Results for “Hardware-in-the-Loop” — Page 7

DOE OSTI2024

A Cybersecurity Testbed for Smart Buildings

Smart buildings are equipped with a plethora of cyber-physical systems, such as Internet of Things (IoT) devices and building automation systems. These devices, especially in commercial buildings, use legacy communications and hardware that were not designed with cybersecurity in mind. With increasing cyber threats in recent years, smart buildings have become an increasing target for attacks, but not enough published data are available from these incidents to study or replicate the scenarios to defend buildings. As part of the U.S. Department of Energy-funded project focusing on developing the Building Intelligence with Layered Defense Using Security-Constrained Optimization and Security Risk Detection (BUILD-SOS) platform, we developed a cybersecurity test bed for smart buildings. This test bed includes a building simulation tool, virtual devices, emulated operational technology networks, and remote hardware-in-the-loop. Using this test bed, we performed different cyberattacks on the smart building model and collected both physical building data, to understand the impacts on the building, and network data, to aid in separating mechanical faults from cyberattacks during the detection. This test bed is a significant tool in protecting smart buildings from cyberattacks because they can aid in both cybersecurity analysis and the evaluation of cyberattack detection tools by testing the tools in a secure environment without impacting the building operations.

alfalfa↗

DOE OSTI2024

Precise Motion Control of Hybrid Hydraulic Electric Architecture (HHEA)

Off-highway heavy-duty vehicles have been long-standing users of hydraulic systems for power transmission and control. However, traditional hydraulic systems suffer from significant energy losses which lead to increased operating costs and a larger carbon footprint due to higher CO2 emissions. Improving the efficiency of these mobile machines is crucial not only for reducing their environmental impact but also for saving billions of dollars in operating costs. Currently, the state-of-the-art Load Sensing Architecture uses throttling valves for control, which significantly reduces its efficiency and does not recuperate energy from over-running loads. Researchers have developed several architectures such as Common Pressure Rail systems, Displacement Control, STEAM, and Electrohydraulic Architecture to improve the efficiency of off-road mobile machines. However, each of these architectures has its drawbacks. To increase system efficiency and take advantage of electrification benefits, our research group has developed a novel Hybrid Hydraulic-Electric Architecture (HHEA). The HHEA can significantly improve efficiency, decrease the size of electrical components, and maintain control performance. This new architecture has the potential to revolutionize the off-highway mobile machine industry and lead to a more sustainable future. The HHEA uses a set of common pressure rails to provide the majority of power to the actuators via power-dense hydraulics and uses electric motors for precise control and power modulation. In the context of off-road mobile machines, energy savings are undoubtedly important but it is equally important to consider the machines’ ability to perform tasks with precision and accuracy according to given commands. Therefore, precise motion control is of utmost importance to maintain the utility of Hybrid Hydraulic-Electric Architecture (HHEA). The HHEA presents a unique challenge to motion control due to the discrete pressure changes that occur when the system switches between selected pressure rails. These changes are made to minimize system inefficiencies or to keep the system within the torque capability of the electric motor. Hence, it is important to solve the motion control challenges for HHEA. This thesis aims at developing an effective motion control strategy for HHEA. The dissertation presents a two-tiered control strategy for HHEA, comprising a high-level and a low-level controller. The primary responsibility of the high- level controller is to optimize energy efficiency by making informed pressure rail selections. On the other hand, the low-level controller is focused on achieving precise motion control of the HHEA, which is crucial for realizing the desired reference trajectories. To achieve this, the low-level controller utilizes a passivity-based backstepping integral controller as the nominal control, which handles the motion control between two pressure rail switches. Additionally, a separate least norm controller is utilized as a transition controller to manage motion control during pressure rail transitions. The effectiveness of the combined control strategy is demonstrated through experiments conducted on two hardware-in-the-loop testbeds. Furthermore, the HHEA is installed on the boom and stick actuators of a backhoe arm to build a Human-in-the-Loop system that a human operator can control. A real-time rail switching algorithm is developed to determine pressure rail switching based on present duty cycle information from the operator. Modifications have been made to the human-machine interface to achieve more intuitive control. Modifications include performing control in the task-oriented coordinates, incorporating pressure feedback to enhance control with physical interaction, and using velocity field control to simplify multi-degree-of-freedom tasks and to enable novice operators to perform them with reduced risk, improved efficiency, and productivity. The research in this dissertation makes significant contributions to the field of off-road mobile machine control, providing a novel and effective control strategy for the HHEA, and demonstrating the potential for simplified machine operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Hydrogen Production, Grid Integration, and Scaling for the Future

The project will explore near and long-term visions towards the commercialization of grid integrated electrolysis systems to inform deployment across the planning, procurement, and operation stages of hydrogen production on the grid. It will leverage NREL's state-of-the-art 1.25 MW polymer electrolyte membrane (PEM) electrolyzer system to characterize system performance in relevant scenarios, also creating a digital twin for emulation in the Advanced Research on Integrated Energy Systems (ARIES) virtual environment and performing hardware-in-the-loop (HIL) testing of pilot scale, decentralized, and centralized hydrogen systems.

electrolysis systems↗

DOE OSTI2024

Probing Signal-Based Inertia and Frequency Response Estimation for Power Systems with High Penetration of Inverter-Based Resources: Preprint

Power system inertia is the inherent capability of a power system to resist changes in its frequency during disturbances. Real-time inertia estimation technology has become more important due to the low-inertia issues caused by the increasing integration levels of inverter-based resources (IBRs) from renewable energy; however, existing inertia estimation methods hardly consider multiple frequency response controls that act within the same time frame as conventional inertial response, thus making measured inertia values vary under different testing conditions. To resolve this issue, this paper proposes a novel real-time estimation method to simultaneously estimate a power system's inertia constant and frequency response droop constant using a well-designed probing signal. First, we formulate the inertia and frequency response model of a power system with IBRs. Second, through the integration and manipulation of the developed model, we propose a multivariate linear regression- based estimation method that is resilient to measurement noise. Third, we design a probing signal that can be injected by IBRs to incite the required transients for estimation. Finally, we validate the proposed estimation method through comprehensive power- hardware-in-the-loop experiments using inverter hardware and a realistic island power system model. The results demonstrate that the proposed method can accurately estimate the inertia and droop value of the power system with grid-following IBRs and grid-forming IBRs with virtual synchronous machine control.

frequency response↗

DOE OSTI2024

Value-based Insights from the Implementation of Hierarchical Control for Energy Savings and Demand Response in Residential Premises

As the adoption of distributed energy resources and electric vehicles at residential customer premises increases exponentially, behind-the-meter assets can be utilized to achieve energy cost reduction and demand response through coordination and control strategies. A hierarchical control architecture from the utility headend to residential premises is implemented to attain these objectives. This paper extracts the values from the development, implementation, and deployment of that control hierarchy. The development of the control philosophy is built upon the existing advanced metering infrastructure, communication protocols, and industry-compatible application programming interfaces. Results are presented visually with analytical insights by utilizing the data from hardware-in-the-loop testing and simulation analysis out of the collected data from the field.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Real-Time Testbed for Studying Cyberattacks and Defense in DER-integrated Smart Inverter Systems

In this paper, we propose a Hardware-in-the-Loop (HIL) simulation testbed suitable for the implementation and testing of realistic cyberattacks on grid-tied smart inverter systems integrated with Distributed Energy Resources (DER) that use the Distributed Network Protocol-3 (DNP3) protocol for communications between grid components. Specifically, our testbed combines a Real-Time Digital Simulator (RTDS) NovaCor device, outfitted with GNETx2 network interface cards, a gridtied DER topology implemented via the RTDS software package RSCAD, and a custom virtual network that emulates a man in the middle attacker. The Man-in-the-Middle (MITM) attacker captures DNP3 traffic and falsifies telemetry data in DNP3 packets to trigger unwarranted commands from a DNP3 controller that exploit smart inverter grid support functions. We choose DNP3 and implement grid support functions according to the IEEE Std. 1547-2018 mandated for the interconnection and interoperability of DER power systems with associated power components. Furthermore, we develop a protocol payload agnostic attack detection framework that leverages the round-trip time (RTT) anomalies between DNP3 requests and responses and can detect the presence of attacks without having to analyze the payload’s contents, while balancing trade-offs between false alarm counts, missed detections, and time to detection. To facilitate further research, we publicly release benign and attack network traffic exchanged between various sensors, controllers, and actuators in our grid-tied inverter testbed.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Energy Systems Integration Facility Stewardship Summary: Fiscal Year 2025

A summary of NLR's stewardship of the nationally unique Energy Systems Integration Facility (ESIF) highlighting performance metrics, capability upgrades, and examples of R&D impact. 2025 brought a national focus on energy and ESIF is meeting the moment. All eyes are on data centers and domestic manufacturing and bringing the benefits of artificial intelligence to power system planning and operations. In step with national priorities, ESIF is building out capabilities that advance secure, reliable, and affordable power. ESIF hosted 190 multidisciplinary research projects, 855 high-performance computer users, and collaborated with 81 partners from industry, academia, research, and federal agencies. These research projects resulted in an AI method for detecting high-impedance faults with 90% accuracy, a grid controls demonstration in Connecticut, power quality validation of CorePower's flagship inductor, and a cybersecurity assessment of potential rogue capabilities in digitally connected energy devices. Facility infrastructure improvements enhanced the thermal research network, the SCADA system, the cyber range, power hardware-in-the-loop testing, and more. With support from the U.S Department of Energy (DOE), the ESIF laboratories continue to deliver leading solutions for secure, reliable, and affordable power.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Understanding Line Losses and Transformer Losses in Rural Isolated Distribution Systems

Rural, isolated power systems in the mainland U.S. and in states like Alaska and Hawaii are powered by assets like diesel generators. These rural, isolated power systems also cannot operate at the higher band of medium voltage (like 69kV). They are primarily in the 12 to 14 kV range to keep the cost of the distribution investments lower. Because of this mid-band medium voltage range, the line losses and distribution transformers losses consume significant diesel consumption (almost 10 percent of the peak load). This work considers one such power system powering an isolated system and presents key findings online losses, and transformer losses. Understanding and documenting the impacts is critical for these communities operating their power systems and take actions to reduce expensive diesel consumption. In this paper, we will present one such typical grid and model it in electromagnetic transients (EMT) domain. We used the tower structure, under ground cabling installation to develop high fidelity models of lines. We also used high fidelity models of distribution transformers to present the no-load losses and full load loses. We will also present technical solutions available commercially off-the-shelf to reduce these losses and reduce diesel consumption. This work will be a primer for communities to understand the technical challenges and to understand the possible solution available to solve such challenges for rural, isolated power system operators.

blackstart↗

DOE OSTI2024

Understanding Line Losses and Transformer Losses in Rural Isolated Distribution Systems: Preprint

Rural, isolated power systems in the mainland U.S. and in states like Alaska and Hawaii are powered by assets like diesel generators. These rural, isolated power systems also cannot operate at the higher band of medium voltage (like 69kV). They are primarily in the 12 to 14 kV range to keep the cost of the distribution investments lower. Because of this mid-band medium voltage range, the line losses and distribution transformers losses consume significant diesel consumption (almost 10 percent of the peak load). This work considers one such power system powering an isolated system and presents key findings online losses, and transformer losses. Understanding and documenting the impacts is critical for these communities operating their power systems and take actions to reduce expensive diesel consumption. In this paper, we will present one such typical grid and model it in electromagnetic transients (EMT) domain. We used the tower structure, under ground cabling installation to develop high fidelity models of lines. We also used high fidelity models of distribution transformers to present the no-load losses and full load loses. We will also present technical solutions available commercially off-the-shelf to reduce these losses and reduce diesel consumption. This work will be a primer for communities to understand the technical challenges and to understand the possible solution available to solve such challenges for rural, isolated power system operators.

blackstart↗

DOE OSTI2024

Interoperable, Inverter-Based Distributed Energy Resources (DERs) Enable 100% Renewable and Resilient Utility Microgrids

Project overcomes frequency stability and system control issues when operating distribution microgrids in a low inertia, high PV penetration environment without fossil fuel generators. The team implemented a grid-forming inverter and advanced control features at SDG&E's Borrego Springs Microgrid to demonstrate islanding and blackstart using renewable resources. Simulation and emulation in advance of deployment de-risks field operations.

battery energy storage systems↗

DOE OSTI2024

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

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 proposed; however, these technologies lack comprehensive validation under real-world application scenarios. This paper addresses this gap by designing and developing a controller-hardware-in-the-loop framework to evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. Simulation results indicate the superior performance of an ML-based approach compared to the conventional reference-control grouping-based approach, showcasing its potential to support grid stability and operational efficiency.

closed-loop validation↗

DOE OSTI2025

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

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

17 - WIND ENERGY↗

DOE OSTI2025

Demonstration of a Novel Technology to Manage Electricity Demand in Grid-Independent Military Microgrids

This research was conducted by the National Renewable Energy Laboratory (NREL) in collaboration with the S&C Electric Inc. through funding provided by the ESTCP. The project demonstrates use of cybersecure Automated Demand Response (ADR) technology to effectively manage microgrid loads during grid-independent, also known as "islanded," operation. When military microgrids become isolated from the main electrical grid, they are required to balance electricity supply and demand locally. Given that local generation may be constrained, the prevailing strategy involves shedding all but the most critical loads by tripping smart circuit breakers, which then necessitate manual resetting. This approach is generally implemented at the building level, which means that the buildings with mission-critical activities are exempt from load management and remain fully powered, whereas those deemed non-critical can experience a complete loss of service. In this research we developed a method that allows building automation systems to selectively control their assets in response to load shedding request from a microgrid controller, avoiding total loss of service in contrast to the conventional control approach. A commercial OpenADR client server by GridFabric is used for communication between the microgrid controller and the building management system (BMS). The microgrid controller monitors both generation capacity and various assets within the microgrid and issues a demand reduction request when necessary. This request is communicated to the OpenADR server via Modbus. Upon receiving the request, the OpenADR server forwards it to the BMS utilizing the OpenADR protocol. The BMS is pre-configured with various levels of load reduction strategies based on the controllable assets available, allowing for a nuanced approach to demand reduction. Both lab and field tests were performed that considered load shedding needed to achieve closed transition into island mode and to accommodate changing loads and power source availability while islanded. A commercial microgrid controller was used for these tests with normal programming within the expected constraints of the system capabilities. That is, the solution did not require any specialized modification to the code base of the controller. Given the latency of the round-trip communication path between the microgrid controller and the various devices involved with the load shed processes, there are certain scenarios for which the demonstrated solution are appropriate and some which are not. The methods described in this report can be used for load shedding/restoration during transitions between islanded and grid-tied modes of operation, as well as accommodating normal variations in load and the need to remove a power source from operation for maintenance. These methods should not be used for scenarios that require load shedding within a second or two such as sudden and unanticipated significant load increases or loss of power sources through equipment faults.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

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

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 proposed; however, these technologies lack comprehensive validation under real-world application scenarios. This paper addresses this gap by designing and developing a controller-hardware-in-the-loop framework to evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. Simulation results indicate the superior performance of an ML-based approach compared to the conventional reference-control grouping-based approach, showcasing its potential to support grid stability and operational efficiency.

14 SOLAR ENERGY↗

DOE OSTI2026

SuperLab 2.0 Showcase: Connecting Five Labs to Tackle Grid Complexity and Unlock Unique Grid Asset Potential

SuperLab 2.0 (a five-lab demonstration) is a collaborative, national-scale experiment showcasing the coordination of geographically distributed energy assets in real time. The demonstration integrates 25 physical and digital assets, spanning wind, photovoltaics, batteries, electrolyzers, DC fast chargers, microgrid controllers, building automation systems, small modular reactors, control centers, and gas turbines, across five U.S. Department of Energy (DOE) national laboratories: National Laboratory of the Rockies (NLR), Idaho National Laboratory, National Energy Technology Laboratory, Lawrence Berkeley National Laboratory, and Sandia National Laboratories. These assets are unified using Energy Sciences Network (ESnet), a low-latency, high-performance DOE network, and are controlled via a centralized energy controller hosted at NLR's Advanced Research on Integrated Energy Systems facility. The demonstration validates the ability to stress-test hybrid energy systems under dynamic scenarios to de-risk advanced control strategies for greater resilience and flexibility.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Model Quality and Measurement Density Impact on Volt/Volt Ampere Reactive Optimization Performance

The operation of the utility grid is being reshaped by the continuous addition of distributed energy resources and advanced metering infrastructure, which challenge existing grid control strategies. Some utilities deploy advanced distribution management systems (ADMS) to assist with the consolidation of various applications and to augment situational awareness in response to the new power delivery dynamics. An ADMS is an integrated software platform that provides utilities with a way to enhance their reliability, control, and optimization with advanced applications, such as volt/VAR optimization (VVO). A VVO application could serve as a vehicle to deliver cost savings by providing the utility with a method to reduce rates by controlling the voltage and decreasing the energy usage in their service territory. Some utilities are reluctant to integrate an ADMS, because it is a significant investment that requires approval from the public regulatory commission and/or their customers. This paper evaluates the impact on VVO performance when using a lower-quality network model supplemented with additional measurements, which could provide an implementation for cost savings. The results show that a better model quality would provide the highest energy savings; however, some level of telemetry is necessary in all scenarios to prevent voltage exceedances.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Building Operation Model (Morpheus) for Dallas Fort Worth Airport (CRADA CRD-19-16301 Final Report)

The primary objective of this project was to leverage digital twin technology to enhance the design and operation of DFW Airport terminals and their associated energy systems. To achieve this, Morpheus, a building digital twin, was developed to guide improvements in airport operations, specifically targeting reductions in peak power demand and overall energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

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

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 proposed; however, these technologies lack comprehensive validation under real-world application scenarios. This paper addresses this gap by designing and developing a controller-hardware-in-the-loop framework to evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. Simulation results indicate the superior performance of an ML-based approach compared to the conventional reference-control grouping-based approach, showcasing its potential to support grid stability and operational efficiency.

closed-loop validation↗