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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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The startup of systems composed of power electronic systems is becoming more complex. As the systems grow, standard pre-configuration sequencing methods will struggle. This work proposes a linear programming optimization method to couple power electronic systems in a series of startup commands. This formulation is demonstrated in a real-time implementation on hardware.
The RF Test Facility (RFTF) at the Spallation Neutron Source (SNS) is used for the conditioning of RF compo-nents such as ceramic vacuum windows and power cou-plers prior to their installation in the H- ion linear accel-erator. This process exposes components to high-power RF fields and thermal cycling to improve performance and remove surface impurities. To automate and optimize this process, a Python-based EPICS control system was developed alongside targeted hardware upgrades. The system enables real-time monitoring and control of RF power levels, temperature, and vacuum pressure. A user-friendly graphical interface was implemented using CS-Studio (Phoebus), allowing operators to adjust parameters and collect data efficiently. The system integrates a High-Power Protection Module (HPM) for interlocks based on vacuum and arc detection, ensuring safe operation. These upgrades have significantly improved the efficiency, accuracy, and safety of RF conditioning at the SNS RFTF. This paper describes the updated RF conditioning sys-tem, highlighting the software and hardware develop-ments and their application in support of the Proton Pow-er Upgrade (PPU) project.
This paper proposes an applicable approach to deploy the Coordinative Real-time Sub-Transmission Volt-Var Control Tool (CReST-VCT), and a holistic system integration framework considering both the energy management system (EMS) and distribution system management system (DMS). This provides an architectural basis and can serve as the implementation guideline of CReST-VCT and other advanced grid support tools, to co-optimize the operation benefits of DERs and assets in both transmission and distribution networks. Potential communication protocols for different physical domains of a real application is included. Performance and security issues are also discussed, along with specific considerations for field deployment. Finally, the paper presents a viable pathway for CReST-VCT and other advanced grid support tools, which could be integrated in an open-source standardized-based platform that supports distribution utilities.
We explore the innovative use of MLP-Mixer models for real-time jet tagging and establish their feasibility on resource-constrained hardware like FPGAs. MLP-Mixers excel in processing sequences of jet constituents, achieving state-of-the-art performance on datasets mimicking Large Hadron Collider conditions. By using advanced optimization techniques such as High-Granularity Quantization and Distributed Arithmetic, we achieve unprecedented efficiency. These models match or surpass the accuracy of previous architectures, reduce hardware resource usage by up to 97%, double the throughput, and half the latency. Additionally, non-permutation-invariant architectures enable smart feature prioritization and efficient FPGA deployment, setting a new benchmark for machine learning in real-time data processing at particle colliders.
Phase retrieval, the problem of recovering lost phase information from measured intensity alone, is an inverse problem that is widely faced in various imaging modalities ranging from astronomy to nanoscale imaging. The current process of phase recovery is iterative in nature. As a result, the image formation is time consuming and computationally expensive, precluding real-time imaging. Here, we use 3D nanoscale X-ray imaging as a representative example to develop a deep learning model to address this phase retrieval problem. We introduce 3D-CDI-NN, a deep convolutional neural network and differential programing framework trained to predict 3D structure and strain, solely from input 3D X-ray coherent scattering data. Our networks are designed to be “physics-aware” in multiple aspects; in that the physics of the X-ray scattering process is explicitly enforced in the training of the network, and the training data are drawn from atomistic simulations that are representative of the physics of the material. We further refine the neural network prediction through a physics-based optimization procedure to enable maximum accuracy at lowest computational cost. 3D-CDI-NN can invert a 3D coherent diffraction pattern to real-space structure and strain hundreds of times faster than traditional iterative phase retrieval methods. Our integrated machine learning and differential programing solution to the phase retrieval problem is broadly applicable across inverse problems in other application areas.
In-situ monitoring of defect formation remains a significant challenge in the laser powder bed fusion (LPBF) process. Recent advances have enabled real-time defect detection with machine learning and in-situ sensing technologies; however, most studies focus on binary classification of keyhole pores, limiting nuanced multi-class pore differentiation and formation mechanisms. This work introduces a multi-class pore detection framework (no pore, small pores < 15 µm, and large pores > 15 µm) by leveraging photodiode sensor data alongside high-fidelity synchrotron X-ray imaging. The 15 µm threshold is selected to distinguish between two fundamentally different defect mechanisms, following the physical size-mechanism boundary established by prior high-resolution synchrotron X-ray characterization of Al6061 LPBF. Distinguishing these classes is critical because large keyhole pores are structurally detrimental, whereas small gas pores are often benign, requiring different process control strategies. Thermal emission monitoring data collected simultaneously with high-speed X-ray imaging at the Stanford Synchrotron Radiation Lightsource (SSRL), are correlated with subsurface melt pool dynamics to establish ground truth. Continuous Wavelet Transform (CWT) with optimized parameters converts the photodiode time-series signals into time–frequency images, facilitating feature extraction. Convolutional Neural Networks (CNN) are then applied for real-time multi-class pore classification in an average inference time of 1 ms per signal window. It achieves 79% accuracy and an Area Under the Receiver Operating Characteristic curve (AUC ROC) score of 0.89 with five-fold cross-validation. The results demonstrate that coupling CWT-based feature engineering with CNN architecture enables reliable multi-class pore detection in Al6061 builds using affordable in-situ sensors. This approach advances scalable and affordable quality assurance in additive manufacturing by moving beyond binary defect detection toward more nuanced classification of porosity mechanisms with in-situ sensors and machine learning.
Charge management, which lowers charging costs for fleets and prevents straining the electrical grid, is critical to the successful deployment of medium- and heavy-duty battery-electric trucks (MHD BETs). This study introduces an energy demand and cost management framework that optimizes depot charging for MHD BETs by combining an energy consumption machine learning model and a linear program optimization model. The framework considers key factors impacting real-world MHD BET operations, including vehicle and charger configurations, duty cycles, use cases, geographic and climate conditions, operation schedules, and utilities’ time-of-use (TOU) rates and demand charges. The framework was applied to a hypothetical fleet of 100 MHD BETs in California under three different utilities for 365 days, with results compared to unmanaged charging. The optimized charging solution avoided more than 90% of on-peak charging, reduced fleet charging peak load by 64–75%, and lowered fleet energy variable costs by 54–64%. This study concluded that the proposed charge management framework significantly reduces energy costs and peak loads for MHD BET fleets while making recommendations for fleet electrification infrastructure planning and the design of utility TOU rates and demand charges.
This work is the second of a two-part series in which we develop and experimentally demonstrate a hierarchical control solution for optimally coordinating thousands of deferrable loads and distributed energy resources (DERs) to provide fast frequency response (FFR) from an entire distribution feeder. In Part I, we developed and proved practical algorithms for fast, cost-based optimal dispatch and for determining the optimal amount of headroom to operate solar inverters with to support FFR dispatch while minimizing opportunity cost. Simulation results in Part I demonstrated the advantages of the hierarchical dispatch approach in being able to maintain fast solution times needed for FFR even when the problem size increases. In Part II, we implement the algorithms developed in Part I in a novel, large-scale power hardware-in-the-loop experiment including embedded controllers and more than 100 powered appliance loads and DER connected to a simulated real-world distribution system with more than 10,000 controlled devices. Experimental results from multiple scenarios confirm that the optimal FFR dispatch approach scales well and can optimally coordinate more than 10,000 net-load resources across a distribution network while achieving hardware response times within 500 ms, which is not possible using state-of-the-art optimal coordination approaches.
Accurately characterizing vehicle drive cycles plays a fundamental role in assessing the performance of new vehicle technologies. Repeatable, short duration representative drive cycles facilitate more informed decision making, resulting in improved test procedures and more successful vehicle designs. With continued growth in the deployment of onboard telematics systems employing global positioning systems (GPS), large scale, low cost collection of real-world vehicle drive cycle data has become a reality. As a result of these technological advances, researchers, designers, and engineers are no longer constrained by lack of operating data when developing and optimizing technology, but rather by resources available for testing and simulation. Experimental testing is expensive and time consuming, therefore the need exists for a fast and accurate means of generating representative cycles from large volumes of real-world driving data. This paper explores the development and initial validation of a method of generating representative drive cycles from large collections of real-world vehicle data using a deterministic multivariate clustering approach. Starting with theory and diving into the methodology behind representative cycle generation, the paper aims to also present graphical and tabular results of initial validation via vehicle simulation and chassis dynamometer testing. Additional topics for further research and areas for ongoing development will also be presented.
Advancing Scientific Understanding in Fusion Energy and Machine Learning This research represented a significant step forward in machine learning (ML) applications for fusion energy experiments. The project integrated advanced data-driven modeling, optimization techniques, and artificial intelligence to enhance the predictive capabilities and operational efficiency of plasma-based fusion systems. Specifically, tasks focused on ML-enhanced diagnostics, operator guidance tools, and predictive modeling helped improve the ability to interpret complex fusion experiments. Key areas of advancement included: 1) data-driven plasma control, i.e., using ML algorithms to optimize experimental conditions and classify plasma behaviors based on historical data; 2) spectroscopy and diagnostics, i.e., applying AI models to extract previously inaccessible insights from experimental spectroscopy data; and 3) configuration mapping and operator guidance, i.e., developing a predictive framework to assist scientists in identifying the most effective experimental parameters, reducing reliance on manual adjustments. By refining these ML-driven techniques, the project contributed to the broader scientific community’s understanding of plasma dynamics and fusion energy viability. Technical Effectiveness and Economic Feasibility The methods investigated demonstrated high technical effectiveness, as reflected in milestones assessing the predictive accuracy, performance, and optimization of fusion configurations. The development of an Operator Guidance Tool (OGT), for example, led to more precise control of plasma conditions by learning from experimental data and offering real-time adjustments. From an economic standpoint, DeFT provided: 1) the ability to reduce trial-and-error experimentation, which lowered operational costs; 2) improved data interpretation methods, which enabled more efficient resource allocation in large-scale fusion research projects; and 3) the automation of key diagnostic tasks, which reduced manual labor and human error, increasing overall efficiency. 13 The final assessments of predictive models and optimization strategies demonstrated that these approaches were scalable and could be implemented across multiple fusion energy research programs. Public Benefit and Societal Impact This project contributed directly to the broader goal of achieving sustainable and commercially viable fusion energy, which had profound implications for clean energy production and climate change mitigation. The integration of AI-driven solutions into fusion research: 1) sped up scientific discovery, accelerating progress towards achieving energy breakthroughs; 2) reduced the cost of experimentation, making fusion research more accessible; and 3) provided a framework for future AI applications in high-energy physics, benefiting adjacent fields like space exploration, material science, and renewable energy. Additionally, by fostering collaborations between AI researchers and plasma physicists, this project promoted interdisciplinary innovation that could lead to broader applications beyond fusion research.
High-energy physics (HEP) experiments demand data acquisition (DAQ) systems capable of orchestrating complex detector operations, high data throughput, and responsive, real-time feedback. Traditional systems often have steep learning curves, making onboarding difficult for new users. The Off-The-Shelf Data Acquisition $otsdaq$ framework was developed to address these issues by providing a modular and flexible interface that is easier to operate while remaining customizable enough for experimental setups. As the upcoming Mu2e experiment prepares for deployment, improving stability, usability, and performance has become increasingly critical. Our work enhances $otsdaq$ with features that streamline visualization, correct data metrics, improve debugging workflows, and stabilize the user interface.
The integration of variable Renewable Energy Sources (vRES) to alleviate greenhouse gas emissions has introduced significant challenges for power systems operations. These challenges include high levels of uncertainty due to the intermittence associated with vRES and therefore impose the need to devise a reliable and cost-effective day-ahead unit commitment and power and reserves scheduling for real-time operations. Also, this increasing penetration of vRES requires higher ramping capabilities from units originally designed for other purposes (e.g., base-load generation), which might be exacerbated during contingency states. Hence, in this work, we propose a methodology to address the day-ahead Contingency-Constrained Unit Commitment (CCUC) problem that leverages the participation of Battery Energy Storage Systems (BESSs) to address load-following and post-contingency management, therefore alleviating the ramping burden on conventional thermal generators. To do so, we formulate a three-level optimization problem that represents the decision-making process of obtaining the least-cost commitment, generation and reserves scheduling, while restricting the Conditional Value-at-Risk (CVaR) of the system imbalance at real-time operations to user-defined tolerance levels. In addition, we devise a computationally efficient solution approach for the proposed problem based on the Column-and Constraint Generation (CCG) algorithmic framework. Two numerical experiments are conducted to empirically illustrate the benefits of the proposed methodology. Key results indicate a reduction in real-time ramping needs and a better usage of the system resources, with a reduction in the overall system commitment levels and reserve scheduling costs when compared to a benchmark case in which storage is not available.
The example embodiments are directed to a system and method for forecasting load flexibility of a power grid. In one example, the method includes receiving temperature values associated with temperature set points of a plurality of loads that are included on a power grid, forecasting a flexibility of the plurality of loads using a polynomial-time mixed-integer non-linear programming (MINLP) optimization based on the received temperature values for the plurality of loads, and outputting information about the forecasted flexibility for display to a display device. The MINLP optimization performs the forecasting of the load flexibility on a fine-grained basis in comparison to conventional methods and is still fast enough that it can be computed in real-time.
This work describes the initial development of dynamic system models of the cryogenic moderator system (CMS) of the Spallation Neutron Source (SNS) at ORNL as a part of the ORNL LDRD funded project Building TRANSFORM to Accelerate Digital Twin Applications for Nuclear Systems, LOIS 10563. The goal of the work is to start the dynamic system modeling effort with the end goal of using them for real-time applications as digital twins. The CMS is a cryogenic liquid hydrogen flow loop that provides moderation of the neutrons that are generated by the SNS. For optimal neutron production, the CMS needs to maintain a steady and controlled density of cryogenic hydrogen in the moderator section thus requiring precise temperature and pressure control. Due to the varied time scales and system characteristics, control of the system is complex, and diagnostics are also difficult. Difficulty in accessing the flow loop during operations, limited instrumentation and unknown design details of the equipment combine to make the case for having sophisticated digital twin models of the system. Operationally the CMS also provides a strong use case for digital twins due to the constant need of optimization and for troubleshooting/diagnostics. The large amount of data collected which are freely available for using in building the model and verifying and validating the model also makes it a great candidate for a proof-of-concept for digital twins. The project extends ORNL's capacity of development and implementation of the open-source dynamic system modeling tool TRANSFORM for engineering design and digital twin/real-time applications. Specific system configuration data for the CMS have been gathered and an initial dynamic model was created in the TRANSFORM library using Dymola as the solution platform. Models of increasing complexity are created to demonstrate the need for a multi-layered approach in digital twin modeling depending on the scale and phenomena being focused on. The dynamic modeling is shown to bring the dynamic operational aspects to the design process for systems as well as serve as a digital twin to the hardware and allow for models to be tuned and compared against real time operational data. These aims should help to push forward strategic goals of application of digital twins and increase the impact of ORNL systems modeling capabilities with TRANSFORM/Modelica for various advanced energy systems.
Artificial intelligence is emerging as a transformative force in addressing the multifaceted challenges of food safety, food quality, and food security. This review synthesizes advancements in AI-driven technologies, such as machine learning, deep learning, natural language processing, and computer vision, and their applications across the food supply chain, based on a comprehensive analysis of literature published from 1990 to 2024. AI enhances food safety through real-time contamination detection, predictive risk modeling, and compliance monitoring, reducing public health risks. It improves food quality by automating defect detection, optimizing shelf-life predictions, and ensuring consistency in taste, texture, and appearance. Furthermore, AI addresses food security by enabling resource-efficient agriculture, yield forecasting, and supply chain optimization to ensure the availability and accessibility of nutritious food resources. This review also highlights the integration of AI with advanced food processing techniques such as high-pressure processing, ultraviolet treatment, pulsed electric fields, cold plasma, and irradiation, which ensure microbial safety, extend shelf life, and enhance product quality. Additionally, the integration of AI with emerging technologies such as the Internet of Things, blockchain, and AI-powered sensors enables proactive risk management, predictive analytics, and automated quality control. By examining these innovations' potential to enhance transparency, efficiency, and decision-making within food systems, this review identifies current research gaps and proposes strategies to address barriers such as data limitations, model generalizability, and ethical concerns. These insights underscore the critical role of AI in advancing safer, higher-quality, and more secure food systems, guiding future research and fostering sustainable food systems that benefit public health and consumer trust.
Digital twins of complex systems must involve a model that is fast, generalizable, and usable for real-time control. For example, high-fidelity nonlinear multiphysics simulations can capture laser-material interactions, but are too slow for optimization or model predictive control (MPC). Reduced-order models, used to accelerate such computation, frequently fail to generalize to unseen inputs or control states. We show theoretically that this failure is intrinsic, i.e., that a learned model is non-unique outside the sampled subspace when its low-rank structure arises from limited excitation and clustered eigenvalues, rather than from a user-imposed truncation alone. Motivated by this result, we propose a control-ready regional surrogate-construction framework for both autonomous and nonautonomous dynamics; it employs Koopman lifting to represent nonlinearities, while preserving spatial locality. We illustrate our approach by constructing a control-ready surrogate for the digital twin of a thermal component of additive-manufacturing process. Our surrogate, localized in space through a von Neumann stencil, is learned from noisy high-fidelity simulations that emulate thermal-camera images collected during the manufacturing. It is linear in thermo-physically augmented states so that MPC reduces to a convex quadratic program. The surrogate requires no online correction, generalizes to unseen scan paths and power profiles of the laser, and is more than three orders of magnitude faster than a finite-difference solver. Furthermore, when the MPC sequence computed on the digital twin is applied to this solver, closed-loop temperature regulation is recovered, showing that the surrogate preserves control-relevant input-output behavior.
In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.
Here, this paper presents AutonomieAI, a novel toolkit designed for efficient energy estimation of vehicles across diverse trip scenarios, routes, and drive cycles, applicable to a broad range of vehicle powertrain technologies. It leverages state-of-the-art Machine Learning techniques to deliver real-time energy prediction of vehicles, enabling co-simulation with transportation level system tools and opening doors for large-scale optimization at city, network or national level. Benchmark results show that AutonomieAI achieves high accuracy, with an average percentage error below 2% for most powertrain types, and computational efficiency capable of processing over 10,000 trips per second. Applications of AutonomieAI have potential to offer the flexibility to assist in solving eco-routing problems, optimize for vehicle and powertrain selection, study charging decision behavior, and optimize for charging station placement. AutonomieAI is the result of large neural network based model architectures, trained on very large and unique high fidelity vehicle simulation data. It is lightweight, deployable, efficient and has accuracy comparable to specialized and complex physics based simulation softwares.