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NASA NTRS1992

Transonic turbine blade cascade testing facility

NASA LeRC has designed and constructed a new state-of-the-art test facility. This facility, the Transonic Turbine Blade Cascade, is used to evaluate the aerodynamics and heat transfer characteristics of blade geometries for future turbine applications. The facility's capabilities make it unique: no other facility of its kind can combine the high degree of airflow turning, infinitely adjustable incidence angle, and high transonic flow rates. The facility air supply and exhaust pressures are controllable to 16.5 psia and 2 psia, respectively. The inlet air temperatures are at ambient conditions. The facility is equipped with a programmable logic controller with a capacity of 128 input/output channels. The data acquisition system is capable of scanning up to 1750 channels per sec. This paper discusses in detail the capabilities of the facility, overall facility design, instrumentation used in the facility, and the data acquisition system. Actual research data is not discussed.

Verhoff, Vincent G.↗

DOE OSTI2024

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↗

DOE OSTI2025

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↗

DOE OSTI2025

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↗

DOE OSTI2025

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

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

NASA NTRS1998

The Application of Dedicated Controllers to Parallel/Serial Exhauster Trains

Twenty new dedicated controllers were interfaced to the Distributed Control System (DCS) at NASA Lewis Research Center. Better surge avoidance, improved energy savings, interface intricacies, and plant complexities are the subjects of this paper. Problems with the existing Programmable Logic Controller (PLC) control logic are described as well as the solutions implemented with the new controllers. The complexity of the new communication network between the dedicated controllers, Multipurpose Micro-Processor (MMPs), and the operator workstations are illustrated. The complicated nature of the plant and methods of controlling the associated processes are also discussed.

Sadhukhan, Debashis↗

DOE OSTI2024

Integrate Latimer Controls' Solution into RTAC (CRADA Final Report, CRD-23-24672)

Latimer Controls, Inc. was awarded two vouchers under the Department of Energy's American-Made Solar Prize Round 6 to conduct collaborative research at a national laboratory. The National Renewable Energy Laboratory (NREL) was selected as a partner to assist Latimer Controls in the performance evaluation of its photovoltaic (PV) control software. This collaboration focuses on developing a hardware-in-the-loop (HIL) testbed at NREL, which will be used to test and validate the Latimer PV control technology in a realistic yet de-risked environment. Both Latimer and NREL teams will work together to analyze the collected test data, derive insights, and disseminate the scientific findings. Recent studies underscore the potential of solar energy as a zero-marginal-cost and zero-emission flexibility resource within the bulk power system, particularly when integrated with advanced control systems. To enhance the performance of such systems, Latimer Controls has developed leading-edge technologies, including machine learning (ML) algorithms and hierarchical inverter set-point allocation methods. These innovations are designed to estimate the operational headroom of large PV plants for grid integration and control. However, comprehensive validation under real-world conditions remains necessary. To address this gap, the concurrent CRADA project proposes the real-world application and validation of the Latimer Control solution within a HIL environment. Initially, the Latimer algorithm was developed and tested within MATLAB Simulink, a platform suitable for research-level simulations and iterative development. However, transitioning this technology to a real solar site as an industry-ready solution necessitates implementation in a format compatible with widely used solar power plant controllers. In this additional CRADA work, the MATLAB Simulink-based logic will be translated into Structured Text, a programming language compliant with IEC 61131 standards, which is commonly used for custom logic implementations in industry-leading programmable logic controllers (PLCs), such as the Schweitzer SEL real-time automation controller (RTAC). This transition will facilitate the deployment of the Latimer Control solution in real-world solar power plants, thereby advancing the technology towards commercialization.

14 SOLAR ENERGY↗

NASA NTRS2003

The Integration of Fieldbus Devices to an Existing DCS

Existing analog strain gauge transducers and signal conditioners were replaced with new Foundation Fieldbus Transmitters in the Distributed Control System, DCS, at the NASA Glenn Research Center (GRC). The reasons for implementing this upgrade and an evaluation of the results of the project are the subjects of this paper. Problems and advantages with the original transducers and the newly installed transmitters are described and compared. Detail of the physical network layer between the Foundation Fieldbus Transmitters, Programmable Logic Controllers (PLCs), Multipurpose Micro-Processor (MMPs) and the operator workstations are illustrated. The complex nature of the facility and methods of future control of the associated processes are also discussed.

Sadhukhan, Debashis↗

DOE OSTI2026

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

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

Williams, Nicholas [Fermilab; DuPage Coll.]↗

DOE OSTI2025

Real-Time Automated pH Control within Batch Processes Relying on Raman pH Measurement

Nuclear fission is an energy source that can provide consistent power with very low associated carbon emissions. However, management of the used nuclear fuel is an important aspect of the application of nuclear power. Recycling of useful components from used fuel is an attractive option, but this involves chemical processing of the fuel. Possible chemical separation technologies that might be used in this regard are sensitive to solution pH. Raman spectroscopy is a promising technique for monitoring the pH of solutions in real time. Classical pH probes are too fragile to be used in the harsh environments encountered in nuclear fuel processing. Raman probes are robust and can withstand these harsh environments to track pH. Coupled with chemometric analysis, the demonstration of the use of Raman spectroscopy to track and predict the pH in carboxylate-buffered systems is made possible. Utilizing this spectroscopy in conjunction with Programmable Logic Controllers mimics industrial control systems used in many modern industrial settings. This showcases a pragmatic approach toward leveraging Raman spectroscopy and chemometric model outputs as inputs for a real-time control system. The model to predict pH created by chemometrics proved to be successful in tracking pH. The optimal pH for TALSPEAK extraction of lanthanides and actinides from aqueous solution is known to proceed in a narrow pH range of around pH = 2.8 ± 0.1. This study uses Raman optical monitoring and automated control to return and maintain solution pH within this range after acid or base perturbations move the solution pH well outside this region. Root-mean-square errors show that pH changes measured using Raman spectroscopy on the batch process solution are reliably measured and used to automatically correct and maintain solution pH. Measurement of solution pH tracks favorably with electrochemical pH probe comparison measurements. As a result, the ability to showcase Raman spectroscopy paired with chemometrics analysis acts as a durable, better alternative data source compared to traditional pH probes to optimize the separation efficiency in the used nuclear fuel processing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2004

Upgrades at the Propulsion Systems Lab (PSL)

The Propulsion Systems Lab (PSL) does ground testing on full size air breathing engines. These engines range from those on commercial airplanes to fighter jets. At the PSL, engineers receive test requirements from customers and put together the necessary instrumentation, data systems, power requirements, electrical control valves, and engine controls. The engineers are also responsible for facility maintenance, repairs and upgrades. There are four major sections at the PSL; the Test floor, the Data room, the Control room and, the WDPF room. On the test floor are two test cells, cell #3 and cell #4. It is within these cells that the actual engine resides for ground testing. The cells, once sealed and taken up to altitude, are capable of reaching engine inlet temperatures of 1000 F to -90 F, and various atmospheric pressures. The engine, when operational, takes in air and gives out exhaust of up to 2000 F. The exhaust is led to another section of the cell where it is cooled to 150 F before finally redirected to the appropriate disposer. Temperature and pressure transducers detect the conditions within the cell and transmit them to the data room where the results are captured, processed, analyzed, and translated to a more comprehensive language. This is made possible with the aid of several programmable logic controllers (PLCs) and instrumentation and control systems. The translated data is then sent, via the LAN, to the control room where the results can be viewed on monitors by the engineers and customers. From the control room, the test cell conditions can be changed whenever desired. During tests, a lot takes place in the facility. The WDPF control system monitors and controls all facility parameters. This summer, I will assist the engineers; on an upgrade to the facility's distributed control and dynamic data system, in preparation for an engine test that will begin in September, the installation of control systems and various miscellaneous projects around the PSL.

Audu, Abdullahi M.↗

NASA NTRS2004

Software Assurance of PLCs Training Course

Being heavily visually-oriented, I am a firm believer in communication and conveying emotions through the art of color, motion, and transformation. A four-part online training course was created in PowerPoint and needed to be translated over into a Flash format. Issues with the Powerpoint were that the size of the files caused noticeable delays when placed online, there were compatibility issues, and from a composition and design perspective, color schemes and layout left much to be desired. High contrast, pixilated yellow text spiraling and flying on to a background of overly rich hues of blue with cheesy gradient patterns was just not appeasing to my eye, along with the menu directory buttons located at the top resembling blue pills of NyQuil on top of a stale gray border that had nothing to do with the background. The course itself is extremely broad and verbose, and will get monotonous very soon after starting. Moving about the course was very cumbersome as well. efficient by drastically reducing the size (The file size of all four parts of the actual course combined will ultimately not even be a fifth as big as one part of the original PowerPoint alone!); along with that, the course was made to be more interactive and user-friendly, as well as pleasing to the eye. Upon being viewed by fellow co-workers, nothing but positive feedback has been received. When beginning the presentation, onscreen comes a 3' 2" chubby, balding professor, who is a master in his knowledge of Programmable Logic Controllers (PLCs). He introduces himself and presents all of his vast knowledge over PLCs in a fun and innovative manner, making it much easier to acquire the information presented. A Scene Selection feature has been added making it a lot easier to jump from part to part and the back and forth arrows are much easier to utilize, and they are both less obtrusive than its PowerPoint predecessor. The user can also go at their pace, as the presentation pauses after at the end of each statement. computer animation, it was.. .still. ..animation done on a computer. I was able to incorporate my artistic talent and intuitive creativity into it, one thing I am very proficient at doing when it comes to what I do and what I will do in my profession as an artist/computer animator. At first, I felt that there was no place for an artist within a faculty of scientists, engineers, chemists, mathematicians, and programmers, but I managed to fit in quite successfully. My task was to convert the course into a Flash format, which would make it much more My project surprisingly somewhat dealt with my field of interest-though it was not

Threatt, Jamarr↗

DOE OSTI2024

PLC Vulnerabilities and Mitigations

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

42 ENGINEERING↗

DOE OSTI2026

PLC Integration for the Horn A Magnetic Field Mapping Device

This presentation summarizes the integration of a programmable logic controller (PLC) into the Horn A magnetic field mapping device for the Long-Baseline Neutrino Facility (LBNF). The device is used to position magnetic field probes along the centerline of the Horn A inner conductor to verify that the magnetic field within this region is approximately zero. The presentation covers the PLC hardware and electrical integration, stepper motor and encoder control, ladder logic development, mechanical integration, and system testing. Results include successful bidirectional motion and encoder feedback for the translation and rotation axes, as well as characterization of translational motion for repeatable probe positioning.

Bitakis, Kayla [Unlisted, US, IL]↗

NASA NTRS1991

Deployable robotic woven wire structures and joints for space applications

Deployable robotic structures are basically expandable and contractable structures that may be transported or launched to space in a compact form. These structures may then be intelligently deployed by suitable actuators. The deployment may also be done by means of either airbag or spring-loaded typed mechanisms. The actuators may be pneumatic, hydraulic, ball-screw type, or electromagnetic. The means to trigger actuation may be on-board EPROMS, programmable logic controllers (PLCs) that trigger actuation based on some input caused by the placement of the structure in the space environment. The actuation may also be performed remotely by suitable remote triggering devices. Several deployable woven wire structures are examined. These woven wire structures possess a unique form of joint, the woven wire joint, which is capable of moving and changing its position and orientation with respect to the structure itself. Due to the highly dynamic and articulate nature of these joints the 3-D structures built using them are uniquely and highly expandable, deployable, and dynamic. The 3-D structure naturally gives rise to a new generation of deployable three-dimensional spatial structures.

Shahinpoor, MO↗

NASA NTRS1997

Thermal System Upgrade of the Space Environment Simulation Test Chamber

The paper deals with the refurbishing and upgrade of the thermal system for the existing thermal vacuum test facility, the Space Environment Simulator, at NASA's Goddard Space Flight Center. The chamber is the largest such facility at the center. This upgrade is the third phase of the long range upgrade of the chamber that has been underway for last few years. The first phase dealt with its vacuum system, the second phase involved the GHe subsystem. The paper describes the considerations of design philosophy options for the thermal system; approaches taken and methodology applied, in the evaluation of the remaining "life" in the chamber shrouds and related equipment by conducting special tests and studies; feasibility and extent of automation, using computer interfaces and Programmable Logic Controllers in the control system and finally, matching the old components to the new ones into an integrated, highly reliable and cost effective thermal system for the facility. This is a multi-year project just started and the paper deals mainly with the plans and approaches to implement the project successfully within schedule and costs.

Desai, Ashok B.↗

NASA NTRS1998

Recent Productivity Improvements to the National Transonic Facility

Productivity gains have recently been made at the National Transonic Facility wind tunnel at NASA Langley Research Center. A team was assigned to assess and set productivity goals to achieve the desired operating cost and output of the facility. Simulations have been developed to show the sensitivity of selected process productivity improvements in critical areas to reduce overall test cycle times. The improvements consist of an expanded liquid nitrogen storage system, a new fan drive, a new tunnel vent stack heater, replacement of programmable logic controllers, an increased data communications speed, automated test sequencing, and a faster model changeout system. Where possible, quantifiable results of these improvements are presented. Results show that in most cases, improvements meet the productivity gains predicted by the simulations.

Popernack, Thomas G., Jr.↗

NASA NTRS1998

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.↗