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DOE OSTI2023

Reman Co-Design: A Combined Design and Remanufacturing Optimization Framework for the Sustainable Design of High-Value Components

Remanufacturing is a process that returns end-of-life equipment to as-new conditions and offers numerous environmental and economic benefits. To fully capitalize on remanufacturing, its synergistic interactions with design must be fully realized and addressed during the design stage. Although this fact is widely recognized in the literature, most of the current studies focus primarily either on the design or remanufacturing aspects of design for remanufacturing (DfRem). In an effort to offer a more integrated DfRem approach than those reported in the literature, we propose a new combined design and remanufacturing optimization (reman co-design) framework that takes a holistic approach by leveraging the intricate interplay between design and remanufacturing. Here, the aim of this formulation is to identify the optimal decisions that maximize the benefits of remanufacturing throughout the entire lifespan of a product. To showcase the utility of the new formulation, we are using a case study of a hydraulic manifold, (re)manufactured by John Deere. Using this industry example, we compare the results of reman co-design to the ones from a decoupled remanufacturing design approach. Results reveal that remanufacturing benefits are better realized and improved upon when using the developed reman co-design approach.

design for X↗

DOE OSTI2020

MimicGAN: Robust Projection onto Image Manifolds with Corruption Mimicking

In the past few years, Generative Adversarial Networks (GANs) have dramatically advanced our ability to represent and parameterize high-dimensional, non-linear image manifolds. As a result, they have been widely adopted across a variety of applications, ranging from challenging inverse problems like image completion, to problems such as anomaly detection and adversarial defense. A recurring theme in many of these applications is the notion of projecting an image observation onto the manifold that is inferred by the generator. In this context, Projected Gradient Descent (PGD) has been the most popular approach, which essentially optimizes for a latent vector that minimizes the discrepancy between a generated image and the given observation. However, PGD is a brittle optimization technique that fails to identify the right projection (or latent vector) when the observation is corrupted, or perturbed even by a small amount. Such corruptions are common in the real world, for example images in the wild come with unknown crops, rotations, missing pixels, or other kinds of non-linear distributional shifts which break current encoding methods, rendering downstream applications unusable. To address this, we propose corruption mimicking—a new robust projection technique, that utilizes a surrogate network to approximate the unknown corruption directly at test time, without the need for additional supervision or data augmentation. The proposed method is significantly more robust than PGD and other competing methods under a wide variety of corruptions, thereby enabling a more effective use of GANs in real-world applications. Finally, more importantly, we show that our approach produces state-of-the-art performance in several GAN-based applications—anomaly detection, domain adaptation, and adversarial defense, that benefit from an accurate projection.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Performance of the rigorous renormalization group for first-order phase transitions and topological phases

Expanding and improving the repertoire of numerical methods for studying quantum lattice models is an ongoing focus in many-body physics. While the density matrix renormalization group (DMRG) has been established as a practically useful algorithm for finding the ground state in one-dimensional systems, a provably efficient and accurate algorithm remained elusive until the introduction of the rigorous renormalization group (RRG) by Landau [Nat. Phys. 11, 566 (2015)1745-247310.1038/nphys3345]. In this paper, we study the accuracy and performance of a numerical implementation of RRG at first-order phase transitions and in symmetry-protected topological phases. Our study is motivated by the question of when RRG might provide a useful complement to the more established DMRG technique. In particular, despite its general utility, DMRG can give unreliable results near first-order phase transitions and in topological phases, since its local update procedure can fail to adequately explore (near-)degenerate manifolds. Furthermore, the rigorous theoretical underpinnings of RRG, meanwhile, suggest that it should not suffer from the same difficulties. We show this optimism is justified, and that RRG indeed determines well-ordered, accurate energies even when DMRG does not. Moreover, our performance analysis indicates that in certain circumstances seeding DMRG with states determined by coarse runs of RRG may provide an advantage over simply performing DMRG.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2017

Semi-Supervised Learning of Lift Optimization of Multi-Element Three-Segment Variable Camber Airfoil

This chapter describes a new intelligent platform for learning optimal designs of morphing wings based on Variable Camber Continuous Trailing Edge Flaps (VCCTEF) in conjunction with a leading edge flap called the Variable Camber Krueger (VCK). The new platform consists of a Computational Fluid Dynamics (CFD) methodology coupled with a semi-supervised learning methodology. The CFD component of the intelligent platform comprises of a full Navier-Stokes solution capability (NASA OVERFLOW solver with Spalart-Allmaras turbulence model) that computes flow over a tri-element inboard NASA Generic Transport Model (GTM) wing section. Various VCCTEF/VCK settings and configurations were considered to explore optimal design for high-lift flight during take-off and landing. To determine globally optimal design of such a system, an extremely large set of CFD simulations is needed. This is not feasible to achieve in practice. To alleviate this problem, a recourse was taken to a semi-supervised learning (SSL) methodology, which is based on manifold regularization techniques. A reasonable space of CFD solutions was populated and then the SSL methodology was used to fit this manifold in its entirety, including the gaps in the manifold where there were no CFD solutions available. The SSL methodology in conjunction with an elastodynamic solver (FiDDLE) was demonstrated in an earlier study involving structural health monitoring. These CFD-SSL methodologies define the new intelligent platform that forms the basis for our search for optimal design of wings. Although the present platform can be used in various other design and operational problems in engineering, this chapter focuses on the high-lift study of the VCK-VCCTEF system. Top few candidate design configurations were identified by solving the CFD problem in a small subset of the design space. The SSL component was trained on the design space, and was then used in a predictive mode to populate a selected set of test points outside of the given design space. The new design test space thus populated was evaluated by using the CFD component by determining the error between the SSL predictions and the true (CFD) solutions, which was found to be small. This demonstrates the proposed CFD-SSL methodologies for isolating the best design of the VCK-VCCTEF system, and it holds promise for quantitatively identifying best designs of flight systems, in general.

Intelligent Systems↗

DOE OSTI2024

Physics-inspired spatiotemporal-graph AI ensemble for the detection of higher order wave mode signals of spinning binary black hole mergers

We present a new class of AI models for the detection of quasi-circular, spinning, non-precessing binary black hole mergers whose waveforms include the higher order gravitational wave modes ($\ell$, |m|) = {(2,2), (2,1), (3,3), (3,2), (4,4)}, and mode mixing effects in the $\ell$ = 3, |m| = 2 harmonics. These AI models combine hybrid dilated convolution neural networks to accurately model both short- and long-range temporal sequential information of gravitational waves; and graph neural networks to capture spatial correlations among gravitational wave observatories to consistently describe and identify the presence of a signal in a three detector network encompassing the Advanced LIGO and Virgo detectors. We first trained these spatiotemporal-graph AI models using synthetic noise, using 1.2 million modeled waveforms to densely sample this signal manifold, within 1.7 h using 256 NVIDIA A100 GPUs in the Polaris supercomputer at the Argonne Leadership Computing Facility. This distributed training approach exhibited optimal classification performance, and strong scaling up to 512 NVIDIA A100 GPUs. With these AI ensembles we processed data from a three detector network, and found that an ensemble of 4 AI models achieves state-of-the-art performance for signal detection, and reports two misclassifications for every decade of searched data. We distributed AI inference over 128 GPUs in the Polaris supercomputer and 128 nodes in the Theta supercomputer, and completed the processing of a decade of gravitational wave data from a three detector network within 3.5 h. Finally, we fine-tuned these AI ensembles to process the entire month of February 2020, which is part of the O3b LIGO/Virgo observation run, and found 6 gravitational waves, concurrently identified in Advanced LIGO and Advanced Virgo data, and zero false positives. This analysis was completed in one hour using one NVIDIA A100 GPU.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS2006

A New Theory of Trajectory Design and NASA's Vision

This new theory is defined as the use of chaos to design trajectories and orbits that can be used to meet complex mission goals. The benefits are; a) minimizes fuel costs; b) optimizes trajectory profiles; c) provides non-standard and new orbit designs; and d) mitigates operational risks. Other synonymous terms include dynamical systems, invariant manifolds, capture orbits and ballistic orbits.

Folta, David↗

DOE OSTI2023

Covariance Shaping Over Riemannian Manifolds for Massive MIMO Communication

Acquiring accurate instantaneous channel state information (CSI) is a challenging aspect of massive multi-input multi-output (MIMO) communication. Utilizing statistical information, such as channel covariance matrix, to design statistical beamforming vectors is robust when compared to instantaneous CSI. In this paper, we propose a novel MIMO covariance shaping scheme over Riemannian manifolds. It serves as an effective statistical beamforming solution to a number of close proximity user equipment (UE) that are undergoing substantial channel correlation. Proposed algorithm exploits the Hermitian positive definite nature of covariance matrices lying over Riemannian manifold. We introduce Wasserstein distance function as a Riemannian metric to measure distances between channel covariance matrices. Furthermore, K-means clustering technique is utilized to effectively identify the optimal shape of effective optimal covariance matrices. Our findings suggest that maximizing the geodesic distance between covariance matrices ultimately leads to a corresponding increase in the network throughput, as determined by the beamforming vector used to shape the covariance matrices. Simulation results validate that the proposed solution converges faster than Euclidean-based state-of-the-art, while maintaining the same computational complexity. Finally, the sum rate performance asymptotically achieves full capacity for two-UE case and more than 96% of the upper bound exhaustive search benchmark for multi-UE scenario.

42 ENGINEERING↗

DOE OSTI2026

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation) [SWR-26-095]

FOILPOLARS (Grassmannian Foil Shape Sweeps for Polar Generation): Multifidelity aerodynamic polar data generation for hydrofoil/tidal-turbine airfoil sections. Foilpolars ties together three pieces: *AeroSandbox supplies the baseline airfoil coordinates (UIUC database). *G2Aero parameterizes those shapes on a Grassmannian manifold (Karcher mean + PGA basis) and samples new perturbed shapes around that basis. *XFoil (panel method) and NeuralFoil (neural-network surrogate, shipped with AeroSandbox) each solve the resulting shapes for lift, drag, moment, and pressure at the swept angles of attack, Reynolds numbers, and n_crit values. Design optimization of foil shapes in a computationally efficient way requires polars data across many candidate shapes, not just a handful of baseline foils. However, high-fidelity CFD at that scale is too costly, and naive shape perturbation strays from realistic geometries. FOILPOLARS addresses this by loading baseline airfoils (via AeroSandbox) and mapping them onto a Grassmannian manifold (via G2Aero), computing a Karcher mean and principal geodesic analysis (PGA) basis. New shapes are sampled by perturbing PGA coefficients, keeping them close to the manifold of realistic foils. Each sampled shape is evaluated across a configurable sweep of angle of attack, Reynolds number, and critical amplification factor using two solvers: XFoil (panel method) and NeuralFoil (neural-network surrogate), producing a paired dataset of lift, drag, moment, pressure, convergence, and confidence, indexed alongside each shape's PGA coefficients and shared Grassmannian basis in a single xarray dataset. From this, FOILPOLARS produces convergence summaries and comparison plots per shape, Reynolds number, and n_crit. A command-line interface exposes each pipeline stage independently, supporting data-driven design, optimization, and machine-learning workflows for foils.

Sandhu, Rimple [National Laboratory of the Rockies↗

DOE OSTI2025

Conflict Detection in Open RAN with Recurrent Neural Networks Using Geometric Manifolds

Allowing third-party applications on Radio Access Network (RAN) Intelligent Controllers (RICs) within the OpenRAN (O-RAN) framework introduces conflicting interactions that are often difficult to detect in advance. These conflicts, occurring between third-party applications in the Near RealTime RIC (Near-RT RIC), known as xApps, can lead to performance degradation and instability in O-RAN if not identified early. Existing conflict detection and mitigation solutions in the literature assume that the conflicts are known beforehand, which is not always accurate due to the complex and often hidden relationships between control parameters and Key Performance Indicators (KPIs). In this paper, we propose a novel Recurrent Neural Network (RNN) to detect both known and unknown conflicts in O-RAN xApps as specified in the O-RAN standards. We model the xApps, control parameters, and KPIs with nodes and edges to create graph structures and use the hidden nonEuclidean geometric properties of the Riemannian manifold to train the RNN model. The performance of this proposed model is validated using evaluation metrics and compared with benchmarks. Results demonstrate that the proposed RNN model, leveraging Riemannian geometric properties, can achieve 100% of the F1-score provided by an optimal solution in just 20 iterations.

5G↗

DOE OSTI2025

Conflict Detection in Open RAN with Recurrent Neural Networks Using Geometric Manifolds

5G↗

DOE OSTI2023

Experimental Verification of An Electro-Hydraulic Actuation System Driven by An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and a novel-designed electro-hydraulic unit (EHU) consisting of a fixed-displacement hydraulic gear machine and a variable-speed electric machine. The novel EHU design integrates an electric machine and a hydraulic machine in a single housing, targeting optimal compactness, power density, and component reduction. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. Here, the efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The efficiency of the EHA system based on the measurements on the test rig can reach 54% with up to 20 kN load and 6 kW power level. Furthermore, the EHU is implemented on the reference machine to drive the boom function. Preliminary results on the performance of the EHU show an efficiency of up to 68% under different loading conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1981

Design and fabrication of a stringer stiffened discrete-tube actively cooled panel for a hypersonic aircraft

A 0.61 x 1.22 m (2 x 4 ft) test panel was fabricated and delivered to the Langley Research Center for assessment of the thermal and structural features of the optimized panel design. The panel concept incorporated an aluminum alloy surface panel actively cooled by a network of discrete, parallel, redundant, counterflow passage interconnected with appropriate manifolding, and assembled by adhesive bonding. The cooled skin was stiffened with a mechanically fastened conventional substructure of stringers and frames. A 40 water/60 glycol solution was the coolant. Low pressure leak testing, radiography, holography and infrared scanning were applied at various stages of fabrication to assess integrity and uniformity. By nondestructively inspecting selected specimens which were subsequently tested to destruction, it was possible to refine inspection standards as applied to this cooled panel design.

Anthony, F. M.↗

DOE OSTI2020

Learning reference governor for cycle-to-cycle combustion control with misfire avoidance in spark-ignition engines at high exhaust gas recirculation–diluted conditions

Cycle-to-cycle feedback control is employed to achieve optimal combustion phasing while maintaining high levels of exhaust gas recirculation by adjusting the spark advance and the exhaust gas recirculation valve position. The control development is based on a control-oriented model that captures the effects of throttle position, exhaust gas recirculation valve position, and spark timing on the combustion phasing. Under the assumption that in-cylinder pressure information is available, an adaptive extended Kalman filter approach is used to estimate the exhaust gas recirculation rate into the intake manifold based on combustion phasing measurements. The estimation algorithm is adaptive since the cycle-to-cycle combustion variability (output covariance) is not known a priori and changes with operating conditions. A linear quadratic regulator controller is designed to maintain optimal combustion phasing while maximizing exhaust gas recirculation levels during load transients coming from throttle tip-in and tip-out commands from the driver. During throttle tip-outs, however, a combination of a high exhaust gas recirculation rate and an overly advanced spark, product of the dynamic response of the system, generates a sequence of misfire events. In this work, an explicit reference governor is used as an add-on scheme to the closed-loop system in order to avoid the violation of the misfire limit. The reference governor is enhanced with model-free learning which enables it to avoid misfires after a learning phase. Experimental results are reported which illustrate the potential of the proposed control strategy for achieving an optimal combustion process during highly diluted conditions for improving fuel efficiency.

42 ENGINEERING↗

DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

NASA NTRS2019

Operational Stability Limits in Rotating Detonation Engine Numerical Simulations

An instability is described which arises in computational fluid dynamic (CFD) simulations of semi-idealized rotating detonation engines (RDE) configured with a throat at the exit. Its existence is verified by examining output from two independently developed CFD codes simulating the same configuration and producing solutions that agree well. The instability is shown to be thermo-acoustic in that a spatial integral of the product of pressure and heat release fluctuations develops a regular oscillation which grows in time. The instability can become severe enough to cause detonation failure. Its onset is shown to be closely linked to the size of the exit throat and the size of the inlet restriction; both parameters that strongly influence RDE performance. It is shown that the instability places a cap on ideal RDEperformance, but that an optimized exhaust throat and inlet restriction combination still yields substantial pressure gain. Other parametric sensitivities are also examined in terms ofinstability growth. These include axial length, inlet manifold pressure, and air-fuel ratio.

Paxson, Daniel E.↗

NASA NTRS2014

Applying Dynamical Systems Theory to Optimize Libration Point Orbit Stationkeeping Maneuvers for WIND

NASA's WIND mission has been operating in a large amplitude Lissajous orbit in the vicinity of the interior libration point of the Sun-Earth/Moon system since 2004. Regular stationkeeping maneuvers are required to maintain the orbit due to the instability around the collinear libration points. Historically these stationkeeping maneuvers have been performed by applying an incremental change in velocity, or (delta)v along the spacecraft-Sun vector as projected into the ecliptic plane. Previous studies have shown that the magnitude of libration point stationkeeping maneuvers can be minimized by applying the (delta)v in the direction of the local stable manifold found using dynamical systems theory. This paper presents the analysis of this new maneuver strategy which shows that the magnitude of stationkeeping maneuvers can be decreased by 5 to 25 percent, depending on the location in the orbit where the maneuver is performed. The implementation of the optimized maneuver method into operations is discussed and results are presented for the first two optimized stationkeeping maneuvers executed by WIND.

WIND↗

NASA NTRS1992

Motion and force control of multiple robotic manipulators

This paper addresses the motion and force control problem of multiple robot arms manipulating a cooperatively held object. A general control paradigm is introduced which decouples the motion and force control problems. For motion control, different control strategies are constructed based on the variables used as the control input in the controller design. There are three natural choices; acceleration of a generalized coordinate, arm tip force vectors, and the joint torques. The first two choices require full model information but produce simple models for the control design problem. The last choice results in a class of relatively model independent control laws by exploiting the Hamiltonian structure of the open loop system. The motion control only determines the joint torque to within a manifold, due to the multiple-arm kinematic constraint. To resolve the nonuniqueness of the joint torques, two methods are introduced. If the arm and object models are available, an optimization can be performed to best allocate the desired and effector control force to the joint actuators. The other possibility is to control the internal force about some set point. It is shown that effective force regulation can be achieved even if little model information is available.

Wen, John T.↗

NASA NTRS1974

Estimation for bilinear stochastic systems

Three techniques for the solution of bilinear estimation problems are presented. First, finite dimensional optimal nonlinear estimators are presented for certain bilinear systems evolving on solvable and nilpotent lie groups. Then the use of harmonic analysis for estimation problems evolving on spheres and other compact manifolds is investigated. Finally, an approximate estimation technique utilizing cumulants is discussed.

Willsky, A. S.↗