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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Even Higher-Level Synthesis: An Exploration of AI Hardware Accelerators using HLS4ML

With the rise of artificial intelligence, the popularization of deep learning, and a constantly evolving industry, the demand for flexible and efficient tools has never been greater. As algorithms grow more complex, their runtime and energy consumption increase exponentially. Customized hardware accelerators, long used for specific mathematical operations, remain essential for managing modern applications' computational and power demands. Hardware accelerators can speed up complex computations by orders of magnitude, but their manual design and verification processes are often challenging and time-consuming. High-Level Synthesis (HLS) provides a solution by transforming high-level algorithm descriptions, typically written in C++ or SystemC, into synthesizable RTL suitable for hardware implementation. This approach reduces development time for RTL engineers while offering flexibility beyond what traditional handwritten RTL can provide. We extended this capability to the machine-learning domain with the open-source framework hls4ml, which allows neural networks trained in Python frameworks like Tensorflow or PyTorch to be synthesized into efficient hardware representations for the traditional FPGA and ASIC flows. This breakthrough addresses the growing need for reduced design turnaround and easy verification of ML hardware accelerators with low latency and power efficiency constraints. During this tutorial, we will demonstrate how Python complements HLS by simplifying the ML design process, bridging the gap between software and hardware development. Attendees will explore how we translate neural networks modeled in Python into fixed-point C++ models suitable for HLS workflows. We will dive into strategies like Value-Range Analysis and Quantization-Aware Training, which optimize these designs for deployment and evaluate their accuracy, power consumption, and energy efficiency. To exemplify these concepts, experts from Fermilab will share their experiences applying this technology to high-energy physics experiments, where real-time, low-latency processing is critical. Over the years, Fermilab engineers have demonstrated how deep neural networks, optimized for hardware using hls4ml, can meet the stringent requirements of trigger systems at the CERN Large Hadron Collider. These systems rely on rapid decision-making to process immense data volumes while retaining only the most relevant events for further analysis. The application of hls4ml has also been extended to innovative technologies like smart pixel arrays. These smart pixels integrate ML inference capabilities directly into sensor devices, enabling localized data processing at the pixel level. This approach drastically reduces the need to transmit raw data to external processing units, significantly decreasing power consumption and latency. By embedding neural networks within the pixel architecture, the smart pixels can identify and prioritize relevant data in real time, providing a highly efficient solution for edge computing in scenarios such as particle detectors and imaging systems. Fermilab's work highlights the potential of hardware-accelerated ML in scenarios where both speed and power efficiency are mission-critical. Through this tutorial, attendees will gain valuable insights into the challenges and solutions of deploying ML in hardware. Understanding how HLS and hls4ml streamline the development of neural network-based hardware accelerators is fundamental for the industry's future. Participants will learn how these technologies are shaping the future of AI and scientific computing.

Di Guglielmo, Giuseppe [Fermilab]↗

DOE OSTI2025

Power-Capping Metric Evaluation for Improving Energy Efficiency in HPC Applications

With high-performance computing systems now running at exascale, optimizing power-scaling management and resource utilization has become more critical than ever. This paper explores runtime power-capping optimizations that leverage integrated CPU-GPU power management on architectures like the NVIDIA GH200 superchip. We evaluate energy-performance metrics that account for simultaneous CPU and GPU power-capping effects by using two complementary approaches: speedup-energy-delay and a Euclidean distance-based multi-objective optimization method. By targeting a mostly compute-bound exascale science application, the Locally Self-Consistent Multiple Scattering (LSMS), we explore challenging scenarios to identify potential opportunities for energy savings in exascale applications, and we recognize that even modest reductions in energy consumption can have significant overall impacts. Our results highlight how GPU task-specific dynamic power-cap adjustments combined with integrated CPU-GPU power steering can improve the energy utilization of certain GPU tasks, thereby laying the groundwork for future adaptive optimization strategies.

Patrou, Maria [ORNL] (ORCID:0000000339754638)↗

DOE OSTI2026

Building Operation Model (Morpheus) for Dallas Fort Worth Airport (CRADA CRD-19-16301 Final Report)

The primary objective of this project was to leverage digital twin technology to enhance the design and operation of DFW Airport terminals and their associated energy systems. To achieve this, Morpheus, a building digital twin, was developed to guide improvements in airport operations, specifically targeting reductions in peak power demand and overall energy consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Dilated causal convolutional neural networks for forecasting zone airflow to estimate short-term energy consumption

Here this paper investigates the use of dilated causal convolutional neural networks for fine- grained temporal forecasting of building zone states. Specifically, we build and evaluate models using a small set of exogenous features (e.g., external temperature) to autoregressively predict zone airflow setpoints every minute for a 24-hour prediction window. We carefully explore the trade-off between generality and specificity in these models, training and evaluating them based on zone, zone type, month, season, and combinations thereof. When evaluated for a commercial office building in Eastern Washington with 16 zones served by variable air volume air handling units, we find that the highest performance comes from a zone-specific, season-agnostic approach; with it, we obtain an R 2 of 0.704 (averaged over zones) and an average normalized root mean square error (nRMSE) of 0.111. In contrast, the most general model (trained across all zones and seasons) yields an R 2 of only 0.416 and a nRMSE of 0.168, while a baseline zone-specific reduced order model obtains 0.443 R 2 and 0.159 nRMSE. We also report on factors affecting airflow forecasting performance, on the ability of models trained on a specific zone to generalize to other zones, and on the capability of those models trained on a specific month to generalize to other months.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Infinitely Recyclable Network Polymers, Enabling Sustainable Manufacturing (CRADA Final Report)

This FLO Materials project was aimed at commercializing a new, infinitely recyclable material that can enable closed-loop lifecycles for hard-to-recycle plastics and plastic products. Four hundred million metric tons of virgin plastic is produced each year, yet less than 10% of this material is recycled. In the US alone, 2% of energy consumption is dedicated to the manufacture of virgin plastics, polymer resin, and synthetic rubbers. By keeping plastic materials in circulation longer, we can reduce waste, lower manufacturing costs, cut energy and oil consumption, and drastically reduce greenhouse gas (GHG) emissions. Specifically, FLO’s innovation overcomes the complications associated with salvaging difficult-to-recycle plastics (i.e., contaminated thermoplastic linear polymers, thermoset cross-linked network polymers), which represent at least 20% of total polymer global production, with a recycling rate of near 0%. Chemical recycling of these new polymers through depolymerization allows all additives to be easily removed at room temperature and the recovered monomers to be remanufactured into next generation materials with 100% recovery of mechanical performance and aesthetic quality.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Validating Simulated Models of Energy Consumption by a Battery Electric Motorcoach: A real-world deployment in a harsh climate.

Many efforts have been made to simulate energy consumption of battery electric buses (BEBs) to optimize their deployment into existing fleets. The models produced, however, are rarely validated against real-world consumption data, limiting their generalizability and widespread application to fleets around the US. Furthermore, a major concern specific to BEBs is the effects of harsh climates on their performance. We build upon the state-of-the-art energy consumption modeling techniques developed for BEBs and apply them to a unique geographic context and a unique electrified vehicle. This geography, climate, and vehicle further the existing understanding of the factors affecting medium- and heavy-duty electric vehicles (MHDEVs) by allowing for new relationships to be tested and by assessing the generalizability of known relationships to new contexts. We find that temperature is less predictive of energy consumption for the battery electric motorcoach (BEM) in the case study environment than it is for BEBs in other studies. A mitigating factor that we presume to be working on the relationship between temperature and energy consumption is the fact that the BEM route does not stop between origin and destination to exchange passengers, and in turn, conditioned cabin air. Our model also incorporates wind speed and direction relative to travel, which is a novel contribution of our methodology. Results from our study are helpful for transit service planners, fleet operators, and logistics firms for improving their ability to predict performance of potential deployments of MHDEVs into existing operations.

32 - ENERGY CONSERVATION, CONSUMPTION, AND UTILIZA↗

DOE OSTI2020

Specifying Calibration of Energy-Measuring Equipment

Instruments and standards need to be calibrated periodically to ensure that their use yields accurate measurements. Calibration needs, however, vary in sophistication, based on user expectations. This white paper reviews calibration terminology and standards, and describes best practices that have been developed for a) calibrating measurement equipment to ensure some known level of accuracy, and b) accrediting calibration service providers. Calibration is discussed in the context of metrological traceability, and excerpts from laboratory scopes of accreditation are shared to reveal the diversity of terminology and format among them. In an effort to aid those who currently calibrate measuring equipment or who have new or changing needs for calibrating measuring equipment, rationale is provided for why a specification might be used to request calibration services that meet specific test needs. Given the growing interest in using data to manage the energy consumption of systems, and the increasing number and variety of systems (e.g., building, computing) that can report such information, use cases requiring energy data are used to facilitate further discussion and provide examples. Commercially available service providers who are accredited for energy-measuring equipment calibration are compared and contrasted, and a specification template that might be used for requesting this calibration is presented. The specification template should be tailored to meet each user’s needs. To illustrate, an example set of energy-measuring-equipment test conditions (reflecting the planned usage of the device to be calibrated) is used to develop a customized calibration specification, and commercially available service providers are assessed in terms of their qualifications for calibration to that particular implementation of the specification template.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

A Multi-Dimensional Benefit Assessment of Automated Mobility Platforms (AMP) for Large Facilities: Mobility, Energy, Equity, and Facility Management & Design

The goal of the automated mobility platforms (AMPs) initiative is to raise the bar of service regarding equity and sustainability for public mobility systems that are crucial to large facilities, and doing so using electrified, energy efficient technology. Using airports as an example, the rapid growth in air travel demand has led to facility expansions and congested terminals, which directly impacts equity (e.g., increased challenges for Passengers with Reduced Mobility [PRMs]) and sustainability - both of which are important metrics often overlooked during the engineering design process. Therefore, to evaluate systems and inform critical near- and long-term decisions more effectively, a holistic evaluation framework is proposed focused on four key areas: (1) mobility, with emphasis on travel time and accessibility within an airport, (2) environment, focused on energy consumption and greenhouse gas (GHG) emissions associated with intra-airport mobility, (3) equity, specifically to the PRM community, but with an eye to the whole of society, and (4) built environment, or the fundamental changes in building design enabled by different mobility systems for larger and more flexible, functional, and energy-efficient structures. Below, AMPs are defined, and each metric is discussed further, all with a focus on airport mobility.

ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1983

Advanced single permanent magnet axipolar ironless stator ac motor for electric passenger vehicles

A program was conducted to design and develop an advanced-concept motor specifically created for propulsion of electric vehicles with increased range, reduced energy consumption, and reduced life-cycle costs in comparison with conventional systems. The motor developed is a brushless, dc, rare-earth cobalt, permanent magnet, axial air gap inductor machine that uses an ironless stator. Air cooling is inherent provided by the centrifugal-fan action of the rotor poles. An extensive design phase was conducted, which included analysis of the system performance versus the SAE J227a(D) driving cycle. A proof-of-principle model was developed and tested, and a functional model was developed and tested. Full generator-level testing was conducted on the functional model, recording electromagnetic, thermal, aerodynamic, and acoustic noise data. The machine demonstrated 20.3 kW output at 1466 rad/s and 160 dc. The novel ironless stator demonstated the capability to continuously operate at peak current. The projected system performance based on the use of a transistor inverter is 23.6 kW output power at 1466 rad/s and 83.3 percent efficiency. Design areas of concern regarding electric vehicle applications include the inherently high windage loss and rotor inertia.

Beauchamp, E. D.↗

DOE OSTI2020

RL-HEMS: Reinforcement Learning Based Home Energy Management System for HVAC Energy Optimization

Heating, ventilation, and air conditioning (HVAC) is one of the major energy consumers in the residential sector. It is important to be able to monitor and control the energy consumed to provide utility services such as load shaping while satisfying the comfort and economic constraints of the homeowner. The objective of this work is to create the optimal schedule for HVAC operation to reduce the cost while satisfying the home-owner and equipment’s constraints using a model-free Reinforcement Learning (RL)-based optimization. The specific goal is to find the right balance between reducing energy cost, consumption, and customer comfort level. Our research effort addresses this optimization problem using multiple components: the development of initial learning test-bed and implementation of RL techniques on a real home. This will enable the rapid evaluation of the RL techniques and provide an early baseline to train before implementation on site. The RL algorithm is designed to learn the energy use patterns and generate the optimized schedule for HVAC within an acceptable time-interval to satisfy the homeowner’s comfort and minimize the energy usage. Our preliminary results are promising and we have observed a 17% reduction in the total cost and a 15% reduction in the power utilization using our RL-based HVAC model—RL-HEMS.

Kotevska, Olivera↗

DOE OSTI2020

THE CASE FOR MULTICRITERIA ANNUAL SUNLIGHT EXPOSURE GUIDELINES

This paper explored the effects of the current Annual Sunlight Exposure (ASE1000 lux, 250 hours) requirements on energy consumption and thermal comfort of an office space in five cities representing different U.S. climates. Specifically, the goal was to quantify the extent to which the current ASE metric requirements may be adjusted allowing for more/ less annual sunlight exposure to address climatic differences, energy, and thermal comfort criteria. A south-facing perimeter office space was simulated in the five climates to assess differences in energy and thermal comfort between the current ASE requirements and best-case scenarios. The results highlight the need to incorporate thermal comfort and energy as primary criteria informing target ASE requirements and guidelines. Lastly, the paper discusses research pathways to help develop multi-criteria ASE guidelines.

Abboushi, Belal K.↗

DOE OSTI2022

Particle scale impacts on deconstruction energy of pine residues

The goal of this Case Study was to quantify the impacts of variable moisture and ash on hammer mill throughput and energy consumption and on generation of fines that are not able to be fed to conversion, as compared to a status quo Base Case system. Also considered was convertible carbon content (minimum carbon specification) and maximum ash content and the delivered feedstock cost impacts of not being able to feed residue not meeting both specifications to the conversion reactor. Laboratory data on the impacts of input particle size and moisture content on the exit particle size were received from FCIC Subtask 5.2 from their single particle impact population balance modeling study. Additional throughput and energy consumption data were obtained from FCIC Subtask 5.2 for the same grinder with a 6 mm screen in place. These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the ash contents in the separated fines had not been analyzed in the laboratory at the time of the model runs, we chose to assume that the ash distributed proportionally with total mass into the overs and unders in the disk screen following grinding. Key takeaways from this Case Study are that it is significantly more cost effective to hammer mill the residue prior to drying, even though the grinder throughput is lower and energy consumption is higher versus drying first before grinding. An effect of dry grinding versus high moisture grinding is the production of higher amounts of fines during dry grinding, leading to significantly more of the ground feedstock being rejected by conversion for being below a minimum particle size. With wet grinding the system is still able to produce more preprocessed feedstock meeting the minimum particle size specification even though the instantaneous throughput is lower than for the case of grinding dry feedstock. Additionally, even without the higher fines production from dry grinding, the status quo would still be more costly than wet grinding because the material is rejected after the drying energy has already been input for the dry grinding case. Finally, significant reductions in drying energy are obtained by drying after grinding, and those reductions are of far greater magnitude than the grinding energy increase.

09 BIOMASS FUELS↗

DOE OSTI2026

Heavy-Duty Nonroad Material Handler Electrification Part 1: Real-World Drive Cycle Development

Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy consumption enabling equivalent comparison to future electrified prototype builds. This article presents a solution specifically for a 23-ton nonroad material handler in which material handling, machine transport, and extended idle were homologated to form representative short cycles defined by machine velocity and hydraulic cylinder position. The most intensive material handling short cycles had a load factor of 40% and an average fuel rate of 16 L/h. Combined with a visual aid, the short cycles exhibited low variability, having less than 5% root mean square (RMS) error in lift and reach position with respect to the average. The machine’s performance on these short cycles at the Advanced Power Systems Research Center (APSRC) was compared to results from two real-world customer locations operating the instrumented test machine in a cyclical manner, and for similar ground conditions were found to be comparable in fuel consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Development of near-optimal advanced control sequences for chiller plants with water-side economizers in U.S. Climates (ASHRAE RP-1661)

Various advanced control sequences for chiller plants with water-side economizers (WSE) have been proposed in literature, but the evaluation and optimization of those controls is limited. It is possible to maximize energy savings by selecting different sequences and related parameters based on the plant configuration, load, and climate. This paper addresses this gap by developing near-optimal advanced control sequences for chiller plants with WSEs. First, advanced control sequences for chiller plants with WSEs are categorized into condenser water, chilled water, and hybrid controls and representative sequences from each category are identified. Next, 504 different scenarios are optimized. These scenarios represent all possible combinations of two plant configurations, a constant or variable load profile, three advanced control sequences, and seven optimization parameter combinations in six climate zones. The results show the recommended near-optimal sequences can reduce energy consumption by up to 15% relative to the baseline depending on the configuration, load profile, and climate. Specifically, the CW-CHW sequence is recommended for the majority of systems because it is often the most energy efficient and/or reduces the runtime of chillers. The methodology in this paper provides practical guidance for achieving energy savings through near-optimal control of chiller plants with WSEs.

42 ENGINEERING↗

DOE OSTI2022

Impact of anatomical fractionation of corn stover on hammer mill throughput and energy consumption

The goal of this Case Study was to quantify the impacts of variable moisture and ash on hammer mill throughput and energy consumption and on loss of very wet stover that causes failures in the first stage grinder and that are not able to be fed to conversion, as compared to a status quo Base Case system. Also considered was convertible carbohydrate content (minimum total carbohydrate specification) and maximum ash content and the delivered feedstock cost impacts of not being able to feed stover not meeting the total carbohydrate specification to the conversion reactor. Laboratory data on the impacts of moisture content and tissue fraction on throughput and energy consumption in a stage 2 hammer mill were received from FCIC Subtask 5.1. Additional air classifier throughput, energy consumption and separation efficiency data were obtained from FCIC Subtask 5.1 for the new air classifier, which has three exit streams (lights, middle and heavies). These data were utilized to develop the necessary response surface equations to perform throughput analysis using discrete event simulation. Because the ash contents and particle sizes had not been analyzed in the laboratory at the time of the model runs, we assumed that the ash distributed proportionally with total mass into the lights and heavies in an air classifier having two exit streams (lights and heavies) and that the lights fraction from the air classifier was not removed. Key takeaways from this Case Study are that due to lower energy consumption, it is more cost effective to hammer mill fractionated corn stover tissues than whole stover. Reduction of grinding energy was significant and may possibly be connected to particle-particle interactions in the grinder that lead to increased residence time of leaves and husks, resulting in decreased throughput and higher generation of fines when milling whole stover. While we did not see significant impacts to throughput, this was due to moisture failures of the first stage grinder in each system dominating failures and downtime. The operating cost savings of reduced grinding energy savings in the second stage hammer mills alone was high enough to offset the added capital cost of the air classifier and extra grinding line.

09 BIOMASS FUELS↗

DOE OSTI2023

Impact of Anatomical Fractionation of Corn Stover on Hammer Mill Throughput and Energy Consumption

ash content↗

DOE OSTI2020

Data-driven occupant-behavior analytics for residential buildings

Many advances have been made in building technology to help save energy, but influencing the behavior of the occupants is still necessary to achieve low-energy use targets. One of the most practical ways to influence and change occupant behaviors is through incentives. Developing incentives for energy-saving and quantifying the impact of occupant behaviors are both active areas of research. Here, we propose a data analytics framework for detecting changes in occupant behaviors, which will help build an analytics feedback loop from behavior impact to incentive design. The framework has two major parts. The first forecasts energy consumption for each occupant, while the second determines a probability distribution for changes in energy consumption. The parts are interchangeable with other existing machine learning and statistical methods. A specific instantiation of the framework, using kernel ridge-regression for forecasting and k-means to find an empirical behavior distribution, is described in detail. An HVAC use-case with 5 different incentivized behaviors is used as an example to show that the framework can detect behavior changes induced by incentives. Furthermore, we show that some simpler behavior-change detection methods do not work, further justifying the use of advanced analytics.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Electricity Bill Calculator (elecprice) v0.1.0

The Electricity Bill Calculator Library is a generic tool for manipulating the tariffs of electricity, with an emphasis on commercial Time-Of-Use (TOU) rates in the U.S. and residential Net Energy Metering tariffs in CA. Typical uses of the package are price signal generation and bill computation. To generate price signals from a specific tariff and given a time window, the tool creates a pandas dataframes containing the various components of the electricity charges, at each time step. This is particularly useful for Demand Response (DR) applications, such as price-based optimization of energy in buildings. The tool also computes bills given a building's power consumption and a specific tariff and returning the corresponding cost of electricity, as well as a breakdown per type of rate.

Prakash, Anand Krishnan↗