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Cross-domain digital twin architecture for predictive maintenance via machine learning and Large Language Models

This research introduces a comprehensive framework for creating and deploying a digital twin platform for continuous monitoring and predictive maintenance within industrial settings. Through utilizing advanced technologies, including Unreal Engine 5, Unity 3D, the Message Queue Telemetry Transport protocol, Random Forest machine learning algorithms, and Large Language Models (LLMs), we establish a platform that digitally reproduces physical equipment and translates digital controls into real-world actions. This facilitates preventive maintenance approaches and improves operational effectiveness. The digital twin platform gathers sensor data from operational equipment, analyzes it using machine learning, and delivers practical insights to prevent potential malfunctions and enhance equipment performance. Furthermore, the incorporation of a web portal enables efficient monitoring and access to historical data, educational materials, and equipment status information. Preliminary findings indicate that digital twins can transform industrial equipment management and maintenance methodologies.

97 MATHEMATICS AND COMPUTING↗

A novel digital pulse processing architecture for nuclear instrumentation

The field of nuclear instrumentation covers a wide range of applications, including counting, spectrometry, pulse shape discrimination and multi-channel coincidence. These applications are the topic of many researches, new algorithms and implementations are constantly proposed thanks to advances in digital signal processing. However, these improvements are not yet implemented in instrumentation devices. This is especially true for neutron-gamma discrimination applications which traditionally use charge comparison method while literature proposes other algorithms based on frequency domain or wavelet theory which show better performances. Another example is pileups which are generally rejected while pileup correction algorithms also exist. These processes are traditionally performed offline due to two issues. The first is the Poissonian characteristic of the signal, composed of random arrival pulses which requires to current architectures to work in data flow. The second is the real-time requirement, which implies losing pulses when the pulse rate is too high. Despite the possibility of treating the pulses independently from each other, current architectures paralyze the acquisition of the signal during the processing of a pulse. This loss is called dead-time. These two issues have led current architectures to use dedicated solutions based on re-configurable components like Field Programmable Gate Arrays (FPGAs) to overcome the need of performance necessary to deal with dead-time. However, dedicated hardware algorithm implementations on re-configurable technologies are complex and time-consuming. For all these reasons, a programmable Digital pulse Processing (DPP) architecture in a high level language such as Cor C++ which can reduce dead-time would be worthwhile for nuclear instrumentation. This would reduce prototyping and test duration by reducing the level of hardware expertise to implement new algorithms. However, today's programmable solutions do not meet the need of performance to operate online and not allow scaling with the increase in the number of measurement channel. That is why an innovative DPP architecture is proposed in this paper. This architecture is able to overcome dead-time while being programmable and is flexible with the number of measurement channel. Proposed architecture is based on an innovative execution model for pulse processing applications which can be summarized as follow. The signal is not composed of pulses only, consequently, pulses processing does not have to operate on the entire signal. Therefore, the first step of our proposal is pulse extraction by the use of dedicated components named pulse extractors. The triggering step can be achieved after the analog-to-digital conversion without any signal shaping or filtering stages. Pileup detection and accurate pulse time stamping are done at this stage. Any application downstream this step can work on adaptive variable-sized array of samples simplifying pulse processing methods. Then, once the data flow is broken, it is possible to distribute pulses on Functional Units (FUs) which perform processing. As the date of each pulse is known, they can be processed individually out-of-order to provide the results. To manage the pulses distribution, a scheduler and an interconnection network are used. pulses are distributed on the first FU which is not busy without congesting the interconnection network. For this reason, the process duration does not result anymore in dead-time if there are enough FUs. FUs are designed to be standalone and to comprises at least a programmable general purpose processor (ARM, Microblaze) allowing the implementation of complex algorithms without any modification of the hardware. An acquisition chain is composed of a succession of algorithms which lead to organize our FUs as a software macro-pipeline, A simple approach consists in assigning one algorithm per FU. Consequently, the global latency becomes the worst latency of algorithms execution on FU. Moreover, as algorithms are executed locally - i.e. on a FU - this approach limits shared memory requirement. To handle multichannel, we propose FUs sharing, this approach maximize the chance to find a non-busy FU to process an incoming pulse. This is possible since each channel receive random event independently, the pulse extractors associated to them do not necessarily need to access simultaneously to all Computing resources at the same time to distribute their pulses. The major contribution of this paper is the proposition of an execution model and its associated hardware programmable architecture for digital pulse processing that can handle multiple acquisition channels while maintaining the scalability thanks to the use of shared resources. This execution model and associated architecture are validated by simulation of a cycle accurate architecture SystemC model. Proposed architecture shows promising results in terms of scalability while maintaining zero dead-time. This work also permit the sizing of hardware resources requirement required for a predefined set of applications. Future work will focus on the interconnection network and a scheduling policy that can exploit the variable-length of pulses. Then, the hardware implementation of this architecture will be performed and tested for a representative set of application.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of electron cyclotron emission imaging system on the HL-2A tokamak

A 2D electron cyclotron emission imaging (ECEI) system has been developed for measurement of electron temperature fluctuations in the HL-2A tokamak. It is comprised of a front-end 24 channel heterodyne imaging array with a tunable RF range spanning 75–110 GHz, and a set of back-end ECEI electronics that together generate 24 × 8 = 192 channel images of the 2nd harmonic X-mode electron cyclotron emission from the HL-2A plasma. The simulated performance of the local oscillator (LO) optics and radio frequency (RF) optics is presented, together with the laboratory characterization results. The Gaussian beams from the LO optics are observed to properly cover the entire detector array. The ECE signals from the plasma are mixed with the LO signal in the array box, then delivered to the electronics system by low-loss microwave cables, and finally to the digitizers. The ECEI system can achieve temporal resolutions of ∼μs, and spatial resolutions of 1 cm (radially) and 2 cm (poloidally)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

An FPGA-based bolometer for the MAST-U Super-X divertor

A new resistive bolometer system has been developed for MAST-Upgrade. It will measure radiated power in the new Super-X divertor, with millisecond time resolution, along 16 vertical and 16 horizontal lines of sight. The system uses a Xilinx Zynq-7000 series Field-Programmable Gate Array (FPGA) in the D-TACQ ACQ2106 carrier to perform real time data acquisition and signal processing. The FPGA enables AC-synchronous detection using high performance digital filtering to achieve a high signal-to-noise ratio and will be able to output processed data in real time with millisecond latency. The system has been installed on 8 previously unused channels of the JET vertical bolometer system. Initial results suggest good agreement with data from existing vertical channels but with higher bandwidth and signal-to-noise ratio.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of multichannel analyzer using sound card ADC for nuclear spectroscopy system

This paper describes the development of Multi-Channel Analyzer (MCA) using sound card analogue to digital converter (ADC) for nuclear spectroscopy system. The system was divided into a hardware module and a software module. Hardware module consist of detector NaI (Tl) 2” by 2”, Pulse Shaping Amplifier (PSA) and a build in ADC chip from readily available in any computers’ sound system. The software module is divided into two parts which are a pre-processing of raw digital input and the development of the MCA software. Band-pass filter and baseline stabilization and correction were implemented for the pre-processing. For the MCA development, the pulse height analysis method was used to process the signal before displaying it using histogram technique. The development and tested result for using the sound card as an MCA are discussed.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Laser 3D printing of highly compacted protonic ceramic electrolyzer stack

Solid oxide electrolysis cells (SOECs) for H 2 production is a core technology for H2@scale. However, its conventional manufacturing methods adapted from the manufacture of solid oxide fuel cells (SOFC) need high cost, especially for small-volume production. The emerging laser 3D printing (L3DP) technology with computer-aided 3D printing and computer-controlled laser processing can fulfill layer-by-layer digital shaping and rapid in-situ consolidating feedstock into complicated geometries. L3DP, a promising additive manufacturing (AM) technology, has achieved significant success in manufacturing plastic and metal parts, which is currently attracting considerable attention for the cost-effective, rapid, and flexible manufacturing of heterogeneous multilayered ceramic devices (e.g., SOECs, SOFCs, and solid-state batteries). It is believed that the L3DP can integrate the advantages of selective consolidation of heterogeneous layers, accurate control of layer microstructures, high processing heat efficiency, high processing speed, high stack compactness, high stack design flexibility, and low stack sealing area for cost-effective, rapid, and flexible manufacturing of SOECs to meet DOE’s electrolyzer target.

08 HYDROGEN↗

An Approach to Automate tools for the Risk Assessment of Digital Instrumentation and Control Systems

Reliable digital instrumentation and control systems (DI&C) are integral for sustaining the continued operation of nuclear power plants. These systems ensure that nuclear reactors operate safely, efficiently, and within regulatory requirements. Yet, the cost of designing and licensing new nuclear DI&C can be prohibitively expensive. Under the U.S. Department of Energy Light Water Reactor Sustainability Program, Idaho National Laboratory has developed a framework for supporting the risk-informed design of DI&C systems by offering methods to support the identification, quantification, and evaluation of risks for various DI&C design architectures. The framework indicates potential software failure modes and provides pathways for quantifying the potential for these software failures, including common cause failures. Using the framework’s systematic approach, challenges for assessing risks within new and existing nuclear DI&C systems can be reduced. Nevertheless, the current framework can be further improved using the convenience of automation. This paper introduces the development of Software for the Hazard Identification and Evaluation of Digital Systems (SHIELDS). SHIELDS is an engineering software package that enables the identification, elimination, and mitigation of potential risks and reduces the burden of deploying reliable DI&C systems. This work introduces plans and techniques to digitize and improve the manual risk assessment modules of the framework. These improvements will save time and increase the repeatability and usability of the framework, making it more accessible to a wider range of users. Ultimately, this introduces SHIELDS and how its modules support efficient development of safe and reliable DI&C systems.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

A compact, multichannel, and low noise arbitrary waveform generator

A new type of high functionality, fast, compact, and easy programmable arbitrary waveform generator for low noise physical measurements is presented. The generator provides 7 fast differential waveform channels with a maximum bandwidth up to 200 MHz frequency. There are 6 fast pulse generators on the generator board with 78 ps time resolution in both duration and delay, 3 of them with amplitude control. The arbitrary waveform generator is additionally equipped with two auxiliary slow 16 bit analog-to-digital converters and four 16 bit digital-to-analog converters for low frequency applications. Electromagnetic shields are introduced to the power supply, digital, and analog compartments and with a proper filter design perform more than 110 dB digital noise isolation to the output signals. All the output channels of the board have 50 Ω SubMiniature version A termination. The generator board is suitable for use as a part of a high sensitive physical equipment, e.g., fast read out and manipulation of nuclear magnetic resonance or superconducting quantum systems and any other application, which requires electromagnetic interference free fast pulse and arbitrary waveform generation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

The CapiSorb Visible System (CVS) Demonstrations on ISS

Falling liquid film amine sorbent reactors have been successfully employed to scrub CO 2 aboard submarines for decades. However, applying such proven methods aboard orbiting and coast spacecraft is significantly challenged by the nearly weightless environment, where liquid sprays and films do not fall, and vapor bubbles and gases do not rise. The Capillary Sorbent (CapiSorb) Visible System (CVS) is a technology demonstration experiment performed aboard the ISS April 18 – 21, 2023. The system establishes stable steady thin liquid film flows in Contactor (absorber) and Degasser (desorber/stripper) replacing the passive role of gravity with the combined passive roles of surface tension, wetting, and system geometry. A TOX-0 fructose ersatz liquid sorbent is employed enabling ‘transparent’ experiments performed and filmed by the crew safely in the open cabin of the ISS. Completed objectives include demonstrations of stable passive ‘massively’ parallel planar thin film capillary flows across atmospheric pressure Contactor and sealed heated Degasser. The impacts of varying flow rate, flow direction, heat input, viscosity, positive and negative Degasser pressures, condensate collection and return, fluid distribution, interfacial stability, and others are reported. At least 49 diagnostics are recorded for digitization and subsequent thermal-fluids model validation by a single HD video downlink during the nearly 22 hours of operations. An overview of the flight hardware including description of the components, diagnostics, crew procedures, flight operations, and summary of accomplishments is reported in Ref. 1. Further details of the diagnostics, tests performed, and data reduction is reported in Ref. 2. This report collects both1,2 into a single report adding methods of data digitization, reduction, and archive along with analyses and discussions of technology impacts.

microgravity↗

180-GHz Interferometric Imager

A 180-GHz interferometric imager uses compact receiver modules, combined high- and low-gain antennas, and ASIC (application specific integrated circuit) correlator technology, enabling continuous, all-weather observations of water vapor with 25-km resolution and 0.3-K noise in 15 minutes of observation for numerical weather forecasting and tropical storm prediction. The GeoSTAR-II prototype instrument is broken down into four major subsystems: the compact, low-noise receivers; sub-array modules; IF signal distribution; and the digitizer/correlator. Instead of the single row of antennas adopted in GeoSTAR, this version has four rows of antennas on a coarser grid. This dramatically improves the sensitivity in the desired field of view. The GeoSTAR-II instrument is a 48-element, synthetic, thinned aperture radiometer operating at 165-183 GHz. The instrument has compact receivers integrated into tiles of 16 elements in a 4x4 arrangement. These tiles become the building block of larger arrays. The tiles contain signal distribution for bias controls, IF signal, and local oscillator signals. The IF signals are digitized and correlated using an ASIC correlator to minimize power consumption. Previous synthetic aperture imagers have used comparatively large multichip modules, whereas this approach uses chip-scale modules mounted on circuit boards, which are in turn mounted on the distribution manifolds. This minimizes the number of connectors and reduces system mass. The use of ASIC technology in the digitizers and correlators leads to a power reduction close to an order of magnitude.

Kangaslahti, Pekka P.↗

BioSecure Digital Twin: Manufacturing Innovation and Cybersecurity Resilience

U.S. national security, prosperity, economy, and well-being require secure, flexible, and resilient Biopharmaceutical Manufacturing. The COVID-19 pandemic reaffirmed that the biomedical production value-chain is vulnerable to disruption and has been under attack from sophisticated nation-state adversaries. Current cyber defenses are inadequate, and the integrity of critical production systems and processes are inherently vulnerable to cyber-attacks, human error, and supply chain disruptions. The following chapter explores how a BioSecure Digital Twin will improve U.S. manufacturing resilience and preparedness to respond to these hazards by significantly improving monitoring, integrity, security, and agility of our manufacturing infrastructure and systems. The BioSecure Digital Twin combines a scalable manufacturing framework with a robust platform for monitoring and control to increase U.S. biopharma manufacturing resilience. Then, the chapter discusses some of the inherent vulnerabilities and challenges at the nexus of health and advanced manufacturing. Next, the chapter highlights that as the Pandemic evolves, we need agility and resilience to overcome significant obstacles. This section highlights an innovative application of Cyber Informed Engineering to developing and deploying a BioSecure Digital Twin to improve the resilience and security of the biopharma industrial supply chain and production processes. Finally, the chapter concludes with a process framework to complement the Digital Twin platform, called the Biopharma (Observe, Orient, Decide, Act) OODA Loop Framework (BOLF), a four-step approach to decision-making outputs from the Digital Twin. The BOLF will help end users leverage twin technology by distilling the available information, focusing the data on context, and rapidly making the best decision while remaining cognizant of changes that can be made as more data becomes available.

99 GENERAL AND MISCELLANEOUS↗

Burst design and signal processing for the speed of sound measurement of fluids with the pulse-echo technique

The pulse-echo technique determines the propagation time of acoustic wave bursts in a fluid over a known propagation distance. It is limited by the signal quality of the received echoes of the acoustic wave bursts, which degrades with decreasing density of the fluid due to acoustic impedance and attenuation effects. Signal sampling is significantly improved in this work by burst design and signal processing such that a wider range of thermodynamic states can be investigated. Applying a Fourier transformation based digital filter on acoustic wave signals increases their signal-to-noise ratio and enhances their time and amplitude resolutions, improving the overall measurement accuracy. In addition, burst design leads to technical advantages for determining the propagation time due to the associated conditioning of the echo. It is shown that the according operation procedure enlarges the measuring range of the pulse-echo technique for supercritical argon and nitrogen at 300 K down to 5 MPa, where it was limited to around 20 MPa before.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Roadmap to Automated Mobility Systems: Informing the Planning of a Sustainable, Resilient Transportation Ecosystem for Dallas/Fort Worth International Airport

The National Renewable Energy Laboratory (NREL) developed this report to provide Dallas/Fort Worth International Airport (DFW) assistance toward a vision that considers the maturation and proliferation of mobility automation, electrification, and infrastructure integrated with Internet of Things (IoT) technologies as they present themselves on the path to 2035. In planning ongoing infrastructure investments, DFW has goals to accommodate and leverage these enabling technologies toward greater sustainability and enhanced traveler and employee experiences, ensuring that infrastructure investments are fully utilized into the future. The objective of this document is to assist DFW to anticipate and envision future airport access by travelers, employees, and goods by examining existing needs and exploring opportunities enabled by technology that informs longer-term infrastructure planning. The vast infrastructure of DFW, which includes buildings, roadways, and other physical structures, as well as growing digital and energy network infrastructures, requires long-term planning and strategy to fully leverage technology advancement and avoid abandoning assets due to functional obsolescence.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A custom high-stability pulse generator for the test of a novel in-situ magnetic sensor developed to detect radiation damage in undulators

High-performance analog-to-digital converters (ADC) have been widely applied in many areas of science. For instance, magnetic field measurements based on the Faraday’s induction law require high-precision voltmeters to measure induced voltages. In this study in the context of free-electron lasers technology, the Magnetic Measurements Team at SLAC National Accelerator Laboratory proposed a novel in-situ radiation damage detection system (RDDS) for detecting small field variations in undulators. The system measures the flux change in a flexible printed-circuit coil attached to the magnet array during the undulator gap movement. The gap movement changes the magnetic field, which induces a voltage signal in the coil that is measured and integrated with an ADC. Although the system is capable of detecting relative flux changes better than 100 ppm, drift in the ADC’s gain or offset can cause apparent changes in the relative flux. This paper describes the first attempt to developed a high-precision verification circuit to perform ADC testing in the framework of the novel RDDS. The circuit generates a reference voltage pulse with a voltage–time integral relative precision better than 50 ppm for a few hundreds of mVs — the typical order of magnitude measured with the RDDS. The circuit’s design combines a fast and precise switch with a low-noise voltage reference. Long-term measurements allowed statistical analysis and showed that averaging the voltage–time integral of ten pulses gives the required 50 ppm stability. Moreover, reproducibility tests confirmed that the circuit’s output is invariable under small power supply instabilities and equipment shutdown. Instruments and applications designed to quantify the magnetic field by integrating voltage signals may use the pulse generator proposed in this paper for verification purposes.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Momentum spectrometer for electron-electron coincidence studies on superconductors

We present a new experimental setup to study electron-electron coincidences from superconducting surfaces. In our approach, electrons emitted from a surface are projected onto a time- and position-sensitive microchannel plate detector with delayline position readout. Electrons that are emitted within 2 {pi} solid angle with respect to the surface are detected in coincidence. The detector used is a hexagonal delayline detector with enhanced multiple hit capabilities. It is read out with a Flash analog-to-digital converter. The three-dimensional momentum vector is obtained for each electron. The intrinsic dead time of the detector has been greatly reduced by implementing a new algorithm for pulse analysis. The sample holder has been matched to fit the spectrometer while being capable of cooling down the sample to 4.5 K during the measurement and heating it up to 420 K for the cleaning procedure.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Development of the NASA VALT digital navigation system

The research to develop and fabricate a terminal area navigation system for use in the NASA VTOL Approach and Landing Technology (VALT) program. The results of that effort are reported. The navigation system developed and fabricated was based on a general purpose airborne digital computer. A set of flight hardware units was fabricated to create the necessary analog, digital and human interface with the computer. A comprehensive package of software was created to implement the control and guidance laws required for automatic and flight director approaches that are curved in two planes. A technique was developed that enables the generation of randomly shaped lateral paths from simple input data. The lateral path concept combines straight line and elliptical-curved segments to fit a continuous curved path to the data points. A simple, fixed base simulation was put together to assist in developing and evaluating the system. The simulation was used to obtain system performance data during simulated curved-path approaches.

Mcconnell, W. J., Jr.↗

Flight test evaluation of a digital controller used in a VTOL automatic approach and landing system

As part of the NASA Langley Research Center's effort to develop technology for VTOL operation in the air transportation system in the late 1980's and beyond, research has been conducted aimed at developing digital controller design procedures. This paper describes the verification of one design procedure by the flight evaluation of an advanced digital control algorithm. The control algorithm, operating at 10 iterations per second, follows step guidance commands with zero steady state error and thus provides an autotrim capability for the nonlinear vehicle. Changes in vehicle dynamics are accounted for using a gain scheduling technique. This control algorithm is combined with sensor filters, a trajectory generator, and a closed loop guidance algorithm to form a VTOL autoland system. A CH-47 tandem rotor helicopter which contains a set of sensors, onboard digital flight computers and electro-hydraulic actuators is used in the evaluation. All software, except input-output routines, is coded in FORTRAN using floating point arithmetic and executed in the flight computer. This autoland system is exercised by automatically flying straight-in descending decelerating trajectories typical of VFR manual approaches to a predetermined landing pad.

Downing, D. R.↗

Mobile satellite communications technology - A summary of NASA activities

Studies in recent years indicate that future high-capacity mobile satellite systems are viable only if certain high-risk enabling technologies are developed. Accordingly, NASA has structured an advanced technology development program aimed at efficient utilization of orbit, spectrum, and power. Over the last two years, studies have concentrated on developing concepts and identifying cost drivers and other issues associated with the major technical areas of emphasis: vehicle antennas, speech compression, bandwidth-efficient digital modems, network architecture, mobile satellite channel characterization, and selected space segment technology. The program is now entering the next phase - breadboarding, development, and field experimentation.

Dutzi, E. J.↗