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DOE OSTI2026

Quality Control of Silicon Sensor Modules for Particle Detectors

The High-Luminosity Large Hadron Collider (HL-LHC) will produce a higher rate of particle collisions than the current Large Hadron Collider (LHC), requiring significant upgrades to the Compact Muon Solenoid (CMS) to handle the increased amount of data. An important upgrade is the Phase-2 Outer Tracker Upgrade, which consists of 13,000 silicon sensor modules made of two parallel silicon sensors and readout electronics. These modules undergo careful quality control checks both during and after module assembly to ensure precise and reliable detector performance. This project focuses on precision testing for quality control of silicon sensor modules at Fermilab. Hands-on work includes visual inspection, current-voltage testing, module testing, and ultraviolet (UV) light exposure of modules showing abnormal current-voltage behavior. The ultraviolet exposure process improves the abnormal sensor readout data by placing the selected sensor side of the module directly under the UV light inside a controlled box. In addition to laboratory testing and ultraviolet experiments, I developed a Python-based data tool that connects to a module database and allows selected testing conditions and module information to be retrieved and displayed efficiently. These different testing procedures, experimental processes, and computational tools support the broader goal of identifying module issues and improving modules that will be used in the CMS Outer Tracker Phase-2 Upgrade.

Siddiqui, Hooriya [DuPage Coll.; Fermilab] (ORCID:↗

DOE OSTI2026

Lessons learned from the development and implementation of a workforce training curriculum for advanced controls for high performance HVAC systems

Over the past decade, academic research on advanced controls has slowly transitioned into new software platforms, giving rise to various companies developing and deploying these innovative products, including solutions for light commercial HVAC systems. However, the current workforce remains widely unprepared to install, maintain and operate these systems, particularly complex software-based control platforms, as most workforce training programs still focus on traditional building automation for large commercial buildings. This paper presents the development and piloting of curriculum for three key types of professionals: ● Technicians (trade-level): installing and maintaining modern high-performance HVAC systems and controls ● Programmers (undergrad-level): developing and implementing advanced controls ● Engineers and energy professionals (undergrad/grad-level): managing and evaluating system performance We share details of the material developed including training videos, open-source software, instruction manuals. We also present the results of a pilot implementation of the training materials with real students.

Casillas, Armando↗

DOE OSTI2021

Recommendations for Distributed Energy Resource Access Control

Cybersecurity for internet - connected Distributed Energy Resources (DER) is essential for the safe and reliable operation of the US power system. Many facets of DER cybersecurity are currently being investigated within different standards development organizations, research communities, and industry committees to address this critical need. This report covers DER access control guidance compiled by the Access Controls Subgroup of the SunSpec/Sandia DER Cybersecurity Workgroup. The goal of the group was to create a consensus - based technical framework to minimize the risk of unauthorized access to DER systems. The subgroup set out to define a strict control environment where users are authorized to access DER monitoring and control features through three steps: (a) user is identified using a proof-of-identity, (b) the user is authenticated by a managed database, (c) and the user is authorized for a specific level of access. DER access control also provides accountability and nonrepudiation within the power system control environment that can be used for forensic analysis and attribution in the event of a cyber-attack. This paper covers foundational requirements for a DER access control environment as well as offering a collection of possible policy, model, and mechanism implementation approaches for IEEE 1547-mandated communication protocols.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2020

Systems and methods for control of polymer reactions and processing using automatic continuous online monitoring

Manual and automatic methods and devices using a ACOMP system for active control of polymerization reaction processes. An ideal desired trajectory of one or more reaction and polymer characteristics can be established to produce a desired final polymer product with specified characteristics from a polymerization reaction process. A current reaction trajectory of a polymerization reaction process can be driven to an ideal or desired reaction trajectory. In a manual embodiment an operator can use ACOMP data to adjust process variables in order to drive the current reaction trajectory toward the ideal or desired reaction trajectory. In an automated mode a control program can use ACOMP data to make adjustments to process variables to drive the polymerization reaction process toward the desired trajectory as closely as possible either empirically or by solving the governing equations for the polymerization reaction process.

Reed, Wayne Frederick↗

DOE OSTI2026

Submodule-Level Decentralized Control for Cascaded Quadruple Active Bridge-Based Medium-Voltage Converters

High-power, low-voltage DC (LVDC) loads, such as AI data centers, electric vehicle fast-charging hubs, and hydrogen electrolyzers, are accelerating the deployment of solid-state transformers (SSTs) that directly interface medium-voltage AC (MVAC) to LVDC, streamlining power delivery. This paper proposes a submodule-level decentralized control strategy for an SST comprising a cascaded H-bridge (CHB) active rectifier on the MVAC side and per-module quadruple-active-bridge (QAB) converters on the LVDC side with local controllers. The proposed strategy eliminates the need for high-fidelity, real-time cross-isolation communication by synchronizing all active bridges to a common heartbeat signal and enabling the primary- and secondary-side controllers to generate independent local control signals (phase shifts). The resultant phase shifts naturally govern average and double-line frequency power transfer between active bridges, enabling each side to meet its control objectives using only local measurements. Detailed controller design considerations are presented based on a stability analysis. Comprehensive electromagnetic-transient simulations demonstrate tight DC-link voltage regulation, high-quality grid currents, and robust operation under load transients and grid disturbances, without real-time communication among the submodule controllers. These results indicate that the proposed scheme can significantly enhance the reliability, scalability, and flexibility of cascaded bridge-based medium-voltage converters.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Submodule-Level Decentralized Control for Cascaded Quadruple Active Bridge-Based Medium-Voltage Converters: Preprint

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Recommended Functionalities for Improving Cybersecurity of Distributed Energy Resources

The current electric grid is transitioning through increasing penetration of distributed energy resources (DERs), which include intermittent renewable generation resources on the distribution side. Both the monitoring and control of DERs require extensive data-exchange and communication networks. These networks lead to cyber vulnerabilities and risks of new kinds of cyberattacks that may be extremely destructive for power system operations. Although current standards, such as IEEE Std. 1547-2018, do not discuss cybersecurity measures for DERs, cybersecurity controls should be developed for securing DER systems at the device level, communications level, and applications level. This paper discusses the current industry's best practices related to DER cybersecurity and proposes recommended functionalities for improving the cybersecurity posture of DERs, specifically at the device/distribution level. These practical recommendations have been discussed and verified with the industry through a DER cybersecurity working group.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Grid Parameters and Voltage Estimation Approach Integrating Data-Driven Converter Model

With Measurements of grid voltage and current are essential for the optimal operation of the grid protection and control (P&C) systems. Grid parameters vary through time during the faults and especially in the converter interfaced resources (CIRs) rich power grid, and thus accurate estimation is critical to avoid the mis-operation of the P&C systems. In this paper, a moving horizon estimation (MHE) as an observer is devised and applied to estimate the grid line parameters and grid voltages for protection enhancement. Due to the proprietary and confidentiality of CIRs, the proposed approach uses the black-box model to represent their dynamics. Leveraging the easily accessible measurements of output current from the black-box model of CIR and voltage at the point of common coupling, the proposed method estimates the grid impedance and grid voltage during normal and faulty operating conditions. The performance shows that the optimization-based observer was able to closely observe the accurate states and parameters, which can be utilized by the P&C systems.

Subedi, Sunil↗

DOE OSTI2020

Analysis of High Frequency AC Link Isolated Three Port Resonant Converter for UAV Applications

A high frequency AC link isolated three port semi-bridgeless resonant converter is analyzed for unmanned aerial vehicle (UAV) applications in this study. The proposed topology is established by replacing rectifier lover diodes with synchronous switches. A phase shifted pulse width modulation (PS-PWM) technique adjusts bi-directional power flow between ports. Proposed control technique provides high efficiency by reducing switching losses with zero voltage switching (ZVS) and zero current switching (ZCS) in a wide power range regulation. Compared to integrated PWM converters in a bi-directional mode, the proposed topology reduces the number of converter stages and allows centralized control at high operating frequency. Theoretical and experimental results demonstrate the feasibility and effectiveness of the proposed converter at a full power of 500 W in laboratory conditions.

Asa, Erdem↗

DOE OSTI2023

Polarization and phase control of electron injection and acceleration in the plasma by a self-steepening laser pulse

Abstract We describe an interplay between two injection mechanism of background electrons into an evolving plasma bubble behind an intense laser pulse: one due to the overall bubble expansion, and another due to its periodic undulation. The two mechanisms occur simultaneously when an intense laser pulse propagating inside a plasma forms a shock-like steepened front. Periodic undulations of the plasma bubble along the laser propagation path can either inhibit or conspire with electron injection due to bubble expansion. We show that carrier-envelope-phase (CEP) controlled plasma bubble undulation induced by the self-steepening laser pulse produces a unique electron injector—expanding phase-controlled undulating bubble (EPUB). The longitudinal structure of the electron bunch injected by the EPUB can be controlled by laser polarization and power, resulting in high-charge (multiple nano-Coulombs) high-current (tens of kilo-amperes) electron beams with ultra-short (femtosecond-scale) temporal structure. Generation of high-energy betatron radiation with polarization- and CEP-controlled energy spectrum and angular distribution is analyzed as a promising application of EPUB-produced beams.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Control, Fault Management, and Grid Support Functionality of an MV AC-DC Solid State Transformer based EV Extreme Fast Charging Station

Electric vehicles (EVs) have become increasingly popular in recent times while revolutionizing the consumer and commercial transportation market. The development of charging infrastructure has become one of the priorities for increasing the adoption of EVs. Extreme fast charging (XFC) technology can reduce the so-called ’range anxiety’ of consumers as they significantly reduce the charging time. With the advent of wide band-gap (WBG) power devices and improvement in power electronic converters, medium voltage (MV) solid state transformer (SST) based XFC system has the potential to replace the traditional XFC stations because of the lower footprint, ease of installation, enhanced control feature, and better system efficiency. The control system design is one of the critical aspects of the SST development process. Careful consideration and detailed analysis are required to find out suitable control method for the SST based on its topology among different centralized and decentralized control architectures. Also, the control parameters selection and potential improvement to the transient response of the controller ought to be investigated. Another major concern of the SST is different types of internal fault which reduces the overall reliability of the XFC system. As a result, designing a robust protection system is essential. Among different fault modes, open circuit switch faults have received significant attention as an active research area because of their likelihood and severe effects on converters. Therefore, the power stages used in the XFC system require functional and accurate open circuit switch fault management methods. An equally significant aspect of this SST based XFC is its compatibility in a microgrid where there is no synchronous generator present. When the grid is not available, the XFC SSTs can provide grid forming capability and continue supplying the critical loads in islanded mode. The transition between grid connected and islanded mode, especially the grid resynchronization process has to be carefully performed for the safety of the microgrid components. The challenges posed by the aforementioned issues have inspired the work done in this dissertation. Here, a 13.2 kV, 1 MVA, AC/DC SST for the XFC system is examined and a comparative analysis is conducted to select the control architecture based on feasibility of implementation and performance. A detailed control parameter design process is demonstrated considering the sensor dynamics and delay. The selected decentralized control method is augmented by introducing a novel sensor-less load current feedforward method to provide better voltage regulation at the DC bus during a change of load. Next, in the fault management section, a hierarchical failure mode effect analysis (FMEA) is proposed to enable a systematic design of the internal fault protection of the XFC SST as there are limited examples in the literature regarding the analysis of the safety and design of the protection of a power electronic converter system. Novel open circuit switch fault management methods for the converters in the system are presented. Finally, XFC SST based MV microgrid operations in grid connected mode and islanded mode are explored. A secondary control method for grid resynchronization is presented and a design process of control parameters is shown to ensure the stability of the secondary voltage and frequency regulation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

T-Type Modular DC Circuit Breaker (T-Breaker) for Future DC Networks

The developed T-Type Modular DC Circuit Breaker (T-Breaker) technology offers an all-in-one solution to challenges in DC networks. This includes swift fault detection and protection, power transient stability, and power quality improvement, achieved through the utilization of wide bandgap (WBG) power semiconductors and energy storage devices. The T-Breaker not only facilitates rapid fault current detection and interruption but also implements fault current limiting through active insertion of storage devices or by operating WBG devices in the saturation region. Additionally, with the assistance of energy storage devices, potential overvoltage issues on power devices induced by control signal misalignment can be mitigated. The T-Breaker can be regulated to perform shunt current injection/absorption using the vertical arm and series voltage insertion via the horizontal arm, thereby enhancing DC system stability during voltage or load power fluctuation transients. The OSU team and Raytheon team actively worked together on designing, fabricating, assembling, and testing of two T-Breaker prototypes. The first prototype is rated at 1 kV, 500 A with half-bridge (unipolar) structure to validate the T-Breaker concept. The second prototype is rated at 20 kV, 50 A with full-bridge (bipolar) topology which can reach an efficiency of 99.977%, realize a power density of 60.2 MW/m3, and eliminate the 500-A fault current with a fault response time of around 20 µs. The prototypes show great feasibility of adopting this technology in multiple applications including electrified aircraft, super charging stations, data centers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Control System Plans for SNS Upgrade Projects

The Spallation Neutron Source at Oak Ridge National Laboratory is planning two major upgrades to the facility. The Proton Power Upgrade project, currently underway, will double the machine power from 1.4 to 2.8 MW by adding seven additional cryomodules and associated equipment. The Second Target Station project, currently in conceptual design, will construct a new target station effectively doubling the potential scientific output of the facility. This paper discusses the control system upgrades required to integrate these projects into the existing EPICS based control systems used for the machine and neutron instrument beamlines. While much of the control system can be replicated from existing solutions, some systems require new hardware and software. Operating two target stations simultaneously will require a new run permit system to safely manage beam delivery.

Hartman, Steven↗

DOE OSTI2021

Controllable X-ray Pulse Trains from Enhanced Self-Amplified Spontaneous Emission

We report the demonstration of optical compression of an electron beam and the production of controllable trains of femtosecond, soft x-ray pulses with the Linac Coherent Light Source (LCLS) freeelectron laser (FEL). This is achieved by enhanced self-amplified spontaneous emission with a 2 μm laser and a dechirper device. Optical compression was achieved by modulating the energy of an electron beam with the laser and then compressing with a chicane, resulting in high current spikes on the beam which we observe to lase. A dechirper was then used to selectively control the lasing region of the electron beam. Field autocorrelation measurements indicate a train of pulses, and we find that the number of pulses within the train can be controlled (from 1 to 5 pulses) by varying the dechirper position and undulator taper. These results are a step toward attosecond spectroscopy with x-ray FELs as well as future FEL schemes relying on optical compression of an electron beam.

Duris, Joseph P↗

DOE OSTI2020

Toward fusion plasma scenario planning for NSTX-U using machine-learning-accelerated models

One of the most promising devices for realizing power production through nuclear fusion is the tokamak. To maximize performance, it is preferable that tokamak reactors achieve advanced operating scenarios characterized by good plasma confinement, improved magnetohydrodynamic (MHD) stability, and a largely non-inductively driven plasma current. Such scenarios could enable steady-state reactor operation with high \emph{fusion gain} --- the ratio of produced fusion power to the external power provided through the plasma boundary. Precise and robust control of the evolution of the plasma boundary shape as well as the spatial distribution of the plasma current, density, temperature, and rotation will be essential to achieving and maintaining such scenarios. The complexity of the evolution of tokamak plasmas, arising due to nonlinearities and coupling between various parameters, motivates the use of model-based control algorithms that can account for the system dynamics. In this work, a learning-based accelerated model trained on data from the National Spherical Torus Experiment Upgrade (NSTX-U) is employed to develop planning and control strategies for regulating the density and temperature profile evolution around desired trajectories. The proposed model combines empirical scaling laws developed across multiple devices with neural networks trained on empirical data from NSTX-U and a database of first-principles-based computationally intensive simulations. The reduced execution time of the accelerated model will enable practical application of optimization algorithms and reinforcement learning approaches for scenario planning and control development. An initial demonstration of applying optimization approaches to the learning-based model is presented, including a strategy for mitigating the effect of leaving the finite validity range of the accelerated model. The approach shows promise for actuator planning between experiments and in real-time.

machine learning↗

DOE OSTI2022

Fundamentals of Spark-Plasma Sintering (Final Report)

This project was focused on the development of the general theory of spark-plasma sintering (SPS) taking into account the role of both thermal and non-thermal factors in the acceleration of SPS mass transport. SPS is a particular kind of field-assisted sintering, which provides potentially revolutionary capabilities to the processing of materials into configurations previously unattainable. This approach significantly improves the processing time- and quality-wise. It carries the potential of maintaining the nano and sub-micron structure in nano-powder-based materials after consolidation. SPS gains particular prominence in connection with its exceptional potential of rapid and ultra-rapid processing of very hard-to-deform materials, which would typically require lengthy consolidation times at significantly elevated temperatures under conditions of conventional powder pressing or sintering. The achievement of the ultimate goal of the formulation of the general theory of spark plasma sintering required the identification of the contributions of all the thermal and non-thermal factors in the enhancement of mass transport under SPS processing conditions. As our research indicated, this enhancement is mostly reduced to the creation of the conditions of controlled non-equilibrium, which is especially important in ultra-rapid field-assisted sintering techniques. Thus, the main project objective was the analysis of the SPS physical basis at multiple scales specifically exploring the role of electric current in the acceleration of mass transport and with an emphasis on the conditions of controlled non-equilibrium.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A Knowledge-based Framework for Building Energy Model Performance Verification

Building energy modeling (BEM) has been widely used by researchers, regulators, and engineers to quantify building energy performance. Quality assurance (QA) and quality control (QC) of the model's performance are essential parts of such analysis. Currently, QA/QC is done in a manual and ad-hoc manner, which is tedious, error-prone, and time-consuming when QA/QC a large number of models. To solve these challenges, we propose a a dAta-driveN buIlding perforMance verificATion framEwork (ANIMATE), which conducts automated output-based verification of building operations requirements (especially for time-series output-based verification of control requirements). While this framework was developed for verifying energy model performance, it can be extended for other applications such as BEM software testing and performance verification of real buildings in the field.

Chen, Yan↗

DOE OSTI2022

Current‐Dependent Lithium Metal Growth Modes in “Anode‐Free” Solid‐State Batteries at the Cu|LLZO Interface

Abstract Controlling the lithium growth morphology in lithium reservoir‐free cells (RFCs), so‐called “anode‐free” solid‐state batteries, is of key interest to ensure stable battery operation. Despite several benefits of RFCs like improved energy density and easier fabrication, issues during the charging of the cell hinder the transition from lithium metal batteries with a lithium reservoir layer to RFCs. In RFCs, the lithium metal anode is plated during the first charging step at the interface between a metal current collector and the solid electrolyte, which is prone to highly heterogeneous growth instead of the desired homogeneous film‐like growth. Herein, the lithium morphology during the first charging step in RFCs is explored as a function of current density and current collector thickness. Using operando scanning electron microscopy, an increase in the lithium particle density is observed with increasing current density at the Cu|Li 6.25 Al 0.25 La 3 Zr 2 O 12 interface. This observation is then applied to improve the area coverage of lithium by pulsed plating. It is also shown that thin current collectors ( d = 100 nm) are unsuited for RFCs, as lithium whiskers penetrate them, resulting in highly heterogeneous interfaces. This suggests the use of thicker metal layers (several µm) to mitigate whisker penetration and facilitate homogeneous lithium plating.

25 ENERGY STORAGE↗