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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Model predictive control of heating, ventilation, and air conditioning (HVAC) systems: A state-of-the-art review

Due to the fast advancement of communication and information technology, intelligent buildings have garnered great interest. These buildings can forecast weather, ambient temperature, and sun irradiation and can modify heating, ventilation, and air conditioning (HVAC) operations appropriately, based on current and previous data. This change is intended to reduce HVAC system energy usage while maintaining an appropriate degree of thermal comfort and indoor air quality. Since its inception, model predictive control (MPC) has been one of the prospective solutions for HVAC management systems to reduce both costs and energy usage. Additionally, MPC is becoming increasingly practical as the processing capacity of building automation systems increases and a large quantity of monitored building data becomes available. MPC also provides the potential to improve the energy efficiency of HVAC systems via its capacity to consider limitations, to predict disruptions, and to factor in multiple competing goals such as interior thermal comfort and building energy consumption. Although substantial research has been conducted on MPC in building HVAC systems, there is a shortage of critical reviews and a lack of a comprehensive framework that formulates and defines the applications. Here, this article provides a comprehensive state-of-the-art overview of MPC in HVAC systems. Detailed discussions of modeling approaches and optimization algorithms are included. Numerous design aspects such as prediction horizon, occupancy behavior, building type, and cost function, that impact MPC performance are discussed in detail. The technical characteristics, advantages, and disadvantages of various types of modeling software are discussed. The primary objective of this work is to highlight critical design characteristics for the MPC control scheme and to give improved suggestions for future research. Moreover, numerous prospective scenarios have been suggested that might provide future research direction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Probabilistic error estimation for non-intrusive reduced models learned from data of systems governed by linear parabolic partial differential equations

This work derives a residual-based a posteriori error estimator for reduced models learned with non-intrusive model reduction from data of high-dimensional systems governed by linear parabolic partial differential equations with control inputs. It is shown that quantities that are necessary for the error estimator can be either obtained exactly as the solutions of least-squares problems in a non-intrusive way from data such as initial conditions, control inputs, and high-dimensional solution trajectories or bounded in a probabilistic sense. Here, the computational procedure follows an offline/online decomposition. In the offline (training) phase, the high-dimensional system is judiciously solved in a black-box fashion to generate data and to set up the error estimator. In the online phase, the estimator is used to bound the error of the reduced-model predictions for new initial conditions and new control inputs without recourse to the high-dimensional system. Numerical results demonstrate the workflow of the proposed approach from data to reduced models to certified predictions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

A Comparison of Pre‐Construction and Operational Wake Loss Estimates for Land‐Based Wind Plants

The overall bias between pre‐construction energy yield assessment (EYA) estimates of wind plant energy production and the achieved operational production is improving in the wind industry, but uncertainty remains high for individual wind plants. Wake effects within wind plants are one of the largest sources of energy loss considered in the EYA process, and previous work shows wake loss estimates to be a major source of disagreement among wind energy consultants who perform EYAs. To better understand the accuracy of wake loss predictions, we compare overall operational wake loss estimates based on supervisory control and data acquisition data to pre‐construction estimates provided by six wind energy consultants for five land‐based wind plants in North America. By augmenting existing approaches for quantifying operational wake losses, we estimate wake losses during the period of record for which operational data are available as well as the expected long‐term wake losses, based on historical reanalysis weather data, to which the EYA estimates are compared. To account for power variations at different turbine locations caused by terrain‐induced wind resource heterogeneity, we correct the operational wake loss estimates using predicted freestream wind speed variations from the Wind Systems Engineering Reynolds‐averaged Navier–Stokes (RANS) tool. We identify long‐term corrected operational wake losses between 1.9% and 6.4% for the five plants, with a mean loss of 4%. For the project deemed most acceptable for operational wake loss assessment, which is located in the simplest terrain and isolated from neighboring plants, the mean EYA wake loss estimate is within 0.7 percentage points of the operational value of 6.4%. For most of the remaining plants, results suggest that wake losses are generally overpredicted by 2.6–6.3 percentage points. However, operational wake losses may be underestimated for many of these projects because of spatial wind resource variations not captured by the RANS model, external wake effects that are unaccounted for in the estimation process, and wind plant blockage effects. To better understand factors that contribute to the observed wake losses, we investigate operational wake losses as a function of wind direction and wind speed. As expected, wake losses are generally concentrated near wind directions that are aligned with rows of closely spaced turbines and at below‐rated wind speeds; however, for some projects, the energy produced by the wind plant exceeds the estimated potential energy of the plant without wake interactions for certain wind directions and wind speeds, suggesting inaccurate assumptions in the wake loss estimation method for those plants. Lastly, we compare predicted and operational wake losses for individual wind turbines, finding that even when overall wake losses are predicted accurately, large uncertainty exists at the turbine level.

17 WIND ENERGY↗
DOE OSTI2022

SAFE-OCC: A novelty detection framework for Convolutional Neural Network sensors and its application in process control

Herein we present a novelty detection framework for Convolutional Neural Network (CNN) sensors that we call Sensor-Activated Feature Extraction One-Class Classification (SAFE-OCC). We show that this framework enables the safe use of computer vision sensors in process control architectures. Emergent control applications use CNN models to map visual data to a state signal that can be interpreted by the controller. Incorporating such sensors introduces a significant system operation vulnerability because CNN sensors can exhibit high prediction errors when exposed to novel (abnormal) visual data. Unfortunately, identifying such novelties in real-time is nontrivial. To address this issue, the SAFE-OCC framework leverages the convolutional blocks of the CNN to create an effective feature space to conduct novelty detection using a desired one-class classification technique. This approach engenders a feature space that directly corresponds to that used by the CNN sensor and avoids the need to derive an independent latent space. We demonstrate the effectiveness of SAFE-OCC via simulated control environments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Mobility and Energy Improvements Realized through Prediction-based Vehicle Powertrain Control and Traffic Management (Research Performance Final Report)

The goal of this project was to utilize individual vehicle and systems-level transportation big data to develop real-world implementable techniques for energy efficiency. We collected a real world dataset in Fort Collins, CO using technology that is currently available. This dataset was used to (1) create individual vehicle prediction models and emissions models using cutting-edge artificial intelligence (AI) techniques, (2) create traffic prediction models, (3) create boundary condition constraints for optimal trajectory derivation, and (4) develop a novel Mobility Energy Productivity (MEP) model for Fort Collins, CO at a fidelity and flexibility which did not previously exist. Each of these techniques is novel but the most interesting results occurred from the intersection of all techniques. It was found that when optimal vehicle control is combined with optimal traffic light control, that significant energy efficiency improvements that do not compromise travel time are available.

42 ENGINEERING↗
DOE OSTI2022

A machine learning approach for clinker quality prediction and nonlinear model predictive control design for a rotary cement kiln

Abstract Cement manufacturing is energy‐intensive (5Gj/t) and comprises a significant portion of the energy footprint of concrete systems. Incorporating modern monitoring, simulation and control systems will allow lower energy use, lower environmental impact, and lower costs of this widely used construction material. One of the goals of the CESMII roadmap project on the Smart Manufacturing of Cement included developing an analytical process model for clinker quality that includes the chemistry of the kiln feed and accounts for critical process variables. This predictive model will be used in nonlinear model predictive control system designed to significantly reduce process energy use while maintaining or improving product quality. In the cement manufacturing plant used in this study, the kiln feed (meal) is tested every 12 h and used to estimate the mineral composition of the cement kiln output (clinker) using the stoichiometry‐based Bogue's model and the expertise of the plant operators. During kiln operation, kiln output (clinker) is sampled and tested every 2 h to measure its chemical and mineral composition. The predicted and measured values of the clinker composition are used by the plant operators to adjust the kiln input stream and the production process characteristics to maintain stable operation and uniform product quality. However, the time delay between prediction and testing, along with inaccuracies inherent in the Bogue's model have made any process changes designed to minimize energy use problematic, especially in‐light of potential clinker quality issues that process changes often pose. A new analytical model that integrates quality information and process operation information has been developed from data collected from 2 years of production from an operating cement facility. To make the model fuel‐type‐independent, consumed heat energy was computed in the model instead of fuel type and amount. A Feedforward Network was trained and tailored from collected data. Many data‐based simulations were conducted to quantitatively evaluate the proposed model and the 5‐fold cross‐validation procedure was used to test the models. The resulting predictive model was shown to have a low root mean square error (MSE) with respect to the estimated clinker mineral composition compared to that using the industry standard “Bogue’ model”. The end goal of this work was to develop a single machine learning tool that allows the use of quality control data and process control variables to improve energy efficiency of the process in a continuous fashion. The proposed nonlinear model predictive control system (NMPC) can generate predicted kiln production characteristics based on manipulated variables in manner that accurately follows the target product quality values. Simulation results also show that the proposed model produced accurate predictions of kiln outputs that fell within the required constraints, while manipulating control variables within typical operational ranges.

Ali, Asem M.↗
DOE OSTI2021

Integrative genomics reveals paths to sex dimorphism in Salix purpurea L

Sex dimorphism and gene expression were studied in developing catkins in 159 F 2 individuals from the bioenergy crop Salix purpurea , and potential mechanisms and pathways for regulating sex development were explored. Differential expression, eQTL, bisulfite sequencing, and network analysis were used to characterize sex dimorphism, detect candidate master regulator genes, and identify pathways through which the sex determination region (SDR) may mediate sex dimorphism. Eleven genes are presented as candidates for master regulators of sex, supported by gene expression and network analyses. These include genes putatively involved in hormone signaling, epigenetic modification, and regulation of transcription. eQTL analysis revealed a suite of transcription factors and genes involved in secondary metabolism and floral development that were predicted to be under direct control of the sex determination region. Furthermore, data from bisulfite sequencing and small RNA sequencing revealed strong differences in expression between males and females that would implicate both of these processes in sex dimorphism pathways. These data indicate that the mechanism of sex determination in Salix purpurea is likely different from that observed in the related genus Populus . This further demonstrates the dynamic nature of SDRs in plants, which involves a multitude of mechanisms of sex determination and a high rate of turnover.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Traffic Signal Control for Large-Scale Urban Traffic Networks: Real-World Experiments using Vision-Based Sensors

Effective control of traffic signals plays a critical role in ensuring smooth vehicle flow in urban areas. Expertly engineered traffic signal controllers can considerably minimize travel delays and enhance sustainability. In this paper, the team proposes the Model Predictive Control (MPC) traffic signal control strategy using real-time traffic flow data from a vision-based camera as feedback information. Also, a realistic signal timing plan that considers National Electrical Manufacturers Association (NEMA) constraints has been developed to be applied to real-world scenarios. The primary aim is to reduce the number of vehicles across all links in the controlled area, thereby optimizing traffic flow and reducing energy consumption. To validate the proposed method, several real-life experiments were conducted at 24 intersections in Chattanooga, Tennessee, by collaborating with traffic field engineers. These experiments demonstrated significant performance improvements in comparison to the existing method.

data processing↗
DOE OSTI2024

Pipeline Hydrogen Decarbonization and Repurposing Analyzers (P-HyDRAs)

The Pipeline Hydrogen Decarbonization and Repurposing Analyzers (P-HyDRAs) are a set of prototype computational tools for simulating and optimizing midstream natural gas pipeline system operations subject to location and time-dependent hydrogen blending. The models can accurately resolve dynamic gas flows through large-scale pipeline networks using non-ideal gas equations of state. The codes can be used as decision support for planning and design decisions involving intra-day energy flow schedules as well as spatiotemporal economic values of natural gas, hydrogen, and net energy delivered to consumers while ensuring that pipeline hydraulic limitations, gas compressor station constraints, operational factors, and pre-existing shipping contracts are satisfied. The inputs to the codes are a model of the pipeline system as well as time-series data that specify boundary conditions on the network. For optimization, the code module requires price and quantity offers for natural gas and hydrogen and price and quantity bids for energy, which are used as time-dependent constraints in an optimal control problem. The outputs are time-series data that provide a predictive simulation of gas flows, mass fractions, and pressures, or with additional degrees of freedom give an approximately optimal solution for gas injections/withdrawals, compressor settings, and sensitivities to the objective function that provide locational values of energy.

Zlotnik, Anatoly↗
DOE OSTI2021

The curled wake model: a three-dimensional and extremely fast steady-state wake solver for wind plant flows

Abstract. Wind turbine wake models typically require approximations, such as wake superposition and deflection models, to accurately describe wake physics. However, capturing the phenomena of interest, such as the curled wake and interaction of multiple wakes, in wind power plant flows comes with an increased computational cost. To address this, we propose a new hybrid method that uses analytical solutions with an approximate form of the Reynolds-averaged Navier–Stokes equations to solve the time-averaged flow over a wind plant. We compare results from the solver to supervisory control and data acquisition data from the Lillgrund wind plant obtaining wake model predictions which are generally within 1 standard deviation of the mean power data. We perform simulations of flow over the Columbia River Gorge to demonstrate the capabilities of the model in complex terrain. We also apply the solver to a case with wake steering, which agreed well with large-eddy simulations. This new solver reduces the time – and therefore the related cost – it takes to simulate a steady-state wind plant flow (on the order of seconds using one core). Because the model is computationally efficient, it can also be used for different applications including wake steering for wind power plants and layout optimization.

17 WIND ENERGY↗
DOE OSTI2022

Controlling extrapolations of nuclear properties with feature selection

Predictions of nuclear properties far from measured data are inherently inaccurate because of uncertainties in our knowledge of nuclear forces and in our treatment of quantum many-body effects in strongly-interacting systems. While the model bias can be directly calculated when experimental data is available, only an estimate can be made in the absence of such measurements. Current approaches to compute the estimated bias quickly lose predictive power when their input variables are taken far from the training region, resulting in uncontrolled uncertainties in applications such as nucleosynthesis simulations. In this letter, we present a novel technique to identify the input variables of machine learning algorithms that can provide robust estimates of model bias. Our process is based on selecting input variables, or features, based on their probability distribution functions across the entire nuclear chart. We illustrate our approach on the problem of quantifying the model bias in nuclear binding energies calculated with Density Functional Theory (DFT). We prove that building model biases with only Z and N as features leads to highly unreliable extrapolations. Conversely, we show that proper feature selection can systematically improve theoretical predictions without increasing uncertainties.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2022

Development of a Flotation Simulator That Can Predict Grade vs. Recovery Curves from Mineral Liberation Data

Flotation is a kinetic process designed to separate mineral fines by control of hydrophobicity. In general, both the recovery and selectivity of a flotation process increase with contact angle. It is difficult, however, to model flotation kinetics using the thermodynamic parameter. In the present work, we consider flotation as heterocoagulation so that the bubble-particle interactions occurring in the pulp phase of a flotation cell can be modeled using the hydrophobic force as a kinetic parameter that can represent the role of contact angles in flotation. Here, the pulp-phase model developed in this manner has been combined with a froth-phase model developed earlier by considering the effect of particles in film thinning kinetics and bubble coarsening (Park et al, 2018). The combined model has been used to develop a flotation simulator that can be used to construct grade vs. recovery curves from feed characteristics (e.g., mineral liberation and particle size) and various operating parameters. The simulator has been tested successfully against a set of bench-scale continuous flotation test results reported in the literature (dos Santos and Galery, 2018).

58 GEOSCIENCES↗
DOE OSTI2022

Investigation of Multiple Data Streams for Gearbox Bearing Fault Prediction Through Machine-Learning Models

Operations and maintenance (O&M) cost of wind plant accounts up to 30% of total energy cost, which can be reduced through continuous monitoring and successfully detecting incipient wind turbine failures. To accomplish this, condition monitoring and predictive maintenance systems are being implemented in wind industry to support O&M decision making. A wide range of approaches for condition monitoring and fault prediction have been developed. These approaches generally use historical data of wind turbines collected by Supervisory Control and Data Acquisition (SCADA) system to identify patterns that lead to failure. These SCADA data show the overall condition of a wind turbine and can be leveraged to detect when the turbine's performance is degrading and to identify if a fault is developing. However, it becomes challenging to predict the failure of a specific wind turbine gearbox bearing, because the SCADA data are often not directly linked to the component. To bridge the gap, we have investigated features calculated from SCADA data using physics-based models and the gearbox design over the years. The damaged metric we used in the physics domain is frictional energy. Combining these physics domain variables with SCADA data as inputs to various machine learning models for gearbox bearing fault prediction, we have demonstrated the benefits of leveraging both physics and data domain models. It was an attempt to improve frictional-energy-based damage metric by adding data domain inputs, as we had learned that the frictional-energy-based damage metric alone is not sufficient to single out failed bearings from healthy. As condition monitoring data (either vibration or oil debris data) has become available at more and more wind plants, we would like to evaluate whether by adding the condition monitoring data can help further improve the performance of frictional-energy-based damage metric for gearbox bearing fault prediction. Both cases by modeling through various machine learning algorithms are discussed in this study along with some observations.

fault prediction↗
DOE OSTI2026

A ModEx Framework for Watershed Subsurface Investigation With Limited Geophysical Data Using Machine Learning and Hydrologic Modeling

Abstract Subsurface heterogeneity influences watershed hydrology strongly but remains difficult to characterize at catchment scales with sparse and costly field data. Geophysical surveys such as electromagnetic induction (EMI) provide local spatial subsurface images yet scaling them to watershed scales and converting EMI‐derived resistivity into hydraulic properties remains a challenge. We present a Model–Experiment (ModEx) framework that integrates limited EMI data with machine learning (ML) and hydrologic modeling to improve process representation and guide field investigations. Sparse EMI surveys were scaled to the catchment scale using a Random Forest model, and the resulting resistivity fields were combined with nearby borehole constraints to parameterize a hydrologic model. The EMI‐informed hydrological simulations improved predictions of streamflow sustained by subsurface flow and shallow saturation patterns. By combining EMI data and ML with hydrologic modeling, the ModEx framework guides future subsurface surveys, providing a transferable and efficient strategy for data–model integration across diverse watersheds. Plain Language Summary Mapping the underground network of soil and rock that controls water is essential for predicting floods and droughts, but seeing underground is difficult and expensive. We cannot drill everywhere, so scientists use geophysical tools to scan broad areas. There are two key challenges: these geophysical scans are often sparse across the whole watershed, and the geophysical data is hard to translate into water‐related properties. We used artificial intelligence to solve these problems. We taught a computer to find patterns linking the limited geophysical data to the land surface properties. This allowed it to fill in the gaps and create a complete, useful subsurface map for the entire watershed. This new map improves hydrologic simulations, leading to more accurate predictions of water movement in the watershed. It also helps scientists build better models with less data and generates a priority map showing where to measure next, making future investigations more efficient. Key Points Limited EMI scaled with ML improves catchment‐scale subsurface parameterization for hydrologic models The framework integrates hydrologic modeling with limited geophysical data to support subsurface investigation design ModEx framework offers a transferable data–model integration strategy that quantifies and reduces uncertainty guiding watershed studies

Chen, Hang↗
DOE OSTI2020

Data-Driven Preemptive Voltage Monitoring and Control Using Probabilistic Voltage Sensitivities

Increased penetration levels of distributed variable renewable generation can cause random voltage fluctuations and violations at multiple nodes. Traditional methods of voltage control typically involve reactionary responses of capacitor banks, tap changers, and recently even smart inverters. But because of the lack of foresight in voltage violations, these controls are ineffective to completely mitigate the issue. Therefore, new methods of predicting voltage violations subject to random power injection changes in the distribution network are needed, which can be used to guide optimal and dynamic methods of voltage control. This work lays the foundation for such preemptive voltage monitoring and control by proposing an analytical and sensor data-driven voltage sensitivity analysis method. Driven by stochastic data and forecasts, the method can be used to develop probabilistic voltage sensitivities and consequently to predict system nodes with high likelihood of voltage limit violations. The effectiveness of this method is tested on IEEE 69-node distribution system integrated with distributed solar. The results demonstrate the proposed method's ability to successfully predict nodes with high probability of voltage violations for a specific time-series simulation. The results also demonstrate the ability to guide timely power injection control actions to mitigate future voltage violations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Model form and sensitivity analysis of CALPHAD-based nucleation models in b-stabilized Ti alloys

Accurate prediction of α-phase nucleation and growth in β-stabilized titanium alloys is crucial for designing heat treatments to optimize mechanical properties in additively manufactured lightweight components. Ideally, predictions of nucleation and growth would incorporate both top-down observations of past experimental heat treatments and bottom-up modeling of phase transformations; however, the appropriate method of combining these information sources is not self-evident. Combining top-down and bottom-up information requires a unified form of model that can connect between spatiotemporal scales, as well as sets of fitting parameters that can be identified by each data source. The selection of which parameters to fit to which data source can be made based on expert opinion, or by performing a sensitivity analysis. In solid-solid nucleation, direct observation of the nucleation and growth process is challenging. Most data on the heat treatment-controlled phase transformations are not in-situ. To predict the process and outcome of the nucleation, growth and coarsening of precipitates, theoretical models of the nucleation pathway are used to bridge the gap. Many sources of uncertainty affect the modeling of this nucleation process. It can be influenced by small variations in the thermomechanical processing history, chemical composition, and initial microstructure. If molecular dynamics (MD) simulations are used to determine thermodynamic quantities and inform CALPHAD modeling, additional uncertainty can be introduced and accounted for using Bayesian methods. Top-down uncertainties require additional steps to quantify. The influence of nucleation model form on the sensitivity of predictions to input parameters and physical conditions is the focus of this study. Classical nucleation theory (CNT) allows modeling to formulate the nucleation as homogeneous or, more commonly, heterogeneous. Non-classical nucleation models are also increasingly explored as a means of reconciling top-down and bottom-up data. In this study, the sensitivity of the intragranular nucleation of α in a β-annealed, slow-cooled aging (BASCA) heat treatment of β-stabilized Ti5553 alloy is explored using CNT and both heterogeneous and homogeneous assumptions. The Kampmann-Wagner Numerical model of precipitate nucleation and growth is employed. Using open-source tools (pyCalphad and thermodynamic modeling of TiMo as a surrogate system, a sensitivity analysis is performed to measure variations in key parameters, including chemical driving force, interfacial energy, and diffusivity, as they relate to predictions of precipitate number density. The inclusion of top-down and bottom-up data in selection of nucleation model form is discussed.

Rodriguez Negron, A. M.↗
DOE OSTI2023

Benchmarking magnetised three-wave coupling for laser backscattering: analytic solutions and kinetic simulations

Understanding magnetised laser–plasma interactions is important for controlling magneto-inertial fusion experiments and developing magnetically assisted radiation and particle sources. For nanosecond pulses at non-relativistic intensities, interactions are dominated by coherent three-wave interactions, whose nonlinear coupling coefficients became known only recently when waves propagate at oblique angles with the magnetic field. In this paper, backscattering coupling coefficients predicted by warm-fluid theory are benchmarked using particle-in-cell simulations in one spatial dimension, and excellent agreements are found for a wide range of plasma temperatures, magnetic field strengths and laser propagation angles, when the interactions are mediated by electron-dominant hybrid waves. Systematic comparisons between theory and simulations are made possible by a rigorous protocol. On the theory side, the initial boundary value problem of linearised three-wave equations is solved, and the transient-time solutions allow the effects of growth and damping to be distinguished. On the simulation side, parameters are carefully chosen and calibration runs are performed to ensure that comparisons are well controlled. Fitting simulation data to analytical solutions yields numerical growth rates that match theory predictions within error bars. Although warm-fluid theory is found to be valid for a wide parameter range, genuine kinetic effects have also been observed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Regional surrogates for predictive control of digital twins

Digital twins of complex systems must involve a model that is fast, generalizable, and usable for real-time control. For example, high-fidelity nonlinear multiphysics simulations can capture laser-material interactions, but are too slow for optimization or model predictive control (MPC). Reduced-order models, used to accelerate such computation, frequently fail to generalize to unseen inputs or control states. We show theoretically that this failure is intrinsic, i.e., that a learned model is non-unique outside the sampled subspace when its low-rank structure arises from limited excitation and clustered eigenvalues, rather than from a user-imposed truncation alone. Motivated by this result, we propose a control-ready regional surrogate-construction framework for both autonomous and nonautonomous dynamics; it employs Koopman lifting to represent nonlinearities, while preserving spatial locality. We illustrate our approach by constructing a control-ready surrogate for the digital twin of a thermal component of additive-manufacturing process. Our surrogate, localized in space through a von Neumann stencil, is learned from noisy high-fidelity simulations that emulate thermal-camera images collected during the manufacturing. It is linear in thermo-physically augmented states so that MPC reduces to a convex quadratic program. The surrogate requires no online correction, generalizes to unseen scan paths and power profiles of the laser, and is more than three orders of magnitude faster than a finite-difference solver. Furthermore, when the MPC sequence computed on the digital twin is applied to this solver, closed-loop temperature regulation is recovered, showing that the surrogate preserves control-relevant input-output behavior.

Data-driven model↗