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At least 145 records · Page 8

Development of an Integrated Electro-Hydraulic Machine to Electrify Off-highway Vehicles

Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper proposes and develops an axial flux machine integrated with a hydraulic pump to realize a single modular, electro-hydraulic machine to electrify off-highway vehicle implements. This integrated machine eliminates redundant bearings, couplings, and shaft seals, re-uses surfaces, and enables direct cooling of the electric machine with the hydraulic fluid, to significantly increase power density. Three popular axial flux machine variants are first compared using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to characterize the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and enamelled copper wire). Furthermore, a prototype axial flux machine has been experimentally characterized and integrated with a hydraulic pump to demonstrate the integrated electro-hydraulic machine concept.

33 ADVANCED PROPULSION SYSTEMS↗

What Machine Learning Can and Cannot Do for Inertial Confinement Fusion

Machine learning methodologies have played remarkable roles in solving complex systems with large data, well-defined input–output pairs, and clearly definable goals and metrics. The methodologies are effective in image analysis, classification, and systems without long chains of logic. Recently, machine-learning methodologies have been widely applied to inertial confinement fusion (ICF) capsules and the design optimization of OMEGA (Omega Laser Facility) capsule implosion and NIF (National Ignition Facility) ignition capsules, leading to significant progress. As machine learning is being increasingly applied, concerns arise regarding its capabilities and limitations in the context of ICF. ICF is a complicated physical system that relies on physics knowledge and human judgment to guide machine learning. Additionally, the experimental database for ICF ignition is not large enough to provide credible training data. Most researchers in the field of ICF use simulations, or a mix of simulations and experimental results, instead of real data to train machine learning models and related tools. They then use the trained learning model to predict future events. This methodology can be successful, subject to a careful choice of data and simulations. However, because of the extreme sensitivity of the neutron yield to the input implosion parameters, physics-guided machine learning for ICF is extremely important and necessary, especially when the database is small, the uncertain-domain knowledge is large, and the physical capabilities of the learning models are still being developed. In this work, we identify problems in ICF that are suitable for machine learning and circumstances where machine learning is less likely to be successful. This study investigates the applications of machine learning and highlights fundamental research challenges and directions associated with machine learning in ICF.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Servomotor-driven leveling elements for machine tool frame-to-floor alignment

This paper presents the results of aligning the frame to concrete floor of a large 5-axis machine tool by leveling element adjustments using servomotors instead of manual operation. The machine tool leveling elements used in this study are mechanical devices that attach the machine tool frame to the concrete foundation. These leveling elements are also adjustable so that each location along the machine tool can be uniquely adjusted such that the geometric errors of the frame are minimized, and the accuracy of the machine tool is improved. Off-the-shelf servomotors and connection equipment were installed at each of 12 leveling element locations for a precision 5-axis machine tool at Oak Ridge National Laboratory. The servomotors allow a technician to align the machine tool frame remotely, instead of crawling under the machine tool to iteratively manually adjust each of the 12 leveling elements. The open-loop servomotor-leveling element system design is presented in this paper as well as machine tool frame alignment results. The servomotor system significantly reduces leveling element adjustment time, eliminates the need for under-machine access, reduces technician physical strain, and significantly improves the adjustment repeatability.

Honeycutt, Andrew [ORNL]↗

A contextual sensor system for non-intrusive machine status and energy monitoring

Event-driven contexts in manufacturing occur pervasively as a result of interactions among involved entities such as machines, workers, materials, and environment. One of the primary tasks in smart manufacturing is to derive a context-aware system conveniently incorporating worker knowledge for generating timely actionable intelligence for workers on factory floor and supervisors to respond. In this paper, we propose to design a human-and-machine interaction recognition framework by using a causality concept to collect contextual data for classifications of normal and abnormal machine operations. The causes and effects are between workers and machines for this initial research. To apply the causality to recognize worker interactions, initially a reliable way to identify the states of machines is necessary. The proposed contextual sensor system, consisting of a power meter for measuring machine operation conditions, a visual camera for capturing worker and machine interactions via a finite state machine model, and an algorithm for determining power signatures of individual components via energy disaggregation is implemented on semiconductor fabrication machines (manual or PLC controlled) each with multiple components. The experiment results demonstrate its context extraction capability such as components states and their corresponding energy usage in real time as well as its ability to identify anomalous operation conditions.

47 OTHER INSTRUMENTATION↗

Design of an Axial Flux Machine With an Integrated Hydraulic Pump for Off-Highway Vehicle Electrification

Axial flux machines offer an inherent torque density advantage over conventional radial flux machines and are increasingly being considered for transportation electrification applications. Electrification of off-highway vehicles is notoriously challenging due to extreme power density requirements. This paper investigates the use of axial flux machines for off-highway vehicle electrification. To maximize the power density, a hydraulic pump is integrated with the axial flux machine, resulting in a single modular, electric/hydraulic machine. This paper first compares three popular axial flux machine variants using an FEA-based design optimization approach. The single rotor, single stator variant is identified to be the most promising for integration with the hydraulic pump. Next, a multi-physics framework of the complete integrated hydraulic pump and axial flux machine is developed to search the design space. The results indicate promising potential for this concept to realize efficiency over 85% and power density over 5kW/kg for the complete machine (electric machine, hydraulic pump, and thermal management system), while utilizing conventional materials (thin gauge silicon steel, N45 magnets, and magnet wire)

Off-highway vehicles, Axial flux machines, Multi-p↗

The importance of round-robin validation when assessing machine-learning-based vertical extrapolation of wind speeds

The extrapolation of wind speeds measured at a meteorological mast to wind turbine rotor heights is a key component in a bankable wind farm energy assessment and a significant source of uncertainty. Industry-standard methods for extrapolation include the power-law and logarithmic profiles. The emergence of machine-learning applications in wind energy has led to several studies demonstrating substantial improvements in vertical extrapolation accuracy in machine-learning methods over these conventional power-law and logarithmic profile methods. In all cases, these studies assess relative model performance at a measurement site where, critically, the machine-learning algorithm requires knowledge of the rotor-height wind speeds in order to train the model. This prior knowledge provides fundamental advantages to the site-specific machine-learning model over the power-law and log profiles, which, by contrast, are not highly tuned to rotor-height measurements but rather can generalize to any site. Furthermore, there is no practical benefit in applying a machine-learning model at a site where winds at the heights relevant for wind energy production are known; rather, its performance at nearby locations (i.e., across a wind farm site) without rotor-height measurements is of most practical interest. To more fairly and practically compare machine-learning-based extrapolation to standard approaches, we implemented a round-robin extrapolation model comparison, in which a random-forest machine-learning model is trained and evaluated at different sites and then compared against the power-law and logarithmic profiles. We consider 20 months of lidar and sonic anemometer data collected at four sites between 50 and 100 km apart in the central United States. We find that the random forest outperforms the standard extrapolation approaches, especially when incorporating surface measurements as inputs to include the influence of atmospheric stability. When compared at a single site (the traditional comparison approach), the machine-learning improvement in mean absolute error was 28 % and 23 % over the power-law and logarithmic profiles, respectively. Using the round-robin approach proposed here, this improvement drops to 20 % and 14 %, respectively. These latter values better represent practical model performance, and we conclude that round-robin validation should be the standard for machine-learning-based wind speed extrapolation methods.

17 WIND ENERGY↗

Review of machine learning and deep learning models for toxicity prediction

The ever-increasing number of chemicals has raised public concerns due to their adverse effects on human health and the environment. To protect public health and the environment, it is critical to assess the toxicity of these chemicals. Traditional in vitro and in vivo toxicity assays are complicated, costly, and time-consuming and may face ethical issues. These constraints raise the need for alternative methods for assessing the toxicity of chemicals. Recently, due to the advancement of machine learning algorithms and the increase in computational power, many toxicity prediction models have been developed using various machine learning and deep learning algorithms such as support vector machine, random forest, k-nearest neighbors, ensemble learning, and deep neural network. This review summarizes the machine learning- and deep learning-based toxicity prediction models developed in recent years. Support vector machine and random forest are the most popular machine learning algorithms, and hepatotoxicity, cardiotoxicity, and carcinogenicity are the frequently modeled toxicity endpoints in predictive toxicology. It is known that datasets impact model performance. The quality of datasets used in the development of toxicity prediction models using machine learning and deep learning is vital to the performance of the developed models. The different toxicity assignments for the same chemicals among different datasets of the same type of toxicity have been observed, indicating benchmarking datasets is needed for developing reliable toxicity prediction models using machine learning and deep learning algorithms. This review provides insights into current machine learning models in predictive toxicology, which are expected to promote the development and application of toxicity prediction models in the future.

Research & Experimental Medicine↗

Application of Quantum Machine Learning to High Energy Physics Analysis at LHC Using Quantum Computer Simulators and Quantum Computer Hardware

Machine learning enjoys widespread success in High Energy Physics (HEP) analyses at LHC. However the ambitious HL-LHC program will require much more computing resources in the next two decades. Quantum computing may offer speed-up for HEP physics analyses at HL-LHC, and can be a new computational paradigm for big data analyses in High Energy Physics.We have successfully employed three methods (1) Variational Quantum Classifier (VQC) method, (2) Quantum Support Vector Machine Kernel (QSVM-kernel) method and (3) Quantum Neural Network (QNN) method for two LHC flagship analyses: ttH (Higgs production in association with two top quarks) and H->mumu (Higgs decay to two muons, the second generation fermions). We shall address the progressive improvements in performance from method (1) to method (3).We will present our experiences and results of a study on LHC High Energy Physics data analyses with IBM Quantum Simulator and Quantum Hardware (using IBM Qiskit framework), Google Quantum Simulator (using Google Cirq framework), and Amazon Quantum Simulator (using Amazon Braket cloud service). The work is in the context of a Qubit platform (a gate-model quantum computer). Taking into account the present limitation of hardware access, different quantum machine learning methods are studied on simulators and the results are compared with classical machine learning methods (BDT, classical Support Vector Machine and classical Neural Network). Furthermore, we do apply quantum machine learning on IBM quantum hardware to compare performance between quantum simulator and quantum hardware. The work is performed by an international and interdisciplinary collaboration with the Department of Physics and Department of Computer Sciences of University of Wisconsin, CERN Quantum Technology Initiative, IBM Research Zurich, IBM T.J. Watson Research Center, Fermilab Quantum Institute, BNL Computational Science Initiative, State University of New York at Stony Brook, and Quantum Computing and AI Research of Amazon Web Services. This work pioneers a close collaboration of academic institutions with industrial corporations in the High Energy Physics analyses effort. Though the size of event samples in future HL-LHC physics and the limited number of qubits pose some challenges to the Quantum Machine learning studies for High Energy Physics, more advanced quantum computers with larger number of qubits, reduced noise and improved running time (as envisioned by IBM and Google) may outperform classical machine learning in both classification power and in speed.Although the era of efficient quantum computing may still be years away, we have made promising progress and obtained preliminary results in applying quantum machine learning to High Energy Physics. A PROOF OF PRINCIPLE.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Generalizability analysis of tool condition monitoring ensemble machine learning models

Tool condition monitoring (TCM) is an essential research area for the optimization and automation of metal machining processes, and could help manufacturers reduce costs, production time, machine downtime, energy use, and part scrappage. However, TCM systems developed in prior studies have struggled to reach the high level of generalizability which is necessary for industrial applications. This study addresses TCM system generalizability to new machining conditions, how variations in machining and environmental conditions may be used to improve model generalizability, and ensemble machine learning techniques for TCM. Further, milling tool life experiments were conducted using various machining conditions, and the processes' sound, spindle power, and axial load signals were collected. Different machine learning models were evaluated for the prediction of tool wear levels, including four individual models and five ensemble models. Changes in cutting speed were found to display a large effect on model performance, while the chip load showed some effect, and the feed rate had little effect. A simulated noise data augmentation technique for model improvement is applied within TCM for the first time, and resulted in increased model generalizability and reduced overfitting. Across several performance metrics the extremely randomized trees ensemble machine learning model generally performed the best for this application, achieving a leave-one-group-out cross validation accuracy score of 92.4 %, a 10-fold cross validation score of 98.9 %, and an averaged accuracy across 11 generalizability tests of 87.3 %.

42 ENGINEERING↗

Detection of Part Porosity in Additive Manufacturing Using Machining

Monitoring of part porosity in additive manufacturing is critical for part qualification and process parameter development. This article describes the monitoring of porosity in additive manufacturing using machining. Grade 91 steel samples with different levels of porosity were additively manufactured using a laser blown-powder process. The samples were machined, and the tool position and cutting power were monitored using the machine controller and an external power transducer, respectively. Results show that the power transducer is sensitive to machining porosities. A novel approach using the standard deviation of cutting power was developed to determine the location of porosities along the length of the machining pass. Test cuts were completed at different machining process parameters. Results showed that the probability of detection was one for pore volume greater than 0.3 mm 3 at different machining parameters. In conclusion, although the detection of porosity using machining is a destructive method for evaluation, it offers a low-cost and fast approach for monitoring porosity in additive manufacturing.

36 MATERIALS SCIENCE↗

Machine learning assisted modeling of mixing timescale for LES/PDF of high-Karlovitz turbulent premixed combustion

Accurate modeling of mixing in the transported probability density function (PDF) method remains a great challenge, especially for turbulent premixed combustion under extreme conditions such as high Karlovitz number Ka. Recently, a power-law based mixing timescale model was developed for the large-eddy simulations (LES)/PDF modeling of high-Ka number turbulent premixed flames. It is found in this work that the power-law mixing timescale model is highly sensitive to the model parameters. It is thus critically needed to develop accurate calibration of these model parameters. The empirical specification of the model parameters developed in Zhang et. al. is found to be inadequate for accurate modeling of the mixing timescale. Here, machine learning is introduced as an attractive alternative in this work for the specification of the model parameters. A high-Ka number DNS jet flame is used as the training and validation of the machine learning models. The choices of the input parameters are discussed and compared for the machine learning models. The effect of differential molecular diffusion on mixing is examined by including the effect of the Lewis number in the training of the machine learning models. The performance of different machine learning algorithms is compared for the specification of the mixing model parameters. Overall, excellent performance of the machine learning models is observed for assisting the mixing modeling. The feasibility, interpretability, applicability, generality, and portability of using machine learning are discussed in general to provide a perspective on applying data-driven machine learning for turbulent combustion modeling studies.

42 ENGINEERING↗

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗

Microstructure analysis and machinability of additively manufactured A205 aluminum with heat treatments

A205 aluminum is one of the few high-strength aluminum alloys discovered for additive manufacturing (AM). The microstructure and heat treatment effects of AM A205 vary from those of its cast form, indicating possible differences in machinability during post-processing. Here, the objective of this research is to determine these variations of AM A205 and their effects on machinability using the cast condition as the baseline. As built and two heat-treated conditions (solution treatment and age hardening) were applied and compared in terms of their microstructures, micro-hardness, and machinability including vibration, specific cutting energy, chip morphology, and surface finish. The effects of print orientations on machinability were tested as well and found to be insignificant. AM as built had a higher hardness and slightly better machinability than its cast as built cast counterpart due to a smaller grain size (1 µm vs. 15 µm), eutectic θ-Al 2 Cu lattice and a fine, homogeneous TiB 2 distribution. The solution treatment dissolved this θ-Al 2 Cu lattice and increased the grain size (3 µm) which decreased the hardness, increased the ductility seen in the chips, and reduced the overall machinability. The presence of θ’-Al 2 Cu precipitates improved the machinability of aged AM A205. In addition, it was found that A205 exhibited both ductile and brittle behavior depending on the cutting speed, thus producing different machinability. The speed dependency is related to the material condition and heat treatment.

36 MATERIALS SCIENCE↗

Entropic control of the free-energy landscape of an archetypal biomolecular machine

Biomolecular machines are complex macromolecular assemblies that utilize thermal and chemical energy to perform essential, multistep, cellular processes. Despite possessing different architectures and functions, an essential feature of the mechanisms of action of all such machines is that they require dynamic rearrangements of structural components. Surprisingly, biomolecular machines generally possess only a limited set of such motions, suggesting that these dynamics must be repurposed to drive different mechanistic steps. Although ligands that interact with these machines are known to drive such repurposing, the physical and structural mechanisms through which ligands achieve this remain unknown. Using temperature-dependent, single-molecule measurements analyzed with a time-resolution-enhancing algorithm, here, we dissect the free-energy landscape of an archetypal biomolecular machine, the bacterial ribosome, to reveal how its dynamics are repurposed to drive distinct steps during ribosome-catalyzed protein synthesis. Specifically, we show that the free-energy landscape of the ribosome encompasses a network of allosterically coupled structural elements that coordinates the motions of these elements. Moreover, we reveal that ribosomal ligands which participate in disparate steps of the protein synthesis pathway repurpose this network by differentially modulating the structural flexibility of the ribosomal complex (i.e., the entropic component of the free-energy landscape). Here, we propose that such ligand-dependent entropic control of free-energy landscapes has evolved as a general strategy through which ligands may regulate the functions of all biomolecular machines. Such entropic control is therefore an important driver in the evolution of naturally occurring biomolecular machines and a critical consideration for the design of synthetic molecular machines.

Science & Technology - Other Topics↗

Rapid Commissioning of Large Machine Tools Using Finite Element-Based Correction of Geometric Errors

Large computer numerical control (CNC) machine tools derive their stiffness from monolithic cast iron bases or weldments that are sometimes integral to machine motion systems like box ways or guideways. However, the sheer size of castings and even floor flatness deviations result in dimensional errors in these systems, which manifest as machine motion errors. Typical geometric alignment processes rely on an iterative approach, where measurements are taken to assess alignment (straightness, squareness, and parallelism), followed by adjustment of the machine supports (fixators or leveling pads), which can take weeks even for an experienced operator. Conversely, a novel method is proposed to shorten the correction time by eliminating the trial-and-error process in favor of a more deterministic approach guided by a finite element (FE) method. A feasibility study is conducted on a CNC polymer hybrid machine, with a steel weldment frame, supported by six leveling pads. An FE model of the frame is utilized to obtain recommended leveling pad adjustments, based on measurement of machine errors taken using a laser tracker. After a single adjustment cycle, measurements reveal that geometric errors of the machine tool are reduced from 2.22 mm of flatness deviation to 0.32 mm, achieving an 85.6% reduction. Furthermore, the entire process including measurement, adjustment, and assessment is completed in just 6 h by two operators who are not professional service engineers. In conclusion, this methodology demonstrates feasibility for scaling up, especially to large, high-precision CNC machine tools with bases mounted by fixators, offering the capability for bidirectional adjustment.

42 ENGINEERING↗

A data-driven framework for predicting machining stability: employing simulated data, operational modal analysis, and enhanced transfer learning

Chatter, a self-excited vibration phenomenon, presents a significant challenge in machining operations, particularly in high-speed milling, where it can degrade tool life, reduce material removal efficiency, and compromise workpiece quality. Addressing this challenge requires a reliable predictive model that can accommodate the complex dynamics of various machining scenarios. This study introduces a novel, data-driven approach to predicting machining stability, leveraging over 140,000 simulated datasets and employing advanced techniques such as operational modal analysis (OMA), enhanced transfer learning (TL), and receptance coupling substructure analysis (RCSA). By integrating these methodologies, the framework effectively classifies and predicts chatter across diverse operational modes, achieving robust and accurate outcomes. Our model utilizes a Random Forest (RF) classifier trained with the comprehensive dataset, which demonstrates substantial improvements in both predictive accuracy and robustness. Specifically, the RF model achieved an accuracy rate of 85%, an area under the curve (AUC) of 0.90, and an F1 score of 0.88, underscoring its capability to adapt to varying machining configurations. These results highlight the framework’s potential to enhance operational efficiency and machining quality by providing reliable chatter predictions across a broad range of machining parameters. In conclusion, this research thus offers a significant advancement in predictive maintenance for machining processes, enabling more stable and efficient manufacturing operations.

42 ENGINEERING↗

Scientific machine learning benchmarks

Deep learning has transformed the use of machine learning technologies for the analysis of large experimental datasets. In science, such datasets are typically generated by large-scale experimental facilities, and machine learning focuses on the identification of patterns, trends and anomalies to extract meaningful scientific insights from the data. In upcoming experimental facilities, such as the Extreme Photonics Application Centre (EPAC) in the UK or the international Square Kilometre Array (SKA), the rate of data generation and the scale of data volumes will increasingly require the use of more automated data analysis. Furthermore, at present, identifying the most appropriate machine learning algorithm for the analysis of any given scientific dataset is a challenge due to the potential applicability of many different machine learning frameworks, computer architectures and machine learning models. Historically, for modelling and simulation on high-performance computing systems, these issues have been addressed through benchmarking computer applications, algorithms and architectures. Extending such a benchmarking approach and identifying metrics for the application of machine learning methods to open, curated scientific datasets is a new challenge for both scientists and computer scientists. Here, we introduce the concept of machine learning benchmarks for science and review existing approaches. As an example, we describe the SciMLBench suite of scientific machine learning benchmarks.

42 ENGINEERING↗

Moore Machine Motion Controls Refurbishment Statement of Work and Specification

Diamond Turning Machines known as “Moore” machines are used in the production of Potassium diHydrogen Phosphate (KDP) optics required for the National Ignition Facility (NIF). These machines are owned by the Department of Energy, as provided by Lawrence Livermore National Security LLC (LLNS). Moore Machines 1 and 2 are located at the Gooch & Housego (G&H) facility in Highland Heights, OH. The existing Aerotech motion controllers, motor drivers/amplifiers, input/output (I/O) hardware, control computer, software user interface, human machine interface (HMI), cabling, and encoders are beyond service life and require replacement. This Statement of Work (SoW) defines the motion control system refurbishment requirements for the Moore diamond turning machines designated Moore 1 and Moore 2. The motion controls system design shall include a motion control computer, control software, motor drive amplifiers and controllers, linear scale encoders, rotary encoders, HMI, power distribution, emergency stop (E-Stop) and interlocks, cabling, switches, solenoids, transducers, sensors, actuators, ancillary system interfaces, and related components necessary for a complete machine tool control system. The Subcontractor shall include effort to standardize systems between the two machines if reasonably possible.

42 ENGINEERING↗