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DOE OSTI2026

Multibody for Everybody (M4E): A Symbolic Dynamics Modeling Tool with Applications in Simulation, Control, and Optimization

Developing the analytical model of a multibody system is often the initial step in control and optimization. The analytical model (equations of motion) describes a system’s time evolution under specified forcing conditions. Although developing these equations is easy for simple systems, this process becomes more complex for systems composed of multiple bodies. Deriving equations of motion for complex multibody systems requires specialized expertise in multibody dynamics, is time-consuming, and is susceptible to error. To address this issue, this paper presents an open-source, easy-to-use, systematic framework to derive symbolic equations of motion in both Python and MATLAB using the joint coordinate formulation. This formulation results in a set of ordinary differential equations that use the minimum set of coordinates needed to model a system. The symbolic representation provides better insight into the influence of design parameters on system performance, facilitates sensitivity analysis and parameter studies, and supports direct implementation of control and optimization routines. The tool enables numerical simulation for specified parameter sets, is modular for straightforward integration with other tools and libraries, and allows incorporation of hydrodynamics, mooring, and other external forces. The result is a reproducible, extensible pipeline for modeling, simulation, and design of complex multibody systems. The proposed tool is versatile and can be applied to domains such as robotics, control, and design. In addition, we integrated external libraries that provide capabilities for modeling offshore systems such as underwater robots and marine energy converters.

16 TIDAL AND WAVE POWER↗

DOE OSTI2023

NdFeB Permanent Magnet Uses, Projected Growth Rates and Nd Plus Dy Demands across End-Use Sectors through 2050: A Review

Rare earth element (REE) permanent magnets (NdFeB) are a critical element in a vast and growing number of industrial applications. In consumer electronics, a broad category encompassing computer, CD, and DVD hard drives, in addition to the ubiquitous cell phones, the nominal NdFeB magnet content may be small, but the global market share for this sector accounts for almost 30% of NdFeB demand, due to a large and continually increasing consumer base. It is estimated that wind turbines that primarily employ permanent magnets will add roughly 110 GW annually of on- and off-shore capability over the next few years. Electric vehicles (EVs) and E-bicycles (EBs) equipped with permanent magnet motors comprise the transportation contribution. Permanent magnet motors have garnered nearly 100% of the market share among EV manufacturers worldwide. Industrial, professional service, and personal robots, most using permanent magnets, are also included in the projected global need for rare earths, particularly Nd and Dy. The sector projects significant growth of approximately 10% across robotic categories. In this paper, we calculate the future demand for Nd and Dy through 2050 across these sectors using a compounded annual growth rate coupled with magnet weight and rare earth content. Uncertainties in the estimates, such as the true global production of Nd, a range of end-product scales and/or unit types in each sector, varied magnet compositions, and the variety of uses within a sector, are all considered.

Geochemistry & Geophysics↗

DOE OSTI2024

Correcting Turbulence-induced Errors in Fiber Positioning for the Dark Energy Spectroscopic Instrument

Highly multiplexed, robotic, fiber-fed spectroscopic surveys are observing tens of millions of stars and galaxies. For many systems, accurate positioning relies on imaging the fibers in the focal plane and feeding that information back to the robotic positioners to correct their positions. Inhomogeneities and turbulence in the air between the focal plane and the imaging camera can affect the measured positions of fibers, limiting the accuracy with which fibers can be placed on targets. For the Dark Energy Spectroscopic Instrument, we dramatically reduced the effect of turbulence on measurements of positioner locations in the focal plane by taking advantage of stationary positioners and the correlation function of the turbulence. We were able to reduce positioning errors from 7.3 to 3.5 μm, speeding the survey by 1.6% under typical conditions.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

The EGS Collab Project – Stimulations at Two Depths

The EGS Collab project, supported by the US Department of Energy, is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory to address challenges in implementing enhanced geothermal systems (EGS). Data and observations from the field tests are compared to simulations to understand processes and build confidence in numerical modeling of the processes. We have completed Experiment 1 (of 3), which examined hydraulic fracturing in a well-characterized underground fractured phyllite test bed at a depth of approximately 1.5 km at the Sanford Underground Research Facility (SURF) in Lead, South Dakota. Testbed characterization included fracture mapping, borehole acoustic and optical televiewers, full waveform sonic, conductivity, resistivity, temperature, campaign p- and s-wave investigations and electrical resistance tomography. Borehole geophysical techniques including passive seismic, continuous active source seismic monitoring, electrical resistance tomography, fiber-based distributed strain, distributed temperature, and distributed acoustic monitoring, were used to carefully monitor stimulation events and flow tests. More than a dozen stimulations and nearly one year of flow tests were performed. Quality data and detailed observations were collected and analyzed during stimulation and water flow tests using ambient temperature and chilled water. We achieved adaptive control of the tests using real-time monitoring and rapid dissemination of data and near-real-time simulation. More detailed numerical simulation was performed to answer key experimental design questions, forecast fracture propagation trajectories and extents, and analyze and evaluate results. Data are freely available from the Geothermal Data Repository. Experiment 2 examines the potential for hydraulic shearing in amphibolite at a depth of about 1.25 km at SURF. This site has a different set of stress and fracture conditions than Experiment 1. The Experiment 2 testbed consists of nine subhorizontal boreholes configured in two fans of two boreholes which surround the testbed and contain grouted-in electrical resistance tomography, seismic sensors, active seismic sources and distributed fiber sensors. A “five-spot” set of test wells that extends from a custom mined alcove includes an injection well and four production/monitoring wells. The testbed was characterized geophysically and hydrologically, and three stimulations have been performed using the Step-Rate Injection Method for Fracture In-Situ Properties (SIMFIP) tool to measure strains, and a new strain quantifying tool (downhole robotic strain analysis tool -DORSA) was deployed in a monitoring hole during stimulation. Real-time data were broadcast during stimulations to allow real-time response to arising issues.

EGS Collab, Enhanced Geothermal Systems, EGS, fiel↗

DOE OSTI2015

Freeform fluidics

A robotic, prosthetic or orthotic member includes a body formed of a solidified metallic powder. At least one working fluid cylinder is formed in the body. A piston is provided in the working fluid cylinder for pressurizing a fluid in the cylinder. At least one working fluid conduit receives the pressurized fluid from the cylinder. The body, working fluid cylinder and working fluid conduit have a unitary construction. A method of making a robotic member is also disclosed.

42 ENGINEERING↗

DOE OSTI2013

MODELING OF HIGH SPEED FRICTION STIR SPOT WELDING USING A LAGRANGIAN FINITE ELEMENT APPROACH

Friction stir spot welding (FSSW) has been shown to be capable of joining steels of very high strength, while also being very flexible in terms of controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding (RSW) if tool life is sufficiently high, and if machine spindle loads are sufficiently low so that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11-14 kN. Therefore, in the current work tool speeds of 3000 rpm and higher were employed, in order to generate heat more quickly and to reduce welding loads to acceptable levels. The FSSW process was modeled using a finite element approach with the Forge® software package. An updated Lagrangian scheme with explicit time integration was employed to model the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate [3]. The modeling approach can be described as two-dimensional, axisymmetric, but with an aspect of three dimensions in terms of thermal boundary conditions. Material flow was calculated from a velocity field which was two dimensional, but heat generated by friction was computed using a virtual rotational velocity component from the tool surface. An isotropic, viscoplastic Norton-Hoff law was used to model the evolution of material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures and the movement of the joint interface with reasonable accuracy for the welding of a dual phase 980 steel.

Advanced High strength steel↗

DOE OSTI2016

j5 v2.8.4

j5 automates and optimizes the design of the molecular biological process of cloning/constructing DNA. j5 enables users to benefit from (combinatorial) multi-part scar-less SLIC, Gibson, CPEC, Golden Gate assembly, or variants thereof, for which automation software does not currently exist, without the intense labor currently associated with the process. j5 inputs a list of the DNA sequences to be assembled, along with a Genbank, FASTA, jbei-seq, or SBOL v1.1 format sequence file for each DNA source. Given the list of DNA sequences to be assembled, j5 first determines the cost-minimizing assembly strategy for each part (direct synthesis, PCR/SOE, or oligo-embedding), designs DNA oligos with Primer3, adds flanking homology sequences (SLIC, Gibson, and CPEC; optimized with Primer3 for CPEC) or optimized overhang sequences (Golden Gate) to the oligos and direct synthesis pieces, and utilizes BLAST to check against oligo mis-priming and assembly piece incompatibility events. After identifying DNA oligos that are already contained within a local collection for reuse, the program estimates the total cost of direct synthesis and new oligos to be ordered. In the instance that j5 identifies putative assembly piece incompatibilities (multiple pieces with high flanking sequence homology), the program suggests hierarchical subassemblies where possible. The program outputs a comma-separated value (CSV) file, viewable via Excel or other spreadsheet software, that contains assembly design information (such as the PCR/SOE reactions to perform, their anticipated sizes and sequences, etc.) as well as a properly annotated genbank file containing the sequence resulting from the assembly, and appends the local oligo library with the oligos to be ordered j5 condenses multiple independent assembly projects into 96-well format for high-throughput liquid-handling robotics platforms, and generates configuration files for the PR-PR biology-friendly robot programming language. j5 thus provides a new way to design DNA assembly procedures much more productively and efficiently, not only in terms of time, but also in terms of cost. To a large extent, however, j5 does not allow people to do something that could not be done before by hand given enough time and effort. An exception to this is that, since the very act of using j5 to design the DNA assembly process standardizes the experimental details and workflow, j5 enables a single person to concurrently perform the independent DNA construction tasks of an entire group of researchers. Currently, this is not readily possible, since separate researchers employ disparate design strategies and workflows, and furthermore, their designs and workflows are very infrequently fully captured in an electronic format which is conducive to automation.

Hillson, Nathan↗

DOE OSTI2017

Reconfigurable assembly work station

A reconfigurable autonomous workstation includes a multi-faced superstructure including a horizontally-arranged frame section supported on a plurality of posts. The posts form a plurality of vertical faces arranged between adjacent pairs of the posts, the faces including first and second faces and a power distribution and position reference face. A controllable robotic arm suspends from the rectangular frame section, and a work table fixedly couples to the power distribution and position reference face. A plurality of conveyor tables are fixedly coupled to the work table including a first conveyor table through the first face and a second conveyor table through the second face. A vision system monitors the work table and each of the conveyor tables. A programmable controller monitors signal inputs from the vision system to identify and determine orientation of the component on the first conveyor table and control the robotic arm to execute an assembly task.

42 ENGINEERING↗

DOE OSTI2018

High density grids

An X-ray data collection grid device is provided that includes a magnetic base that is compatible with robotic sample mounting systems used at synchrotron beamlines, a grid element fixedly attached to the magnetic base, where the grid element includes at least one sealable sample window disposed through a planar synchrotron-compatible material, where the planar synchrotron-compatible material includes at least one automated X-ray positioning and fluid handling robot fiducial mark.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Automated, multi-pot high-pressure radio-synthesizer for production of pet tracers

An automated radiosynthesizer device includes a plurality of reactor assemblies, each reactor assembly being operatively connected to a horizontal actuator for moving the reactor assembly in the horizontal direction and a vertical actuator for moving the reactor assembly in the vertical direction. A plurality of disposable cassettes are disposed above each of the plurality of reactor assemblies, each cassette comprising a lower surface comprising a plurality of sealed and un-sealed gaskets, wherein the un-sealed gaskets are connected to internal fluid paths within the cassette. The device includes a three-axis reagent and gas handling robot disposed above the plurality of cassettes and terminates in a vial gripper and a gas manifold having an inert gas port and a vacuum port. The device includes a control system configured to control the horizontal actuator and vertical actuator of each reactor assembly and the three-axis reagent and gas handling robot.

Moore, Melissa↗

DOE OSTI2020

Solar panel field array support system and apparatus and method for construction use

A combined PV panel assembly jig and forklift transport pallet is used to assemble PV panels for transport to a field array from a protected manufacturing environment. The panels are assembled to have adhesively applied rails for transport by a robotic drone on a ground-support rack and are pre-wired. The PV panel assembly jig holds, protects, and aligns the PV panels in an upside down position, opposite to their operational position, for ease of wiring in order to decrease the manual labor required in the field. Once the pallet is transported to the load station at the end of a row of solar panel racks in the field array, a robotic loader lifts the upside down PV panels from the combined PV panel assembly jig and forklift transport pallet in an arcing overhead motion that lifts, tilts, and deposits the PV panels in an upright position at the loading station of a railed rack support as ground-mounted in a solar panel field array.

14 SOLAR ENERGY↗

DOE OSTI2021

System and method for passive assay of holdup deposits in nuclear piping

Disclosed herein are a method, apparatus, and software for passive, non-destructive assay of holdup deposits in nuclear piping by in-pipe apparatus. A detector deployed within a pipe is collimated to observe radiation impinging radially inward from decay of deposits that lie on the pipe wall. A radiation detector is centered in the pipe and collimated by a pair of coaxial shielding discs disposed equidistant from the detector. This arrangement causes radiation from a truncated cylinder of pipe deposit within a field of regard to impinge on the detector, while precluding radiation emanating from pipe walls beyond the field of regard from reaching the detector. Hence, observations are unique to a known cylindrical length of pipe. The detector assembly is translated through pipes by an autonomous mobile robotic apparatus. Computer software controls the robotic apparatus, logs data, and post-processes to assay deposits.

Whittaker, William Lawrence↗

DOE OSTI2023

Automated recovery of rare earth permanent magnets from electric machines

A method for the automated recovery of rare earth permanent magnets from electric machines are provided. The method includes identifying electric machines in a mixed product stream for performing a unique robotic disassembly routine. Electric machines that are not identified are diverted to a robot training station, during which time the system and the method include implementing a suitable disassembly routine. A conveyor delivers the remaining electric machines to a rotary platform having multiple stations for the simultaneous disassembly of multiple electric machines. Permanent magnets are removed from the electric machines and are then sorted for recycling operations.

McIntyre, Timothy J.↗

DOE OSTI2023

Methods and systems of proteome analysis and imaging

Provided herein are methods and systems for proteome analysis that are at least partially automated and/or performed robotically. In some aspects, the methods and systems described herein can rapidly and efficiently provide protein identification of each of the proteins from a proteome, or a complement of proteins, obtained from extremely small amounts of biological samples. The identified proteins can be imaged quantitatively over a spatial region. Automation and robotics facilitates the throughput of the methods and systems, which enables protein imaging and/or rapid proteome analysis.

Piehowski, Paul D.↗

DOE OSTI2013

Activities for the remediation of TEPCO's Fukushima Daiichi nuclear power plant

With the aim of fulfilling recovery work for the Fukushima Daiichi NPP, technological efforts have been made for the development of a survey robot system, adequate communication infrastructure technologies, high radiation environment compatible gamma cameras, heavy machinery-type robots (ASTACO-SoRa), remote decontamination devices (AROUNDER), and contaminated waste water treatment system. We have developed a new type of absorbents which remove cesium (Cs) and strontium (Sr) simultaneously at a high removal rate of 99 % or more. We will provide valuable solutions and rational systems for waste water treatment using this developed adsorbent as well as other various adsorbents for the recovery of Fukushima Daiichi NPP.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2012

The Complex Challenges of Remotely Removing Redundant Pipework and Cleaning/Remediation of Aging Civil Structures at Sellafield - 12446

This paper identifies how a joint Sellafield Ltd/Nuclear Management Partners Tactical Review Team and main contractor, SA Robotics, developed and successfully deployed a solution to clean and coat the wall surface of an aging structure on the Sellafield Site. This involved removal of redundant pipework from the wall, cleaning and coating of the surface using a bespoke designed robotic manipulator with various end effectors. This system was able to safely and in a controlled manner remove the pipework, clean down the wall and prime and coat it within the required programme duration which was 5 months earlier than a previous shielding only option. This was done in a high radiation field and in the challenging conditions of winter in Northern England. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Integrating commercially available remote systems to address current D and D challenges - 15399

Many current D and D challenges across the DOE complex require some form of remote handling expertise and equipment. For example, high visibility projects such as Building 324 D and D and the recovery of wastes from the Alpha-Caissons and the 618 10-11 caissons at Hanford all require the development and application of advanced remote systems. Additionally although alternate solutions and options are being sought, robotic/remote systems will likely be required for completion of D and D at Savannah River Site's Building 235-F, at the West Valley Demonstration Project and many other DOE facilities that are scheduled for D and D. Similar systems are also needed to support the UK cleanup program on projects such as the decommissioning of the Pile Fuel Cladding Silo. As a result, there are a significant number of R and D and Technology Development projects underway in order to address the growing need for remote systems in D and D. In addition to these significant R and D efforts, there are also numerous remote systems in use in multiple applications in both nuclear and non-nuclear industries and the use of remote systems at the Fukushima Daiichi plant has been extensive in the past 12-24 months. In many cases, the systems developed are customized for their given application but there are also multiple systems in use which could be applied to the worldwide D and D challenge either directly or with some minor adaptation. During FY14, the Office of D and D and Facility Engineering (EM13) funded a review/assessment of the current state-of-the-art of robotics and remote technologies in order to generate a baseline of what is available, what has been used where and for what applications and what has been successful and what hasn't. Where possible, the assessment was extended to identify remote systems that have been used in non-nuclear industries but which, with limited modification, may have application in the nuclear industry. The work also included a review of the most recent publicly available TBuRD (Technical Baseline and Underpinning R and D) activities being undertaken by the UK NDA and their Site Licensed Companies (SLCs) in the area of remote systems in order to compile a searchable database of both available, commercial-off-the-shelf (COTS) remote systems and developing technologies. Other suitably qualified organizations in the US and the UK (such as UK National Nuclear Laboratory, SRNL, PNNL ORNL, OC Robotics and others) were also engaged to identify other ongoing technology development efforts which may be of interest and benefit to the decommissioning community. In all, of the order of 500 remote systems were identified and cataloged in both hard copy and as a searchable database. These systems were categorized in terms of their main application e.g. manipulator, wheeled land-based platform, track land-based platform, water-based platform, air-based platform, end effectors, sensor, crawler etc to clearly demonstrate the depth and breadth of available systems in each category. In addition, single page summaries of each system were produced and used, in a workshop setting, to identify technologies which, when integrated with other currently-available technologies, could provide a workable system to address existing needs. An initial workshop was held with CH2 Washington Idaho (CWI) and DOE Idaho in August 2014 to explore how the available systems could be integrated to address current and future D and D needs at that site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Decommissioning Experience at Rokkasho; Standing Type Manipulator: A1000S for Dismantling Tasks - 16434

Decommissioning is a technical process which includes various steps and processes from the clean-up of radioactive materials to the progressive demolition of the plant. One of these steps is the cutting of subassemblies, like tanks, pipes or walls in small pieces suitable for the sorting and disposal. Different solutions are offered for this cutting work and can be grouped as following: - Chip forming - sawing, drilling, milling, turning etc. - Shearing - punching, stamping, scissoring. - Abrading - Grinding, lapping, polishing; water-jet. - Heat - flame cutting, plasma cutting, laser cutting. - Electro-Chemical - Etching, Electrical discharge machining (EDM). Each method has its limitations in accuracy, cost, and effect on the material. In 2013, Waelischmiller Engineering won a contract for two remote handling systems dedicated to the dismantling cell at Rokkasho Nuclear Fuel Reprocessing Facility in Japan. For this project, Inconel and other metals needed to be cut. One of the main cutting methods was decided to use of an angle grinder handled by a robotic arm. Because the use of the overhead systems (bridges and cranes) was difficult for this installation, it was determined, that the best alternative was a power manipulator A1000 installed on the floor with a pre-positioning system. The project proceeded to go forward with the adaptation of the standard A1000 with integration of a control system in a Cartesian coordinate frame; resulting in a heavy duty arm; A1000S with 6 degrees of freedom. The heavy duty power arm A1000S was developed and designed for mechanical cutting with an angle grinder, especially for thick and hard material for example stainless steel and Inconel. Cutting a thick material with an angle grinder requires repeatable precise linear motion, in order not to damage the disc. The angle grinder should be handled with a manipulator which can cut in all directions in a linear motion, since the objects which should be cut are usually very large and fixed in any direction For these requirements, the Cartesian control function was added to our standard power manipulator type A1000. In some cases, the decommissioning work includes repeated access routes or fixed access points that the manipulator arm has to pass repeatedly. For example a fixed point where the waste materials are collected, or repeated transport route that the arm has to go along for each step. For this requirement, the A1000S has been equipped with the 'Go To-Mode'. It is a 'teach and playback mode' which has been developed especially for remote operating manipulators. Quick direct teach, quick play function and an intuitive touch-panel layout are some of the features. With the Go To-Mode high working efficiency was achieved. After rigorous testing at Waelischmiller premises; the manipulator was delivered to JNFL in Rokkasho. It was found that the obtained functionality and precision can be applicable not only for the cutting with a disc grinder, but also the laser cutting method, which requires precise trajectory control. This paper will provide: - A project description, - Presentation of solution process, - Technical description of the A1000S, - Future Applications of the robotic Arm A1000S. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗