Wide Range Counting System Digital Upgrade at the High Flux Isotope Reactor
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digital controls↗
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Architectural Improvements and New Processing Tools for the Open XAL Online Model
The online model is the component of Open XAL providing accelerator modeling, simulation, and dynamic synchronization to live hardware. Significant architectural changes and feature additions have been recently made in two separate areas: 1) the managing and processing of simulation data, and 2) the modeling of RF cavities. Simulation data and data processing have been completely decoupled. A single class manages all simulation data while standard tools were developed for processing the simulation results. RF accelerating cavities are now modeled as composite structures where parameter and dynamics computations are distributed. The beam and hardware models both maintain their relative phase information, which allows for dynamic phase slip and elapsed time computation.
Accelerator Control↗
Walnut v1.2 Code Abstract
Abstract for publication for copyright assertion for Walnut v1.2 software code to satisfy prime contract requirements. HQ approval to assert copyright on this code was granted to NNSS on 9/30/2024
47 OTHER INSTRUMENTATION↗
Comprehensive Automated Welder System
The Comprehensive Automated Welder System - PDRD SR-17-007 project was initiated to develop hardware and software to eliminate possible error pre-cursor functions of the pinch welding process that require manual manipulation and data entry as well as leveraging 21st century technology advances by replacing obsolete hardware with state of the art maintainable equipment. The project plan targeted three primary areas for improvement: 1. Replacing the existing welding power supply system with a solid-state power supply, 2. Improving the data acquisition system, sensors and controls, and 3. Updating the software to a FPGA “real-time” program with automated steps. SRNL purchased, designed and installed in 723-A, a system to meet the requirements for these areas. While improvements in hardware controls and sensor selection were achieved and a successful software automation routine was demonstrated, the performance goals were not met with the custom solid-state power transformer.
42 ENGINEERING↗
Lighting System Control Data to Improve Design and Operation: Tunable Lighting System Data from NICU Patient Rooms
The advancement of LED and controls technology, computing capacity, and software provides new opportunities for researchers and designers to work together to further optimize spaces for occupant benefit. Here, lighting system control data from five neonatal intensive care unit patient rooms was collected over a 25-week monitoring period and analyzed to better understand occupant response to a tunable lighting system with automatic transitions throughout the day. Lighting systems are very rarely refined after installation based on actual use. Objective data detailing how the lighting system is used by the actual occupants highlights the opportunities for optimization after installation and provides insight for improving the next design. As use of the data becomes more commonplace, it can be leveraged for design recommendations. The collection of the data required no additional cost beyond the time for examining the data. The analysis revealed several clear opportunities for improvement, including adjustments to the default control setting at night, re-labeling of the control stations, and adjustments to the nighttime fade rate. The patient room occupants were active users of the different zones, dimming options, and manual overrides made available by the lighting system.
60 APPLIED LIFE SCIENCES↗
Cascaded Control for Building HVAC Systems in Practice
Actuator hunting is a widespread and often neglected problem in the HVAC field. Hunting is typically characterized by sustained or intermittent oscillations, and can result in decreased efficiency, increased actuator wear, and poor setpoint tracking. Cascaded control loops have been shown to effectively linearize system dynamics and reduce the prevalence of hunting. This paper details the implementation of cascaded control architectures for Air Handling Unit chilled water valves at three university campus buildings. A framework for implementation the control in existing Building Automation software is developed that requires only a single line of additional code. Results gathered for more than a year show that cascaded control not only eliminates hunting in control loops with documented hunting issues, but provides better tracking and more consistent performance during all seasons. A discussion of efficiency losses due to hunting behavior is presented and illustrated with comparative data. Furthermore, an analysis of cost savings from implementing cascaded chilled water valve control is presented. Field tests show 2.2–4.4% energy savings, with additional potential savings from reduced operational costs (i.e., maintenance and controller retuning).
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
An Update on Microreactor Automated Control System (MACS)
Automation of control systems is expected to be important in the economic and safe operation of microreactors. 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 microreactor automated control system (MACS) testbed developed to test control system automation. While a future goal is to demonstrate this system using a prototypic microreactor such as MARVEL, the present focus is on developing and testing within a non-nuclear testbed. The testbed, developed in collaboration with Idaho National Laboratory, includes hardware-in-the-loop simulation and uses a Modelica-based model of a prototypic microreactor for use in testing control automation. Research to date at Oak Ridge National Laboratory has focused on the development of prototypic software for automating plant-level control under selected scenarios. Empirical testing on the integrated MACS testbed was performed to quantify key characteristics of the integrated testbed and to demonstrate the use of the software for automating the calculation and use of actuation setpoints for selected load-following scenarios. 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↗
Abrasive Waterjet Machining
The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.
36 MATERIALS SCIENCE↗
Wire Scanner Beam Profile Measurements for the LANSCE Facility
The Los Alamos Neutron Science Center (LANSCE) is replacing beam profile measurement systems, commonly known as Wire Scanners (WS). Using the principal of secondary electron emission, the WS measurement system moves a wire or fiber across an impinging particle beam, sampling a projected transverse-beam distribution. Because existing WS actuators and electronic components are either no longer manufactured or home-built with antiquated parts, a new WS beam profile measurement is being designed, fabricated, and tested. The goals for these new WS's include using off-the-shelf components while eliminating antiquated components, providing quick operation while allowing for easy maintainability, and tolerating external radioactivation. The WS measurement system consists of beam line actuators, a cable plant, an electronics processor chassis, and software located both in the electronics chassis (National Instruments LabVIEW) and in the Central Control Room (EPICS-based client software). This WS measurement system will measure Hand H{sup +} LANSCE-facility beams and will also measure less common beams. This paper describes these WS measurement systems.
43 PARTICLE ACCELERATORS↗
Database Performance Monitoring for the Photovoltaic Systems
The Database Performance Monitoring (DPM) software (copyright in processes) is being developed at Sandia National Laboratories to perform quality control analysis on time series data. The software loads time indexed databases (currently csv format), performs a series of quality control tests defined by the user, and creates reports which include summary statistics, tables, and graphics. DPM can be setup to run on an automated schedule defined by the user. For example, the software can be run once per day to analyze data collected on the previous day. HTML formatted reports can be sent via email or hosted on a website. To compare performance of several databases, summary statistics and graphics can be gathered in a dashboard view which links to detailed reporting information for each database. The software can be customized for specific applications.
97 MATHEMATICS AND COMPUTING↗
Master-Slave Control Scheme in Electric Vehicle Smart Charging Infrastructure
WINSmartEV is a software based plug-in electric vehicle (PEV) monitoring, control, and management system. It not only incorporates intelligence at every level so that charge scheduling can avoid grid bottlenecks, but it also multiplies the number of PEVs that can be plugged into a single circuit. This paper proposes, designs, and executes many upgrades to WINSmartEV. These upgrades include new hardware that makes the level 1 and level 2 chargers faster, more robust, and more scalable. It includes algorithms that provide a more optimal charge scheduling for the level 2 (EVSE) and an enhanced vehicle monitoring/identification module (VMM) system that can automatically identify PEVs and authorize charging.
42 ENGINEERING↗
Advanced Control Architecture and Sensor Information Development for Process Automation, Optimization, and Imaging of Chemical Looping Systems
The Syngas Chemical Looping (SCL) process developed at The Ohio State University (OSU) uses an iron-based oxygen carrier to convert syngas into high-purity hydrogen while simultaneously capturing carbon dioxide that is readily sequestrable. A 25 kWth sub-pilot unit was successfully demonstrated multiple times on the OSU Clean Coal Research Facility, and a 250 kWth – 3 MWth pilot demonstration unit has been designed and constructed at the National Carbon Capture Center (NCCC) in Wilsonville, Alabama. The focus of this project is to develop multiple technologies to automate the startup and shutdown of chemical looping system. Success of this project will propel the advanced carbon capture method toward commercialization, hence be disruptive to the fossil fuel and power industries. Advanced process automation control architecture and imaging and optimization sensor software were developed for OSU chemical looping process. A high-level controller (HLC) consisting of decision-making and controller-selection logic integrated with sliding mode controllers (SMCs) were developed to perform chemical looping process startup and shutdown. Babcock & Wilcox Power Generation Group’s FocalPoint Optimization System was implemented to optimize the process operating conditions. The process automation controller and optimization information were realized and tested on OSU’s existing sub-pilot chemical looping test unit under atmospheric condition. The implemented control architecture was able to perform the complete process procedure from startup, steady-state reaction operation to shutdown with minimal operator intervention. The controller was also implemented on the pressurized syngas chemical looping (SCL) pilot test unit constructed at the National Carbon Capture Center (NCCC), demonstrating its pressure control capability with a designed transient state trajectory. An electrical capacitance volume tomography (ECVT) sensor device and its software were developed to image the packed moving bed and slugging fluidized bed of oxygen carriers in chemical looping systems at elevated temperatures. The ECVT device constructed was capable of tracking the subtle voidage variance along the moving bed axis as a feature for directly measuring the oxygen carrier particles’ linear velocity. Also, the high temperature ECVT device was used to study the fluidization characteristics of Geldart Group D particles.
08 HYDROGEN↗
An Erlang-Based Front End Framework for Accelerator Controls
We have developed a new front-end framework for the ACNET control system in Erlang. Erlang is a functional programming language developed for real-time telecommunications applications. The primary task of the front-end software is to connect the control system with drivers collecting data from individual field bus devices. Erlang's concurrency and message passing support have proven well-suited for managing large numbers of independent ACNET client requests for front-end data. Other Erlang features which make it particularly well-suited for a front-end framework include fault-tolerance with process monitoring and restarting, real-time response,and the ability to change code in running systems. Erlang's interactive shell and dynamic typing make writing and running unit tests an easy part of the development process. Erlang includes mechanisms for distributing applications which we will use for deploying our framework to multiple front-ends, along with a configured s et of device drivers. We've developed Erlang code to use Fermilab's TCLK event distribution clock and Erlang's interface to C/C++ allows hardware-specific driver access.
43 PARTICLE ACCELERATORS↗
Hot, cold, or just right? An infrared biometric sensor to improve occupant comfort and reduce overcooling in buildings via closed-loop control
To improve occupant comfort and save energy in buildings, we have developed a closed-loop air conditioning (AC) sensor-controller that predicts occupant thermal sensation from the thermographic measurement of skin temperature distribution, then uses this information to reduce overcooling (cooling-energy overuse that discomforts occupants) by regulating AC output. Taking measures to protect privacy, it combines thermal-infrared (TIR) and color (visible spectrum) cameras with machine vision to measure the skin-surface temperature profile. Since the human thermoregulation system uses skin blood flow to maintain thermoneutrality, the distribution of skin temperature can be used to predict warm, neutral, and cool thermal states. We conducted a series of human-subject thermal-sensation trials in cold-to-hot environments, measuring skin temperatures and recording thermal sensation votes. We then trained random-forest classification machine-learning models (classifiers) to estimate thermal sensation from skin temperatures or skin-temperature differences. The estimated thermal sensation was input to a proportional integral (PI) control algorithm for the AC, targeting a sensation level between neutral and warm. Our sensor-controller includes a sensor assembly, server software, and client software. The server software orients the cameras and transmits images to the client software, which in turn assesses occupant skin temperature distribution, estimates occupant thermal sensation, and controls AC operation. A demonstration conducted in a conference room in an office building near Houston, TX showed that our system reduced overcooling, decreasing AC load by 42% when the room was occupied while improving occupant comfort (fraction of “comfortable” votes) by 15 percentage points.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
SoS-SDQN: System of Systems Software-defined Quantum Networking
Quantum networks are needed for quantum domain applications that may run across different network deployments - point-to-point, multi-node networks, and possibly across inter-domain quantum networks, like the quantum internet. Unlike classical computing networks, quantum networks involve heterogeneous systems nodes that currently require local and manual control. This needs a unified control approach to help them integrate, work seamlessly, and have global knowledge. Software-defined Networking (SDN) has been successfully leveraged in classical networking for seamless and software-driven control of network infrastructure and packet switching, but not in management of quantum network applications across heterogeneous systems. In this paper, we review the current state of the art and present early developments of a System-of-Systems Software-defined Quantum Networking architecture (SoS-SDQN), a generic architecture that supports software-driven quantum network experiments across heterogeneous quantum systems. The architecture modifies the generic SDN to address the domain requirements of quantum networks and proposes a multilevel SDQN to provide a global view of network status, running applications, and control of incorporated heterogeneous quantum systems. We also design and implement a SoS SouthBound Quantum Interface (SoS-SBQI), a quantum infrastructure protocol that abstracts automation of applications across the network.
Alnajjar, Anees [ORNL] (ORCID:0000000237101601)↗
From fault-detection to automated fault correction: A field study
A fault detection and diagnostics (FDD) tool, as addressed by this study, is a tool that continuously identifies the presence of faults and efficiency improvement opportunities through a one-way interface to the building automation system and the application of automated analytics. Although FDD tools can inform operators of building operational faults, currently an action is always required to correct the faults to generate energy savings. Fault auto-correction integrating with commercial FDD technology offerings can close the loop between the passive diagnostics and active control, increase the savings generated by FDD tools, and reduce the reliance on human intervention. This paper presents the field study of seven fault auto-correction algorithms implemented in commercial FDD platforms. Implementation includes software changes in the FDD tools and additional controls hardware or software changes in the BAS that were required to enable the execution of different types of auto-correction algorithms in real buildings. The routines successfully and automatically correct faults and improve the operation of large built-up Heating, Ventilation, and Air Conditioning (HVAC) systems, common in most commercial buildings. The auto-correction algorithms are tested across four buildings and three different building automation systems, following a rigorous procedure to make sure they work properly and do not negatively impact the system and building occupants. Finally, technology benefits, market drivers, and scalability changes are drawn from the implementation effort and test results, to drive future research and industry engagement.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Innovating the next generation of commercial smart building software
Nearly 30% of commercial building energy use is wasted due to equipment faults and HVAC controls problems. The result is increased emissions, compromised comfort and productivity, and less reliable coordination of building power needs with a clean grid. The energy impact alone represents $17 billion in potential savings. Today’s smart building software provides a robust solution to address these operational deficiencies. Energy management and information systems (EMIS) are saving up to 9% on average, with two-year paybacks. They are being incorporated into energy management processes, commissioning services, and utility programs. As effective as they are, two barriers prevent even deeper benefits; limited personnel to fix problems once they are identified, and the expense and time to manually implement changes in control systems. In partnership with the research community, the EMIS industry is developing new capabilities to overcome these barriers. Moving beyond siloed products for either fault detection and diagnostics, or optimal control, these new capabilities empower users to not only automatically identify faults, but also to push corrective action, and control improvements to their buildings. In this paper, several areas for enhancements are documented: ‘one-time’ correction of faults such as setpoints, schedules, and economizer lockouts; short-term active testing for automated proportional integral derivative (PID) loop tuning and functional testing; and continuous supervisory control for demand flexibility and year-round efficiency. Results are presented from a pair of partner implementations out of a dozen providers integrating these enhancements into their products, including field tests from across the country, and insights into operator acceptance and integration into operations and maintenance practices.
Casillas, Armando↗
Automation for Grid Interconnected Laboratory Emulation
As computational capabilities improve, digital twins are becoming vital for evaluating equipment realistically in laboratories. This paper outlines a digital twin architecture for the power grid, employing electromagnetic transient (EMT) simulation alongside real-time simulation of power hardware and hierarchical control systems. EMT simulation occurs on a high-performance computing server for scalability. Additionally, the paper describes a workflow and real-time data streaming software facilitating connectivity among EMT simulation, hierarchical control systems, and power hardware. This software enables automated equipment connectivity in the laboratory for realistic evaluations, aiding in identifying necessary upgrades for both equipment control systems and the power grid.
Marthi, Phani Ratna Vanamali [ORNL] (ORCID:0000000↗