vital for ensuring efficient coordinated operation of EAP subsystems. This paper presents results from real-time hardware-in-the-loop testing of a control design for a single aisle partially-turboelectric aircraft propulsion concept conducted at the NASA Electric Aircraft Testbed (NEAT) facility. The control system under test is designed for a propulsion concept consisting of two wing-mounted turbofan engines that produce thrust and generate electrical power to drive a boundary layer ingesting tailfan propulsor via an electrical motor. An integrated control strategy is applied to ensure coordinated operation of the turbofan and tailfan subsystems during steady-state and transient operation throughout the flight envelope. The NEAT test of this integrated control design consists of a partially hardware-in-the-loop, partially simulated configuration. A subscale representation of the electrical system design is implemented in hardware and mechanically coupled to electric machines that emulate turbomachinery and propulsor shaft dynamics. The hardware configuration is then operated under the control of a real-time computer application that runs a simulation of the propulsion system and the developed control logic. The NEAT facility test campaign includes a series of experiments that subject the control design to throttle transients conducted throughout the flight envelope and full-flight mission profiles. Testing under simulated performance degradation is also conducted to evaluate control design robustness. This includes constant and abrupt changes in degradation levels. Results from the hardware-in-the-loop test are presented and shown to be in good agreement with pre-test simulation predictions demonstrating the efficacy of the integrated control design approach.

Electrified Aircraft Propulsion↗

DOE OSTI2026

Design of Controller Hardware-In-the-Loop Model of Microgrid with Modular Building Blocks and Automated Design Script

The scalability of controller hardware-in-the-loop (CHIL) simulation is critical for validating control coordination and energy management in microgrids with distributed energy resources, especially as these modern systems become more complex and decentralized. This paper presents a CHIL modeling methodology that combines modular building blocks with an automated design script to streamline the development of high-fidelity microgrid models. Standardized subsystem templates for resources, converters, and buses are integrated with a Python-based script that compiles structured JSON configuration files into simulation-ready initialization code. The proposed approach reduces development time, improves model consistency, and enhances simulation fidelity. The methodology is validated on a Typhoon HIL604 platform and is broadly applicable to real-time simulation of complex, networked microgrid systems. This framework establishes a foundation for automated, scalable CHIL validation and accelerates the design of next-generation distributed energy systems.

Kim, Namwon [ORNL] (ORCID:0000000200438489)↗

NASA NTRS1986

Integrated Application of Active Controls (IAAC) technology to an advanced subsonic transport project: Program review

This report summarizes the Integrated Application of Active Controls (IAAC) Technology to an Advanced Subsonic Transport Project, established as one element of the NASA/Boeing Energy Efficient Transport Technology Program. The performance assessment showed that incorporating ACT into an airplane designed to fly approximately 200 passengers approximately 2,000 nmi could yield block fuel savings from 6 to 10 percent at the design range. The principal risks associated with incorporating these active control functions into a commercial airplane are those involved with the ACT system implementation. The Test and Evaluation phase of the IAAC Project focused on the design, fabrication, and test of a system that implemented pitch axis fly-by-wire, pitch axis augmentation, and wing load alleviation. The system was built to be flight worthy, and was planned to be experimentally flown on the 757. The system was installed in the Boeing Digital Avionics Flight Controls Laboratory (DAFCL), where open loop hardware and software tests, and a brief examination of a direct drive valve (DDV) actuation concept were accomplished. The IAAC Project has shown that ACT can be beneficially incorporated into a commercial transport airplane. Based on the results achieved during the testing phase, there appears to be no fundamental reason(s) that would preclude the commercial application of ACT, assuming an appropriate development effort is included.

Source record↗

DOE OSTI2026

De-Risking Field Deployment of Storage Assets Using Hardware-in-the-Loop Experiments [Slides]

This presentation provides an overview of de-risking the field deployment of controller and power hardware technologies.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Operating Wind Turbine as Synchronous Generator: Modeling and Power-Hardware-in-the-Loop Demonstration

Grid-forming (GFM) control of Type 3 and Type 4 wind turbine generators (WTGs) has attracted substantial attention in power systems research; however, the limited overcurrent capability of power electronics converters continues to deteriorate the grid strength of the evolving power systems. Synchronous wind, also referred to as a Type 5 WTG, offers a unique GFM solution to address grid integration and grid strength issues by keeping the grid largely synchronous at very high integration levels of renewable generation. A Type 5 WTG interfaces with the electric grid via a synchronous generator driven by a variable speed hydraulic torque converter; hence, the wind rotor operates in variable-speed mode for maximum power generation, and the generator shaft remains synchronous to the grid. This paper develops and tests a high-fidelity model of a Type 5 WTG in a power-hardware-in-the-loop testing environment, and it presents its operation characteristics under different grid contingencies. The power-hardware-in-the-loop demonstration shows that a Type 5 WTG inherently behaves as a GFM unit and can obtain similar performance in terms of power response, wind rotor dynamics, and stability enhancement compared to a Type 3 WTG in GFM control mode. Furthermore, the paper provides further insight into how Type 5 WTGs can support the smooth transition to power systems with high integration levels of inverter-based resources.

17 - WIND ENERGY↗

NASA NTRS2003

First Results from a Hardware-in-the-Loop Demonstration of Closed-Loop Autonomous Formation Flying

A closed-loop system for the demonstration of autonomous satellite formation flying technologies using hardware-in-the-loop has been developed. Making use of a GPS signal simulator with a dual radio frequency outlet, the system includes two GPS space receivers as well as a powerful onboard navigation processor dedicated to the GPS-based guidance, navigation, and control of a satellite formation in real-time. The closed-loop system allows realistic simulations of autonomous formation flying scenarios, enabling research in the fields of tracking and orbit control strategies for a wide range of applications. The autonomous closed-loop formation acquisition and keeping strategy is based on Lyapunov's direct control method as applied to the standard set of Keplerian elements. This approach not only assures global and asymptotic stability of the control but also maintains valuable physical insight into the applied control vectors. Furthermore, the approach can account for system uncertainties and effectively avoids a computationally expensive solution of the two point boundary problem, which renders the concept particularly attractive for implementation in onboard processors. A guidance law has been developed which strictly separates the relative from the absolute motion, thus avoiding the numerical integration of a target trajectory in the onboard processor. Moreover, upon using precise kinematic relative GPS solutions, a dynamical modeling or filtering is avoided which provides for an efficient implementation of the process on an onboard processor. A sample formation flying scenario has been created aiming at the autonomous transition of a Low Earth Orbit satellite formation from an initial along-track separation of 800 m to a target distance of 100 m. Assuming a low-thrust actuator which may be accommodated on a small satellite, a typical control accuracy of less than 5 m has been achieved which proves the applicability of autonomous formation flying techniques to formations of satellites as close as 50 m.

Gill, E.↗

DOE OSTI2024

Hardware-in-the-Loop Testing of Wide-Area Damping Controller for Field Implementation in Large-scale Power Grid

In our previous work, an adaptive measurement-driven wide-area damping controller (WADC) for suppressing inter-area oscillations has been proposed and a hardware prototype was developed and validated through hardware-in-the-loop tests. As a continuation of the work, this paper introduces a WADC software prototype to handle the realistic challenges for field implementation in the control room of the power grid. The WADC software is developed and operated as an openPDC adapter with a graphical user interface (GUI) to monitor the WADC inputs and output, the communication delays and other variables. The software prototype has been fully tested through an enhanced hardware-in-the-loop (HIL) test setup. Its performance is verified under various realistic communication uncertainties, such as random time delays and data losses, with different communication protocols. The experiment results have proven the WADC software can deliver sufficient damping to suppress the targeted oscillation mode in handling various communication uncertainties for future field deployment.

Jia, Xinlan↗

DOE OSTI2026

Modeling and Power-Hardware-in-the-Loop Validation of Synchronous Machine Governor

This paper introduces the development of a high-fidelity gas turbine governor model using a programmable logic controller for power-hardware-in-the-loop (PHIL) validation. The governor model is integrated with the National Renewable Energy Laboratory's (NREL) PHIL test bed, featuring a 2-MVA synchronous machine and a 2.5-MW variable-speed drive, to emulate NG-driven HRSGs and CTs under various operational scenarios. The primary objective of this research is to study the grid-connected and islanding operations of conventional generation sources, with representative startup sequences including turbine purge, ignition, speed ramp-up, synchronization, and breaker closure. Preliminary results of the generator governor model on NREL PHIL platform, particularly using the 2.5-MW dynamometer system, offered significant insights into the modeling techniques, hardware integration, scaling, and real-world simulation dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Nuclear Thermal Rocket Emulator for a Hardware-in-the-Loop Test Bed

To support NASA’s mission to use nuclear thermal rockets for future Mars missions, an instrumentation and control test bed has been built at Oak Ridge National Laboratory. The system is designed as a hardware-in-the-loop test bed for testing control elements and autonomous control algorithms for nuclear thermal propulsion rockets. The mock reactor system consists of a modular and scalable framework, using inexpensive components and open-source software. The hardware system consists of a two-phase flow loop and a mock reactor with six control drums. A single-board computer (NVIDIA Jetson) handles reactor core emulation and hosts a message queuing telemetry transport broker that allows user-deployed control algorithms to interact with the system hardware. The reactor emulator receives sensor data from the hardware and provides the simulated performance of the reactor under steady-state, transient, and fault conditions. The emulator uses a reactivity lookup table and the point kinetics equations to solve for the reactor dynamics in real time. Emulated reactor dynamics and sensor input inform the autonomous control algorithm’s decision-making in a closed-loop manner. The current system is capable of operating at 10 Hz, but faster cycle rates are an area of ongoing research. This test bed will enable NASA and other space vendors to rigorously test their autonomous control systems for NTP rockets under transient (reactor startup and shutdown), steady-state, and fault conditions to reduce development time and risk for autonomous control systems in future missions.

autonomous control↗

NASA NTRS2007

Expanding Hardware-in-the-Loop Formation Navigation and Control with Radio Frequency Crosslink Ranging

The Formation Flying Testbed (FFTB) at the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) provides a hardware-in-the-loop test environment for formation navigation and control. The facility continues to evolve as a modular, hybrid, dynamic simulation facility for end-to-end guidance, navigation, and control (GN&C) design and analysis of formation flying spacecraft. The core capabilities of the FFTB, as a platform for testing critical hardware and software algorithms in-the-loop, are reviewed with a focus on recent improvements. With the most recent improvement, in support of Technology Readiness Level (TRL) 6 testing of the Inter-spacecraft Ranging and Alarm System (IRAS) for the Magnetospheric Multiscale (MMS) mission, the FFTB has significantly expanded its ability to perform realistic simulations that require Radio Frequency (RF) ranging sensors for relative navigation with the Path Emulator for RF Signals (PERFS). The PERFS, currently under development at NASA GSFC, modulates RF signals exchanged between spacecraft. The RF signals are modified to accurately reflect the dynamic environment through which they travel, including the effects of medium, moving platforms, and radiated power.

Mitchell, Jason W.↗

NASA NTRS2016

The Application of Hardware in the Loop Testing for Distributed Engine Control

The essence of a distributed control system is the modular partitioning of control function across a hardware implementation. This type of control architecture requires embedding electronics in a multitude of control element nodes for the execution of those functions, and their integration as a unified system. As the field of distributed aeropropulsion control moves toward reality, questions about building and validating these systems remain. This paper focuses on the development of hardware-in-the-loop (HIL) test techniques for distributed aero engine control, and the application of HIL testing as it pertains to potential advanced engine control applications that may now be possible due to the intelligent capability embedded in the nodes.

Distributed Engine Control↗

NASA NTRS2016

The Application of Hardware in the Loop Testing for Distributed Engine Control

The essence of a distributed control system is the modular partitioning of control function across a hardware implementation. This type of control architecture requires embedding electronics in a multitude of control element nodes for the execution of those functions, and their integration as a unified system. As the field of distributed aeropropulsion control moves toward reality, questions about building and validating these systems remain. This paper focuses on the development of hardware-in-the-loop (HIL) test techniques for distributed aero engine control, and the application of HIL testing as it pertains to potential advanced engine control applications that may now be possible due to the intelligent capability embedded in the nodes.

Control↗

NASA NTRSDate not supplied

Hardware-in-the-Loop Simulation of Modular Antenna Assembly

Robots are playing an increasing role in space exploration and in-space servicing. Robotic arms are good for performing in-space tasks such as modular assembly. The SPIDER arm (SPace Infrastructure Dexterous Robot) of the OSAM-1 mission represents an example of a system that can perform modular antenna assembly tasks in environmental conditions that would be dangerous for astronauts. One of the WVRTC activities is to perform independent verification and validation of the SPIDER assembly operations. Space robotic systems adopting large manipulators such as the SPIDER arm are complex to test and verify under normal 1-G conditions. Our work involves proof-of-principle testing of a hardware-inthe-loop (HIL) simulator operating in 1-g conditions, which replicates the motion of the space robot end-effector under the same geometric, kinematic and dynamic conditions, and in response to externally applied forces from its space environment. In particular, our software simulates in real-time the robot dynamics inclusive of flexibility, an important aspect in case of a long robotic arms operating in 0-G conditions. For example, the same oscillatory motions of the space manipulator’s end-effector can be mimicked on ground through our industrial manipulator, allowing us to test the feasibility of complex operation such as assembling modular components.

Robotic Assembly↗

NASA NTRS2016

Design, Development, and Testing of a UAV Hardware-in-the-Loop Testbed for Aviation and Airspace Prognostics Research

The airspace is becoming more and more complicated, and will continue to do so in the future with the integration of Unmanned Aerial Vehicles (UAVs), autonomy, spacecraft, other forms of aviation technology into the airspace. The new technology and complexity increases the importance and difficulty of safety assurance. Additionally, testing new technologies on complex aviation systems & systems of systems can be very difficult, expensive, and sometimes unsafe in real life scenarios. Prognostic methodology provides an estimate of the health and risks of a component, vehicle, or airspace and knowledge of how that will change over time. That measure is especially useful in safety determination, mission planning, and maintenance scheduling. The developed testbed will be used to validate prediction algorithms for the real-time safety monitoring of the National Airspace System (NAS) and the prediction of unsafe events. The framework injects flight related anomalies related to ground systems, routing, airport congestion, etc. to test and verify algorithms for NAS safety. In our research work, we develop a live, distributed, hardware-in-the-loop testbed for aviation and airspace prognostics along with exploring further research possibilities to verify and validate future algorithms for NAS safety. The testbed integrates virtual aircraft using the X-Plane simulator and X-PlaneConnect toolbox, UAVs using onboard sensors and cellular communications, and hardware in the loop components. In addition, the testbed includes an additional research framework to support and simplify future research activities. It enables safe, accurate, and inexpensive experimentation and research into airspace and vehicle prognosis that would not have been possible otherwise. This paper describes the design, development, and testing of this system. Software reliability, safety and latency are some of the critical design considerations in development of the testbed. Integration of HITL elements in the development phases and veri cation/ validation are key elements to this report.

HITL↗

DOE OSTI2025

Microgrid Building Block Architecture, and Subcomponents Modeling and Demonstration in Controller Hardware-in-the-Loop

The recently proposed Microgrid Building Blocks (MBB) are ready-to-use components to build microgrids quickly, cheaply, and modularly. This work presents and demonstrates in controller hardware-in-the-loop (CHIL) three key subcomponents of an MBB architecture: power converter topology, control scheme, and communication framework. The addressed architecture aims for systems interconnection such as microgrid to grid and microgrid to microgrid. This paper studies each subcomponent in detail and validates the efficacy of the architecture through CHIL results.

Adib, Aswad [ORNL] (ORCID:000000020997056X)↗

DOE OSTI2025

Controller Hardware-in-the-Loop Evaluation of a Microgrid Controller for a Microgrid System with Multiple Grid-Forming Inverters

This paper presents the laboratory evaluation of a commercial Microgrid Management System (MGMS) implemented in the real-world Bronzeville Microgrid which features a futuristic scenario with high renewable energy integration and the use of multiple Grid-Forming (GFM) inverters. The primary objective of the performance evaluation for the MGMS is to assess the MGMS's capability to dispatch GFM units, including a GFM PV unit and two GFM battery units, to maintain the system stability and ensure economic operation, thus guaranteeing the microgrid's resilience during prolonged outages and dynamic events. The laboratory controller hardware-in-the-loop provides realistic testing environment through detailed electromagnetic transient modeling of the microgrid system, hardware MGMS, and standard communication protocols (DNP3). The CHIL evaluation shows how the MGMS effectively manages the GFM inverters, highlighting its performance in maintaining stability, reliability, and survivability in a microgrid environment with a high penetration of renewable energy sources.

controller hardware-in-the-loop↗