Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “machining processes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 811 records · Page 45

Natural Language Processing Methods for Air Traffic Management Text and Speech Data

This presentation discusses two efforts of the NARI AI/ML Intern team during the Fall 2021 OSTEM Internship term. For Letters of Agreement (LoA), we have studied how LoAs are structured and explored the question ‘What is an LoA constraint?’ To do this, our approach is data-driven, iterative, and assisted by machine learning when available. In this presentation, we will walk through our tasks of manually scanning through documents, performing a preliminary entity labelling task, and our unsupervised analysis on LoA procedures sections. After this research phase, we define the smallest constraint unit in an LoA, and start to perform entity extraction. Looking towards constraint extraction, we are also exploring the use of a one-class support vector machine (OneClassSVM) model to identify patterns within the data. The second effort of our team this term is focused on Air Traffic Control System Command Center (ATCSCC) advisory meetings, and the subsequent advisory documents that get published from their content. These advisory documents are important to give readily accessible summaries of daily operations, so that data centers, airline officials, and other stakeholders can easily understand the context of these meetings in real time. In applying machine learning to this scenario, two natural language processing tasks are used. First is developing machine learning models to convert the meeting speech data into text. With this text, use of extractive and abstractive text summarization models are used to automatically generate preliminary versions of the advisory documents.

Natural Language Processing↗

Air Traffic Complexity Measurement Environment (ACME): Software User's Guide

A user's guide for the Air Traffic Complexity Measurement Environment (ACME) software is presented. The ACME consists of two major components, a complexity analysis tool and user interface. The Complexity Analysis Tool (CAT) analyzes complexity off-line, producing data files which may be examined interactively via the Complexity Data Analysis Tool (CDAT). The Complexity Analysis Tool is composed of three independently executing processes that communicate via PVM (Parallel Virtual Machine) and Unix sockets. The Runtime Data Management and Control process (RUNDMC) extracts flight plan and track information from a SAR input file, and sends the information to GARP (Generate Aircraft Routes Process) and CAT (Complexity Analysis Task). GARP in turn generates aircraft trajectories, which are utilized by CAT to calculate sector complexity. CAT writes flight plan, track and complexity data to an output file, which can be examined interactively. The Complexity Data Analysis Tool (CDAT) provides an interactive graphic environment for examining the complexity data produced by the Complexity Analysis Tool (CAT). CDAT can also play back track data extracted from System Analysis Recording (SAR) tapes. The CDAT user interface consists of a primary window, a controls window, and miscellaneous pop-ups. Aircraft track and position data is displayed in the main viewing area of the primary window. The controls window contains miscellaneous control and display items. Complexity data is displayed in pop-up windows. CDAT plays back sector complexity and aircraft track and position data as a function of time. Controls are provided to start and stop playback, adjust the playback rate, and reposition the display to a specified time.

Source record↗

MSL Telecom Automated Anomaly Detection

The Mars Science Laboratory (MSL) Telecom Operations Team at the Jet Propulsion Laboratory (JPL) has implemented a machine learning system in order to automate the anomaly detection process as a part of daily operations. Machine learning enables reliable detection of anomalies in Telecom-related telemetry and automated reporting of Telecom subsystem status, resulting in an 90% reduction in team workload and improved anomaly detection reliability. At present, machine learning methods are used to detect: 1. Anomalous long-term trends in telemetry data 2. Anomalous time-domain evolution of telemetry values Both types of anomalies pose their own unique challenges that are addressed in different ways. In the first case, long term trending of daily minima, maximum, and mean telemetry values in temperatures, currents, voltages, and radio frequency (RF) power levels is used in addition to hard threshold safety checks to look for changes in long-term equipment health and performance. Long-term trending methods allow for ordinary seasonal variations in these quantities caused by temperature changes over the course of the Martian year while allowing operators to determine whether current performance remains in line with historical values from previous years. Changes in long-term trends can provide important insights into the health and status of the rover's on-board systems as well as valuable early warning if subtle degradation begins to take hold. But while trending of daily statistics is valuable, it does not detect anomalies in the short-term time evolution of data over the course of minutes or hours during a day, and this task is handled with short-term shape analysis. Principal components analysis (PCA) has been found to provide robust detection of short-term anomalies, and several examples of the use of PCA to detect actual anomalous events will be provided here. In using PCA, we use both the percentage of explained variance and also a log likelihood test on the PCA expansion coefficients to flag telemetry data for human review. Previous work in the field of spacecraft anomaly detection includes [1] for MSL and [2] for some other JPL missions.

Mukai, Ryan↗

Teaching AI when to care about gender

Natural Language Processing (NLP) is a branch of Artificial Intelligence (AI) concerned with solving language tasks by modeling large amounts of textual data. Some NLP techniques use word embeddings which are semantic models where machine learning (ML) is used to learn to cluster semantically related words by learning about word co-occurrences in the original training text. Unfortunately, these models tend to reflect or even exaggerate biases that are present in the training corpus. Here we describe the Word Embedding Navigator (WEN), which is a tool for exploring word embedding models. We examine a specific potential use case for this tool: interactive discovery and neutralization of gender bias in word embedding models, and compare this human-in-the-loop approach to reducing bias in word embeddings with a debiasing post-processing technique.

97 MATHEMATICS AND COMPUTING↗

Finding Electronic Structure Machine Learning Surrogates without Training

A myriad of phenomena in materials science and chemistry rely on quantum-level simulations of the electronic structure in matter. While moving to larger length and time scales has been a pressing issue for decades, such large-scale electronic structure calculations are still challenging despite modern software approaches and advances in high-performance computing. The silver lining in this regard is the use of machine learning to accelerate electronic structure calculations – this line of research has recently gained growing attention. The grand challenge therein is finding a suitable machine-learning model during a process called hyperparameter optimization. This, however, causes a massive computational overhead in addition to that of data generation. We accelerate the construction of machine-learning surrogate models by roughly two orders of magnitude by circumventing excessive training during the hyperparameter optimization phase. We demonstrate our workflow for Kohn-Sham density functional theory, the most popular computational method in materials science and chemistry.

36 MATERIALS SCIENCE↗

Development of advanced Czochralski growth process to produce low-cost 150 kG silicon ingots from a single crucible for technology readiness

The modified CG2000 crystal grower construction, installation, and machine check out was completed. The process development check out proceeded with several dry runs and one growth run. Several machine calibrations and functional problems were discovered and corrected. Exhaust gas analysis system alternatives were evaluated and an integrated system approved and ordered. Several growth runs on a development CG2000 RC grower show that complete neck, crown, and body automated growth can be achieved with only one operator input.

Source record↗

Freeform thermoelectrics in single-step manufacturing: additive manufacturing of bismuth-telluride thermoelectrics

The project succeeded in producing crack-free Bismuth Telluride thermoelectric parts with density exceeding 98% through laser powder bed fusion (LPBF) additive manufacturing (AM). This greatly exceeded the highest previously reported density of 88% and is the highest among all semiconducting materials processed by LPBF. The additively manufactured material shows comparable Seebeck coefficient as conventional form and can be made into complex geometries with reduced material loss. On the other hand, measured properties are dramatically sensitive to the AM process parameters used, such that with identical composition, the Seebeck coefficient can be controllably tuned from +120 µV/K to -207 µV/K, which means the material switches between an n-type to a p-type semiconductor depending on processing. These changes are accompanied by significant differences in the as-processed microstructure due to rapid solidification. A machine learning protocol was developed and greatly reduced the experimental burden of the project, reducing the typical process optimization period of 2 years to 6 months. The project was fully successful in the objective of producing defect-free, complex geometry of bismuth-telluride parts through LPBF, but only partially successful in achieving performance goals. First, cost reduction of manufacturing, as measured by material waste, was successfully reduced by up to 70% compared to conventional manufacturing methods. This exceeded the proposed 30% reduction in materials waste needed to reach the 20% cost reduction goal of the project. On the other hand, the device performance, as measured by Seebeck coefficient, failed to reach the 40% improvement in efficiency. Rather, we observe comparable Seebeck coefficient between AM samples and conventionally processed counterparts. The device-level efficiency improvement does exceed 40% for complex geometry samples due to shape-induced increase in temperature gradients, but this was not the originally proposed metric. The machine learning approach developed in this project greatly accelerated the process optimization and can be adopted for fast development of AM processing parameters for other brittle and otherwise difficult-to-print materials. For the public, we deliver an efficient and widely adoptable process for incorporating waste-heat harvesting thermoelectric devices in both industrial and commercial heat exchangers. The geometric flexibility allows the capturing device to conform to the shape of the heat source to improve the system-level conversion efficiency. The technique can be deployed on any commercial LBPF systems with zero modifications, thus poses minimal adoption barrier for any manufacturer that already employed AM technology. Beyond bismuth-telluride, the machine-learning guided optimization protocol can be used in the future to reduce both the time and cost of process development for AM of other energy conversion and harvesting materials.

36 MATERIALS SCIENCE↗

Machine-Protection System for the PIP-II Linear Accelerator: Architecture and Data Processing Schemes

PIP-II at Fermilab features a brand-new, 800 MeV leading-edge Linear Accelerator (Linac) that will enable the Fermilab complex to deliver more than a megawatt of beam power to the Long Base-line Neutrino Facility (LBNF), requiring a robust Machine Protection System (MPS) to prevent beam-induced damage to delicate cryomodules and vacuum components. Signals in various accelerator components, in both analog and digital format, are collected and processed to assest the operating conditions of the accelerator. In the situation a potential damage is foreseen, the beam permit signal will be drop. A critical element of this system is the fast Analog Machine Protection System, a high-bandwidth platform designed for real-time beam loss monitoring. The system utilizes a modular, FPGA-based architecture to digitize signals from beam-sensing devices, such as AC Current Transformers (ACCTs), non-invasive Ring Pickups (RPUs) and beam scrapers. To eliminate both high frequency as well as 60 Hz noise that might be picked up in the industrial environment, data processing schemes beyond regular digital filtering are planned and implemented.

Wu, Jinyuan [Fermilab] (ORCID:0000000344329521)↗

Learning Model Structural Uncertainty with Gaussian Processes

The advent of commercially available quantum computers has marked the beginning of quantum computing as a reality. Both quantum gate and annealing computers have been released by major computer hardware companies. In this work, the D-Wave 2XTM quantum annealing computer housed at the NASA Advanced Systems computational facility is investigated to accelerate Machine Learning (ML) for image registration. NASA collects large amounts of images over the globe remotely using space-based monitoring. Images of a fixed areas of the land surface are taken over time. Due to the orbit of the sensors, the viewing angles deviate slightly, and it is necessary to align or register the images precisely to create image time series over the land surface. Unaligned images can lead to substantial analysis errors. These time-series are then used in modeling Earth Systems models such as hydrological, weather, and carbon monitoring models. In this work, we consider the Moderate Resolution Image Spectrometer (MODIS) data collected by the NASA's terra satellite. Artificial Neural Networks (ANNs) is a natural fit for ML modelling of images. Several successes have been reported using machine learning related to image processing. We investigate the use of ML to register MODIS images. ANNs are investigated in combination with a Restricted Boltzmann Machines (RBM) as an auto-encoder. We will present results showing the accuracy and efficiency of this approach.The D-Wave 2XTM quantum annealer samples the ground-state wave-function of a spin-Ising systems with quadratic interactions between qubits and a Chimera connectivity. The system sits in a ~15 mK thermal bath. One can think of the system as being placed in the ground state initially and subject to thermal excitations governed by Boltzmann statistics. If this is assumed true, one can use the statistics from the D-Wave 2XTM to train RBMs. Generating statistics for training Boltzmann machines is an NP-hard problem and constitutes the largest compute cost. We investigate the use of the D-Wave 2XTM to accelerate the training of the RBMs in our ANNs and report on the results.

Kouatchou, Jules↗

Recent advances in integrated hydrologic models: Integration of new domains

Over the past several decades, hydrologic models have advanced from independent models of the surface and subsurface to integrated models that can capture the terrestrial hydrologic cycle within one framework. In recent years, these coupled frameworks have seen the inclusion of biogeochemical processes, ecohydrology, sedimentation and erosion, cold region hydrology, anthropogenic activities, and atmospheric processes. This expansion is the result of increased computational, data, and modeling capabilities and capacities, as well as improved understanding of the processes that drive these integrated systems. Here, in this study, we review these recent advances to integrate new processes and systems into existing terrestrial hydrologic models and highlight the significant challenges and opportunities that remain. We identify that with so many models currently available and in development, selecting the most appropriate model is difficult, and we suggest a path for new or novice modelers to find the most appropriate code based on their needs. In addition, data required to parameterize and calibrate these models can often constrain their applicability and usefulness. However, advances in environmental sensors and measurement technology, in addition to data assimilation of non-traditional data (e.g. remote sensing, qualitative data) are providing new ways of addressing this issue. As we expand hydrologic models to integrate more processes and systems, our computational demands also increase. Recent and emerging advances in computational platforms, including cloud and quantum computing, in addition to the use of machine learning to capture some processes, will continue to support the use of increasingly larger and more complex, process-based models. Finally, we highlight that it is critical to develop state-of-the-science models that are accessible to all model users, not just those applied for research and development. We encourage continued development of diverse modeling platforms, considering the user needs, data availability, and computational resources.

54 ENVIRONMENTAL SCIENCES↗

Rapid Commissioning of Large Machine Tools Using Finite Element-Based Correction of Geometric Errors

Large computer numerical control (CNC) machine tools derive their stiffness from monolithic cast iron bases or weldments that are sometimes integral to machine motion systems like box ways or guideways. However, the sheer size of castings and even floor flatness deviations result in dimensional errors in these systems, which manifest as machine motion errors. Typical geometric alignment processes rely on an iterative approach, where measurements are taken to assess alignment (straightness, squareness, and parallelism), followed by adjustment of the machine supports (fixators or leveling pads), which can take weeks even for an experienced operator. Conversely, a novel method is proposed to shorten the correction time by eliminating the trial-and-error process in favor of a more deterministic approach guided by a finite element (FE) method. A feasibility study is conducted on a CNC polymer hybrid machine, with a steel weldment frame, supported by six leveling pads. An FE model of the frame is utilized to obtain recommended leveling pad adjustments, based on measurement of machine errors taken using a laser tracker. After a single adjustment cycle, measurements reveal that geometric errors of the machine tool are reduced from 2.22 mm of flatness deviation to 0.32 mm, achieving an 85.6% reduction. Furthermore, the entire process including measurement, adjustment, and assessment is completed in just 6 h by two operators who are not professional service engineers. In conclusion, this methodology demonstrates feasibility for scaling up, especially to large, high-precision CNC machine tools with bases mounted by fixators, offering the capability for bidirectional adjustment.

42 ENGINEERING↗

Cost Estimation of a Permanent Magnet Synchronous Machine for Use in Adjustable Speed-Pumped Storage Hydropower

Electric machine design has become an easier process with the availability of computers in recent decades. However, the interest in electric machine design among students has declined. University-level design courses must compete with courses perceived as more desirable by the potential job market. Hence, the power system engineers with this expertise are very few and are nearing retirement. Contrarily, renewable energy has been picking up in the past few decades. The indeterminacy and variation of renewable energy sources require a balancing mechanism to maintain the constant voltage and frequency of the grid. Adjustable-Speed Pumped-Storage Hydropower plants are considered the contender for future energy storage, providing large capacity and fast-acting response. Large-scale hydropower applications depend on the natural characteristics of each project site, making less expensive, off-the-shelf generators unfeasible. This work gives a shortcut to estimate the cost of constructing a permanent magnet generator for low-volume manufacturing.

13 HYDRO ENERGY↗

Deep learning categorization of infrasound array data

Here we develop a deep learning-based infrasonic detection and categorization methodology that uses convolutional neural networks with self-attention layers to identify stationary and non-stationary signals in infrasound array processing results. Using features extracted from the coherence and direction-of-arrival information from beamforming at different infrasound arrays, our model more reliably detects signals compared with raw waveform data. Using three infrasound stations maintained as part of the International Monitoring System, we construct an analyst-reviewed data set for model training and evaluation. We construct models using a 4-category framework, a generalized noise vs non-noise detection scheme, and a signal-of-interest (SOI) categorization framework that merges short duration stationary and non-stationary categories into a single SOI category. We evaluate these models using a combination of k-fold cross-validation, comparison with an existing “state-of-the-art” detector, and a transportability analysis. Although results are mixed in distinguishing stationary and non-stationary short duration signals, f-scores for the noise vs non-noise and SOI analyses are consistently above 0.96, implying that deep learning-based infrasonic categorization is a highly accurate means of identifying signals-of-interest in infrasonic data records.

47 OTHER INSTRUMENTATION↗

Fitness For Service Assessment of a Corroded Heat Exchanger

Within the Fermi National Accelerator complex, there exist various water systems that support accelerator operations. One of these systems is extremely vital to the operation of the machine; that is the cooling system. The cooling system consists of nine relatively large heat exchangers that take untreated pond water and use it to cool the process fluid that further cools machine components. Over the 30 years these heat exchangers have been in operation, they have undergone significant material loss on the channels. This material loss, due to various forms of corrosion such as galvanic and microbiologically influenced corrosion (MIC) and possibly others, has deteriorated more than 80% of the nominal wall thickness of some of the exchangers and placed them in a questionable state. ASME FFS-1 (API 579) has been applied to address the condition of the heat exchangers due to their noncompliance with the governing code, BPVC Sec. VIII Div. 1. The assessments encompassed ASME FFS-1 parts 4: General Metal Loss and 9: Crack Like Flaw using level 1, 2, and 3 analysis techniques based on inspection data obtained by API 510 inspections. Level 1 and 2 assessments were deemed unfit for the corroded regions due to their location relative to a major structural discontinuity (channel to tube-sheet joint), so a level 3 analysis was conducted according to ASME Sec. VIII Div. 2 (design by analysis) rules for pressure vessels. Supplemental information included pond water tests to determine an accurate future corrosion allowance due to lacking inspection history. A leak before break (LBB) route was chosen to evaluate the possibility of leaking prior to the onset of failure. The analysis of one heat exchanger shows that the possibility the channel will develop a pinhole leak over 2.5 more years of operation should not be overlooked, but burst was unlikely from operation. The use of fracture mechanics show, that if a through-wall crack were to develop, it would not propagate further than the channel geometry and cause a leak not greater than 35 GPM. Using ASME Section XI Code Case N-705-1, allowing us to operate with a leak until the next outage given certain operating conditions and developing a leak mitigation procedure, this heat exchanger is deemed fit-for-service.

Humenik, Alex [Fermilab]↗

On the Stability of Jump-Linear Systems Driven by Finite-State Machines with Markovian Inputs

This paper presents two mean-square stability tests for a jump-linear system driven by a finite-state machine with a first-order Markovian input process. The first test is based on conventional Markov jump-linear theory and avoids the use of any higher-order statistics. The second test is developed directly using the higher-order statistics of the machine s output process. The two approaches are illustrated with a simple model for a recoverable computer control system.

Patilkulkarni, Sudarshan↗

Bayesian Active Learning for Scanning Probe Microscopy: From Gaussian Processes to Hypothesis Learning

Recent progress in machine learning methods and the emerging availability of programmable interfaces for scanning probe microscopes (SPMs) have propelled automated and autonomous microscopies to the forefront of attention of the scientific community. However, enabling automated microscopy requires the development of task-specific machine learning methods, understanding the interplay between physics discovery and machine learning, and fully defined discovery workflows. This, in turn, requires balancing the physical intuition and prior knowledge of the domain scientist with rewards that define experimental goals and machine learning algorithms that can translate these to specific experimental protocols. Here, we discuss the basic principles of Bayesian active learning and illustrate its applications for SPM. We progress from the Gaussian process as a simple data-driven method and Bayesian inference for physical models as an extension of physics-based functional fits to more complex deep kernel learning methods, structured Gaussian processes, and hypothesis learning. These frameworks allow for the use of prior data, the discovery of specific functionalities as encoded in spectral data, and exploration of physical laws manifesting during the experiment. Here, the discussed framework can be universally applied to all techniques combining imaging and spectroscopy, SPM methods, nanoindentation, electron microscopy and spectroscopy, and chemical imaging methods and can be particularly impactful for destructive or irreversible measurements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Knowledge elicitation for an operator assistant system in process control tasks

A knowledge based system (KBS) methodology designed to study human machine interactions and levels of autonomy in allocation of process control tasks is presented. Users are provided with operation manuals to assist them in normal and abnormal situations. Unfortunately, operation manuals usually represent only the functioning logic of the system to be controlled. The user logic is often totally different. A method is focused on which illicits user logic to refine a KBS shell called an Operator Assistant (OA). If the OA is to help the user, it is necessary to know what level of autonomy gives the optimal performance of the overall man-machine system. For example, for diagnoses that must be carried out carefully by both the user and the OA, interactions are frequent, and processing is mostly sequential. Other diagnoses can be automated, in which the case the OA must be able to explain its reasoning in an appropriate level of detail. OA structure was used to design a working KBS called HORSES (Human Orbital Refueling System Expert System). Protocol analysis of pilots interacting with this system reveals that the a-priori analytical knowledge becomes more structured with training and the situation patterns more complex and dynamic. This approach can improve the a-priori understanding of human and automatic reasoning.

Boy, Guy A.↗