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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Fermilab Automation of Coil Winding System

The automated coil winder project creates a repeatable, scalable method for producing superconducting magnet coils with increased accuracy and efficiency. The design uses an ortho cyclic winding method to achieve high fill factors by combining computer numerical control (CNC), microcontroller-based controls, and sophisticated optimization techniques. The method optimizes coil turns, core geometry, and current consumption by utilizing analytical models based on magnetic moment, Ohm’s law, and power constraints. For particle accelerator applications, prototype testing using a 3D-printed coil winder has shown enhanced winding repeatability, thermal management, and manufacturability.

Dzida, Rafal [Northern Illinois U.]↗

DOE OSTI2025

Summer Internship Report: ARA2 Benchmarking

Over the past decade, the RISC-V Instruction Set Architecture (ISA) has emerged as a significant player in both academic and industrial processor design due to its open-source nature, modular extension system, and versatility across domains ranging from microcontrollers to high-performance computing (HPC). One of its most important recent advancements is the RISC-V Vector Extension (RVV), which enables explicit data-level parallelism through vector registers and vectorized instructions. Unlike traditional SIMD (Single Instruction, Multiple Data) architectures that fix vector lengths at design time, RVV uses the concept of VLEN (vector register length) as a hardware-independent parameter and allows software to adapt dynamically to the available vector width. This flexible approach ensures portability across implementations while enabling scalable performance. The ARA2 core is a parameterizable RISC-V vector processor developed at the Integrated Systems Lab at ETH Zürich and the University of Bologna. Designed as a tightly-coupled accelerator to a scalar RISC-V core, ARA2 implements the RVV 1.0 specification and offers tunable architectural parameters such as the number of vector lanes, VLEN, and cache sizes.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Enhanced Lighting Signals for Safety and Efficiency - Experiments With Addressable LEDs

For enhanced roadway safety, clear and immediate visual cues are essential for preventing accidents between drivers and pedestrians. At intersections, however, the line of sight to other roadway users may be obstructed by vehicles and infrastructure. Additionally, adverse conditions, including low visibility, poor weather, or inadequate lighting can increase the potential for collisions. Distracted drivers and pedestrians can further exacerbate the risk of accidents, particularly when using a smartphone, rather than focusing on roadway surroundings. These issues demonstrate the need for infrastructure upgrades that enhance visibility and awareness at crosswalks. A potential solution is through enhanced lighting signals integrated into the roadway infrastructure. One such example is the use of addressable LEDs, individually controllable lights that can change color and brightness instantaneously through programmable microcontrollers. They can be installed and integrated into crosswalks to maintain visibility in conditions where pedestrians may be difficult to see, while also offering peripheral cues to pedestrians who may be distracted by their phones or other objects rather than the road. Such a system (as one example) that is integrated into a traffic intersection digital twin that tracks all roadway users accurately, has the potential to enhance visibility of vulnerable road users, and thus enhance safety. This paper examines the potential implementation and feasibility of this technology, as well as the safety benefits it could provide. Laboratory experiments with addressable LEDs reveal the capabilities and challenges of this technology for roadway infrastructure safety. These findings could pave the way for more integrated lighting in infrastructure for vehicles and pedestrians at intersections, merge and diverge locations, and other areas where complex interactions present safety hazards. Such lighting solutions, enabled by modern computation and communications, could enhance safety and efficiency in our transportation system and improve overall mobility.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Design and implementation of a real-time underwater acoustic telemetry system for fish behavior study and environmental sensing

Underwater acoustic telemetry is an important tool for studying the behavior of aquatic animals and assessing the environmental impact of man-made structures such as water power turbines. However, current design of the acoustic telemetry system lacks the ability to transmit collected data continuously in real-time and requires manual retrieval of the recorded measurements, leading to a long delay of data retrieval, high operational cost associated with manpower as well as safety risk for the operators. In addition, there is no efficient way to monitor the status of the acoustic telemetry system, including acoustic transmitters and receivers. For example, if multiple receivers in an array fail, the detection efficiency could be significantly reduced. Herein, we developed a cloud-based, real-time underwater acoustic telemetry system that can be used to estimate behavior or survival of tagged aquatic animals and monitor environmental parameters in near-real-time (< 2 hours). The system incorporates microcontrollers and integrated circuits to create real-time data communication and processing units with a cloud-based service that processes the transmitted data stream to derive behavior and survival information of the tagged animals.

Yang, Yang↗

DOE OSTI2025

IoT Firmware Emulation and Its Security Application in Fuzzing: A Critical Revisit

As IoT devices with microcontroller (MCU)-based firmware become more common in our lives, memory corruption vulnerabilities in their firmware are increasingly targeted by adversaries. Fuzzing is a powerful method for detecting these vulnerabilities, but it poses unique challenges when applied to IoT devices. Direct fuzzing on these devices is inefficient, and recent efforts have shifted towards creating emulation environments for dynamic firmware testing. However, unlike traditional software, firmware interactions with peripherals that are significantly more diverse presents new challenges for achieving scalable full-system emulation and effective fuzzing. This paper reviews 27 state-of-the-art works in MCU-based firmware emulation and its applications in fuzzing. Instead of classifying existing techniques based on their capabilities and features, we first identify the fundamental challenges faced by firmware emulation and fuzzing. We then revisit recent studies, organizing them according to the specific challenges they address, and discussing how each specific challenge is addressed. We compare the emulation fidelity and bug detection capabilities of various techniques to clearly demonstrate their strengths and weaknesses, aiding users in selecting or combining tools to meet their needs. Finally, we highlight the remaining technical gaps and point out important future research directions in firmware emulation and fuzzing.

Zhou, Wei (ORCID:0000000178340839)↗

DOE OSTI2023

Self-Sustainable IoT-Based Remote Sensing Powered by Energy Harvesting Using Stacked Piezoelectric Transducer and Thermoelectric Generator

We propose a self-powered remote multi-sensing system for traffic sensing which is powered by the collective energy harvested from the mechanical vibration of the road caused by the passing vehicles and from the temperature gradient between the asphalt of the road and the soil underneath. A stacked piezoelectric transducer converts mechanical vibrations into electrical energy and a thermoelectric generator harvests the thermal energy from the thermal gradient. Electrical energy signals from the stacked piezoelectric transducer and the thermoelectric generators are converted into usable DC power to recharge the battery using AC-DC and DC-DC converters working simultaneously. The multi-sensing system comprises an embedded system with a microcontroller that acquires data from the sensors and sends the sensory data to an IoT transceiver which transmits the data as RF packets to an ethernet gateway. The gateway converts the RF packets into Internet Protocol (IP) packets and sends them to a remote server. Laboratory and road-testing results showed over 98% sensory data accuracy with the system functioning solely powered by the energy harvested from the alternative energy sources. The successful maximum transmission distance obtained between the IoT, and the gateway was approximately 1 mile, which is a considerable transmission distance achieved in an urban environment. Successful operation of the self-powered multi-sensing system under both laboratory and road conditions contributes considerably to the fields of energy harvesting and self-powered remote sensing systems. The energy flow chart and efficiency for the steps in the system were found to be mechanical power from vehicles to the energy harvester of 0.25%, stacked PZT transducer efficiency was found to be 37%, and for the TEGs the efficiency is 11%. AC-to-DC and DC-to-DC converters’ efficiencies were found to be 90% and 11%. The wireless communication RF transceiver efficiency was found to be 62.5%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Low-Cost and Portable Biosensor Based on Monitoring Impedance Changes in Aptamer-Functionalized Nanoporous Anodized Aluminum Oxide Membrane

We report a low-cost, portable biosensor composed of an aptamer-functionalized nanoporous anodic aluminum oxide (NAAO) membrane and a commercial microcontroller chip-based impedance reader suitable for electrochemical impedance spectroscopy (EIS)-based sensing. The biosensor consists of two chambers separated by an aptamer-functionalized NAAO membrane, and the impedance reader is utilized to monitor transmembrane impedance changes. The biosensor is utilized to detect amodiaquine molecules using an amodiaquine-binding aptamer (OR7)-functionalized membrane. The aptamer-functionalized membrane is exposed to different concentrations of amodiaquine molecules to characterize the sensitivity of the sensor response. The specificity of the sensor response is characterized by exposure to varying concentrations of chloroquine, which is similar in structure to amodiaquine but does not bind to the OR7 aptamer. A commercial potentiostat is also used to measure the sensor response for amodiaquine and chloroquine. The sensing response measured using both the portable impedance reader and the commercial potentiostat showed a similar dynamic response and detection threshold. The specific and sensitive sensing results for amodiaquine demonstrate the efficacy of the low-cost and portable biosensor.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Exploring MDSplus data-acquisition software and custom devices

MDSplus is a software tool designed for data acquisition, storage, and analysis of complex scientific experiments. Over the years, MDSplus has primarily been used for data management for fusion experiments. This paper demonstrates that MDSplus can be used for a much wider variety of systems and experiments. We present a step-by-step tutorial describing how to create a simple experiment, manage the data, and analyze it using MDSplus and Python. To this end, a custom example device was developed to be used as the data source. This device was built on an opensource electronic hardware platform, and it consists of a microcontroller and two sensors. We read data from these sensors, store it in MDSplus, and use JupyterLab to visualize and process it. This project and code demo are available on the GitHub site at this URL: https://github.com/santorofer/MDSplusAndCustomeDevices

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2016

Low-cost scalable quartz crystal microbalance array for environmental sensing

Proliferation of environmental sensors for internet of things (IoT) applications has increased the need for low-cost platforms capable of accommodating multiple sensors. Quartz crystal microbalance (QCM) crystals coated with nanometer-thin sensor films are suitable for use in high-resolution (~1 ng) selective gas sensor applications. We demonstrate a scalable array for measuring frequency response of six QCM sensors controlled by low-cost Arduino microcontrollers and a USB multiplexer. Gas pulses and data acquisition were controlled by a LabVIEW user interface. We test the sensor array by measuring the frequency shift of crystals coated with different compositions of polymer composites based on poly(3,4-ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS) while films are exposed to water vapor and oxygen inside a controlled environmental chamber. Our sensor array exhibits comparable performance to that of a commercial QCM system, while enabling high-throughput 6 QCM testing for under $1,000. We use deep neural network structures to process sensor response and demonstrate that the QCM array is suitable for gas sensing, environmental monitoring, and electronic-nose applications.

Anazagasty, Cristain↗

DOE OSTI2016

Sensor Fish: an autonomous sensor package for characterizing complex flow fields and fish passage

Fish passing through dams or other hydraulic structures may be injured or killed despite advances in turbine design, project operations, and other fish bypass systems. The Sensor Fish (SF) device is an autonomous sensor package that characterizes the physical conditions and stressors to which fish are exposed during passage through hydro facilities. It was designed to move passively as a neutrally buoyant object through severe hydraulic environments, while collecting high-resolution sensor data. Since its first generation1, the SF device has been successfully deployed in many fish passage studies and has evolved to be a major tool for characterizing fish passage conditions during fish passage in the Columbia River Basin. To better accelerate hydropower development, the U.S. Department of Energy Water Power Program provided funding to develop a new generation (Gen 2 SF) to incorporate more capabilities and accommodate a wider range of users over a broader range of turbine designs and operating environments. The Gen 2 SF (Figure 1) is approximately the size and density of a yearling salmon smolt and is nearly neutrally buoyant. It contains three-dimensional (3D) rotation sensors, 3D linear acceleration sensors, a pressure sensor, a temperature sensor, a 3D orientation sensor, a radiofrequency (RF) transmitter, and a recovery module2. A low-power microcontroller collects data from the sensors and stores up to 5 min of data on internal flash memory at a sampling frequency of 2048 Hz. The recovery module makes the SF positively buoyant after a pre-programmed period of time, causing it to float to the surface for recovery.

Sensor Fish↗

DOE OSTI2018

Advancing the Authenticatable Container Tracking System (ACTS)

The Authenticatable Container Tracking System (ACTS) is an extensible secure container tag that can be used to optimize chain-of-custody monitoring for packaged nuclear materials as they are being stored, processed, and transported. Based on the ultra–low power TI MSP430 mixed-signal microcontroller, ACTS is an active device that uses an almost-universal core platform that can be appropriately configured with expansion modules to provide the application-specific data acquisition, data logging, container sealing, and communications functions needed for 21st century material accountancy, monitoring, and tracking applications. This core architecture enables appropriately designed modules to be easily interfaced to the basic system, providing an integration path for current and new technologies. ACTS contains a built-in set of sensors and supports an expansion bus for up to six additional communications, tracking, authentication, encryption, sealing, location, or sensing modules that may enhance the monitoring and tracking of designated containers for specific applications. To date, testing has used an IEEE 802.15.4-2011 ultra-wideband–compliant wireless transceiver module that has additional capabilities for indoor positioning and proximity location. Proximity-based location (i.e., where an ACTS tag knows where it is relative to other ACTS tags) will be explored as a continuity-of-knowledge mechanism to determine unauthorized movement of containers in storage arrays of many items. Partners for this system are Oak Ridge National Laboratory, Argonne National Laboratory, Savannah River National Laboratory, Pacific Northwest National Laboratory and commercialization partner the Aquila Group.

Younkin, Jim↗

DOE OSTI2018

Autonomous sensor fish to support advanced hydropower development

An improved sensor fish with robust design and enhanced measurement capabilities. This sensor fish contains sensors for acceleration, rotation, magnetic field intensity, pressure, and temperature. A low-power microcontroller collects data from the sensors and stores up to 5 minutes of data on a non-volatile flash memory. A rechargeable battery supplies power to the sensor fish. A recovery system helps locating sensor fish. The package, when ready for use is nearly neutrally buoyant and thus mimics the behavior of an actual fish.

Deng, Daniel Z.↗

DOE OSTI2018

System and method of detecting and analyzing a threat in a confined environment

A system and method of detecting and analyzing a threat in a confined environment is disclosed. An audio board detects and analyzes audio signals. A RF board transmits the signals for emergency response. A battery provides power to the audio board and the RF board. The audio board includes a microcontroller with at least one band-pass filter for distinguishing between a threat and a non-threat event and for measuring or counting pulses if the event is a threat.

47 OTHER INSTRUMENTATION↗

DOE OSTI2019

Management of gas pressure and electrode state of charge in alkaline batteries

An inventive, new system that measures gas composition and pressure in the headspace of an aqueous electrolyte battery is described. The system includes a microcontroller that can use the composition and pressure information to connect a third electrode to either the anode(s) or the cathode(s) in order to balance the state of charge between the two. Results have shown that such a system can control the gas pressure inside a sealed flooded aqueous electrolyte battery to remain below 20 kPa (3 psi) and greatly extend the useable life of the battery.

25 ENERGY STORAGE↗

DOE OSTI2020

Payload interposer (PIP) system and control software

A payload interposer (PIP) system and its control software provide an interface between a space vehicle and a payload. The PIP board facilitates power and communications between a command and data handler (CDH) of the space vehicle and the payload. A microcontroller of the PIP board may control operation of the payload, format messages between the space vehicle and the payload, and extract data from the payload for downlink via the space vehicle.

42 ENGINEERING↗

DOE OSTI2021

Control-Theory-Informed Feature Selection for Detecting Malicious Tampering in Additive Layer Manufacturing Processes

Additive layer manufacturing (ALM) is rapidly becoming an appealing solution to the low-volume manufacturing of metal, polymer, or composite parts. However, ALM’s reliance on digital part specifications, microcontrollers, and modern networking makes these devices vulnerable to malicious tampering by cyber attackers, which can negatively affect part performance and even result in catastrophic failure. We present a hybrid analytic approach to feature discovery using control theoretic techniques and linear modelling on input-output data collected from a representative controller system. Employing this approach, we design, train, and test an anomaly detection system. The preliminary results show that the proposed approach effectively discovers useful input-output relationships for anomaly detection in a simulated ALM process. Application to larger and more complex systems are discussed.

Dawson, Joel↗

DOE OSTI2021

Autonomous sensor fish to support advanced hydropower development

Deng, Z. Daniel↗

DOE OSTI2021

Multi-sensor agent devices

Apparatus, methods, and systems implementing multi-sensor agent devices are described herein. The agent devices can each include a plurality of sensors for measuring parameters of interest to an entity such as an electric power utility. The sensors can be organized in individually-IP-addressable sensor clusters, with each sensor cluster including an associated microcontroller. The agent devices can be controlled by a control center of the entity to operate in a coordinated manner, such as to gather and transmit data regarding parameters of interest. The agent devices can be transported to desired areas for data collection by unmanned aerial systems such as drones, and the collected data can be stored in a distributed blockchain ledger.

Fuhr, Peter L.↗