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At least 433 records · Page 24

White Paper: Scalable Digital Twin Capabilities for Aging and Surveillance of Engineered Systems

This white paper presents a multi-year initiative to develop practical, secure, and scalable digital twin capabilities for engineered systems in aging and surveillance contexts—an approach pioneered at the National Nuclear Security Administration (NNSA) Lawrence Livermore National Laboratory (LLNL) that maps directly onto the needs and ambitions of the Navy for ship- and fleet-level digital twins. LLNL’s work in building part- and process-level digital twins for advanced manufacturing, with a vision to scale up to entire factory floors and, ultimately, enterprise-wide digital twins, offers an adaptable pathway for the Navy as it seeks to modernize lifecycle management, readiness, and predictive maintenance across ships and fleets. For our application, we integrate physics-based modeling with automated data ingestion, processing, and AI-driven calibration, creating hybrid models that are both interpretable and data responsive. We modernized legacy workflows, established centralized data infrastructure, automated experimental pipelines, and demonstrated end-to-end coupling of accelerated aging data with finite element simulations via optimization and surrogate modeling. The result is a generalizable framework that supports part-level digital twins today and lays the groundwork for future system-level twins suitable for Navy applications.

36 MATERIALS SCIENCE↗

Emerging Technologies for Improved Plug Load Management Systems: Learning Behavior Algorithms and Automatic and Dynamic Load Detection

Plug loads are responsible for a significant portion of the energy consumed in commercial buildings, yet their distributed and ever-changing nature makes them one of the most challenging building end uses to manage. Plug load management systems exist today that utilize smart plugs to meter and control devices at the outlet level, however, their uptake has been relatively slow in part due to the significant labor required for installation and maintenance. Learning behavior algorithms and automatic and dynamic load detection have been identified as two technology areas that could accelerate the adoption of plug load management systems by reducing these labor demands and providing additional energy efficiency and non-energy benefits. Learning behavior algorithms learn occupant behavior and adjust plug load management systems accordingly, allowing for the automatic creation of optimized control schedules. Automatic and dynamic load detection allows a plug load management system to identify devices as they are plugged in to a building and keeps the system up to date as devices are moved throughout a building. In this paper, we present our findings with respect to the current state of these two technologies based on a review of existing research and patents, as well as a series of interviews with companies working in the plug load space. We have found that, as of now, no commercialized solutions exist for these plug load technologies and that more work is needed to bring them to market. In addition, we summarize our findings related to the technology challenges, market barriers, drivers, and opportunities for these technologies moving forward.

30 DIRECT ENERGY CONVERSION↗

CELCAP: A Computer Model for Cogeneration System Analysis

A description of the CELCAP cogeneration analysis program is presented. A detailed description of the methodology used by the Naval Civil Engineering Laboratory in developing the CELCAP code and the procedures for analyzing cogeneration systems for a given user are given. The four engines modeled in CELCAP are: gas turbine with exhaust heat boiler, diesel engine with waste heat boiler, single automatic-extraction steam turbine, and back-pressure steam turbine. Both the design point and part-load performances are taken into account in the engine models. The load model describes how the hourly electric and steam demand of the user is represented by 24 hourly profiles. The economic model describes how the annual and life-cycle operating costs that include the costs of fuel, purchased electricity, and operation and maintenance of engines and boilers are calculated. The CELCAP code structure and principal functions of the code are described to how the various components of the code are related to each other. Three examples of the application of the CELCAP code are given to illustrate the versatility of the code. The examples shown represent cases of system selection, system modification, and system optimization.

Source record↗

Optimizing Selection Pressures and Pest Management to Maximize Cultivation Yield (OSPREY) (Final Technical Report)

This project was proposed in response to AOI 1, Cultivation Intensification Processes for Algae, within the FY19 Bioenergy Technologies Office Multi-Topic Funding Opportunity Announcement (FOA Number: DE-FOA-0002029). The work was designed to address a critical industry need to improve annualized productivity, stability, and quality of algal production strains for biofuels and bioproducts. The overall project goals were to generate process innovations rooted in established outdoor systems for strain selection, improvement, maintenance, and cultivation as well as pest detection and tracking. Planned advances included a 50% improvement in harvest yield based on AFDW (g m 2 d -1 ), 50% improvement in robustness based on stability metrics (e.g., high-productivity cultivation days, pond uptime), and 20% improvement in conversion yield. Individually, each of our planned process improvements (e.g., pest tracking) had the potential to increase productivity. However, to realize increases in yield at the system level, improvements to one unit’s process must be balanced against potential effects on other processes. For example, changes to strains, cultivation, and pest management developed in isolation may hurt other unit operations. Therefore, a critical success factor of the project was the integration of the pipeline components, achieved through iterative field-to- (short term) lab testing. In addition, through sustainability models, we evaluated how improvements would alter industry scenarios.

09 BIOMASS FUELS↗

Automatic Calibration and Health Monitoring of Infrastructure Sensors

Smart transportation infrastructure relies on networks of heterogeneous sensors - cameras, radars, and lidars - continuously monitoring traffic conditions. However, executing the initial spatial calibration of multiple sensors and the subsequent health monitoring presents significant operational challenges. Environmental factors, mechanical vibrations, and gradual drift cause spatial misalignment, degrading fusion performance and tracking accuracy. Traditional calibration approaches require manual intervention with specialized targets or survey equipment, resulting in service interruptions and high maintenance costs. This work presents an automated framework for initial calibration and continuous health monitoring without human intervention or service disruption. Our approach addresses two critical problems: (1) detecting when sensors become miscalibrated during operation, and (2) automatically re-establishing spatial alignment using only operational traffic data. The health monitoring component analyzes measurement innovations - differences between sensor observations and predicted object states - to detect systematic biases indicative of calibration drift. By computing bias magnitude, directional consistency, and rejection rates, the system identifies miscalibrations as small as 0.5 meters. Unlike traditional methods requiring known calibration targets, our diagnostic operates continuously on live traffic observations, enabling early detection before fusion quality degrades. The automatic recalibration algorithm leverages overlapping sensor fields-of-view and temporal correlation of vehicle observations. Using graph-based optimization, the system automatically discovers which sensor pairs observe common regions, estimates pairwise spatial transformations using RANSAC-based robust estimation, and jointly optimizes all sensor poses through bundle adjustment. The framework handles practical deployment challenges, including different sensor sampling rates (1-10 Hz), varying installation positions, unknown orientations, and limited overlap regions (>10%). When approximate sensor positions are available from installation surveys (+/-1m accuracy), the algorithm additionally estimates sensor orientations, refining both position and rotation to sub-meter and sub-degree accuracy. We validate the framework on multi-hour traffic datasets from six heterogeneous sensors with sampling rates ranging from 1 Hz to 10 Hz. Results demonstrate successful calibration even with sparse overlap (<20%) and automatic detection of miscalibrations exceeding 0.8 meters. This work enables a "deploy-and-forget" sensor infrastructure that maintains calibration autonomously, reducing maintenance costs while improving tracking accuracy. The techniques generalize beyond transportation to any multi-sensor monitoring application requiring robust spatial alignment, including smart cities, industrial monitoring, and surveillance systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Outlook towards deployable continual learning for particle accelerators

Particle accelerators are high power complex machines. To ensure uninterrupted operation of these machines, thousands of pieces of equipment need to be synchronized, which requires addressing many challenges including design, optimization and control, anomaly detection and machine protection. With recent advancements, machine learning (ML) holds promise to assist in more advance prognostics, optimization, and control. While ML based solutions have been developed for several applications in particle accelerators, only few have reached deployment and even fewer to long term usage, due to particle accelerator data distribution drifts caused by changes in both measurable and non-measurable parameters. In this paper, we identify some of the key areas within particle accelerators where continual learning can allow maintenance of ML model performance with distribution drifts. Particularly, we first discuss existing applications of ML in particle accelerators, and their limitations due to distribution drift. Next, we review existing continual learning techniques and investigate their potential applications to address data distribution drifts in accelerators. By identifying the opportunities and challenges in applying continual learning, this paper seeks to open up the new field and inspire more research efforts towards deployable continual learning for particle accelerators.

43 PARTICLE ACCELERATORS↗

A Self-Sustained CPS Design for Reliable Wildfire Monitoring

Continuous monitoring of areas nearby the electric grid is critical for preventing and early detection of devastating wildfires. Existing wildfire monitoring systems are intermittent and oblivious to local ambient risk factors, resulting in poor wildfire awareness. Ambient sensor suites deployed near the gridlines can increase the monitoring granularity and detection accuracy. However, these sensors must address two challenging and competing objectives at the same time. First, they must remain powered for years without manual maintenance due to their remote locations. Second, they must provide and transmit reliable information if and when a wildfire starts. The first objective requires aggressive energy savings and ambient energy harvesting, while the second requires continuous operation of a range of sensors. To the best of our knowledge, this paper presents the first self-sustained cyber-physical system that dynamically co-optimizes the wildfire detection accuracy and active time of sensors. The proposed approach employs reinforcement learning to train a policy that controls the sensor operations as a function of the environment (i.e., current sensor readings), harvested energy, and battery level. Here, the proposed cyber-physical system is evaluated extensively using real-life temperature, wind, and solar energy harvesting datasets and an open-source wildfire simulator. In long-term (5 years) evaluations, the proposed framework achieves 89% uptime, which is 46% higher than a carefully tuned heuristic approach. At the same time, it averages a 2-minute initial response time, which is at least 2.5× faster than the same heuristic approach. Furthermore, the policy network consumes 0.6 mJ per day on the TI CC2652R microcontroller using TensorFlow Lite for Micro, which is negligible compared to the daily sensor suite energy consumption.

54 ENVIRONMENTAL SCIENCES↗

Influence of cellular redox reactions on the structure and function of light harvesting and photosystems

Photosynthesis enables the conversion of one of the most abundant and free forms of energy, sunlight, into chemical bonds through the utilization of highly tailored protein complexes. These enzymes work in unison to absorb, convert, and transform light into high-energy electrons which are used for various functions important to metabolism and cellular protection. Over the last ∼50 years, photosynthetic organisms, such as cyanobacteria, have been adapted and engineered to produce valuable compounds like hydrogen and ethylene, among others. Often this is performed by removing native and/or adding in exogenous energy utilization pathways so that light energy is re-directed towards the synthesis of desired compounds. However, the interplay between primary light capture, conversion reactions, and the downstream electron utilization sinks is not fully understood. Further complicating these strategies are the plethora of compensatory mechanisms that facilitate steady electron flow and the maintenance of photosynthesis under dynamic conditions. This manifests as structural and functional plasticity of the photosynthetic machinery, often seen in modulations of oligomeric compositions or changes in protein-protein interactions and coupling with redox enzymes. Understanding these mechanisms is crucial to biotechnology applications because re-engineering electron utilization sinks has profoundly different effects on the light capture and conversion reactions of photosynthesis. Optimization requires a molecular-level understanding of the functional interrelationships between electron sinks and photosynthetic components that influence photosynthetic efficiencies to realize potential improvements in product yields. Here, we aim to highlight how perturbation of reductive reactions is revealing the functional plasticity in key components of the photosynthetic energy transduction pathway.

59 BASIC BIOLOGICAL SCIENCES↗

Lunar lander conceptual design

This paper is a first look at the problems of building a lunar lander to support a small lunar surface base. A series of trade studies was performed to define the lander. The initial trades concerned choosing number of stages, payload mass, parking orbit altitude, and propellant type. Other important trades and issues included plane change capability, propellant loading and maintenance location, and reusability considerations. Given a rough baseline, the systems were then reviewed. A conceptual design was then produced. The process was carried through only one iteration. Many more iterations are needed. A transportation system using reusable, aerobraked orbital transfer vehicles (OTV's) is assumed. These OTV's are assumed to be based and maintained at a low Earth orbit (LEO) space station, optimized for transportation functions. Single- and two-stage OTV stacks are considered. The OTV's make the translunar injection (TLI), lunar orbit insertion (LOI), and trans-Earth injection (TEI) burns, as well as midcourse and perigee raise maneuvers.

Stecklein, J. M.↗

Computational Infrastructure for Engine Structural Performance Simulation

Select computer codes developed over the years to simulate specific aspects of engine structures are described. These codes include blade impact integrated multidisciplinary analysis and optimization, progressive structural fracture, quantification of uncertainties for structural reliability and risk, benefits estimation of new technology insertion and hierarchical simulation of engine structures made from metal matrix and ceramic matrix composites. Collectively these codes constitute a unique infrastructure readiness to credibly evaluate new and future engine structural concepts throughout the development cycle from initial concept, to design and fabrication, to service performance and maintenance and repairs, and to retirement for cause and even to possible recycling. Stated differently, they provide 'virtual' concurrent engineering for engine structures total-life-cycle-cost.

Chamis, Christos C.↗

Three-Dimensional Venturi Sensor for Measuring Extreme Winds

A three-dimensional (3D) Venturi sensor is being developed as a compact, rugged means of measuring wind vectors having magnitudes of as much as 300 mph (134 m/s). This sensor also incorporates auxiliary sensors for measuring temperature from -40 to +120 F (-40 to +49 C), relative humidity from 0 to 100 percent, and atmospheric pressure from 846 to 1,084 millibar (85 to 108 kPa). Conventional cup-and-vane anemometers are highly susceptible to damage by both high wind forces and debris, due to their moving parts and large profiles. In addition, they exhibit slow recovery times contributing to an inaccurately high average-speed reading. Ultrasonic and hot-wire anemometers overcome some of the disadvantages of the cup and-vane anemometers, but they have other disadvantageous features, including limited dynamic range and susceptibility to errors caused by external acoustic noise and rain. In contrast, the novel 3D Venturi sensor is less vulnerable to wind damage because of its smaller profile and ruggedness. Since the sensor has no moving parts, it provides increased reliability and lower maintenance costs. It has faster response and recovery times to changing wind conditions than traditional systems. In addition, it offers wide dynamic range and is expected to be relatively insensitive to rain and acoustic energy. The Venturi effect in this sensor is achieved by the mirrored double-inflection curve, which is then rotated 360 to create the desired detection surfaces. The curve is optimized to provide a good balance of pressure difference between sensor ports and overall maximum fluid velocity while in the shape. Four posts are used to separate the two shapes, and their size and location were chosen to minimize effects on the pressure measurements. The 3D Venturi sensor has smart software algorithms to map the wind pressure exerted on the surfaces of the design. Using Bernoulli's equation, the speed of the wind is calculated from the differences among the pressure readings at the various ports. The direction of the wind is calculated from the spatial distribution and magnitude of the pressure readings. All of the pressure port sizes and locations have been optimized to minimize measurement errors and to reside in areas demonstrating a stable pressure reading proportional to the velocity range.

Zysko, Jan A.↗

Evaluation of Hands-Free Devices for the Display of Maintenance Procedures

Over the past year, NASA's focus has turned to crewed long duration and exploration missions. On these journeys, crewmembers will be required to execute thousands of procedures to maintain life support systems, check out space suits, conduct science experiments, and perform medical exams. To support the many complex tasks crewmembers undertake in microgravity, NASA is interested in providing crewmembers a hands-free work environment to promote more efficient operations. The overarching objective is to allow crewmembers to use both of their hands for tasks related to their mission, versus holding a paper manual or interacting with a display. The use of advanced, hands-free tools will undoubtedly make the crewmembers task easier, but they can also add to overall task complexity if not properly designed. A leading candidate technology for supporting a hands-free environment is the Head-Mounted Display (HMD). A more recent technology (e-book reader) that could be easily temp-stowed near the work area is also a potential hands-free solution. Previous work at NASA involved the evaluation of several commercially available HMDs for visual quality, comfort, and fit, as well as suitability for use in microgravity. Based on results from this work, three HMDs were selected for further evaluation (along with an e-book reader), using International Space Station (ISS)-like maintenance procedures. Two evaluations were conducted in the Space Station Mockup and Trainer Facility (SSMTF) located at the NASA Johnson Space Center (building 9). The SSMTF is a full scale, medium fidelity replica of the pressurized portions of the ISS. It supports crew training such as ingress and egress, habitability, and emergency procedures. In each of the two evaluations, the participants performed two maintenance procedures. One maintenance procedure involved inspecting air filters in a life support system and replacing them with a clean filter if one were found to be contaminated. The second maintenance procedure focused on working in a confined space; specifically, pulling down a rack to inspect wiring configurations, and rewiring in a different pattern. The maintenance procedures were selected to assess mobility, tool use, and access to multiple document sources during task performance. That is, the participant had to move from rack to rack, use a wrench, a camera, etc., replace components, and refer to diagrams to complete tasks. A constraint was imposed that the ISS-like format of the procedures was to be retained, and not modified or optimized for the electronic device ("plug and play" approach). This was based on future plans to test with real procedures on ISS.

Ronald B Hoffman↗

Comprehensive Land Use and Environmental Stewardship

Comprehensive Land Use and Environmental Stewardship (CLUES) Report serves as a summary document of the land use and environmental stewardship activities occurring on the Idaho National Laboratory (INL) Site (Desert) and the Research and Education Campus (REC) within Idaho Falls. Land and facility use planning and decisions at the INL Site are guided by a comprehensive planning process in accordance with the United States (U.S.) Department of Energy (DOE) Order 430.1C, “Real Property Asset Management,” which states "Establish a data-driven, risk-informed, performance-based approach to the life-cycle management of real property assets that aligns the real property portfolio with DOE mission needs; acquire, manage, positively account for, and dispose of real property assets in a safe, secure, cost-effective, and sustainable manner; and ensure the real property portfolio is appropriately sized, aligned, and in the proper condition to support efficient mission execution." Land use planning, like Campus Master Planning and 5-Year Facility Planning, provides a means for better, more sustainable use of the INL Site in a coordinated effort to ensure current and future mission needs are met, including acquisition, recapitalization, maintenance, disposition, real property utilization and long-term stewardship. This document and all functions of INL are guided by the DOE Vision for INL and the INL Mission and builds on the baseline established in the FY 2015 CLUES Report. However, it delivers a revised structure with focus on new resource management zones, which provide organization of key management considerations and access restrictions to optimize land use and environmental stewardship. A new set of thematic Guiding Principles presented in this report provide the intent and sustainable management direction to protect the INL Site natural environment. They demonstrate that the mission and vision of DOE and INL can be realized with inclusion of first of a kind technology, private sector development, and globally recognized testing and demonstration. This CLUES Report encourages comprehensive management decision-making with additional resource discussions for sustainability, the built environment, and the ecological landscape at the INL Site. Enhanced resource considerations and trends emphasize the importance of air, land use, environmental, subsurface, and cultural resources. The INL Site supports exceptional and interdependent resources. A diversity of bat species are accommodated by culturally significant caves distributed around the Site. Big game species like elk, deer, and moose seek vegetation communities which are protected by long-term stewardship and monitoring programs.

99 GENERAL AND MISCELLANEOUS↗

Additive Manufacturing of Heat Pipes for Microreactor Applications

Heat pipes are highly effective devices used to passively transport heat by two-phase capillary action. Their small footprint, light weight and lack of moving parts make them ideal for transportable nuclear microreactors, where size and weight are limited, minimal to no operation and maintenance are required, and high reliability is desired. The use of additive manufacturing allows for the fabrication of heat pipes with performance enhancements, such as microchannels, grooves, arteries, or tailored porosity, which are difficult, expensive or impossible to achieve with traditional fabrication techniques. We are evaluating the capabilities of the Admaflex 130 Digital Light Printer to produce these geometries by characterizing feature shrinkage, developing an optimal heat treatment recipe, assessing the effects of heat treatment atmosphere and varying print orientation. Computational simulations are being used to estimate performance of the various 3D printed configurations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Industry Level Integrated Fire Modeling Using Fire Risk Investigation in 3D (FRI3D)

The software Fire Risk Investigation in 3D (FRI3D) has been developed over the last 2 years to integrate 3D spatial modeling with existing fire probabilistic risk assessment (PRA) models and fire simulation codes. The goal of this research and development is to automate many of the fire analysis manual tasks to reduce industry efforts in the initial fire modeling and operational costs for the model maintenance and evaluations required during normal plant operations. The tasks for Fiscal Year (FY) 2021 include first testing the FRI3D modeling capabilities by importing an industry fire model into FRI3D and making a 3D model of a complex/high-risk significant area. (For this work, the switchgear room was chosen.) Then, the second task of FY 2021 is to develop a dynamic fire PRA process that can help optimize traditional fire PRA models. The switchgear room model will be used for the dynamic fire PRA work. This report describes the work and insights learned when using FRI3D software to model both a Nuclear Regulatory Report (NUREG) example models and a full industry switchgear room.

97 MATHEMATICS AND COMPUTING↗

MACOS Version 3.31

Version 3.31 of Modeling and Analysis for Controlled Optical Systems (MACOS) has been released. MACOS is an easy-to-use computer program for modeling and analyzing the behaviors of a variety of optical systems, including systems that have large, segmented apertures and are aligned with the technology of wavefront sensing and control. Two previous versions were described in "Improved Software for Modeling Controlled Optical Systems" (NPO-19841) NASA Tech Briefs, Vol. 21, No. 12 (December 1997), page 42 and "Optics Program Modified for Multithreaded Parallel Computing" (NPO-40572) NASA Tech Briefs, Vol. 30, No. 1 (January 2006) page 13a. The present version incorporates the following enhancements over prior versions: a) A powerful system-optimization facility includes algorithms for linear, nonlinear, unconstrained, and constrained optimization of optical systems under a variety of settings. b) There is now enhanced capability to perturb optical components individually and on subsystem levels, and to optimize system performance by adjusting selected individual components as well as subsystems. c) Capabilities for modeling a variety of new optical aperture types have been added. d) Effects of multilayer thin-film coats on optical surfaces can now be taken into account when tracing polarized rays. e) Major software-engineering work was performed to make MACOS more reliable, flexible, and manageable for purposes of maintenance and further development.

Redding, David↗

Build-to-Replace Strategy to Reduce Operations and Maintenance Costs for Advanced Reactors

This paper targets the reduction of fixed operations and maintenance (O&M) costs for advanced reactor (AR) designs. This goal will be severely constrained if the underlying assumptions of O&M approaches and practices are not questioned and reexamined, especially today when changes can be implemented effectively and efficiently. Achieving a reduction in AR O&M costs requires a completely new way of thinking -a paradigm shift- not through incremental, technology-focused approaches alone. Here, we address this challenge by evaluating the impact of moving to a shorter design life for major structures, systems, and components and shorter, more predictable refurbishment cycles as modeled by the commercial airline industry: the build-to-replace approach. This paper provides a brief overview of this different mindset to O&M applied to ARs and it provided a set of analytical tools based on multi-objective optimization to identify the benefits of such an approach. In conclusion, we provide a direct example analysis of a build-to-replace scenario by identifying and evaluating scenarios for reduced system and component lifetimes and associated replacement and refurbishment schedules to evaluate impacts on O&M costs and other lifecycle elements, such as structure, system, and component reliability.

97 - MATHEMATICS AND COMPUTING↗

Grid-Tied Photovoltaic Power System

A grid-tied photovoltaic (PV) power system is connected directly to the utility distribution grid. Facility power can be obtained from the utility system as normal. The PV system is synchronized with the utility system to provide power for the facility, and excess power is provided to the utility. Operating costs of a PV power system are low compared to conventional power technologies. This method can displace the highest-cost electricity during times of peak demand in most climatic regions, and thus reduce grid loading. Net metering is often used, in which independent power producers such as PV power systems are connected to the utility grid via the customers main service panels and meters. When the PV power system is generating more power than required at that location, the excess power is provided to the utility grid. The customer pays the net of the power purchased when the on-site power demand is greater than the onsite power production, and the excess power is returned to the utility grid. Power generated by the PV system reduces utility demand, and the surplus power aids the community. Modern PV panels are readily available, reliable, efficient, and economical, with a life expectancy of at least 25 years. Modern electronics have been the enabling technology behind grid-tied power systems, making them safe, reliable, efficient, and economical with a life expectancy equal to the modern PV panels. The grid-tied PV power system was successfully designed and developed, and this served to validate the basic principles developed, and the theoretical work that was performed. Grid-tied PV power systems are reliable, maintenance- free, long-life power systems, and are of significant value to NASA and the community. Of particular value are the analytical tools and capabilities that have been successfully developed. Performance predictions can be made confidently for grid-tied PV systems of various scales. The work was done under the NASA Hybrid Power Management (HPM) Program, which is the integration of diverse power devices in an optimal configuration for space and terrestrial applications.

Eichenberg, Dennis J.↗