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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2014

Feasibility Study on the Use of On-line Multivariate Statistical Process Control for Safeguards Applications in Natural Uranium Conversion Plants

The objective of this work was to determine the feasibility of using on-line multivariate statistical process control (MSPC) for safeguards applications in natural uranium conversion plants. Multivariate statistical process control is commonly used throughout industry for the detection of faults. For safeguards applications in uranium conversion plants, faults could include the diversion of intermediate products such as uranium dioxide, uranium tetrafluoride, and uranium hexafluoride. This study was limited to a 100 metric ton of uranium (MTU) per year natural uranium conversion plant (NUCP) using the wet solvent extraction method for the purification of uranium ore concentrate. A key component in the multivariate statistical methodology is the Principal Component Analysis (PCA) approach for the analysis of data, development of the base case model, and evaluation of future operations. The PCA approach was implemented through the use of singular value decomposition of the data matrix where the data matrix represents normal operation of the plant. Component mole balances were used to model each of the process units in the NUCP. However, this approach could be applied to any data set. The monitoring framework developed in this research could be used to determine whether or not a diversion of material has occurred at an NUCP as part of an International Atomic Energy Agency (IAEA) safeguards system. This approach can be used to identify the key monitoring locations, as well as locations where monitoring is unimportant. Detection limits at the key monitoring locations can also be established using this technique. Several faulty scenarios were developed to test the monitoring framework after the base case or normal operating conditions of the PCA model were established. In all of the scenarios, the monitoring framework was able to detect the fault. Overall this study was successful at meeting the stated objective.

Ladd-Lively, Jennifer L↗
DOE OSTI2016

SU-F-T-241: Reduction in Planning Errors Via a Process Control Developed Using the Eclipse Scripting API

Purpose: Errors found during initial physics plan checks frequently require replanning and reprinting, resulting decreased departmental efficiency. Additionally, errors may be missed during physics checks, resulting in potential treatment errors or interruption. This work presents a process control created using the Eclipse Scripting API (ESAPI) enabling dosimetrists and physicists to detect potential errors in the Eclipse treatment planning system prior to performing any plan approvals or printing. Methods: Potential failure modes for five categories were generated based on available ESAPI (v11) patient object properties: Images, Contours, Plans, Beams, and Dose. An Eclipse script plugin (PlanCheck) was written in C# to check errors most frequently observed clinically in each of the categories. The PlanCheck algorithms were devised to check technical aspects of plans, such as deliverability (e.g. minimum EDW MUs), in addition to ensuring that policy and procedures relating to planning were being followed. The effect on clinical workflow efficiency was measured by tracking the plan document error rate and plan revision/retirement rates in the Aria database over monthly intervals. Results: The number of potential failure modes the PlanCheck script is currently capable of checking for in the following categories: Images (6), Contours (7), Plans (8), Beams (17), and Dose (4). Prior to implementation of the PlanCheck plugin, the observed error rates in errored plan documents and revised/retired plans in the Aria database was 20% and 22%, respectively. Error rates were seen to decrease gradually over time as adoption of the script improved. Conclusion: A process control created using the Eclipse scripting API enabled plan checks to occur within the planning system, resulting in reduction in error rates and improved efficiency. Future work includes: initiating full FMEA for planning workflow, extending categories to include additional checks outside of ESAPI via Aria database queries, and eventual automated plan checks.

60 APPLIED LIFE SCIENCES↗
NASA NTRS2014

Implementation of Statistical Process Control: Evaluating the Mechanical Performance of a Candidate Silicone Elastomer Docking Seal

The National Aeronautics and Space Administration has been developing a novel docking system to meet the requirements of future exploration missions to low-Earth orbit and beyond. A dynamic gas pressure seal is located at the main interface between the active and passive mating components of the new docking system. This seal is designed to operate in the harsh space environment, but is also to perform within strict loading requirements while maintaining an acceptable level of leak rate. In this study, a candidate silicone elastomer seal was designed, and multiple subscale test articles were manufactured for evaluation purposes. The force required to fully compress each test article at room temperature was quantified and found to be below the maximum allowable load for the docking system. However, a significant amount of scatter was observed in the test results. Due to the stochastic nature of the mechanical performance of this candidate docking seal, a statistical process control technique was implemented to isolate unusual compression behavior from typical mechanical performance. The results of this statistical analysis indicated a lack of process control, suggesting a variation in the manufacturing phase of the process. Further investigation revealed that changes in the manufacturing molding process had occurred which may have influenced the mechanical performance of the seal. This knowledge improves the chance of this and future space seals to satisfy or exceed design specifications.

docking seal↗
DOE OSTI2024

Development of algorithms for augmenting and replacing conventional process control using reinforcement learning

Here, this work seeks to allow for the online operation and training of model-free reinforcement learning (RL) agents but limit the risk to system equipment and personnel. The parallel implementation of RL alongside more conventional process control (CPC) allows for the RL algorithm to learn from CPC. The past performance of both methods are assessed on a continuous basis allowing for a transition from CPC to RL and, if needed, transitioning back to CPC from RL. This allows for the RL algorithm to slowly and safely assume control of the process without significant degradation in control performance. It is shown that the RL can derive a near optimal policy even when coupled with a suboptimal CPC. It is also demonstrated that the coupled RL-CPC algorithm learns at a faster rate than traditional RL methods of exploration while the algorithm’s performance does not deteriorate below CPC, even when exposed to an unknown operating condition.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2003

Supplier Outreach and Process Control (SOPC) and Supplier Rating Initiative (SRI)

The viewgraph presentation presents an overview of NASA's Supplier Outreach and Process Control (SOPC) and Supplier Risk Initiatives. The discussion of the SOPC examines its importance, current groups who are involved, provides a mission statement, and describes outreach activities and how suppliers are selected. The discussion of the Supplier Risk Initiative examines the variety of ways that integrity, availability, and assurance factor in to supplier risk and describes a new supplier rating program.

quality control↗
DOE OSTI2016

TU-FG-201-05: Varian MPC as a Statistical Process Control Tool

Purpose: Quality assurance in radiotherapy requires the measurement of various machine parameters to ensure they remain within permitted values over time. In Truebeam release 2.0 the Machine Performance Check (MPC) was released allowing beam output and machine axis movements to be assessed in a single test. We aim to evaluate the Varian Machine Performance Check (MPC) as a tool for Statistical Process Control (SPC). Methods: Varian’s MPC tool was used on three Truebeam and one EDGE linac for a period of approximately one year. MPC was commissioned against independent systems. After this period the data were reviewed to determine whether or not the MPC was useful as a process control tool. Analyses on individual tests were analysed using Shewhart control plots, using Matlab for analysis. Principal component analysis was used to determine if a multivariate model was of any benefit in analysing the data. Results: Control charts were found to be useful to detect beam output changes, worn T-nuts and jaw calibration issues. Upper and lower control limits were defined at the 95% level. Multivariate SPC was performed using Principal Component Analysis. We found little evidence of clustering beyond that which might be naively expected such as beam uniformity and beam output. Whilst this makes multivariate analysis of little use it suggests that each test is giving independent information. Conclusion: The variety of independent parameters tested in MPC makes it a sensitive tool for routine machine QA. We have determined that using control charts in our QA programme would rapidly detect changes in machine performance. The use of control charts allows large quantities of tests to be performed on all linacs without visual inspection of all results. The use of control limits alerts users when data are inconsistent with previous measurements before they become out of specification. A. Carver has received a speaker’s honorarium from Varian.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2013

Final Report - Advanced Laser-Based Sensors for Industrial Process Control

The objective of this work is to capture the potential of real-time monitoring and overcome the challenges of harsh industrial environments, Los Gatos Research (LGR) is fabricating, deploying, and commercializing advanced laser-based gas sensors for process control monitoring in industrial furnaces (e.g. electric arc furnaces). These sensors can achieve improvements in process control, leading to enhanced productivity, improved product quality, and reduced energy consumption and emissions. The first sensor will utilize both mid-infrared and near-infrared lasers to make rapid in-situ measurements of industrial gases and associated temperatures in the furnace off-gas. The second sensor will make extractive measurements of process gases. During the course of this DOE project, Los Gatos Research (LGR) fabricated, tested, and deployed both in-situ tunable diode laser absorption spectrometry (TDLAS) analyzers and extractive Off-Axis Integrated Cavity Output Spectroscopy (Off-Axis ICOS) analyzers.

47 OTHER INSTRUMENTATION↗
NASA NTRS1994

QPA-CLIPS: A language and representation for process control

QPA-CLIPS is an extension of CLIPS oriented towards process control applications. Its constructs define a dependency network of process actions driven by sensor information. The language consists of three basic constructs: TASK, SENSOR, and FILTER. TASK's define the dependency network describing alternative state transitions for a process. SENSOR's and FILTER's define sensor information sources used to activate state transitions within the network. Deftemplate's define these constructs and their run-time environment is an interpreter knowledge base, performing pattern matching on sensor information and so activating TASK's in the dependency network. The pattern matching technique is based on the repeatable occurrence of a sensor data pattern. QPA-CIPS has been successfully tested on a SPARCStation providing supervisory control to an Allen-Bradley PLC 5 controller driving molding equipment.

Freund, Thomas G.↗
NASA NTRS1990

Estimation of the processes controlling variability in phytoplankton pigment distributions on the southeastern U.S. continental shelf

Five coastal-zone-color-scanner images from the southeastern U.S. continental shelf are combined with concurrent moored current meter measurements to assess the processes controlling the variability in chlorophyll concentration and distribution in this region. An equation governing the space and time distribution of a nonconservative quantity such as chlorophyll is used in the calculations. The terms of the equation, estimated from observations, show that advective, diffusive, and local processes contribute to the plankton distributions and vary with time and location. The results from this calculation are compared with similar results obtained using a numerical physical-biological model with circulation fields derived from an optimal interpolation of the current meter observations and it is concluded that the two approaches produce different estimates of the processes controlling phytoplankton variability.

Mcclain, Charles R.↗
DOE OSTI2022

Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities

Improvements in process monitoring and control at water resource recovery facilities (WRRFs) could result in reductions in electricity consumption, chemical inputs, and greenhouse gas emissions, as well as improved energy recovery. Many current WRRF data collection, monitoring, and control approaches use 20th century process monitoring and control systems, which require large design safety factors to ensure reliability in the absence of more advanced, precise controls. Implementation of more modern data-driven control tools could lead to more efficient operations that provide intrinsic reliability with better overall process performance at full-scale. This presentation provides an overview of a recently initiated project "Crossing the Finish Line: Integration of Data-Driven Process Control for Maximization of Energy and Resource Efficiency in Advanced Water Resource Recovery Facilities" which will (1) develop and demonstrate data-driven process controls at full-scale facilities for five promising WRRF Applications (i.e., process technologies) that provide whole-plant approaches and offer substantial energy and resource recovery benefits, and (2) create a toolbox of new process control approaches and an implementation guide including five examples for application at utilities. The presentation also provides a detailed overview of the research approach and progress being made on one of the five Applications, namely Application 2: Biological Nutrient Removal (BNR): ammonium-based aeration control (ABAC) / ammonia vs. NOx (AvN) + partial denitration with anammox (PdNA), which is being implemented at Hampton Roads Sanitation District. This project is a collaboration of work being conducted by DC Water, Hampton Roads Sanitation District, Metro Water Recovery, University of Michigan, Northwestern University, US Military Academy - West Point, Black & Veatch, and Oak Ridge National Laboratory. Research partner: U.S. Department of Energy.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1977

Cameras for semiconductor process control

The application of X-ray topography to semiconductor process control is described, considering the novel features of the high speed camera and the difficulties associated with this technique. The most significant results on the effects of material defects on device performance are presented, including results obtained using wafers processed entirely within this institute. Defects were identified using the X-ray camera and correlations made with probe data. Also included are temperature dependent effects of material defects. Recent applications and improvements of X-ray topographs of silicon-on-sapphire and gallium arsenide are presented with a description of a real time TV system prototype and of the most recent vacuum chuck design. Discussion is included of our promotion of the use of the camera by various semiconductor manufacturers.

Porter, W. A.↗
DOE OSTI2020

Sensor Fusion: Comprehensive Real-Time, On-Line Monitoring for Process Control via Visible, Near-Infrared, and Raman Spectroscopy

On-line monitoring based on optical spectroscopy provides unprecedented insight into the chemical composition of process streams or batches. Amplifying this approach through utilizing multiple forms of optical spectroscopy in sensor fusion can greatly expand the number and type of chemical species that can be identified and quantified. This is demonstrated herein, on the analysis of used nuclear fuel recycling streams: highly complex processes with multiple target and interfering analytes. The optical techniques of visible absorbance, near infrared absorbance, and Raman spectroscopy were combined to quantify plutonium (III, IV, VI), uranium (IV, VI), neptunium (IV, V, VI), and nitric acid. Chemometric modeling was used to quantify analytes in process streams in real-time and results were successfully used to enable immediate process control and generation of a product stream at a set composition ratio. This represents a significant step forward in the ability to monitor and control complex chemical processes occurring in harsh chemical environments.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Characterization of Covetic Materials for Process Control. Final CRADA report

GDC Industries LLC has been performing process research on covetic materials since its formation in February 2015. With assistance from DOE and the Air Force via SBIR projects, GDC focused on the enhancement of aluminum alloys to covetics to replicate a previously reported electrical conductivity of about 67% IACS (International Annealed Copper Standard). GDC has established a joint development agreement with General Cable Corporation, wherein General Cable agreed to perform numerous extrusions of as cast covetics and subsequent tensile and electrical conductivity tests on the resultant wire. Covetics conversion was proven but the significant improvement is yet to be replicated. To control the experiments towards enhanced process control, a series of designed experiments was created by an expert in process control from the automotive industry. Six process variables were identified and a designed experiment matrix requiring 18 independent conversions was created at GDC. The result of those designed experiments has now allowed GDC to focus on two process variables, namely, residence time and DC current in the conversions with the other four variable held constant. While this work is useful in replicating the earlier enhancements, GDC feels it will not be sufficient for the necessary process knowhow for scale up required by industry as GDC still does not have a direct correlation of the process variables to the actual carbon in the finished covetics. Since 2015, GDC has been aware of the capabilities existing at Argonne National Laboratory for performing carbon analysis that exceeds the precision commonly available to Industry. GDC and ANL submitted a proposal in response to the DOE-EERE – Small Business Vouchers Pliot Program announcement and the proposal was selected for funding. GDC will melt-process covetic aluminum samples following their design of experiment criteria and have the as-casted samples extruded by their partner, General Cable. Argonne will measure the conductivity, analyze carbon content, perform X-ray diffraction, and examine the microstructural features of the samples. Careful process variable measurements will be recorded by each party such that correlations can be developed indicating process parameters that yield the best carbon concentration in covetics.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Feasibility study of using statistical process control to customized quality assurance in proton therapy

Purpose: To evaluate and improve the reliability of proton quality assurance (QA) processes and, to provide an optimal customized tolerance level using the statistical process control (SPC) methodology. Methods: The authors investigated the consistency check of dose per monitor unit (D/MU) and range in proton beams to see whether it was within the tolerance level of the daily QA process. This study analyzed the difference between the measured and calculated ranges along the central axis to improve the patient-specific QA process in proton beams by using process capability indices. Results: The authors established a customized tolerance level of ±2% for D/MU and ±0.5 mm for beam range in the daily proton QA process. In the authors’ analysis of the process capability indices, the patient-specific range measurements were capable of a specification limit of ±2% in clinical plans. Conclusions: SPC methodology is a useful tool for customizing the optimal QA tolerance levels and improving the quality of proton machine maintenance, treatment delivery, and ultimately patient safety.

60 APPLIED LIFE SCIENCES↗