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DOE OSTI2022

Experimental testing of a control barrier function on an automated vehicle in live multi-lane traffic

This paper experimentally tests an implementation of a control barrier function (CBF) designed to guarantee a minimum time-gap in car following on an automated vehicle (AV) in live traffic, with a majority occurring on freeways. The CBF supervises a nominal unsafe PID controller on the AV’s velocity. The experimental testing spans two months of driving, of which 1.9 hours of data is collected in which the CBF and nominal controller are active. We find that violations of the guaranteed minimum time-gap are observed, as measured by the vehicle’s on-board radar unit. There are two distinct causes of the violations. First, in multi-lane traffic, Cut-ins from other vehicles represent external disturbances that can immediately violate the minimum guaranteed time gap provided by the CBF. When cut-ins occur, the CBF does eventually return the vehicle to a safe time gap. Second, even when cut-ins do not occur, system model inaccuracies (e.g., sensor error and delay, actuator error and delay) can lead to violations of the minimum time-gap. These violations are small relative to the violations that would have occurred using only the unsafe nominal control law.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Microreactor Automated Control System Test Bed Digital Architecture for Real-Time, Hardware-in-the-Loop Simulation

This work describes progress made towards the development of a real-time hardware-in-the-loop (HIL) test bed for non-nuclear testing of microreactor control schemes and failure modes. Non-nuclear testing is a crucial step in developing robust control algorithms for managing microreactor dynamics. The creation of an HIL simulation harnesses the realistic dynamics of physical analogue systems while additionally considering the challenges of variable communication delay. This collaborative effort between Oak Ridge National Laboratory and Idaho National Laboratory has resulted in a LabVIEW-based gRPC communication protocol which couples a TRANSFORM Modelica simulation of nuclear components to the ViBRANT physical hardware for realistic feedback and visual representation of control action in real time. A modular python client structure is developed to manage FMU-based Modelica simulation and real-time gRPC communication. HIL testing suggests that the modeled reactor with natural convection molten salt loop coolant configuration responds well to PID control of drum positioning for modulation of reactor core power, however, future efforts will be made to explore the added thermal inertial delay of system level control and downstream demand changes. Development of this platform with a generalized methodology provides a foundation for exploring a variety of reactor configurations and failure modes in rapid order to provide insight into the most effective avenues of study for further research and development.

McConnell, Jono [ORNL] (ORCID:0000000238984741)↗

DOE OSTI2025

Real-Time Sea State Estimation for Wave Energy Converter Control via Machine Learning

Wave energy converters (WECs) harness the untapped power of ocean waves to generate renewable energy, offering a promising solution to sustainable energy. An optimal WEC control strategy is essential to maximize power capture that dynamically adjusts system parameters in response to rapidly changing sea states. This study presents a novel control approach that leverages neural networks to estimate sea states from onboard WEC measurements such as position, velocity, and force. Using a point absorber WEC device as a test platform, our proposed approach estimates sea states in real-time and subsequently adjusts PID controller gains to maximize energy extraction. Simulation results across diverse sea conditions demonstrate that our strategy eliminates the need for external wave monitoring equipment while maintaining power capture efficiency. The results show that our neural network-based control technique can improve power capture by 25.6% while significantly reducing system complexity. This approach offers a practical alternative for WEC deployments where direct wave measurements are either infeasible or cost prohibitive.

PIDcontrol↗

DOE OSTI2026

Preliminary proof-of-concept of real-time divertor heat flux control from infrared cameras with nitrogen injection in the DIII-D tokamak

In future tokamak reactors like ITER and the Fusion Pilot Plant (FPP), real-time feedback control of heat flux to the plasma-facing components (PFC) will be critical for steady-state operation. This work presents the first experimental demonstration of real-time divertor heat flux estimation with infrared thermography and feedback control with impurity seeding on the DIII-D tokamak. The flexible infrastructure of the Plasma Control System (PCS) on DIII-D makes this new capability possible. The PCS software runs on a gateway computer system, and five real-time compute nodes. An array of low latency streaming digitizers from D-TACQ Solutions connects to these real-time computers to collect and process data, and send commands to actuators during plasma discharges. This system handles the signal IO from the tokamak and allows the PCS to utilize the diagnostic data necessary to perform control in real-time. Feedback control on heat flux was accomplished by feeding infrared camera data from the “Infrared TV” (IRTV) camera to a custom-developed User Datagram Protocol (UDP) server. This server transmits infrared data to a newly developed PCS algorithm that estimates the heat flux to PFC. Here, a proportional integral derivative (PID) controller minimizes the error between a heat flux reference and the real-time estimate by injecting nitrogen gas into the divertor.

Algorithm development↗

DOE OSTI2025

Flexible Resource Scheduler for FAST-DERMS (FRS-FASTDERMS) v0.9

The Flexible Resource Scheduler is a hierarchical controller that manages the distributed energy resources in a distribution substation or distribution feeder to provide a firm commitment of power flow at the substation or feeder head to be scheduled in transmission-level markets as an aggregated demand resource. It is the reference controller for the FAST-DERMS Architecture, developed in tandem with the architecture under the DOE FAST-DERMS project. It is comprised of a day-ahead stochastic optimization, which schedules substation power flow and reserves, a intra-hour MPC, which generates dispatch base points for DER, and a real-time PID controller maintaining that dispatches DER to maintain the substation power around the base points. The repository also includes a representative aggregator controller, and all of the necessary components to run a simulation using PNNL's GridAPPS-D software with the controller.

MacDonald, Jason [Lawrence Berkeley National Labor↗

DOE OSTI2023

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

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

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Considerations for testing full-scale wind turbine nacelles with hardware-in-the-loop

In this paper, pole placement control techniques are utilized to compensate for variations in the torsional dynamics resulting from the different boundary conditions experienced by a wind turbine nacelle when mounted on a test bench. Simulation case studies are used to understand the baseline torsional characteristics of the nacelle coupled to the test bench versus that coupled to the rotor. It was found that the frequency shifts by up to 200% and 400% for the first and second torsional modes, respectively. The feasibility of utilizing pole placement technique to match the torsional characteristics of the turbine on the test bench is investigated using PI and PID controllers. Here, the performance of the tuned controller is then verified under two test scenarios: Low Voltage Ride Through (LVRT), and a highly dynamic turbulent wind input. It is demonstrated that tuning the test bench speed controller can effectively shift the poles of the closed-loop system to match the desired first and second modes of the full turbine and replicate transient field events on the test bench.

17 WIND ENERGY↗

DOE OSTI2019

Development of a Semi-autonomous Miniature Rover for Inspection of Double Shell Tank Floors - 19575

Leaks in the primary liner of double-shell tank (DST) 241-AY-102 at Hanford have prompted the need for the development of inspection tools that are able to access confined spaces around and underneath the tanks. Last year, Florida International University (FIU) has continued to improve inspection tools that were developed in the previous years, to ensure that the resultant tools are able to overcome the challenges posed by the DSTs. Experimental testing conducted last year at the full-scale sectional mock-up of the DST's refractory slots revealed some shortcomings of the miniature rover, particularly in traversing over weld seams of different heights. The weld seams are the results of welded steel plate-joints for the DST. It was advised by the site engineers that the weld seams height could range from 6.35 mm - 9.525 mm (1/4 to 3/8 inches), and with 12.7 mm (1/2 inches) width. As the rover traverses over a weld seam, the gap between the rover's magnets and tank surface increases, causing the adhesive force to drop. The rover loses its surface contact if this adhesive force drops below its weight, jeopardizing the inspection tasks. In this paper, we present the numerical studies to calculate the minimum magnetic force required for the miniature rover to traverse over weld seams with different heights and the corresponding modifications to the rover design. Initial bench scale tests were conducted using a steel bar with 5 welds of varying heights. The testing validated the results from the simulation studies and established the rover's capability in traversing weld seams. Another challenge for the miniature rover is the use of a joystick or keypad for manual control. Utilizing these controls will likely be difficult for the operators due to the tight channels underneath the tank. Having a semi-autonomous navigational capability would alleviate the complexity of the inspection tasks and allow the operator to focus on the channel inspection. The goal is to implement lane-keeping capability, akin to that of a driverless car, for the inspection tool, so that it will maintain its relative position with respect to the wall of the channels. Am image processing pipeline has been developed using both the Robot Operating System (ROS) and OpenCV to process the image stream coming from the onboard camera, for the purpose of lane identification. Additionally, a PID controller has been implemented to navigate the miniature rover along the central location of the detected lane, while allowing the operator to control the tool's forward and backward motion. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Model predictive control of mixing controlled compression ignition operation for low reactivity fuels

Using gasoline or other low reactivity fuels with a pilot injection or port fuel injection in a compression ignition engine has shown great potential in reducing NOx emissions while keeping high thermal efficiency compared to diesel. However, excessive combustion noise is caused by a high maximum pressure rise rate in the cylinder due to the higher fractions of premixed charge of the low-reactivity fuel. This noise can result in structural damage to engine components and as such, combustion noise limits the range of the operating parameters and makes the control of such engines challenging. In this study, a simulation environment was built up in MATLAB/Simulink leveraging a physics-based zero-dimension combustion model to capture the in-cylinder pressure time traces as well as metrics relevant to thermal efficiency and combustion noise. Here, in order to also facilitate the control of emissions, machine learning models were investigated to capture NOx emissions. A kernel-based extreme learning machine (K-ELM) performed best and had a coefficient of correlation (R-squared) of 0.998. The combustion and NOx emission models are valid for not only conventional gasoline fuel but also oxygenated alternative fuel blends at three different pilot injection strategies. In order to track key combustion metrics while keeping noise and emissions within constraints, a model predictive control (MPC) was applied for a compression ignition engine operating with a range of potential fuels and fuel injection strategies. The MPC is validated under different scenarios, including a load step change, fuel type change, and injection strategy change, with proportional–integral (PI) control as the baseline. The simulation results show that MPC reduces about 26% of ringing intensity in the transient process and 17% at the steady state for E30. Generally, MPC can optimize the overall performance through modifying the main injection timing, pilot fuel mass, and exhaust gas recirculation (EGR) fraction.

42 ENGINEERING↗

DOE OSTI2023

Beam optics tuning with 6dsim framework

Poster will detail different method for tuning a PID controller. The purpose of this is to control the temperature of a metal block inside a vacuum chamber. This will by useful for experiments that involves Skipper CCDs, such as SENSEI or Obscura.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Reinforcement Learning for In-Spill Optimization of the Mu2e Resonant Extraction: Compensating Non-Stationarity

We present design considerations and challenges for the fast machine learning component of a third-order resonant beam extraction regulation system being commissioned to deliver steady beam rates to the mu2e experiment at Fermilab. Dedicated quadrupoles drive the tune toward the 29/3 resonance each spill, extracting beam at kV multiwire septa. The overall Spill Regulation System consists of (1) a “slow” process using ~100-spill averages to adjust the base quad ramp infrequently, (2) a feedforward harmonic content compensator, and (3) the “fast” ML agent reacting during each ongoing spill with on-the-fly additive corrections to the sum of (1) and (2). We have demonstrated improved beam-rate steadying for a fast ML agent compared to a PID controller using a quasi-physical spill simulation, and demonstrated distillation of that simulation into a predictive surrogate model. Current work includes a data-and-training pipeline to generate data-aware surrogates with real-world dynamics, even as the dynamics shift unpredictably. The surrogates are to act as RL environments against which to train our fast ML control agents before deploying them on FPGA in the live system. Further current efforts focus on modeling and controlling beam loss around the storage ring, understanding additional available hardware inputs to the model, and the interplay of these with beam-steadying performance.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

PIP-II LLRF Master Oscillator and Precision Reference Line - Station Level Design and Testing

The PIP-II superconducting linac at Fermilab requires a highly stable RF Reference Line to maintain phase syn- chronization throughout the accelerator. Temperature- induced changes in the electrical length of long coaxial cables can introduce phase drift and measurement errors. The reference-line architecture mitigates these effects by phase averaging the forward and reflected RF signals, while a phase-locked loop anchors the system to the mas- ter oscillator. This work focuses on the characterization, validation, and mechanical integration of station-level RF assemblies using CAD modeling, vector network analyzer measurements, and spectrum analyzer testing. PID-controlled thermal plates will stabilize critical RF components and further reduce temperature-dependent phase and amplitude variations. These methods sup- port repeatable, standardized designs that can be reliably integrated across the different reference-line stations.

Mosher, Alexander [U. Illinois, Chicago]↗

DOE OSTI2019

Designing and Testing a Simplified Thermal Comfort Sensor

The goal of this project was to design and test an inexpensive device to replace the need for air velocity and mean radiant temperature measurements in thermal comfort studies. The new device works by measuring heat flux across plates maintained at body temperature, mimicking the heat transfer between a person and their surroundings. Two designs were prototyped and tested. One uses thin-film heat flux sensors and one calculates heat flux from power input and surface area. Both designs consist of two plates, insulated on all but the front face, heated to 37 °C by PID controlled relays. One plate is covered in a low emissivity tape and the other in a high emissivity tape, allowing differentiation between convective and radiative heat flux. Preliminary results and literature suggest the device is feasible and responsive to environmental changes. More testing and alteration of design is necessary to fully quantify sensitivity and applicability.

Moring, Hannah↗

DOE OSTI2023

Modelling Nuclear Thermal Propulsion Reactor Expander Cycle Startup Transients

As the interest in nuclear thermal propulsion grows, the need for high fidelity and comprehensive models of the system increases. An expander cycle model was developed using RELAP-7 for the thermal-hydraulic performance and Griffin to provide the power level using a point kinetics approximation, for a reference NTP system. The tank and pump are approximated using boundary conditions. Flow is split between the moderator cooling channels flow path and the regenerative cooling/reflector cooling channels flow path. The flow recombines before entering the turbine and the fuel cooling channels. The turbine pressure ratio is maintained at 1.44 using a PID controller. A startup transient was simulated and shows the capability of the model to run from low temperature and pressures to nominal conditions.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Modelling Nuclear Thermal Propulsion Reactor Expander Cycle Startup Transients

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

PIP-II LLRF Master Oscillator and Precision Reference Line- Station Level Design and Testing

The PIP-II superconducting linac at Fermilab requires a highly stable RF Reference Line to maintain phase synchronization throughout the accelerator. Temperature-induced changes in the electrical length of long coaxial cables can introduce phase drift and measurement errors. The reference-line architecture mitigates these effects by phase averaging the forward and reflected RF signals, while a phase-locked loop anchors the system to the master oscillator. This work focuses on the characterization, validation, and mechanical integration of station-level RF assemblies using CAD modeling, vector network analyzer measurements, and spectrum analyzer testing. PID-controlled thermal plates will stabilize critical RF components and further reduce temperature-dependent phase and amplitude variations. These methods support repeatable, standardized designs that can be reliably integrated across the different reference-line stations.

Mosher, Alexander [U. Illinois, Chicago; Fermilab]↗

DOE OSTI2026

Analysis of Slow Spill Data for the Mu2e Experiment

The execution of the Mu2e experiment requires a stable, low-intensity proton beam from the Delivery Ring to produce clean data and protect equipment. This is done by performing a “slow extraction,” which is the gradual contraction of the stable region within the accelerator’s beam pipe. The Delivery Ring is currently unable to perform slow extraction with the stability required by Mu2e. To resolve this, the FAN-C team is training machine learning models with the purpose of replacing the Delivery Ring’s current PID controllers with AI-powered controllers. Training these models requires clean, processed data from slow spills. Over the course of this project, data from previous slow spills were processed and analyzed, and the clean data, graphs, and insights gained from the process were provided to the FAN-C team to assist them in their efforts.

Osborn, Thomas [Purdue U., West Lafayette]↗

DOE OSTI2024

Robust Disturbance Rejection Rotor Current Control of Doubly-Fed Induction Generators

This article proposes a robust transient disturbance rejection current controller (TDRCC) to improve the transient performance of doubly-fed induction generators (DFIGs) in wind turbines during grid disturbances, such as short circuits. Here, the proposed robust TDRCC replaces the proportional-integral-derivative (PID) current controllers conventionally used in the vector control scheme of the DFIG rotor side converter (RSC). The TDRCC estimates the transient disturbances caused by grid faults or other external disturbances and provides compensation to the DFIG rotor voltage in the current control loops of the RSC to improve the robustness of the controller to disturbance. A sliding-mode current controller (SMCC) is also designed to highlight the transient performance improvement of the DFIG using the TDRCC over the state-of-the-art control methods during grid short circuit faults. Simulation studies are conducted in PSCAD/EMTDC for a 3.6-MW DFIG wind turbine with the proposed TDRCC, the conventional PI controller, and the SMCC, respectively during the most severe balanced three-phase grid short circuit fault specified by the U.S. grid code as well as an unbalance single-phase grid short circuit fault. Hardware experiments are conducted on a 200-W DFIG wind turbine emulator with the three different controllers for the same three-phase short circuit fault. Simulation and hardware experiment results show that the TDRCC reduces the peak rotor current significantly when compared with the PI and SMCC controlled DFIG system and, therefore, would help prolong the lifespan of the DFIG's power electronics and reduce maintenance costs.

42 ENGINEERING↗