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DOE OSTI2024

Advanced grid-forming (GFM) inverter controls, modeling and system impact study for inverter dominated grids

Our main goals in this project are to understand: 1) the stability of the power system with very high penetration of PV or other inverter-based resources (IBR), 2) the interactions among IBRs and traditional generators, and 3) the impact of the GFM inverters on bulk power system. To achieve these goals, we took a holistic research and development approach. First, an impedance-based large system modeling and stability analysis tool was developed to aid the large IBR system small-signal stability analysis. Second, consensus-based control and transient overload ride through were developed to control and coordinate multiple GFM inverters in a large system to maintain transient stability during big grid events. Third, high fidelity electromagnetic transient (EMT) IBR models were developed and integrated into a large reduced WECC model to study the system impact from IBRs. Lastly, extensive validation tests of the GFM control which was developed in this project and implemented in two 1MW commercial solar inverters were performed using different validation platforms, e.g., control hardware-in-the-loop (CHIL) platform, power hardware- in-the-loop (PHIL) platform, and a real PV plant.

14 SOLAR ENERGY↗

DOE OSTI2025

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗

DOE OSTI2025

Microreactor Automated Control System - Digital Twin Models and Advanced Control Systems Updates

Automation of control systems is expected to be important in the economic and safe operation of microreactors. Therefore, there is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a nonnuclear microreactor automated control system (MACS)—a real-time, hardware-in-the-loop testbed for non-nuclear testing of microreactor control system automation. A real-time hardware-in-the-loop testbed incorporates the realistic dynamics of physical systems into control system development and testing. The collaborative effort between Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL) resulted in the development of a prototypic microreactor plant-level digital twin that includes the reactor and a balance of plant system. Advanced control strategies were incorporated to demonstrate testing of control automation solutions. The gRPC communication protocol, which was implemented in the hardware-in-the-loop testbed by INL, was coupled to a digital twin model developed using the TRANsient Simulation Framework of Reconfigurable Models (TRANSFORM) library in Modelica. This digital twin simulation was tested with the ViBRANT hardware for realistic feedback and visual representation of control action in real time. A modular Python client structure was developed to manage functional mock-up unit-based simulation and real-time gRPC communication. Hardware-in-the-loop testing indicated that the modeled reactor—a natural-convection, molten-salt coolant loop configuration—responds well to control of drum positioning for modulation of reactor core power, as well as system-level control and downstream demand changes. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

A CHIL Validation of Machine Learning-Assisted Methods for Real-Time Controls of Solar PV for Grid Services

14 SOLAR 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 formation flying technologies has been developed at NASA s Goddard Space Flight Center. 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. A sample scenario has been set up where the autonomous transition of a satellite formation from an initial along-track separation of 800 m to a final distance of 100 m has been demonstrated. As a result, a typical control accuracy of about 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.↗

NASA NTRS2005

Recent Developments in Hardware-in-the-Loop Formation Navigation and Control

The Formation Flying Test-Bed (FFTB) at NASA Goddard Space Flight Center (GSFC) provides a hardware-in-the-loop test environment for formation navigation and control. The facility is evolving as a modular, hybrid, dynamic simulation facility for end-tc-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 many recent improvements. Two significant upgrades to the FFTB are a message-oriented middleware (MOM) architecture, and a software crosslink for inter-spacecraft ranging. The MOM architecture provides a common messaging bus for software agents, easing integration, arid supporting the GSFC Mission Services Evolution Center (GMSEC) architecture via software bridge. Additionally, the FFTB s hardware capabilities are expanding. Recently, two Low-Power Transceivers (LPTs) with ranging capability have been introduced into the FFTB. The LPT crosslinks will be connected to a modified Crosslink Channel Simulator (CCS), which applies realistic space-environment effects to the Radio Frequency (RF) signals produced by the LPTs.

Mitchell, Jason W.↗

NASA NTRS2007

Development of a Radio Frequency Space Environment Path Emulator for Evaluating Spacecraft Ranging Hardware

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 is evolving 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, have expanded to include S-band Radio Frequency (RF) modems for inter-spacecraft communication and ranging. To enable realistic simulations that require RF ranging sensors for relative navigation, a mechanism is needed to buffer the RF signals exchanged between spacecraft that accurately emulates the dynamic environment through which the RF signals travel, including the effects of medium, moving platforms, and radiated power. The Path Emulator for RF Signals (PERFS), currently under development at NASA GSFC, provides this capability. The function and performance of a prototype device are presented.

Mitchell, Jason W.↗

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 NTRS2007

Characterization of a Prototype Radio Frequency Space Environment Path Emulator for Evaluating Spacecraft Ranging Hardware

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 is evolving 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, have expanded to include S-band Radio Frequency (RF) modems for interspacecraft communication and ranging. To enable realistic simulations that require RF ranging sensors for relative navigation, a mechanism is needed to buffer the RF signals exchanged between spacecraft that accurately emulates the dynamic environment through which the RF signals travel, including the effects of the medium, moving platforms, and radiated power. The Path Emulator for Radio Frequency Signals (PERFS), currently under development at NASA GSFC, provides this capability. The function and performance of a prototype device are presented.

Mitchell, Jason W.↗

NASA NTRS2008

Ares I and Ares V First Stage - Powering Exploration

The National Aeronautics and Space Administration (NASA) Ares Projects Office (APO) is continuing to make progress toward the final design of the first stage propulsion system for the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Ares I and Ares V will provide the space launch capabilities needed to fulfill NASA' s exploration strategy of sending human beings to the Moon, Mars, and beyond. As primary propulsion for the Ares launch vehicles, the Space Shuttle-derived Reusable Solid Rocket Motor (RSRM) is one of the first and most important components to be tested. The first flight of Ares I, called Ares I-X, will occur in April 2009, with booster integration to begin at Kennedy Space Center (KSC) by autumn 2008. The Ares I-X flight will use a combination of flight and simulation hardware to obtain data on controlling the long and narrow crew launch vehicle configuration. The test will use a four-segment RSRM from the Shuttle inventory and a fifth spacer segment to simulate the size and weight of the operational five-segment motor to be used on later flights. The upper stage, Orion crew exploration vehicle, and launch abort system will all be replaced with simulator hardware. Manufacturing work has begun on the spacer segment, as well as the new forward hardware for the booster. Atlas V avionics will be adapted to control Ares I-X' s first stage. That hardware is undergoing hardware-in-the-loop testing in a contractor-provided systems integration laboratory (SIL); a critical design review (CDR) was completed in December 2007. Drogue and main parachute drop tests have also been conducted successfully at Yuma Proving Grounds, allowing the First Stage team to begin fabricating parachutes for Ares I-X. The Ares I-X flight test will be the first flight test for the parachutes. A series of preliminary design technical interchange meetings is being conducted prior to the Ares I-X CDR in January 2007 to ensure readiness for the flight. Much of the First Stage activity in 2007 has focused on a series of preliminary design (PDR) activities associated with each booster subsystem. These events will culminate in a formal preliminary design review in 2008, where subsystems and component specifications will be developed and associated analyses and drawings will be evaluated for technical adequacy. The first stage also has been undergoing a series of trade studies to determine means for upgrading booster performance and reducing operational costs. Performance improvement studies have included changing from polybutadiene acrylonitrile (PBAN) propellant to hydroxyl-terminated polybutadiene (HTPB); replacing aluminum with composite motor casings; and optimizing or upgrading the propellant grain and nozzle structures. Some or all of these changes could result in a block upgrade to the Ares I first stage, after becoming the standard configuration for the Ares V. The cost reduction studies included a change from reusable or recoverable boosters to completely expendable boosters; changing from hydrazine-powered to more environmentally friendly electrohydrostatic actuators (EHAs) on the thrust vector control (TVC) system; and changing the location of the separation plane to reduce the likelihood of recontact upon booster separation. The expendability trade study resulted in a decision to keep the recoverable boosters, as the new hardware costs significantly outweighed the potential operational cost savings due to reduced ground operations. Likewise, due to cost considerations, the team continued using existing hydrazine-powered actuators for the TVC system. The separation plane location for Ares I is still being studied, with results to be announced in 2008. In short, the Ares launch vehicles' first stage is building upon NASA's close familiarity with this Shuttle-derived system, while continuing to seek out improvements for long-term exploration.

Priskos, Alex S.↗

NASA NTRS2016

NASA Operational Simulator for Small Satellites: Tools for Software Based Validation and Verification of Small Satellites

The NASA Operational Simulator for Small Satellites (NOS3) is a suite of tools to aid in areas such as software development, integration test (IT), mission operations training, verification and validation (VV), and software systems check-out. NOS3 provides a software development environment, a multi-target build system, an operator interface-ground station, dynamics and environment simulations, and software-based hardware models. NOS3 enables the development of flight software (FSW) early in the project life cycle, when access to hardware is typically not available. For small satellites there are extensive lead times on many of the commercial-off-the-shelf (COTS) components as well as limited funding for engineering test units (ETU). Considering the difficulty of providing a hardware test-bed to each developer tester, hardware models are modeled based upon characteristic data or manufacturers data sheets for each individual component. The fidelity of each hardware models is such that FSW executes unaware that physical hardware is not present. This allows binaries to be compiled for both the simulation environment, and the flight computer, without changing the FSW source code. For hardware models that provide data dependent on the environment, such as a GPS receiver or magnetometer, an open-source tool from NASA GSFC (42 Spacecraft Simulation) is used to provide the necessary data. The underlying infrastructure used to transfer messages between FSW and the hardware models can also be used to monitor, intercept, and inject messages, which has proven to be beneficial for VV of larger missions such as James Webb Space Telescope (JWST). As hardware is procured, drivers can be added to the environment to enable hardware-in-the-loop (HWIL) testing. When strict time synchronization is not vital, any number of combinations of hardware components and software-based models can be tested. The open-source operator interface used in NOS3 is COSMOS from Ball Aerospace. For testing, plug-ins are implemented in COSMOS to control the NOS3 simulations, while the command and telemetry tools available in COSMOS are used to communicate with FSW. NOS3 is actively being used for FSW development and component testing of the Simulation-to-Flight 1 (STF-1) CubeSat. As NOS3 matures, hardware models have been added for common CubeSat components such as Novatel GPS receivers, ClydeSpace electrical power systems and batteries, ISISpace antenna systems, etc. In the future, NASA IVV plans to distribute NOS3 to other CubeSat developers and release the suite to the open-source community.

Verification↗

NASA NTRS2018

NOS3: NASA Operational Simulator for Small Satellites

The NASA Operational Simulator for Small Satellites (NOS3) is a suite of open-source software tools to aid in areas such as software development, integration & test (I&T), mission operations/training, verification and validation (V&V), and software systems check-out. NOS3 provides a software development environment, a multi-target build system, operational interface/ground software, dynamics and environment simulations, and software-based hardware models. NOS3 has just recently been open-sourced by NASA and is available for immediate use. It enables the development of flight software (FSW) early in the project life cycle when hardware availability is limited. Small satellite development suffers from extensive lead times on many of the commercial-off-the-shelf (COTS) components as well as limited funding for engineering test units (ETUs). To alleviate the need to provide a hardware test-bed for each developer/tester, NOS3 hardware models are based upon characteristic data or manufacturer's data sheets for each individual component. The NOS3 hardware models' fidelity is such that FSW executes unaware that physical hardware is not present. This allows FSW binaries to be compiled for both the simulation environment and the flight computer without changing the FSW source code. For hardware models that provide data which is dependent upon the environment and spacecraft dynamics, such as a GPS receiver or magnetometer, an open-source tool from NASA GSFC (42 Spacecraft Simulator) is used to provide the necessary data. The underlying infrastructure used to transfer messages between FSW and the hardware models can also be used to monitor, intercept, and inject messages, which has proven to be beneficial for V&V of larger missions such as James Webb Space Telescope (JWST). As hardware is selected and becomes available, drivers can be added to the NOS3 environment to enable hardware-in-the-loop (HWIL) testing. When strict time synchronization is not vital, any number of combinations of hardware components and software-based models can be tested. NOS3 was actively used for FSW development and component testing of the Simulation-to-Flight 1 (STF-1) CubeSat and the Lunar IceCube CubeSat. As NOS3 matures, hardware models have been added for common small satellite components such as GPS receivers, electrical power systems and batteries, and antenna systems.

Suder, Mark↗

NASA NTRSDate not supplied

Design, Instrumentation, and Data Analysis for the SLS Core Stage Green Run Test Series

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The actuators are powered by a Shuttle-derived hydraulic Core Auxiliary Power Unit (CAPU), and integrated with an all-new Core Stage thrust structure. The actuators are interfaced to the SLS Vehicle Management (VM) software via an all-new TVC Actuator Control (TAC) avionics subsystem. Despite the significant test and flight experience of the Shuttle hardware, the SLS Green Run ambient and hot fire test activities revealed a number of new findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC system did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. This paper is the fifth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the design of the TVC analyses conducted during the Core Stage Green Run test series are discussed in detail. Throughout the course of the test activities, the SLS flight control team worked diligently with the Core Stage contractor to revise test command profiles and ensure sufficient instrumentation was available to collect data. Post-test analysis combined the Green Run modal, ambient, and hot fire test data, MSFC 2- axis Core Stage TVC Inertial Load Simulator (ILS) data, Hardware-In-the-Loop (HWIL) Systems Integration Lab (SIL) results, and actuator Acceptance Testing Procedure (ATP) responses. These data were used to characterize the response, validate critical math models of the TVC subsystem, and isolate the probable cause of the unexpected responses. Through comprehensive analysis of the available test data sources, the integrated team identified the dominant contributors to the observed response and developed test-correlated rationale for vehicle flight control system performance, ultimately leading to a confident posture for the Artemis I mission.

John H. Wall↗

NASA NTRSDate not supplied

Harnessing the Digital Transformation for Development of Electrified Aircraft Propulsion Control Systems

Hybrid electric aircraft propulsion is an emerging technology that presents a variety of potential benefits along with technical integration challenges. Developing these new propulsion architectures with their complex control systems, and ultimately proving their benefit, is a multistep process that goes from concept, to analysis, to dynamic simulation, to hardware in the loop testing, to full scale testing and beyond. This effort is being revolutionized and indeed enabled by new digital tools that support the increasing technology readiness level throughout the maturation process. NASA has developed and made available a suite of digital tools that ease the path from concept to implementation. The three packages are the Toolbox for the Modeling and Analysis of Thermodynamic Systems (T-MATS), the Electrical Modeling and Thermal Analysis Toolbox (EMTAT), and the Thermal Systems Analysis Toolbox (TSAT). These tools are interactive, complementary, and compatible with each other. T-MATS is a modular thermodynamic modeling framework designed for creating custom component level models of jet engines. EMTAT is a modeling framework used to simulate a variety of power electronic devices, using both physics-based and power flow calculations. TSAT is a framework for modeling and analysis of dynamic heat transfer. These packages all consist of graphical, drag-and-drop, parameterizable building blocks representing various components of the system to be modeled, e.g., compressors, turbines, motors, energy storage devices, etc. They are designed to enable the user to model and simulate the end-to-end dynamic operation of a hybrid powertrain at the timescale of the turbomachinery, capturing mechanical, electrical, and thermal interactions. This paper will describe through multiple examples how these tools have been used successfully in several of the early stages of hybrid electric propulsion system development, from the initial system modeling to real-time interactive pilot-in-the-loop simulation to physical hardware-in-the-loop testing, each step bringing the technology closer to fruition.

Hybrid electric propulsion↗

NASA NTRS2023

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-theloop (HIL) 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 HIL, 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 HIL test are presented and shown to be in good agreement with pretest simulation predictions demonstrating the efficacy of the integrated control design approach.

Electrified Aircraft Propulsion↗

NASA NTRSDate not supplied

Harnessing the Digital Transformation for Development of Hybrid Electric Aircraft Propulsion Control Systems

Electrified Propulsion↗

NASA NTRSDate not supplied

Initial Development of A Digital Twin Model for an Electrified Aircraft Propulsion Emulation Rig

In support of aviation fuel burn and emission reduction goals, NASA is pursing high-payoff research investments that promise to transform aviation. This includes investments in Electrified Aircraft Propulsion (EAP), which relies on the generation, storage, transmission, and use of electrical power for producing thrust and optimizing propulsion system efficiency. Multiple technology challenges must be addressed to unlock the full potential of EAP. This includes advances in propulsion controls, which will be vital for ensuring coordinated efficient operation of the complex integrated subsystems that comprise EAP architectures. To support EAP controls research, the NASA Glenn Research Center has developed the Hybrid Propulsion Emulation Rig (HyPER). The HyPER laboratory hardware includes shaft-mounted electric machines, power converters, power supplies, power distribution cables, and an energy storage device that can be reconfigured to represent a variety of EAP architectures. It also includes an integrated real-time computer system that hosts developed EAP control software and turbomachinery simulations. This enables the electrical system and rotating shafts of EAP designs to be implemented in actual hardware and integrated with turbomachinery simulations and system-level EAP control logic implemented in software. In this form, the HyPER laboratory provides a partially simulated, partially hardware-in-the-loop test environment enabling the initial development and evaluation of EAP control technology. A prerequisite for the development of EAP control designs is the availability of a system model that accurately reflects the operation of the electrical system hardware. To support this need, a digital twin model of the HyPER electrical system hardware is under development. This model is being coded in the MATLAB Simulink environment and uses the NASA-developed Electrical Modeling and Thermal Analysis Toolbox (EMTAT) to construct a digital twin framework. EMTAT contains generic electrical component building blocks that are simulated at turbomachinery timescales. Associated inputs and outputs allow the blocks to be combined to model complete electrical systems. The EMTAT blocks also contain adjustable internal maps and parameters that can be set to reflect the operation of a specific electrical component. For the HyPER digital twin, the settings of these EMTAT block internal maps and parameters is determined through machine learning approaches applied to characterization run data collected from the laboratory. During characterization runs the laboratory electrical system hardware is subjected to a full range of torque, speed, and power settings. Acquired data is then used to estimate EMTAT block parameters using a variety of machine learning techniques. The resulting digital twin model is found to match the operation of actual HyPER hardware with an accuracy suitable for control development purposes. It also holds promise for other applications including modeling the performance of HyPER laboratory reconfigurations and model-based anomaly detection. Planned follow-on work to automate post-processing of acquired laboratory data to update the HyPER digital twin model will also be presented and discussed.

Electrified Aircraft Propulsion↗

DOE OSTI2023

Parallel Grid-Forming Inverter-Driven Black Start: Power-Hardware-in-the-Loop Validation: Preprint

With power systems encountering increasing deployment levels of inverter-based resources (IBRs), system restoration using grid-forming (GFM) IBRs has gained attention. Engineered to establish grid voltages in the absence of a stiff grid, black-start-capable GFM IBRs are expected to enhance power system resilience by playing a critical role in bottom-up system restoration. This paper experimentally studies the feasibility of the novel approach through power-hardware-in-the-loop (PHIL) testing and validation with a commercial GFM inverter. The PHIL test setup demonstrates an inverter-driven black start of a 5-MW unbalanced distribution feeder where two GFM inverters collectively black start the feeder: one is a commercial hardware GFM inverter interacting through the PHIL interface, and the other is a software GFM emulated by a real-time simulation with full electromagnetic transient (EMT) models. Both GFM inverters are equipped with negative-sequence voltage control to suppress the voltage imbalance resulting from the unbalanced loading, allowing us to study the dynamic interactions between the GFMs with their control parameters unknown. To evaluate the dynamic behavior of the GFM inverters under the entire black-start process, the EMT model of the distribution system details the transformer and motor dynamics to emulate their inrush and startup behaviors. It abstracts conventional grid-connected inverter dynamics, i.e., grid-following inverters. Oscilloscope measurements of the hardware GFM inverter are also presented for critical steps. Takeaways for further study and field deployment are provided.

grid-forming inverter↗