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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.

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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Grid‐responsive smart manufacturing: A perspective for an interconnected energy future in the industrial sector

Abstract With the growing amount of renewable energy sources, the grid has become responsible for accounting for intermittency and the flexibility needed to utilize dynamic sources. Expensive peaking plants and energy storage systems have been proposed as ways to mitigate those problems. There is a large group of energy consumers that can respond to grid conditions. Historically, these consumers have been residential and commercial users, but with modern innovations and practices, industrial consumers have the potential to become a major player in this space. Grid‐responsive smart manufacturing can be used to utilize modern tools in manufacturing innovation as enablers for grid response. These modern tools already exist but are not widely used for industrial grid‐side energy management. This article defines grid‐responsive smart manufacturing, identifies five major barriers to its widespread implementation, and portrays the path to getting industrial users to be key players in grid stability and flexibility.

Billings, Blake W.↗
DOE OSTI2023

Colloidal State Machines as Smart Tracers for Chemical Reactor Analysis

A widely utilized tool in reactor analysis is passive tracers that report the residence time distribution, allowing estimation of the conversion and other properties of the system. Recently, advances in microrobotics have introduced powered and functional entities with sizes comparable to some traditional tracers. This has motivated the concept of Smart Tracers that could record the local chemical concentrations, temperature, or other conditions as they progress through reactors. Herein, the design constraints and advantages of Smart Tracers by simulating their operation in a laminar flow reactor model conducting chemical reactions of various orders are analyzed. It is noted that far fewer particles are necessary to completely map even the most complex concentration gradients compared with their conventional counterparts. Design criteria explored herein include sampling frequency, memory storage capacity, and ensemble number necessary to achieve the required accuracy to inform a reactor model. Cases of severe particle diffusion and sensor noise appear to bind the functional upper limit of such probes and require consideration for future design. The results of the study provide a starting framework for applying the new technology of microrobotics to the broad and impactful set of problems classified as chemical reactor analysis.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Introduction to the special issue on smart transportation

Transportation is getting smarter and smarter, with the prominence of connected automated vehicle technologies in the global auto industry’s near-term growth strategies, of big data analytics and unprecedented access to sensing data of mobility, and of integration of this analytics into the optimization of mobility and transport. Further, these developments are setting off a wave of smart transportation innovations, which are featured by new methods and applications driven by various forms of sensor data such as GPS, CAN bus, LIDA, images, etc. At the same time, complexities surrounding the use, conflation, and processing of disparate data in near real-time is of essence for the design and development of futuristic smart transportation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Explainable AI (XAI)-driven vibration sensing scheme for surface quality monitoring in a smart surface grinding process

Local Interpretable and Model-agnostic Explanation (LIME), an explainable artificial intelligence (XAI) approach is adapted to identify the globally important time-frequency bands for predicting average surface roughness (Ra) in a smart grinding process. The smart grinding setup consisted of a Supertech CNC precision surface grinding machine, instrumented with a Dytran piezoelectric accelerometer attached to the tailstock quill along the tangential direction (Y-axis). For every grinding pass, vibration signatures were captured, and the ground truth surface roughness values were recorded using a Mahr Marsurf M300C portable surface roughness profilometer. The roughness values ranged from 0.06 to 0.14 microns over the complete set of experiments. Time-frequency domain spectrogram frames were extracted for each of the vibration signals collected during the grinding process. Convolutional Neural Networks (CNNs) were modeled to predict the surface roughness based on these spectrogram frames and their image augmentations. The best CNN model was able to predict the roughness values with an overall R2-score of 0.95, training R2-score of 0.99, and testing R2-score of 0.81 with only 80 sets of vibration signals corresponding to 4 experiments with 20 trials each. Although the data size is not large enough to guarantee such performance metrics in real-world scenarios, one can extract statistically consistent explanations underlying the relationships these complex deep learning models capture. Further, the LIME methodology was implemented on the developed surface roughness CNN model to identify the important time-frequency bands (i.e., the superpixels of a spectrogram) influencing the predictions. Based on the identified important regions on the spectrogram frames, the corresponding frequency characteristics were determined that influence the surface roughness predictions. The important frequency range based on LIME results was approximately 11.7 to 19.1 kHz. The power of XAI was demonstrated by cutting down the sampling rate from 160 kHz to 30, 20, 10, and 5 kHz based on the important frequency range and considering Nyquist criteria. Separate CNN models were developed for these ranges by only extracting time-frequency contents below their corresponding Nyquist cut-offs. A proper data acquisition strategy is proposed by comparing the model performances to argue the selection of a sufficient sampling rate to capture the grinding process successfully and robustly.

42 ENGINEERING↗
DOE OSTI2023

Reprint of: Explainable AI (XAI)-driven vibration sensing scheme for surface quality monitoring in a smart surface grinding process

Local Interpretable and Model-agnostic Explanation (LIME), an explainable artificial intelligence (XAI) approach is adapted to identify the globally important time-frequency bands for predicting average surface roughness (Ra) in a smart grinding process. The smart grinding setup consisted of a Supertech CNC precision surface grinding machine, instrumented with a Dytran piezoelectric accelerometer attached to the tailstock quill along the tangential direction (Y-axis). For every grinding pass, vibration signatures were captured, and the ground truth surface roughness values were recorded using a Mahr Marsurf M300C portable surface roughness profilometer. The roughness values ranged from 0.06 to 0.14 microns over the complete set of experiments. Time-frequency domain spectrogram frames were extracted for each of the vibration signals collected during the grinding process. Convolutional Neural Networks (CNNs) were modeled to predict the surface roughness based on these spectrogram frames and their image augmentations. The best CNN model was able to predict the roughness values with an overall R2-score of 0.95, training R2-score of 0.99, and testing R2-score of 0.81 with only 80 sets of vibration signals corresponding to 4 experiments with 20 trials each. Although the data size is not large enough to guarantee such performance metrics in real-world scenarios, one can extract statistically consistent explanations underlying the relationships these complex deep learning models capture. Further, the LIME methodology was implemented on the developed surface roughness CNN model to identify the important time-frequency bands (i.e., the superpixels of a spectrogram) influencing the predictions. Based on the identified important regions on the spectrogram frames, the corresponding frequency characteristics were determined that influence the surface roughness predictions. The important frequency range based on LIME results was approximately 11.7 to 19.1 kHz. The power of XAI was demonstrated by cutting down the sampling rate from 160 kHz to 30, 20, 10, and 5 kHz based on the important frequency range and considering Nyquist criteria. Separate CNN models were developed for these ranges by only extracting time-frequency contents below their corresponding Nyquist cut-offs. A proper data acquisition strategy is proposed by comparing the model performances to argue the selection of a sufficient sampling rate to capture the grinding process successfully and robustly.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

SMART Perovskite Growth: Enabling a Larger Range of Process Conditions

Cost-effective, high-throughput industrial applications of metal-halide perovskites require a highly tolerant method (i.e., wide process window) that produces high-quality materials with a short annealing time. Here, we introduce a Seed Modulation for ARTificially controlled nucleation (SMART) process that enables rapid fabrication of high-quality perovskite films under a wide set of initial input parameters. Additionally, we characterized the thin-film evolution from the perspective of crystallinity, surface potential, diffusivity, surface carrier dynamics, and interfacial recombination. We find that surface and subsurface defects primarily determine the performance of materials and devices. By modulating the seeds for perovskite nucleation, we were able to improve the overall crystallization. We achieved a >20% power conversion efficiency using only a 5 min annealing step, and we found that the annealing window is widened such that differing initial conditions achieve similar quality. Furthermore, we demonstrated reproducibility and performance improvement in larger-area perovskite cells by incorporating the SMART process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Dynamic Interfacial Design in Adaptive Hybrid Materials Enables Reversible and Tunable Mechano-Optic Smart Responses

Next-generation polymeric materials are shifting toward adaptive and interactive behaviors of living systems; however, designing materials that can reversibly modulate optical properties under mechanical deformation while maintaining mechanical robustness remains a key challenge. Here, we report a mechanically robust vitrimer-based adaptive hybrid material (AHM) that exhibits a stretch-induced reversible transparency-to-opacity transition, enabled by the integration of dynamic interactions at the polymer–silica nanoparticle interface and controlled nanoparticle self-assembly. The AHM combines boronic ester–functionalized polystyrene-b-poly(ethylene-co-butylene)-b-polystyrene (S-Bpin) with diol-functionalized silica nanoparticles (diol-SiNPs) to form a hybrid network hosting both dynamic boronic ester and hydrogen-bonding interactions. These reversible linkages facilitate controlled nanoparticle self-assembly and enable strain-induced nanoparticle alignment/aggregation. Upon stretching, SiNP-rich domains align and aggregate within the polymer matrix, while local modulus mismatch between stiff aggregated SiNP/borylated-styrene-rich regions and the softer elastomeric midblock induces surface microwrinkle formation. These internal aggregates and surface wrinkles cooperatively enhance light scattering, producing the opaque state under strain. Furthermore, the tailored AHM exhibits high toughness, thermomechanical stability, reprocessability, and programmable shape-memory behavior. This work presents a dynamic interfacial design strategy for mechanically robust, optically reconfigurable, and reusable soft materials for adaptive optics, smart windows, sensing, soft robotics, and circular smart-material platforms.

adaptive hybrid materials↗
DOE OSTI2022

Authentication of smart grid communications using quantum key distribution

Smart grid solutions enable utilities and customers to better monitor and control energy use via information and communications technology. Information technology is intended to improve the future electric grid’s reliability, efficiency, and sustainability by implementing advanced monitoring and control systems. However, leveraging modern communications systems also makes the grid vulnerable to cyberattacks. Here we report the first use of quantum key distribution (QKD) keys in the authentication of smart grid communications. In particular, we make such demonstration on a deployed electric utility fiber network. The developed method was prototyped in a software package to manage and utilize cryptographic keys to authenticate machine-to-machine communications used for supervisory control and data acquisition (SCADA). This demonstration showcases the feasibility of using QKD to improve the security of critical infrastructure, including future distributed energy resources (DERs), such as energy storage.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

NEFTSec: Networked federation testbed for cyber-physical security of smart grid: Architecture, applications, and evaluation

As today's power grid is evolving into a densely interconnected cyber-physical system (CPS), a high fidelity and multifaceted testbed environment is needed to perform cybersecurity experiments in a realistic grid environment. Traditional standalone CPS testbeds lack the ability to emulate complex cyber-physical interdependencies between multiple smart grid domains in a real-time environment. Therefore, there are ongoing research and development (R&D) efforts to develop an interconnected CPS testbed by sharing geographically dispersed testbed resources to perform distributed simulation while analysing simulation fidelity. This paper presents a networked federation testbed for cybersecurity evaluation of today's and emerging smart grid environments. Specifically, it presents two novel testbed architectures, including cyber federation and cyber-physical federation, identifies R&D applications, and also describes testbed building blocks with experimental case studies. It also presents a novel co-simulation interface algorithm to facilitate distributed simulation within cyber-physical federation. The resources available at the PowerCyber CPS security testbed at Iowa State University (ISU) and the US Army Research Laboratory are utilised to develop this platform for performing multiple experimental case studies pertaining to wide-area protection and control applications in power system. Finally, experimental results are presented to analyse the simulation fidelity and real-time performance of the testbed federation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

A data-driven network optimisation approach to coordinated control of distributed photovoltaic systems and smart buildings in distribution systems

The increasing integration of distributed energy resources, including demand-side resources and distributed photovoltaics (PVs), into distribution systems has resulted in more complicated power system operation. A data-driven network optimisation approach is proposed to coordinate the control of distributed PVs and smart buildings in distribution networks considering the uncertainties of solar power, outdoor temperature and heat gain associated with building thermal dynamics. These uncertain parameters have a significant impact on the operation and control of distributed PVs and smart buildings, bringing challenges to the distribution system operation. In the proposed data-driven distributionally robust optimisation (DRO) approach, the Wasserstein ball is used to construct an ambiguity set for the uncertain parameters, which does not require the probability distributions to be known. Furthermore, a conditional value-at-risk is incorporated into the Wasserstein-based DRO model and converted into a computationally tractable mixed-integer convex optimisation problem. Benchmarked with robust optimisation and chance-constrained programming, the proposed data-driven model can give a less conservative robust solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Initial electron cyclotron heating/current drive scoping study for the SMall Aspect Ratio Tokamak (SMART)

In this work an initial electron cyclotron heating/current drive (EC H&CD) scoping study is presented for the SMall Aspect Ratio Tokamak (SMART), constructed and operated by the Plasma Science and Fusion Technology (PSFT) Laboratory of the University of Seville. We consider two planned phases of operation with different magnitude of magnetic field (B 0.4, and 1 T). This EC H&CD scoping study is carried out by using the ray tracing code TRAVIS, which allows to quickly perform a series of scans on the main SMART plasma scenarios. A scan in the poloidal and toroidal launching angles is performed for the B 0.4 T plasma scenario assuming three launching locations (mid-plane, off-mid-plane, and top-launcher) and the extraordinary (X-) mode polarization. The absorption occurs at the second harmonic and, overall, the highest power absorption is obtained launching the EC beam from the top of the machine. A numerical analysis of the fundamental X-mode EC H&CD start-up regime for the B 1.0 T plasma scenario with two different wave frequencies (28 and 35 GHz) is presented showing a very high current drive efficiency.

Bertelli, Nicola [Princeton Plasma Physics Laborat↗
DOE OSTI2026

Smart building HVAC control challenge: experience and solutions from the ADRENALIN project

A smart building HVAC control competition crowdsourced and compared algorithms on fair and equal ground using the standardized BOPTEST framework. The competition attracted 138 participants, but only 9% submitted valid solutions for the final stage, highlighting the complexity of advanced HVAC control design. The winning solutions showed significant potential to reduce energy use and cost by shifting demand, without compromising occupant comfort. Across scenarios, thermal energy cost reductions of 36–76% relative to a baseline, were achieved. In peak heat periods, the cost reduction leveraged limited energy use reduction (0–15%), but more significant energy price reduction (34–62%). This shows smart controls' ability to avoid as much as possible consumption during the morning peak hours, when spot prices are tendentially the highest. Hosting the competition has highlighted challenges in creating competitions that both are fair and promotes solutions that are transferable to real life implementation.

BOPTEST↗
DOE OSTI2021

SMART conductor on round core (CORC ® ) wire via integrated optical fibers

Superconducting cables based on high temperature superconductors (HTS) are necessary for applications requiring large currents and low inductance, such as compact fusion reactors. In this paper, we report the proof-of-concept of a SMART Conductor on Round Core (CORC ® ) wire realized via integration of optical fibers into the copper core. A SMART CORC ® wire with integrated optical fibers was manufactured and its capabilities have been experimentally demonstrated. Results show that by interrogating the optical fibers via Rayleigh backscattering, a Spectral Shift signal as a function of time and position along the cable can be used to detect and locate hot-spots that are developed within the wire or its terminations. It has been found that highly localized current injection into the terminations could initiate hot-spots within the cable at locations where current redistribution between tapes occur. This effect is virtually eliminated when adequate current connections are used that inject current evenly along the cable terminations. Normal zone propagation velocities have been calculated as a function of time using Spectral Shift data for a heater-induced quench as well as a quench induced by overcurrent. In both cases the normal zone propagation velocity was about 6 cm s -1 , but in the heater-induced experiment it was preceded by 500 ms of slower propagation at 2.5 cm s -1 .

Physics↗
DOE OSTI2021

Smart Inverter Twin Model for Anomaly Detection

Smart inverters connected to a communication network are vulnerable to various anomalies in the form of cyberattacks. In this paper, a self-security approach is implemented using the digital twin concept for smart inverters. The digital twin is formed using the inverter’s dynamic model. Then, the incoming setpoints are autonomously examined using the digital twin, and only the safe setpoints are engaged to the inverter’s local controller. This paper demonstrates the details of the self-security algorithm and how the inverter’s digital twin is formed. In particular, the stable and unstable operation region is experimentally verified by changing the power setpoints engaged to the local controller, using a laboratory setup including a three-phase 1.5-kVA SiC-MOSFET inverter and a 12-kW NHR 9410 regenerative power grid emulator. The results demonstrate that the digital twin model can potentially protect inverters from abnormal operation by examining the incoming commands (new setpoints) using the inverter’s digital twin before engaging the setpoints to the local controller.

Hossen, Tareq↗
DOE OSTI2021

Digital Twin for Self-Security of Smart Inverters

Smart inverters connected to a communication network are susceptible to man-in-the-middle attacks. In this paper, a self-security approach is implemented using the digital twin concept for smart inverters. The digital twin is formed using the inverter’s normal operating region and the inverter’s dynamic model. Then, the incoming setpoints are autonomously examined using the digital twin, and only the safe setpoints are engaged to the inverter’s local controller. This paper demonstrates how the inverter’s normal operating region and dynamic model are formed. In particular, the normal operation region is experimentally verified by changing the P and Q setpoints engaged to the local controller, using a laboratory setup including a three-phase 3-kVA SiC-MOSFET inverter and a 12-kW NHR 9410 regenerative power grid emulator. The results demonstrate that the self-security technique can potentially protect inverters from man-in-the-middle attacks by examining the incoming commands (new setpoints) using the inverter’s digital twin before engaging the setpoints to the local controller.

Hossen, Tareq↗
DOE OSTI2022

Hybrid Data-Driven Physics-Based Model Framework Implementation: Towards a Secure Cyber-Physical Operation of the Smart Grid

False data injection cyber-attack detection models on smart grid operation have been much explored recently, considering analytical physics-based and data-driven solutions. Recently, a hybrid data-driven physics-based model framework for monitoring the smart grid is developed. However, the framework has not been implemented in real-time environment yet. In this paper, the framework of the hybrid model is developed within a real-time simulation environment. OPAL-RT real-time simulator is used to enable Hardware-in-the-Loop testing of the framework. IEEE 9-bus system is considered as a testing grid for gaining insight. The process of building the framework and the challenges faced during development are presented. The performance of the framework is investigated under various false data injection attacks.

false data injection attack, machine learning, sta↗
DOE OSTI2025

Securing Smart Manufacturing: Detection of Cyber-Physical Attacks in CNC-Based Systems

As Industry 4.0 advances, the integration of computer numerical control (CNC) machines and advanced manufacturing technologies is transforming production into smart manufacturing systems that blend physical and digital processes as cyber-physical systems. However, this increased cyber-physical connectivity exposes manufacturing systems to cyber threats that can cause severe operational and financial disruptions. This paper presents a comparative study on cyber attacks and anomaly detection techniques in manufacturing, focusing on network traffic from CNC machines. The data extracted from network packets includes machine commands and control signals exchanged between the machine's interface and control system, crucial for maintaining operational integrity. We explore two types of cyber attacks, design modification and command injection, which pose substantial risks to CNC machine productivity and system integrity. Our investigation involves experiments on a real CNC system, highlighting the urgent need for effective detection mechanisms. To address these threats, we evaluate three anomaly detection methods: dynamic time warping (DTW), rolling average, and a deep learning, long short-term memory (LSTM) time-series-based autoencoder. Each is assessed for its effectiveness in identifying anomalous behaviors caused by the attacks. Our findings demonstrate the unique strengths and limitations of each detection technique, providing a deeper understanding of their applicability in realworld manufacturing environments. The comparative analysis indicates that while certain methods are highly effective against specific attack types, others offer broader applicability across different attacks. This study contributes to the accurate detection of anomalies in CNC machining processes, thereby enhancing the reliability and security of smart manufacturing systems against diverse cyber threats.

Williams, Bethanie [Tennessee Technological Univer↗
DOE OSTI2026

Rolling Root Mean Square Based Multimodal Anomaly Detection for Real Time Monitoring of Smart Grid

Reliable real-time monitoring is valuable for maintaining the operational integrity of modern electrical smart grids. Deployment of heterogeneous sensing technologies in substations has enabled high-resolution, multichannel waveform monitoring, but also introduces challenges for anomaly detection due to noise, baseline drift, and modality-dependent signal characteristics. In this work, we present a computationally efficient unsupervised method for multimodal event detection based on Rolling Root Mean Square based Event Detection (RRMSED). The method is developed using in-house, field deployed sensors collecting data at a utility substation. The sensing system comprises voltage and current sensors, triaxial accelerometers, and magnetometers, collectively capturing electrical, vibrational, and magnetic waveform measurements at high temporal resolution. RRMSED operates by extracting rolling RMS energy features and their first-order temporal differences from consecutive waveform segments for each channel and then applying channel-specific statistical thresholds learned from historical data. A persistence-based exceedance logic is employed to robustly identify transient events while suppressing impulsive noise, and to provide precise temporal localization with high resolution. The framework is designed for continuous server-side operation and can be deployed in real time without requiring complex models. Experiments on simulated waveform data with known ground truth demonstrate low false positive (FP) and false negative (FN) rates. Application to real substation data shows RRMSED to identify events that are not captured by conventional monitoring indicators including fast transient detection algorithm currently deployed in the system. These results indicate that rolling RMS based features provide an effective and practical basis for real-time multimodal event detection in smart-grid substations.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗