Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “PLC”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3

Refurbishment and Automation of the Thermal/Vacuum Facilities at the Goddard Space Flight Center

The thermal/vacuum facilities located at the Goddard Space Flight Center (GSFC) have supported both manned and unmanned space flight since the 1960s. Of the 11 facilities, currently 10 of the systems are scheduled for refurbishment and/or replacement as part of a 5-year implementation. Expected return on investment includes the reduction in test schedules, improvements in the safety of facility operations, reduction in the complexity of a test and the reduction in personnel support required for a test. Additionally, GSFC will become a global resource renowned for expertise in thermal engineering, mechanical engineering and for the automation of thermal/vacuum facilities and thermal/vacuum tests. Automation of the thermal/vacuum facilities includes the utilization of Programmable Logic Controllers (PLCs) and the use of Supervisory Control and Data Acquisition (SCADA) systems. These components allow the computer control and automation of mechanical components such as valves and pumps. In some cases, the chamber and chamber shroud require complete replacement while others require only mechanical component retrofit or replacement. The project of refurbishment and automation began in 1996 and has resulted in the computer control of one Facility (Facility #225) and the integration of electronically controlled devices and PLCs within several other facilities. Facility 225 has been successfully controlled by PLC and SCADA for over one year. Insignificant anomalies have occurred and were resolved with minimal impact to testing and operations. The amount of work remaining to be performed will occur over the next four to five years. Fiscal year 1998 includes the complete refurbishment of one facility, computer control of the thermal systems in two facilities, implementation of SCADA and PLC systems to support multiple facilities and the implementation of a Database server to allow efficient test management and data analysis.

Donohue, John T.↗

A System for Managing Replenishment of a Nutrient Solution Using an Electrical Conductivity Controller

Control of nutrient solution parameters is very important for the growth and development of plants grown hydroponically. Protocols involving different nutrient solution replenishment times (e.g. one-week, two-week, or two-day replenishment) provide manual periodic control of the nutrient solution's electrical conductivity (EC). Since plants take-up nutrients as they grow, manual control has a drawback in that EC is not held constant between replenishments. In an effort to correct this problem the Center for Food and Environmental Systems for Human Exploration of Space at Tuskegee University has developed a system for managing and controlling levels of EC over a plant's entire growing cycle. A prototype system is being tested on sweetpotato production using the nutrient film technique (NFT), and it is being compared to a system in which sweetpotatoes are grown using NFT with manual control. NASA has played an important role in the development of environmental control systems. They have become a forerunner in growing plants hydroponically with some control systems through the use of networked data acquisition and control using environmental growth chambers. Data acquisition systems which involve the use of real-time, calibration, set points, user panel, and graphical representation programming provide a good method of controlling nutrient solution parameters such as EC and pH [Bledsoe, 19931]. In NASA's Biomass Production Chamber (BPC) at Kennedy Space Center, control is provided by a programmable logic controller (PLC). This is an industrial controller which combines ladder computer logic which has the ability to handle various levels of electrical power. The controller controls temperature, light and other parameters that affect the plant's environment, in the BPC, the Nutrient Delivery System (NIX), a sub-system of the PLC, controls nutrient solution parameters such as EC, pH, and solution levels. When the nutrient EC measurement goes outside a preset range (120-130 mS/m) a set amount of a stock solution of nutrients is automatically added by a metering pump to bring the EC back into operating range [Fortson, 1992]. This paper describes a system developed at Tuskegee University for controlling the EC of a nutrient solution used for growing sweetpotatoes with an EC controller and a computer with LabView data acquisition and instrumentation software. It also describes the preliminary data obtained from the growth of sweetpotatoes using this prototype control system.

Davis, D.↗

NASA Ames Research Center 60 MW Power Supply Modernization

The NASA Ames Research Center 60 MW DC Power Supply was built in 1974 to provide controlled DC power for the Thermophysics Facility Arc Jet Laboratory. The Power Supply has gradually losing reliability due to outdated technology and component life limitation. NASA has decided to upgrade the existing rectifier modules with contemporary high-power electronics and control equipment. NASA plans to complete this project in 2001. This project includes a complete replacement of obsolete thyristor stacks in all six rectifier modules and rectifier bridge control system. High power water-cooled thyristors and freewheeling diodes will be used. The rating of each of the six modules will be 4000 A at 5500 V. The control firing angle signal will be sent from the Facility Control System to six modules via fiberoptic cable. The Power Supply control and monitoring system will include a Master PLC in the Facility building and a Slave PLC in each rectifier module. This system will also monitor each thyristor level in each stack and the auxiliary equipment.

Choy, Yuen Ching↗

Assembly For Moving a Robotic Device Along Selected Axes

An assembly for moving a robotic device along selected axes includes a programmable logic controller (PLC) for controlling movement of the device along selected axes to effect movement of the device to a selected disposition. The PLC includes a plurality of single axis motion control modules, and a central processing unit (CPU) in communication with the motion control modules. A human-machine interface is provided for operator selection of configurations of device movements and is in communication with the CPU. A motor drive is in communication with each of the motion control modules and is operable to effect movement of the device along the selected axes to obtain movement of the device to the selected disposition.

Brentley Craig Nowlin↗

Mechanical stimulation of skeletal muscle generates lipid-related second messengers by phospholipase activation

Repetitive mechanical stimulation of cultured avian skeletal muscle increases the synthesis of prostaglandins (PG) E2 and F2 alpha which regulate protein turnover rates and muscle cell growth. These stretch-induced PG increases are reduced in low extracellular calcium medium and by specific phospholipase inhibitors. Mechanical stimulation increases the breakdown rate of 3H-arachidonic acid labelled phospholipids, releasing free 3H-arachidonic acid, the rate-limiting precursor of PG synthesis. Mechanical stimulation also increases 3H-arachidonic acid labelled diacylglycerol formation and intracellular levels of inositol phosphates from myo-[2-3H]inositol labelled phospholipids. Phospholipase A2 (PLA2), phosphatidylinositol-specific phospholipase C (PLC), and phospholipase D (PLD) are all activated by stretch. The stretch-induced increases in PG production, 3H-arachidonic acid labelled phospholipid breakdown, and 3H-arachidonic acid labelled diacylglycerol formation occur independently of cellular electrical activity (tetrodotoxin insensitive) whereas the formation of inositol phosphates from myo-[2-3H]inositol labelled phospholipids is dependent on cellular electrical activity. These results indicate that mechanical stimulation increases the lipid-related second messengers arachidonic acid, diacylglycerol, and PG through activation of specific phospholipases such as PLA2 and PLD, but not by activation of phosphatidylinositol-specific PLC.

NASA Discipline Number 40-40↗

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.↗

Hardware-Based Demonstration of Temperature Control Functions for Reactor Systems

Establishing autonomy in reactor control systems has become essential for the expansion of nuclear technologies. Thermal regulation in particular 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) for control, a hardware-based demonstration of a reactor heating system validates the efficacy of reactor control over this key parameter. To improve precision, a proportional-integral-derivative (PID) algorithm was implemented in the heating control loop to ensure meticulous control of reactor functions. In addition, the integration of this physical system with a digital simulator tool such as RELAP5-3D establishes a foundation for a comprehensive testing environment. This allows for a refinement of temperature control under various simulated reactor conditions, bringing another layer of reliability to the operation of the system. By facilitating a physical demonstration of reactor thermal management and control strategies, this project provides a foundation for expanded testing and educational outreach. Ultimately, this system advances the broader goal of demonstrating the safety and viability of autonomous reactor operations, contributing to public trust and future reactor deployment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Project Presentation: 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. This report covers internship project presentation as well as relevant experience with nuclear and proposal for project upgrade.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Control System Upgrade for Canal ARC SAW

Upgrading the specific components of the Arc Saw, such as the HMI, the components of the chassis involving the I/O modules, servo motor modules, and PLC modules offers numerous advantages. By enhancing the HMI, the operators will benefit having a user-friendly interface, enabling smoother control and monitoring of the ARC SAW’s functionality. Upgrading the modules will contribute to an improved precision and responsiveness in changing modes of the ARC SAW as well as the adjusting the saw blades position, further enhancing the system's overall performance. These upgrades, while maintaining the same functionality, enable the latest technological advancements without needing significant changes or disruptions to existing operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

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↗

Size-related decline in dryland shrubs is related to reductions in hydraulic efficiency and carbon assimilation and not nonstructural carbohydrate depletion

Plant growth and survival are fundamentally constrained by water transport from roots to leaves, impacting carbon assimilation and associated labile carbon pools. However, physiological constraints on growth and survival vary with plant age, due to changes in metabolic sinks, and increases in hydraulic path length from rhizosphere to canopy. We investigated crown dieback, growth, hydraulics, carbon assimilation and carbohydrate storage in relation to increasing basal diameter of two dominant shrub species (Caragana korshinskii and Artemisia ordosica) at the southeastern edge of the Tengger Desert, China. The aim was to identify mechanisms of decreased performance with plant size in dryland shrubs. Clear contrasts in stomatal regulation of leaf water potentials were detected between species. Despite these contrasts, radial growth, hydraulic transport efficiency (Ks), and photosynthetic efficiency similarly declined in both species with increasing plant size, while non-structural carbohydrate (NSC) reserves remained unchanged. Xylem embolism (PLC) increased with plant size, resulting in significant reductions in carbon assimilation in both species. Results indicate that hydraulic, and potentially carbon assimilation constraints, rather than reductions in carbohydrate storage, govern growth-related dryland shrub decline. These findings improve our understanding of how population demography impacts dryland forest response to climate change.

Zhang, Hongxia↗

Blue Keanu: A Scientific Visualization Tool For Network Data

This software allows the user to visualize complex PCAP-ng files captured from network capture software such as Wireshark. The visualization runs in a GUI window that can be zoomed or moved to areas of interest in a waterfall type display. The user then can see an area of interest that looks different than the typical traffic visually, such as a human interaction or non-repetitive area of data. The program will tell the user the packet number and byte offset of interest for fast analysis of discrete atomic or non-random events. This is particularly useful for visualization of unknown binary format data, such as in PLC or SCADA protocols that may have human or other non-repetitive activity for further analysis, reverse engineering, or fast forensic analysis.

Durller, MichaelGeorge↗

CDL2PLC translator v0.1.0

The CDL-PLC translator aims at translating control sequences for building energy systems from the CDL CXF format to the PLCopen XML format. The CDL CXF developed at LBL within the OpenBuildingControl project, and now being standardized via ASHRAE Standard 231P, enables expressing control sequences developed in the simulation environment Modelica in a JSON format. The PLCopen XML is an existing exchange format standardized in IEC 61131-10 for Programmable Logic Controllers (PLCs) following the IEC 61131 standard as one target system of CDL among others. The translation from the CDL CXF to the PLCopen XML contributes to a seamless workflow from the model-based development of control sequences in simulation environments, which is not building practice today, and their digital implementation on building controllers, which replaces graphical and textual documents used for this purpose today. The translator is at a prototypical stage and enables, as a proof of concept, the translation of very simple control sequences composed of 4 selected function blocks out of 137 function blocks defined in CDL. The translation includes the connection of inputs and outputs of function blocks and the expression of a control function in CDL to the equivalent code in IEC 61131-3.

Walther, Karl↗

Analog Signal Multiplexing System for the Iota Proton Injector

The Fermilab Accelerator Science and Technology (FAST) Facility at FNAL is a dedicated research and development center focused on advancing particle accelerator technologies for future applications worldwide. Currently, a key objective of FAST Operations is to commission the 2.5 MeV IOTA Proton Injector (IPI) and enable proton injection into the Integrable Optics Test Accelerator (IOTA) storage ring. The low and medium-energy sections of the IPI include four frame-style dipole trims and two multi-function correctors with independently controlled coils, requiring readout of 32 analog channels for current and voltage monitoring in total. To reduce cost and optimize rack space within the PLC-based control system, a 32-to-4 analog signal multiplexing system was designed and implemented. This system enables real-time readback of excitation parameters from all magnetic correctors. This paper presents the design, construction, implementation, and performance of the multiplexing system.

MacLean, Daniel R. [Fermilab] (ORCID:0000000210103↗

Full Scale HEPA Filter Encapsulation in Ultra-High-Performance Grout - Proof of Concept

The Hanford Tank Waste Treatment and Immobilization Plant (WTP) currently being constructed to treat radioactive waste, includes vitrification facilities for both the high-level waste (HLW) and low activity waste (LAW) fractions. Operation of the WTP will produce contaminated high-efficiency particulate air filters (HEPA), as part of the solid secondary waste (SSW) stream. The HEPA filters receive off-gas from the vessel vent header and primary off-gas treatment system in LAW Facility and remove particulate contaminants including 99 Tc and 129 I salts. The current disposal method for HEPA filters is encapsulation in metal containers using cementitious material (CM) and disposal in the Integrated Disposal Facility (IDF). Results from the 2017 IDF Performance Assessment (PA) WRPS (2018) demonstrated that while compliance is maintained for the 1000 year compliance period mandated by DOE O 435.1 and its accompanying manual, release of constituents from the HEPA filters result in exceedance of the performance objective imposed as the groundwater regulatory limit at later times. For example, at about 1500 years post-closure, solid secondary waste (SSW), including HEPA filters is predicted to become a dominant contributor to 99 Tc release and over the 10,000-year sensitivity analysis period, SSW is the dominant contributor of 129 I release to the groundwater. The estimated release could potentially be reduced if the HEPA filters are not compacted and waste containers could be distributed throughout a large space, thereby diluting the contaminant release. Additionally, a better cementitious material could be used to encapsulate the HEPA filters. One alternative method for disposal of contaminated HEPA filters is encapsulation of the filters in ultra high-performance grout (UHPG). UHPG is a variation of ultra-high-performance concrete (UHPC) is commonly used in the prestressed concrete industry for large structural members. Recent studies of UHPG show it has excellent properties for containing radionuclides such as 99 Tc and 129 I Nichols and Kaplan (2021). This report presents the results of the first attempt to encapsulate a clean, full-size HEPA filter in UHPG and evaluate the effectiveness of the immobilization process and final waste form. A full-scale proof-of-concept simulated waste form was prepared by encapsulating a HEPA filter in a 110-gallon stainless steel (SS) drum using UHPG. A change from Type I/II PC to Type 1L PLC was made after American Rock Products informed the team that they would no longer be using Type I/II by the end of 2024 and the northwest was phasing out Type I/II PC overall. Type I/II PC used in previous studies of UHPG for encapsulation (Nichols and Kaplan 2021). After the UHPG was cured both the scaled mockup and the full-scale simulated waste forms were sectioned for visual examination. UHPG completely encapsulated the filters and bonded to the external surfaces of materials comprising the filters. No cracks were observed in the sectioned waste forms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Analog Signal Multiplexing System for the IOTA Proton Injector

he Fermilab Accelerator Science and Technology (FAST) Facility at FNAL is a dedicated research and development center focused on advancing particle accelerator technologies for future applications worldwide. Currently, a key objective of FAST Opera-tions is to commission the 2.5 MeV IOTA Proton Injec-tor (IPI) and enable proton injection into the Integrable Optics Test Accelerator (IOTA) storage ring. The low and medium-energy sections of the IPI include four frame-style dipole trims and two multi-function cor-rectors with independently controlled coils, requiring readout of 32 analog channels for current and voltage monitoring in total. To reduce cost and optimize rack space within the PLC-based control system, a 32-to-4 analog signal multiplexing system was designed and implemented. This system enables real-time readback of excitation parameters from all magnetic correctors. This paper presents the design, construction, implementation, and performance of the multiplexing system.

MacLean, Daniel R. [Fermilab] (ORCID:0000000210103↗

A New Era for Bubble Chamber Technology

Neutrino experiments like DUNE are limited by how well we understand the way neutrinos actually interact with atoms. The best way to fix that is to measure interactions on hydrogen, since a hydrogen nucleus is just a single free proton with largely none of the nuclear effects that heavier targets like argon have. The catch is that no one has built a hydrogen bubble chamber for a neutrino beam since the 1980s, mostly because the old chambers had too low of an active time. MAMBA is a project focused on bringing that technology back but built to cycle continuously at 1 Hz. I spent my summer internship on two of the subsystems that make that kind of speed possible. First, I helped install and test a new solid copper thermal link that replaced the old flexible braided cooling path, and it brought the coldhead down to 21.3 K, right at the target temperature. Second, I built and tested a Raspberry Pi based PLC control system, and across 20,000 trials it answered in a median of 0.64 ms, with only 0.66\% of trials running past 1 ms. Both results point the same direction: that inexpensive, off the shelf hardware can perform fast and reliable enough to eventually run a bubble chamber the way MAMBA needs it to run.

Williams, Nicholas [DuPage Coll.]↗

The luminosities of the binary cepheids SU Cyg, SU Cas and W Sgr

Absolute magnitudes for binary classical Cepheids were derived by ratioing IUE low dispersion spectra in regions where the blue companion dominates with spectra of main sequence spectral type standards. The IUE spectra are also used to determine the magnitude difference between the Cepheid and the blue companion. Absolute magnitudes determined for SU Cyg and W Sgr agree with the absolute magnitudes of Sandage and Tammann and Caldwell within the + or - 0m2 estimated uncertainty, but not with the fainter absolute magnitudes of Schmidt. The absolute magnitude of SU Cas is in better agreement with the PLC relations if it is pulsating in the first overtone mode.

Evans, Nancy Remage↗