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At least 109 records · Page 6

Improving the Concrete Crack Detection Process via a Hybrid Visual Transformer Algorithm

Inspections of concrete bridges across the United States represent a significant commitment of resources, given their biannual mandate for many structures. With a notable number of aging bridges, there is an imperative need to enhance the efficiency of these inspections. This study harnessed the power of computer vision to streamline the inspection process. Our experiment examined the efficacy of a state-of-the-art Visual Transformer (ViT) model combined with distinct image enhancement detector algorithms. We benchmarked against a deep learning Convolutional Neural Network (CNN) model. These models were applied to over 20,000 high-quality images from the Concrete Images for Classification dataset. Traditional crack detection methods often fall short due to their heavy reliance on time and resources. This research pioneers bridge inspection by integrating ViT with diverse image enhancement detectors, significantly improving concrete crack detection accuracy. Notably, a custom-built CNN achieves over 99% accuracy with substantially lower training time than ViT, making it an efficient solution for enhancing safety and resource conservation in infrastructure management. These advancements enhance safety by enabling reliable detection and timely maintenance, but they also align with Industry 4.0 objectives, automating manual inspections, reducing costs, and advancing technological integration in public infrastructure management.

42 ENGINEERING↗

TRANSSFORM Workshop Empowering the US manufacturing industry proceedings report

The U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, and Advanced Manufacturing Office (AMO) hosted the TRANSSFORM (Transformative, Resilient, Adaptive, Nimble, Sustainable, Smart, Flexible, Optimal, Robust, and Model-based1 – A Bold Vision for the Future of U.S. Manufacturing) Workshop on September 8–10, 2021. The objective of the workshop was to hear from stakeholders about how manufacturing digitalization can improve manufacturing competitiveness and reduce energy consumption and emissions production from U.S. manufacturing, and what research, development, and demonstrations are needed to have the desired impact.

manufacturing digitalization, decarbonization, IoT↗

Use of computer vision for analysis of image datasets from high temperature plasma experiments

Great strides have been made in improving the quality of x-ray radiographs in high energy density plasma experiments, enabled in part by innovations in engineering and manufacturing of integrated circuits and materials. As a consequence, the radiographs of today are filled with a great deal of detail, but few of these features are extracted in a systematic way. Analysis techniques familiar to plasma physicists tend toward brittle 1D lineout or Fourier transform type analyses. The techniques applied to process our data have not kept pace with improvements in the quality of our data. Fortunately, the field of computer vision has a wealth of tools to offer, which have been widely used in industrial imaging and, more recently, adopted in biological imaging. We demonstrate the application of computer vision techniques to the analysis of x-ray radiographs from high energy density plasma experiments, as well as give a brief tutorial on the computer vision techniques themselves. These tools robustly extract 2D contours of shocks, boundaries of inhomogeneities, and secondary flows, thereby allowing for increased automation of analysis, as well as direct and quantitative comparisons with simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Restoration Hydro: A Watershed Approach to Standard Modular New Hydropower

The objectives of FOA DE- FOA-0001836- “Standard Modular Hydropower” included designing a standardized, modular, and environmentally compatible hydropower schematic for implementation in greenfield sites that generate up to 10 MW of capacity. Utilizing funds competitively awarded under DOE’s Water Power Technologies Office, the Natel Energy team developed a concept for modular new stream reach (NSR) hydropower that incorporates multi species upstream and downstream fish passage, improved river channel connectivity, and recreational modules. The in-stream design of the collective modules minimized site specific design and maximized the opportunities for modularity. Financial data was also presented using actual costs from regional suppliers, with figures provided in 2022 dollars. While the project team did not address potential permitting process improvements, the site selection criteria did consider established barriers to hydropower development such as tribal and preserved lands, interconnection proximity, and endangered species to exclude or deprioritize. The project’s design schematic met the objectives of the FOA, and presented a unique solution that targets alluvial pockets as natural features for sustainable development. Natel’s concept also incorporated the company's fish-safe Restoration Hydro Turbine for safe downstream passage, while featuring a rock arch that integrates fish passage, water, recreation, and grade control modules (including sediment). Alignment with the Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) “Innovative Design Concepts for Standard Modular Hydropower and Pumped-Storage Hydropower” Program: According to the Hydropower Vision (DOE, 2016), approximately 16 GW of hydropower growth is possible with the development of technology solutions that balance efficiency, economics, and environmental sustainability. The desired outcome of the SMH program is transformational innovation specifically in the site identification, conceptual, and detailed design phases of technology development lifecycles (DOE, 2018). In developing the SMH design schematic, the team aimed to address the opportunities outlined in the Vision through an inverted design philosophy; rather than singularly prioritizing efficiency and power production, the team focused on integrating hydropower with restoration of degraded streams to optimal ecosystem function and provision of exceptional recreation value as design criteria. To achieve this, Restoration Hydro incorporates the principles of nature-based engineering (WWAP, 2018) and biomimicry (Biomimicry NL.) to strategically deploy complementary combinations of permanent, semi-permanent, and ephemeral low-head structures - such as natural and engineered log jams - that harness geomorphological and hydrological processes at the landscape-scale. Primary applications of Restoration Hydro include: 1) restoration of degraded watersheds’ natural ecological function and enhancement of hydrological connectivity; and 2) creation of associated co-benefits to hydro production, including increased groundwater recharge, improved sediment transport and management, improved water security and water quality. Restoration Hydro projects build upon proven watershed restoration engineering techniques by integrating hydropower turbines into low-head structures using innovative and evolving civil works concepts that facilitate fish and sediment passage, and in some cases create additional revenue-generating recreational opportunities. Powering low-head structures creates a directly monetizable layer of economic value in the form of flexible, reliable, renewable energy on top of the already high-value water, environmental and recreational benefits of watershed and river restoration. The approach aims to create a virtuous, self-reinforcing cycle whereby Restoration Hydro projects support the scaling of ecosystem restoration activities, creating a water-energy-carbon multiplier effect that, through the principles of adaptive change management: 1) improves the resilience of landscapes and downstream population centers for changing hydrological cycles; 2) creates a reliable energy resource that facilitates the integration of intermittent renewable power sources into grids; and 3) supports climate change mitigation through grid decarbonization and enhanced ecosystem carbon capture and retention.

13 HYDRO ENERGY↗

An autonomous robot for shell and tube heat exchanger inspection

Shell and tube heat exchangers (STHEs) are critical to energy conversion efficiency of power plants. Eddy current examination is a way to evaluate working conditions of these tubes. However, the current testing apparatus requires human to manually insert an eddy current testing (ECT) probe into and extract it out of individual tubes, and meanwhile monitor measurement results for diagnosis. It is a time-consuming and labor-intensive procedure even for an experienced technician. To tackle this challenge, in this study, we developed a robot enabled ECT system for autonomous inspection of STHEs. The robotic platform employs Mecanum wheeled chassis for high mobility, machine vision to locate tube bundle and tube inlets, a rotational Cartesian mechanism to operate at planes with all possible inclinations, and a task-specific mechanism for ECT probe delivery. Machine vision locates tube bundle and tube inlets by an April tag detection algorithm and a Circle Hough Transform algorithm, respectively. Assisted by a guiding cone, the ECT probe is continuously fed into the tubes with a fill factor of 0.819. In conclusion, during this process, the eddy current data are automatically collected and real-time analyzed by convolutional neural networks, showing accuracy of nearly 100% for identifying defective and nondefective tubes and 85% for four types of defective tubes and nondefective tubes.

42 ENGINEERING↗

An Autonomous Robot for Shell and Tube Heat Exchanger Inspection

Shell and tube heat exchangers (STHEs) are critical to energy conversion efficiency of power plants. Eddy current examination is a way to evaluate working conditions of these tubes. However, the current testing apparatus requires human to manually insert an eddy current testing (ECT) probe into and extract it out of individual tubes, and meanwhile monitor measurement results for diagnosis. It is a time-consuming and labor-intensive procedure even for an experienced technician. To tackle this challenge, in this work, we developed a robot enabled ECT system for autonomous inspection of STHEs. The robotic platform employs Mecanum wheeled chassis for high mobility, machine vision to locate tube bundle and tube inlets, a rotational Cartesian mechanism to operate at planes with all possible inclinations, and a task-specific mechanism for ECT probe delivery. Machine vision locates tube bundle and tube inlets by an April tag detection algorithm and a Circle Hough Transform (CHT) algorithm, respectively. Assisted by a guidance cone, the ECT probe is continuously fed into the tubes with a fill factor of 0.819. During this process, the eddy current data are automatically collected and real-time analyzed by convolutional neural networks (CNN), showing accuracy of nearly 100% for identifying defective and non-defective tubes and 85% for four types of defective tubes and non-defective tubes.

autonomy, deep learning, eddy current testing, hea↗

Chapter 11: Renewable Microgrids as a Foundation of the Future Sustainable Electrical Energy System

Renewable microgrids are an integral part of the future sustainable energy system. This chapter focuses on the role of renewable energy-based microgrids in the electricity system transformation. It is seen as a foundation that complements large-scale generation plants and high-voltage transmission lines by providing additional flexibility and resilience. This flexibility and resilience are crucial for balancing the energy system and ensuring its long-term sustainability, given the changing supply and demand patterns due to rooftop solar photovoltaics (PV), battery storage, electric mobility, and heat pumps. It is also an opportunity for residential and commercial consumers to become active participants in the energy market. Innovation, new technologies and business models will act as the key enabler for this transformation. The regulatory restructuring of the energy market will be crucial for successful integration of prosumers and aggregated energy communities. The chapter presents the vision of a sustainable, decentralized, and digitized energy future including market potential, most innovative case study projects and start-up companies, and the shifts needed in the regulatory landscape.

battery storage↗

Western Combined Heat and Power Technical Assistance Partnership (Final Technical Report)

Since 2018, the Western Combined Heat and Power Technical Assistance Partnership (CHP TAP) has been dedicated to advancing the adoption and implementation of Combined Heat and Power. The CHP TAP has diligently worked towards its mission of fostering end-user engagement, promoting technical solutions, and enhancing energy security within the region. As we reflect on our journey, we are proud to announce the completion of the required metrics set forth at the beginning of our endeavor. From the outset, our aim has been clear: to leverage CHP technology as a catalyst for bolstering American competitiveness, utilizing local fuels, and fortifying energy resilience. Through collaborative efforts with a diverse array of stakeholders, including manufacturing, commercial, institutional, and federal facilities, and campuses, we have strived to realize this vision. In this report, we outline the achievements, activities, and impact of the Western CHP TAP, highlighting the transformative journey undertaken since 2018. From providing technical assistance and guidance to conducting educational workshops and advocating for supportive policies, our initiatives have been guided by a commitment to excellence and innovation. As we celebrate the completion of our required metrics, we reaffirm our dedication to continuing our mission, building upon our accomplishments, and shaping a sustainable energy future for the Western region. Through ongoing collaboration and engagement, we are confident that the Western CHP TAP will continue to serve as a beacon of progress and a catalyst for positive change in the years to come.

03 NATURAL GAS↗

NREL Stratus - Enabling Workflows to Fuse Data Streams, Modeling, Simulation, and Machine Learning

Integrating cloud services into advanced computing facilities provides significant new capabilities over focusing solely on traditional high performance computing (HPC) workloads. This brings complementary capabilities as well as enabling new focused roles for HPC. They are especially potent for workflows that fuse data streams, modeling and simulation ('modsim') and machine learning. A key challenge to adopting a hybrid edge-cloud-HPC model is to align optimal capability, data, and user intent on the right resources for each step in a workflow.?The NREL Stratus service provides a basis for this: Stratus layers capabilities needed to make?cloud services accessible to a lab-based scientific community on commercial offerings, and; currently supports upwards of 200 projects ranging from IOT integration to traditional modeling and simulation. This provides a real-world inventory of scientific workflow elements. A growing knowledge base enables placing these elements appropriately between the edge, cloud, and traditional HPC. This paper outlines a vision via reference architecture and the application of that architecture in a typical workflow highlighting multiple components: sensor data intake, cleaning and transforming (edge/cloud suitable); generation of synthetic data through modsim, computationally heavy ML training and hyperparameter optimization (HPC suitable), and; inference and deployment (cloud ideal). Every step in such a workflow involves a cost-benefit analysis regarding the data movement, computational efficiency, availability, latency, and resource capabilities. The reference architecture and examples outlined allow for understanding new opportunities in the context of emerging workflows that combine IOT, cloud, and HPC to bolster scientific productivity.

AI↗

28 NREL Stratus - Enabling Workflows to Fuse Data Streams, Modeling, Simulation, and Machine Learning: Preprint

Integrating cloud services into advanced computing facilities provides significant new capabilities over focusing solely on traditional high performance computing (HPC) workloads. This brings complementary capabilities as well as enabling new focused roles for HPC. They are especially potent for workflows that fuse data streams, modeling and simulation ('modsim') and machine learning. A key challenge to adopting a hybrid edge-cloud-HPC model is to align optimal capability, data, and user intent on the right resources for each step in a workflow.?The NREL Stratus service provides a basis for this: Stratus layers capabilities needed to make?cloud services accessible to a lab-based scientific community on commercial offerings, and; currently supports upwards of 200 projects ranging from IOT integration to traditional modeling and simulation. This provides a real-world inventory of scientific workflow elements. A growing knowledge base enables placing these elements appropriately between the edge, cloud, and traditional HPC. This paper outlines a vision via reference architecture and the application of that architecture in a typical workflow highlighting multiple components: sensor data intake, cleaning and transforming (edge/cloud suitable); generation of synthetic data through modsim, computationally heavy ML training and hyperparameter optimization (HPC suitable), and; inference and deployment (cloud ideal). Every step in such a workflow involves a cost-benefit analysis regarding the data movement, computational efficiency, availability, latency, and resource capabilities. The reference architecture and examples outlined allow for understanding new opportunities in the context of emerging workflows that combine IOT, cloud, and HPC to bolster scientific productivity.

AI↗

An image-driven machine learning approach to kinetic modeling of a discontinuous precipitation reaction

Micrograph quantification is an essential component of several materials science studies. Machine learning methods, in particular convolutional neural networks, have previously demonstrated performance in image recognition tasks across several disciplines (e.g. materials science, medical imaging, facial recognition). Here, we apply these well-established methods to develop an approach to microstructure quantification for kinetic modeling of a discontinuous precipitation reaction in a case study on the uranium-molybdenum system. Prediction of material processing history based on image data (classification), calculation of area fraction of phases present in the micrographs (segmentation), and kinetic modeling from segmentation results were performed. Results indicate that convolutional neural networks represent microstructure image data well, and segmentation using the k-means clustering algorithm yields results that agree well with manually annotated images. Classification accuracies of original and segmented images are both 94% for a 5-class classification problem. Kinetic modeling results agree well with previously reported data using manual thresholding. The image quantification and kinetic modeling approach developed and presented here aims to reduce researcher bias introduced into the characterization process, and allows for leveraging information in limited image data sets.

36 MATERIALS SCIENCE↗

Standard model physics and the digital quantum revolution: thoughts about the interface

Advances in isolating, controlling and entangling quantum systems are transforming what was once a curious feature of quantum mechanics into a vehicle for disruptive scientific and technological progress. Pursuing the vision articulated by Feynman, a concerted effort across many areas of research and development is introducing prototypical digital quantum devices into the computing ecosystem available to domain scientists. Through interactions with these early quantum devices, the abstract vision of exploring classically-intractable quantum systems is evolving toward becoming a tangible reality. Beyond catalyzing these technological advances, entanglement is enabling parallel progress as a diagnostic for quantum correlations and as an organizational tool, both guiding improved understanding of quantum many-body systems and quantum field theories defining and emerging from the standard model. Here, from the perspective of three domain science theorists, this article compiles thoughts about the interface on entanglement, complexity, and quantum simulation in an effort to contextualize recent NISQ-era progress with the scientific objectives of nuclear and high-energy physics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Power Sector Transformation Pathways: Exploring Objectives, Factors, and Technology Innovations to Inform Power Sector Pathway Decisions

The power and heating sectors are responsible for around 30% of global CO2 emissions and this share is likely to grow as countries move towards electrification of the transportation and building sectors. Therefore, enabling forward-thinking, long term strategies in the power sector is a crucial area for international collaboration and support. The rapid transition of power systems toward modern, low-carbon pathways and technologies will be necessary to meet key climate goals while also enabling other critical objectives such as economic development, energy access, and energy system resiliency, among others. Many developed and developing countries are well-poised to champion power sector transformation (PST), however, further support is needed to identify pathways and implement critical near and long-term actions. To address this need, the Low Emission Development Strategies Global Partnership (LEDS GP) together with an expert team including Agora Energiewende, Energy Innovation, European Climate Foundation, Fraunhofer Institute for Systems and Innovation Research , Prayas Energy Group and LEDS Latin America and Caribbean Platform, developed a framework identifying four key pathways that can be integrated and combined to support low-carbon PST. These four pathways are: (1) Distributed Energy Resource Revolution, (2) Bulk Power Transformation, (3) Transmission and Distribution Interactivity, and (4) Distributed Transactional Future. To support exploration of pathways, this study examines PST objectives and factors that may lead countries or jurisdictions to place a greater relative emphasis on certain pathways as well as a framework and complementary tool for considering the emphasis in a hands on manner. The report provides case studies on application of the approach to bring life to the topic. The case studies include Haiti, Kenya, Mexico, Southeast Asia, and the European Union, among others. The report also presents actions to-be-taken in the near-, medium- and long-term to support the realization of pathways and long-term transformation of the power sector. The report, together with a complementary spreadsheet tool developed under the effort, can be used to enable stakeholder engagement and visioning for the power sector over the long-term, taking into account key factors and potential innovations. It can also be used to understand and inform relevant analysis tools and models based on which pathways are emphasized, and to identify key actions in the near- and medium-term to avoid lock-in of carbon-intensive technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

National Smart Manufacturing Strategic Plan: To Facilitate More Rapid Development, Deployment and Adoption of Smart Manufacturing Technologies

Smart manufacturing technologies provide real-time data and insight to improve the productivity, efficiency, and competitiveness of U.S. manufacturing, creating the potential for new jobs in the manufacturing sector. These technologies can support U.S. manufacturers’ ability to increase throughput and energy efficiency, and decrease waste, defects, and costs. A wide range of manufacturing and industrial subsectors, particularly energy-intensive and energy-dependent industries, have the potential to benefit from smart manufacturing technologies. There are technical improvements still needed to reduce the costs and barriers (trained workforce and upskilling, software-hardware integration, cost, and technical barriers to deployment of advanced sensors, computing, and communication technologies for existing manufacturing assets) to the adoption of smart manufacturing technologies, especially to small and medium-sized manufacturers, and subsequently, increase the overall adoption rate of smart manufacturing technologies. This report outlines the Department of Energy’s (DOE) strategic plan to accelerate the development and implementation of smart manufacturing technologies in the United States and the actions DOE has taken to use these technologies in smart manufacturing for the United States. DOE’s plan to facilitate more rapid development, deployment and widespread adoption of smart manufacturing technologies derive from the 2018 Strategy for American Leadership in Advanced Manufacturing. The strategy outlines a vision for America’s leadership in advanced manufacturing including the development of intelligent manufacturing systems to optimize manufacturing facilities and support the manufacturing of transformative materials. DOE’s Clean Energy Smart Manufacturing Innovation Institute (CESMII), a Manufacturing USA Institute, focuses on accelerating the development and adoption of advanced sensors, controls, platforms, and models needed for smart manufacturing. The objective is to enhance U.S. manufacturing productivity and global competitiveness through the research and development of these technologies. Smart manufacturing has the potential to improve the overall performance, energy productivity, and efficiency of manufacturing, fostering the economic competitiveness of the manufacturing sector.

99 GENERAL AND MISCELLANEOUS↗

Universal Polarization Transformations: Spatial Programming of Polarization Scattering Matrices Using a Deep Learning‐Designed Diffractive Polarization Transformer

Abstract Controlled synthesis of optical fields having nonuniform polarization distributions presents a challenging task. Here, a universal polarization transformer is demonstrated that can synthesize a large set of arbitrarily‐selected, complex‐valued polarization scattering matrices between the polarization states at different positions within its input and output field‐of‐views (FOVs). This framework comprises 2D arrays of linear polarizers positioned between isotropic diffractive layers, each containing tens of thousands of diffractive features with optimizable transmission coefficients. After its deep learning‐based training, this diffractive polarization transformer can successfully implement N i N o = 10 000 different spatially‐encoded polarization scattering matrices with negligible error, where N i and N o represent the number of pixels in the input and output FOVs, respectively. This universal polarization transformation framework is experimentally validated in the terahertz spectrum by fabricating wire‐grid polarizers and integrating them with 3D‐printed diffractive layers to form a physical polarization transformer. Through this set‐up, an all‐optical polarization permutation operation of spatially‐varying polarization fields is demonstrated, and distinct spatially‐encoded polarization scattering matrices are simultaneously implemented between the input and output FOVs of a compact diffractive processor. This framework opens up new avenues for developing novel devices for universal polarization control and may find applications in, e.g., remote sensing, medical imaging, security, material inspection, and machine vision.

Optical neural networks↗

Project 1: COLLECTS Project and Project 2: M&V for Saputo Cheese Project: Cooperative Research and Development (Final Report)

Project 1: Combined Power's Hyperlight Energy and NLR will collaborate on the DOE Concentrating Optics for Lower Levelized Energy CosTS (COLLECTS) project, DE-FOA-0001268. COLLECTS funding opportunity announcement (FOA) seeks to further concentrated solar power (CSP) system technologies by soliciting disruptive, transformative projects for the concentrating solar collectors in the CSP plant. These innovative projects will seek to surpass the targets set out in the SunShot Vision Study, enabling CSP to be cost-competitive with conventional forms of electric power generation. Projects will target the design and manufacturing of novel solar collectors with the ability to significantly reduce the solar field contribution to the overall levelized cost of energy (LCOE) of the CSP plant, and which have not been previously specifically targeted by CSP FOAs. Project 2: Hyperlight will perform measurement and verification (M&V) of Green House Gases and NLR will evaluate energy consumption reduction.

14 SOLAR ENERGY↗

Effects of input gradient regularization on neural networks time-series forecasting of thermal power systems

This study proposes using neural networks, specifically gated recurrent unit (GRU), long-short-term memory (LSTM), and transformer networks, to improve control strategies in a 450 MW coal-fired power plant. However, neural networks face issues of becoming overly dependent on just a few variables to make predictions, which negatively impacts control decisions that rely on the model to determine the value of all manipulated variables. The paper introduces regularization techniques, including noise injection and input gradient regularization, during the training phase. Here, the work presents novel contributions in adapting neural networks to control industrial systems and applying regularization techniques from computer vision to industrial process control. Results demonstrate the effectiveness of input gradient regularization in reducing model dependence on subsets of variables, emphasizing the balance between fidelity and controllability. Further exploration is recommended, including the development of recurrent transformers, closed-loop control testing, and a sensitivity analysis on computer models to provide further insight.

20 FOSSIL-FUELED POWER PLANTS↗

3D reconstruction and neural rendering for adversarial machine learning

While evasion attacks on computer vision systems have been widely studied, creating attacks that remain effective under significant changes in viewpoint continues to be challenging. Traditional approaches often rely on affine transformations of images, but these approaches degrade at larger perspective shifts and often produce unrealistic or ineffective perturbations. Recent methods use differentiable renderers to improve viewpoint robustness, but they typically depend on manually constructed 3D models. We introduce a semi-automated pipeline that generates physically printable and perspective-invariant adversarial patches using only a small set of 2D images. Our method integrates 3D reconstruction, neural rendering, adversarial patch optimization, and an object detection victim model into a unified workflow. We use 2D Gaussian Splatting for high fidelity mesh reconstruction and FlexPara for surface parameterization that produces texture maps suitable for patch editing. Together, these components form a fully differentiable pipeline in PyTorch3D that links texture modification to model outputs, enabling efficient optimization of patches that remain effective across many viewpoints. The complete process, from image capture to patch printing and physical evaluation, can be completed within a few hours. We demonstrate the effectiveness of the resulting patches through attacks on the YOLOv8 object detection model and discuss remaining challenges and opportunities for improving robustness and scalability.

Singhvi, Vivaan [ORNL] (ORCID:0009000586288221)↗