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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

BOPTEST as a Platform for Building Controls and Grid-Interactive Buildings Workforce Training

Building automation and controls are becoming increasingly complex with the emergence of Grid Integrated Efficient Buildings (GEBs) as well as new highly efficient sequences of operation and data-driven control schemes. However, there remains a significant gap in hands-on training opportunities for building operators and technicians to gain practical experience with advanced control systems in a low-risk environment. This paper presents BOPTEST (Building Optimization Performance Test) as a suitable platform for workforce training in building controls and GEB technologies. BOPTEST provides a suite of standardized building simulation test cases with a REST API, real-time control interfaces through BACnet, semantic models connecting users to building data, and built-in calculation of control metrics and performance indicators. The platform enables trainees to interact with virtual buildings using industry-standard protocols while learning how to implement and innovate control strategies. The training platform is designed to offer a structured and interactive learning experience for building engineers, helping them effectively develop, learn, and retain skills in fault identification, troubleshooting, and correction. The workflow is divided into three main phases: 1) Setup, 2) Exercise, and 3) Review, each comprising specific activities performed by either the instructor or the student. Initial pilot training sessions have yielded positive feedback from instructors and participants and demonstrates that BOPTEST effectively fills an industry need for a low-risk training resource via simulation of real building control systems, allowing trainees to gain practical experience before working in the field. The platform's ability to provide immediate performance feedback while maintaining familiar industry interfaces makes it particularly suitable for workforce development programs. This work provides a replicable model for leveraging building simulation in control education and training.

Paul, Lazlo↗
DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary optimization where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The new approach to shape optimization resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗
DOE OSTI2023

Robust Parameter Design on Dual Stochastic Response Models With Constrained Bayesian Optimization

In engineering system design, minimizing the variations of the quality measurements while guaranteeing their overall quality up to certain levels, namely the robust parameter design (RPD), is crucial. Recent works have dealt with the design of a system whose response-control variables relationship is a deterministic function with a complex shape and function evaluation is expensive. In this work, we propose a Bayesian optimization method for the RPD of stochastic functions. Dual stochastic response models are carefully designed for stochastic functions. The heterogeneous variance of the sample mean is addressed by the predictive mean of the log variance surrogate model in a two-step approach. We establish an acquisition function that favors exploration across the feasible and optimality-improvable regions to effectively and efficiently solve the stochastic constrained optimization problem. Further, the performance of our proposed method is demonstrated by the extensive numerical and case studies. Note to Practitioners-Many manufacturing processes involve undesirable variations, which create variations in the final products. For example, many emerging manufacturing processes, such as nanomanufacturing, involve complex physical and chemical dynamics and transformation, creating variations in the manufacturing output. In such processes, it is crucial to design the manufacturing processes or products so that they have minimum variations in their quality. Meanwhile, it is also important to maintain the overall quality of the designed processes or products. Furthermore, acquiring data from many advanced manufacturing processes is often very costly, especially in the designing stage. In this work, we propose a data-driven method that automatically finds the best setting of manufacturing processes or products with the minimum variations of quality and a given constraint on the average quality satisfied. Our proposed method is used before conducting every experiment; It analyzes the historical data from previous experiments and provides a setting to be used in the next experiment. Our proposed method efficiently utilizes the historical data, and thus finds the best robust setting by conducting only a small number of experiments.

42 ENGINEERING↗
NASA NTRS1992

Application of Taguchi methods to dual mixture ratio propulsion system optimization for SSTO vehicles

The application of advanced technologies to future launch vehicle designs would allow the introduction of a rocket-powered, single-stage-to-orbit (SSTO) launch system early in the next century. For a selected SSTO concept, a dual mixture ratio, staged combustion cycle engine that employs a number of innovative technologies was selected as the baseline propulsion system. A series of parametric trade studies are presented to optimize both a dual mixture ratio engine and a single mixture ratio engine of similar design and technology level. The effect of varying lift-off thrust-to-weight ratio, engine mode transition Mach number, mixture ratios, area ratios, and chamber pressure values on overall vehicle weight is examined. The sensitivity of the advanced SSTO vehicle to variations in each of these parameters is presented, taking into account the interaction of each of the parameters with each other. This parametric optimization and sensitivity study employs a Taguchi design method. The Taguchi method is an efficient approach for determining near-optimum design parameters using orthogonal matrices from design of experiments (DOE) theory. Using orthogonal matrices significantly reduces the number of experimental configurations to be studied. The effectiveness and limitations of the Taguchi method for propulsion/vehicle optimization studies as compared to traditional single-variable parametric trade studies is also discussed.

Stanley, Douglas O.↗
DOE OSTI2023

Concurrent multi-peak Bragg coherent x-ray diffraction imaging of 3D nanocrystal lattice displacement via global optimization

Abstract In this paper we demonstrated a method to reconstruct vector-valued lattice distortion fields within nanoscale crystals by optimization of a forward model of multi-reflection Bragg coherent diffraction imaging (MR-BCDI) data. The method flexibly accounts for geometric factors that arise when making BCDI measurements, is amenable to efficient inversion with modern optimization toolkits, and allows for globally constraining a single image reconstruction to multiple Bragg peak measurements. This is enabled by a forward model that emulates the multiple Bragg peaks of a MR-BCDI experiment from a single estimate of the 3D crystal sample. We present this forward model, we implement it within the stochastic gradient descent optimization framework, and we demonstrate it with simulated and experimental data of nanocrystals with inhomogeneous internal lattice displacement. We find that utilizing a global optimization approach to MR-BCDI affords a reliable path to convergence of data which is otherwise challenging to reconstruct.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Data-Driven Discovery of Active Nematic Hydrodynamics

Active nematics can be modeled using phenomenological continuum theories that account for the dynamics of the nematic director and fluid velocity through partial differential equations (PDEs). While these models provide a statistical description of the experiments, the relevant terms in the PDEs and their parameters are usually identified indirectly. We adapt a recently developed method to automatically identify optimal continuum models for active nematics directly from spatio-temporal data, via sparse regression of the coarse-grained fields onto generic low order PDEs. After extensive benchmarking, we apply the method to experiments with microtubule-based active nematics, finding a surprisingly minimal description of the system. Furthermore, our approach can be generalized to gain insights into active gels, microswimmers, and diverse other experimental active matter systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1989

The Gamma-Ray Observatory

The scientific goals and the design of the NASA Gamma-Ray Observatory (GRO), planned for launch in mid-1990, are described together with the experiments to be performed on the GRO mission and the instruments to be flown on the Observatory. GRO contains a complement of four instruments to span the spectrum from 0.03 to 20,000 MeV in energy, three of which are optimized to make gamma-ray observations using either the photoelectric effect, the Compton scatter, or the pair production processes; the fourth instrument is optimized for high-sensitivity observations of transient events and time-variable sources. The instruments are the Oriented Scintillation Spectrometer Experiment, the Compton Telescope, the Energetic Gamma-Ray Experiment Telescope, and the Burst and Transient Source Experiment.

Kniffen, Donald A.↗
NASA NTRS1989

Locating damaged members in a truss structure using modal test data - A demonstration experiment

An experiment is designed to demonstrate and verify the performance of the on-orbit assessment approach for large flexible space truss structures. The on-orbit assessment approach can be accomplished, in principle, with dynamic response information, structural identification methods, and model correlation techniques which produce an adjusted mathematical model. An optimal update of the structure model is formed using the response data, then examined to locate damaged members. The experiment uses a laboratory scale model truss structure which exhibits characteristics expected for large space truss structures. Vibration experiments are performed to generate response data for the damaged truss. The damage location approach is described, as well as analytical work performed in support of the vibration tests, the measured response of the test article, and some preliminary results.

Smith, Suzanne Weaver↗
DOE OSTI2020

The Manufacturing Data and Machine Learning Platform: Enabling Real-time Monitoring and Control of Scientific Experiments via IoT

IoT devices and sensor networks present new opportunities for measuring, monitoring, and guiding scientific experiments. Sensors, cameras, and instruments can be combined to provide previously unachievable insights into the state of ongoing experiments. However, IoT devices can vary greatly in the type, volume, and velocity of data they generate, making it challenging to fully realize this potential. Indeed, synergizing diverse IoT data streams in near-real time can require the use of machine learning (ML). In addition, new tools and technologies are required to facilitate the collection, aggregation, and manipulation of sensor data in order to simplify the application of ML models and in turn, fully realize the utility of IoT devices in laboratories. Here we will demonstrate how the use of the Argonne-developed Manufacturing Data and Machine Learning (MDML) platform can analyze and use IoT devices in a manufacturing experiment. MDML is designed to standardize the research and operational environment for advanced data analytics and AI-enabled automated process optimization by providing the infrastructure to integrate AI in cyber-physical systems for in situ analysis. We will show that MDML is capable of processing diverse IoT data streams, using multiple computing resources, and integrating ML models to guide an experiment.

Machine Learning↗
DOE OSTI2024

Novel Materials R&D for Next-Generation Accelerator Target Facilities

High-Entropy Alloys and Electrospun Nanofiber materials are two classes of novel materials that can offer improved resistance to beam-induced radiation damage and thermal shock. Research to develop these new materials specifically for multi-megawatt accelerator target applications, such as beam windows and particle-production targets, are ongoing at Fermilab within the scope of a DOE Early Career Research Program. The research program combines in-beam experiments with complementary simulations to tailor the microstructures of these novel materials for use in next-generation accelerator target facilities. Iterative simulations to optimize the material composition, physics performance, and beam-induced thermomechanical response will guide the material design and fabrication processes based on established figures of merit. This will be followed by material irradiation experiments using low-energy ions and prototypic high-energy protons with extensive post-irradiation material characterization to assess and qualify the selected novel materials. This talk will describe the alloy design and synthesis, microstructural pre-characterization of the alloys, and plans for the eventual down selection following low-energy ion irradiation studies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Design and optimization of the RF input-coupler for a low-frequency, split-coaxial RFQ

The Isotope Decay-At-Rest experiment (IsoDAR) is a proposed underground experiment which is expected to be a definitive search for sterile neutrinos. In order to be decisive within 5 years, high rates of neutrinos must be produced, by impinging a 10 mA continuous wave proton beam at 60 MeV on a high power target. Due to space restrictions, a compact cyclotron was chosen as an accelerator to produce this driver beam. To overcome space charge limitations during injection, H 2 + ions are accelerated and later stripped into protons by means of a carbon foil. IsoDAR uses an especially designed low-frequency (32.8 MHz) split-coaxial Radio-Frequency Quadrupole (RFQ) to effectively bunch H 2 + ions before injecting them into this cyclotron. The RFQ will be embedded vertically in the cyclotron yoke, facilitating a very compact design. This puts stringent limits on RFQ size, type, and accessibility. Here, we present the design and optimization of the low-frequency (32.8 MHz) RF input-coupler for the IsoDAR RFQ. The design is challenging due to the necessarily small diameter of the RFQ (28 cm) and the split-coaxial type, as well as limited access to the RFQ. We have determined the optimal position and shape for the coupler, leading to a low power consumption of < 6 kW for an inter-vane voltage of 22 kV. Finally, the highest calculated fields are safely below the Kilpatrick limit for this structure.

43 PARTICLE ACCELERATORS↗
NASA NTRS2009

Exploration of Habitability Factors Influencing Short Duration Spaceflight: Structured Postflight Interviews of Shuttle Crewmembers

Astronauts report significant difficulties with sleep during Space missions. Psychological, physiological, and habitability factors are all thought to play a role in spaceflight insomnia. Crewmembers gain experience with the spaceflight sleep environment as their missions progress, but this knowledge is not formally collected and communicated to subsequent crews. This lack of information transfer prevents crews from optimizing their capability to sleep during mission, which leads to fatigue and its potentially deleterious effects. The goal of this project is astronauts with recent spaceflight experience to gather their knowledge of and insights into sleep in Space. Structured interviews consisting of standardized closed and open-ended questionnaires are administered to astronauts who have flown on the Space Shuttle since the Columbia disaster. It is hoped that review and analysis of the pooled responses to the interview questions will lead to greater understanding of the sleep environment during short duration spaceflight, with attention placed on problem aspects and their potential solutions.

Locke, James↗
DOE OSTI2022

Development of a Direct Neutral Density Diagnostic for Fusion Edge Plasmas

As magnetically confined plasmas progress towards ignition and long pulse experiments, measurement and control of the neutral density in the plasma edge has become a critical issue for stability, formation of transport barriers, and fueling. Recent experiments by our research group have demonstrated that is possible to use two-photon absorption laser induced fluorescence (TA-LIF) to directly measure the density of neutral hydrogen in helicon sources and in the HIT-SI3 spheromak. While those experiments validated key elements of a diagnostic system that would enable similar measurements in tokamak plasmas, they did not fully address the issue of performance optimization in the presence of intense background light at the fluorescence wavelength and they also identified a number of other issues that must be resolved before successful TALIF neutral density measurements in a tokamak are likely to be achieved. Additional specific concerns raised during design reviews with the leadership of the DIII-D tokamak facility included: the minimum detection threshold for this TALIF diagnostic (currently ~ 5 x 10 15 m -3 ) and the rate at which neutral density measurements could be obtained. Improving the system performance to reduce the minimum detection threshold and demonstrating a faster rate of density determination are required to advance this diagnostic to the level where it could be considered for implementation on a major tokamak facility in the USA. The key issues that will be addressed through additional technological development are: validation of a new, chromatic aberration-free, xenon calibration scheme; increasing the output power of the laser; and suppression of background emission at the fluorescence wavelength through optimization of the collection optics and gating of the photomultiplier detector with a goal of obtaining a minimum detection threshold of 5 x 10 14 m -3 . Another key technological development, so far only tested in helicon source experiments, is the validation of Doppler-free TALIF as a means of obtaining higher speed, calibrated, neutral density measurements in tokamak-like conditions at the full cadence of the pulsed TALIF laser. In this work, we propose to complete these technological advancements through installation and testing of our prototype TALIF system on the proto-MPEX experiment at Oak Ridge National Laboratory (ORNL). The proto-MPEX facility will provide plasma conditions similar to the edge plasma of a major tokamak experiment but with pulse lengths and pulse repetition rates ideally suited for extensive development of a TALIF neutral density diagnostic. Measurement of the absolute neutral density in the edge of a magnetically confined plasma is necessary for plasma density control; calculation of charge-exchange power losses; control of plasma-wall interactions; determination of the braking of plasma flow; determination of the fuel mixture in deuterium-tritium plasma; and understanding the dynamics of the divertor region in the plasma edge. In terms of potential impact on the worldwide fusion program, we note that in burning plasma experiments, such as ITER, a 100 mJ/pulse Doppler-free TALIF diagnostic should be capable of directly measuring the deuterium/tritium (D/T) isotope ratio in the outer 0.5 to 1.0 m of the plasma radius. The D/T ratio is a critically important parameter for the control and optimization of burning plasmas. Therefore, development of the diagnostic system proposed here is also relevant to long-term US participation in diagnostic development for large tokamaks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1988

PI-in-a-box: Intelligent onboard assistance for spaceborne experiments in vestibular physiology

In construction is a knowledge-based system that will aid astronauts in the performance of vestibular experiments in two ways: it will provide real-time monitoring and control of signals and it will optimize the quality of the data obtained, by helping the mission specialists and payload specialists make decisions that are normally the province of a principal investigator, hence the name PI-in-a-box. An important and desirable side-effect of this tool will be to make the astronauts more productive and better integrated members of the scientific team. The vestibular experiments are planned by Prof. Larry Young of MIT, whose team has already performed similar experiments in Spacelab missions SL-1 and D-1, and has experiments planned for SLS-1 and SLS-2. The knowledge-based system development work, performed in collaboration with MIT, Stanford University, and the NASA-Ames Research Center, addresses six major related functions: (1) signal quality monitoring; (2) fault diagnosis; (3) signal analysis; (4) interesting-case detection; (5) experiment replanning; and (6) integration of all of these functions within a real-time data acquisition environment. Initial prototyping work has been done in functions (1) through (4).

Colombano, Silvano↗
DOE OSTI2024

Topological Optimization with Big Steps

Using persistent homology to guide optimization has emerged as a novel application of topological data analysis. Existing methods treat persistence calculation as a black box and backpropagate gradients only onto the simplices involved in particular pairs. We show how the cycles and chains used in the persistence calculation can be used to prescribe gradients to larger subsets of the domain. In particular, we show that in a special case, which serves as a building block for general losses, the problem can be solved exactly in linear time. This relies on another contribution of this paper, which eliminates the need to examine a factorial number of permutations of simplices with the same value. Here, we present empirical experiments that show the practical benefits of our algorithm: the number of steps required for the optimization is reduced by an order of magnitude.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2022

Use of Refractory-Volatile Element Deep Eutectic Regions to Grow Single Crystalline Intermetallic Compounds

Compounds containing both refractory and volatile elements present a unique challenge for crystal growth, given the conflicting realities of high melting temperatures and high vapor pressures. Nevertheless, the discovery of superconductivity in FeAs and FeSe based materials and a Weyl semimetal state in TaP are motivations to explore compounds containing such pairs. Here, we discuss use of the low-melting single phase liquid regions above deep M-X eutectics (M=transition metal, X=P, S) as the basis for high temperature solutions for growing intermetallic compounds containing volatile-refractory pairs. We show that Ni-P, Pd-P, Pt-P, and Pd-S compositions form single phase melts at moderate temperatures below 1000 °C and with minimal vapor pressure. We first present the simple case of growing Ni 2 P from Ni-P and next discuss the more complicated growth of RPd 3 S 4 (R=La, Ce, Nd, Eu) from a Pd-S melt. We show how frit-disc alumina crucible sets allow for contamination-free capture of decanted liquid and its reuse in subsequent experiments, demonstrating a fractionation of the CePd 3 S 4 growth to determine the optimal conditions for crystal growth. We conclude by using the single phase liquid regions above the Pt-P and Pd-P eutectics to grow single crystals of MPt 5 P (M=Mn, Fe) and MnPd 5 P. As these materials have primarily been studied in polycrystalline form, we give an overview of the magnetic and transport properties of our single crystals. The examples outlined here illustrate the utility of using the single phase liquid above deep metal-X eutectics for solution growth and materials discovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Continuously bounds-preserving discontinuous Galerkin methods for hyperbolic conservation laws

For finite element approximations of transport phenomena, it is often necessary to apply a form of limiting to ensure that the discrete solution remains well-behaved and satisfies physical constraints. However, these limiting procedures are typically performed at discrete nodal locations, which is not sufficient to ensure the robustness of the scheme when the solution must be evaluated at arbitrary locations (e.g., for adaptive mesh refinement, remapping in arbitrary Lagrangian–Eulerian solvers, overset meshes, etc.). In this work, a novel limiting approach for discontinuous Galerkin methods is presented which ensures that the solution is continuously bounds-preserving (i.e., across the entire solution polynomial) for any arbitrary choice of basis, approximation order, and mesh element type. Through a modified formulation for the constraint functionals, the proposed approach requires only the solution of a single spatial scalar minimization problem per element for which a highly efficient numerical optimization procedure is presented. Here, the efficacy of this approach is shown in numerical experiments by enforcing continuous constraints in high-order unstructured discontinuous Galerkin discretizations of hyperbolic conservation laws, ranging from scalar transport with maximum principle preserving constraints to compressible gas dynamics with positivity-preserving constraints.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Design, performance, and cost savings of using GF-PC additively manufactured tooling for stamping of HSS 590 sheet metal

Conventional sheet metal forming tooling in the automotive industry is made up of hardened steel and used for mass-production. Prototype tooling made of metal is durable, but it is only used for a small number of parts despite its high cost, contributing heavily to the vehicle development cost. Additive Manufacturing (AM) offers a low-cost alternative for fabricating tooling suitable for low-volume production. Here, this study investigates the feasibility of using AM polymer composite tooling for the stamping of 1.5mm thickness HSS 590 steel sheets through a two-pronged approach – experimental and numerical analysis. Sheet metal stamping experiments were conducted with glass fiber reinforced polycarbonate (GF-PC) AM polymer tooling and their performance was evaluated based on various metrics such as tool deformation and part accuracy. Finite element simulations of the stamping process were performed, which accurately captured the tool deformations seen in experiments with the use of anisotropic material models. The effective use of simulations in optimizing process parameters to achieve the desired final part geometry is also demonstrated. The GF-PC AM polymer composite tooling was found to be well suited for low volume production applications with potential cost savings.

36 MATERIALS SCIENCE↗