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At least 163 records · Page 9

Automated Non-Destructive Mechanical Testing of Fine Pitch Wirebond Arrays

This is the required paper summarizing the poster presentation material to be presented at The 25th European Microelectronics & Packaging Conference (EMPC 2025) (16 – 18 September 2025). The paper will be associated with the conference presentation in the conference proceedings

Menk, Lyle Alexander [Sandia National Laboratories↗

Development and Demonstration of a Class 6 Range-Extended Electric Vehicle for Commercial Pickup and Delivery Operation: Preprint

Range-extended hybrids are an attractive option for medium- and heavy-duty commercial vehicle fleets because they offer the efficiency of an electrified powertrain with the driving range of a conventional diesel powertrain. The vehicle essentially operates as if it was purely electric for most trips, while ensuring that all commercial routes can be completed in any weather conditions or geographic terrain. Fuel use and point-source emissions can be significantly reduced, and in some cases eliminated, as many shorter routes can be fully electrified with this architecture. Under a U.S. Department of Energy (DOE)-funded project for Medium- and Heavy-Duty Vehicle Powertrain Electrification, Cummins has developed a plug-in hybrid electric Class 6 truck with a range-extending engine designed for pickup and delivery application. The National Renewable Energy Laboratory (NREL) assisted by developing representative workday drive cycles for Class 6 operation and an adapted cycle to enable vehicle track testing. A novel, automated driving system was utilized by Southwest Research Institute (SwRI) to improve the repeatability of the track testing conducted to quantify vehicle energy consumption. Cummins used a drivetrain model to design the hybrid control system for increased fuel savings. The control system functionality and fuel savings objective of 50% or more were confirmed by track testing described in this paper.

ADVANCED PROPULSION SYSTEMS↗

Experimental testing of a control barrier function on an automated vehicle in live multi-lane traffic

This paper experimentally tests an implementation of a control barrier function (CBF) designed to guarantee a minimum time-gap in car following on an automated vehicle (AV) in live traffic, with a majority occurring on freeways. The CBF supervises a nominal unsafe PID controller on the AV’s velocity. The experimental testing spans two months of driving, of which 1.9 hours of data is collected in which the CBF and nominal controller are active. We find that violations of the guaranteed minimum time-gap are observed, as measured by the vehicle’s on-board radar unit. There are two distinct causes of the violations. First, in multi-lane traffic, Cut-ins from other vehicles represent external disturbances that can immediately violate the minimum guaranteed time gap provided by the CBF. When cut-ins occur, the CBF does eventually return the vehicle to a safe time gap. Second, even when cut-ins do not occur, system model inaccuracies (e.g., sensor error and delay, actuator error and delay) can lead to violations of the minimum time-gap. These violations are small relative to the violations that would have occurred using only the unsafe nominal control law.

99 GENERAL AND MISCELLANEOUS↗

FORCE Regression Testing

Via programs including the Light Water Reactor Sustainability and Integrated Energy Systems, the U.S. Department of Energy has invested in the Framework for Optimization of ResourCes and Economics (FORCE) software framework (Idaho National Laboratory 2024a) for the technical and economic analysis of nuclear-integrated energy systems (IES). Nuclear IES expand the use of nuclear from traditional baseload electricity generation to a flexible and adaptive source of combined heat and power. Nuclear heat can be used in the production of a variety of energy currencies such as hydrogen and ammonia as well as other heat applications including water desalination and district heating. FORCE is designed with the intent to provide interconnected analysis tools that enable the accurate technical and economic assessment of specific nuclear IES configurations for individual energy markets. FORCE consists of three main analysis pathways: HYBRID (Idaho National Laboratory 2024b), which contains high-resolution physical models for IES; Holistic Energy Resource Optimization Network (HERON) (Idaho National Laboratory 2024c), which analyzes IES long-term economic viability; and Optimization of Real-time Capacity Allocation (ORCA) (Idaho National Laboratory 2024d), designed for real-time control of IES via digital twins and optimal decision making, including autonomous and remote operation research. Development of the FORCE ecosystem is guided by three pillars: capability, which assures that the computational requirements of IES analysis are met by the software tools; reliability, which provides for consistent code performance and expected behaviors; and accessibility, which lowers the barrier to entry for using the software and accelerates analysis by users beyond the FORCE primary developers. Reliability of the FORCE ecosystem is established according to the American Nuclear Society?s Nuclear Quality Assurance (NQA-1) program [American Society of Mechanical Engineers 1982], with specific levels of software quality assurance (SQA) within NQA-1 applied to each software tool in FORCE. As the tools within FORCE have matured, some integration algorithms to accurately connect the software tools for holistic analysis have been developed and deployed within the FORCE software repository. In accordance with NQA-1 standards, regression tests are required to guarantee the software performs consistently even when new capabilities are added to the software. In this report, we document the deployment of both unit tests, which test the consistent behavior of small pieces of the FORCE code base, as well as integration tests, which test the consistent performance of full use cases for the FORCE integration algorithms. We further document the encapsulation of these tests within a test harness, which collectively checks for each successful test completion on demand. Finally, we document the automation of the test harness using GitHub Actions [GitHub 2024], which require all tests succeed before any new capability or other changes can be added to the FORCE integration software

97 MATHEMATICS AND COMPUTING↗

Validating Connected, Automated, and Electric Vehicle Models and Simulation - Research Performance Progress Report

The objective of this project is to test connected and automated vehicles with both electrified and internal combustion engine powertrains to support updates and validation of modeling and simulation tools. This includes the development of the components and network architecture to execute and collect empirical data for multiple scenarios and traffic interactions. Specific program objectives include: • Translate Lab algorithms into vehicle and infrastructure controls • Conduct physical testing at realistic scale • Evaluate system performance • Improve models using empirical data • Improve control algorithms from lessons learned • Identify system and algorithm assumptions which need refinement It is important to note that the objective of this project was not to demonstrate the efficacy of the selected algorithms to improve energy efficiency but rather to validate and improve modeling and simulation tools using empirical data. While it is a desirable outcome to concurrently demonstrate improved energy efficiency through use of these algorithms, and in most cases that was the outcome, the success of this project was not predicated on the performance of the algorithm towards improving energy efficiency across all scenarios and test matrices.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Statistical Tests for Diagnosing Fission Source Convergence and Undersampling in Monte Carlo Criticality Calculations [Slides]

There is a very strong need for statistical testing to determine fission source convergence in Monte Carlo criticality calculations. Automation of such tests will greatly streamline and support the work carried out by NCS practitioners. Recent R&D work has shown that no single statistical test for convergence is sufficiently reliable, robust, and “guaranteed.” However, a combination of several standard statistical tests for the similarity of distributions, coupled with a high-fidelity estimate of the fission-matrix source is sufficiently robust, reliable, and repeatable that convergence can be “guaranteed.” During the course of the EG-AMCT studies, a number of statistical metrics and tests were proposed for diagnosing clustering and undersampling. None of these was robust and reliable enough for practical use in production codes. However, the expert group efforts came close. Some recent R&D work stemming from those past efforts has been very successful and promising. This Sub-Group will provide international input and collaboration on the development and implementation of statistical tests for convergence, with the primary goal of having the MC codes automatically detect convergence (or lack thereof). Newly proposed statistical tests to detect undersampling (after convergence) will also be reviewed.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Tandem column isolation of zirconium-89 from cyclotron bombarded yttrium targets using an automated fluidic platform: Anion exchange to hydroxamate resin columns

The development of a tandem column purification method for the production of high-purity 89Zr is presented. The primary column was a macroporous strongly basic anion exchange resin on styrene divinylbenzene co-polymer. The secondary column, with an internal volume of ~27 µL, was packed with hydroxamate resin. A condition of inverted selectivity was developed, whereby the 89Zr eluent from the primary column is synonymous with the load condition on the secondary column. The ability to transfer 89Zr from one column to the next allows two sequential column clean-up methods to be performed prior to the final elution of the 89Zr. This approach assures delivery of high purity 89Zr product and assures a 89Zr product that is eluted in a substantially smaller volume than is possible when using the traditionally-employed single hydroxamate resin column method. The tandem column purification process has been implemented into a prototype automated fluidic system. The system is configured with on-line gamma detection so column effluents can be monitored in near-real time. The automated method was tested using seven cyclotron bombarded Y foil targets. It was found that 95.1±1.3% of the 89Zr present in the foils was recovered in the secondary column elution fraction. Furthermore, elution peak analysis of several 89Zr elution profile radiochromatograms made possible the determination of 89Zr recovery as a function of volume; a 89Zr product volume that contains 90% of the mean secondary column elution peak can be obtained in 0.29±0.06 mL (representing 86±5% of the 89Zr activity in the target). This product volume represents a significant increase in isotope product concentration over the predominant method used in the field. In addition to the reduced 89Zr product elution volume, titrations of the 89Zr product with deferoxamine mesylate salt across two preparatory methods resulted in mean effective specific activity (ESA) values of 279 and 340 TBq·mmole-1 and mean bindable metals concentrations ([MB]) of 13.5 and 16.7 nmole·g-1. These ESA and [MB] values infer that the 89Zr product resulting from this tandem column isolation method has the highest purity reported to date.

immunoPET, zirconium-89, laboratory automation, de↗

Further Automate Planned Cluster Maintenance to Minimize System Downtime during Maintenance Windows

This report documents the integration and testing of the automated update process of compute clusters in LC to minimize impact to user productivity. Description: A set of scripts will be written and deployed to further standardize cluster maintenance activities and minimize downtime during planned maintenance windows. Completion Criteria: When the scripts have been deployed and used during planned maintenance windows and a timing comparison is completed between the existing process and the new more automated process, this milestone is complete. This milestone was completed on Aug 23, 2016 on the new CTS1 cluster called Jade when a request to upgrade the version of TOSS 3 was initiated while SWL jobs and normal user jobs were running. Jobs that were running when the update to the system began continued to run to completion. New jobs on the cluster started on the new release of TOSS 3. No system administrator action was required. Current update procedures in TOSS 2 begin by killing all users jobs. Then all diskfull nodes are updated, which can take a few hours. Only after the updates are applied are all nodes are rebooted, and then finally put back into service. A system administrator is required for all steps. In terms of human time spent during a cluster OS update, the TOSS 3 automated procedure on Jade took 0 FTE hours. Doing the same update without the Toss Update Tool would have required 4 FTE hours.

97 MATHEMATICS AND COMPUTING↗

Concept, implementation and commissioning of the automation system for the accelerator module test facility AMTF

The European XFEL project launched on June 5, 2007 will require about 103 accelerator modules as a main part of the XFEL linear accelerator. All superconducting components constituting the accelerator module like cavities and magnets have to be tested before the assembly. For the tests of the individual cavities and the complete modules an XFEL Accelerator Module Test Facility (AMTF) has been erected at DESY. The process control system EPICS (Experimental Physics and Industrial Control System) is used to control and operate the cryogenic plant and all its subcomponents. A complementary component of EPICS is the Open Source software suit CSS (Control System Studio). CSS is an integrated engineering, maintenance and operating tool for EPICS. CSS enables local and remote operating and monitoring of the complete system and thus represents the human machine interface. More than 250 PROFIBUS nodes work at the accelerator module test facility. DESY installed an extensive diagnostic and condition monitoring system. With these diagnostic tools it is possible to examine the correct installation and configuration of all PROFIBUS nodes in real time. The condition monitoring system based on FDT/DTM technology shows the state of the PROFIBUS devices at a glance. This information can be used for preventive maintenance which is mandatory for continuous operation of the AMTF facility. The poster will describe all steps form engineering to implementation and commissioning.

43 PARTICLE ACCELERATORS↗

SU-D-201-04: Evaluation of Elekta Agility MLC Performance Using Statistical Process Control

Purpose: to evaluate the performance and stability of the Elekta Agility MLC model using an automated quality control (QC) test in combination with statistical process control tools. Methods: Leaf positions were collected daily for 11 Elekta units over 5–19 months using the automated QC test, which analyzes 23 MV images to determine the location of MLC leaves relative to the radiation isocenter. The leaf positions are measured at 5 nominal positions, and images are acquired at collimator 0° and 180° to capture all MLC leaves in the field-of-view. Leaf positioning accuracy was assessed using individual and moving range control charts. Control limits were recomputed following MLC recalibration (occurred 1–2 times for 4 units). Specification levels of ±0.5, ±1 and ±1.5mm were tested. The mean and range of duration between out-of-control and out-of-specification events were determined. Results: Leaf position varied little over time, as confirmed by very tight individual control limits (mean ±0.19mm, range 0.09–0.44). Mean leaf position error was −0.03mm (range −0.89–0.83). Due to sporadic out-of-control events, the mean in-control duration was 3.3 days (range 1–23). Data stayed within ±1mm specification for 205 days on average (range 3–372) and within ±1.5mm for the entire date range. Measurements stayed within ±0.5mm for 1 day on average (range 0–17); however, our MLC leaves were not calibrated to this level of accuracy. Conclusion: The Elekta Agility MLC model was found to perform with high stability, as evidenced by the tight control limits. The in-specification durations support the current recommendation of monthly MLC QC tests with a ±1mm tolerance. Future work is on-going to determine if Agility performance can be optimized further using high-frequency QC test results to drive recalibration frequency. Factors that can affect leaf positioning accuracy, including beam spot motion, leaf gain calibration, drifting leaves, and image artifacts, are under investigation.

60 APPLIED LIFE SCIENCES↗

Evaluation of Damage in Medium Voltage Cable Using Machine Learning

Developments in cable test instrumentation coupled with artificial intelligence and machine learning (ML) to aid in interpretation of cable test signals supports the feasibility for automated analysis of reflectometry tests for low voltage power cables. This work seeks to leverage prior ML work and success for low voltage cables to evaluate potential application to medium voltage (2kV to 10kV) installations. The Accelerated and Real-Time Environmental Nodal Assessment (ARENA) Cable Motor Test Bed at Pacific Northwest National Laboratory (PNNL) was used to test a medium voltage cable with several types of damage including thermal aging and low resistance conductor-to-shield faults. The cable was tested using an inductive clamshell coupler to protect the test instruments from the energized cable voltages that would damage the test instruments if coupled directly to the energized conductor.

42 ENGINEERING↗

Modernization efforts for the R -Matrix code SAMMY [Abstract]

The R-Matrix code SAMMY is a widely used nuclear data evaluation code focused on the resolved range, which includes corrections for experimental effects. The code is still mostly written in Fortran 77, and uses a memory management system suitable for the time of its initial writing (1984). A modernization effort is under way to bring the code in-line with modern software development practices. A continuous-integration testing framework was added, automating the large existing set of test cases. It is run on every commit. The memory management was updated to current standard practices suitable for modern software analysis tools. The code can be obtained from https://code.ornl.gov/RNSD/SAMMY. The resonance parameters and covariance information are now stored in C++ objects shared by SAMMY and AMPX, the processing code that generates nuclear data libraries for SCALE. This allows for easier maintenance and access to the resonance parameters inside and outside of SAMMY. This feature is already used by accessing and changing parameters in memory in the Bayesian Monte Carlo Evaluation Framework for Cross Sections Nuclear Data and Integral Benchmark Experiments project, Further plans include the switch to the ENDF reading and writing routines in AMPX, as these routines are more robust, easier to maintain, and support more features. Of note here is support for the new GNDS format. Previously it wasn’t easy to share the full covariance matrix for evaluations containing more than one isotope due to limitations on the ENDF format; this is now supported in GNDS. The data are currently available in a binary SAMMY format and can be exported to GNDS to make them more widely available and sharable. The next step will be to use the same resonance processing code at 0K in AMPX and SAMMY as one of the available Reich-Moore R-Matrix formalism. The first step toward this goal is to isolate the reconstruction into a module that takes resonance parameters as its input and does not depend on SAMMY global parameters. This goal has been achieved and it should now be possible to more easily change the resonance formalism and add enhancements as the Phenomenological R-Matrix parameterization of direct, doorway, and compound nuclear reactions discussed elsewhere on this conference. This concerted modernization and enhancement effort provides multiple advantages to the nuclear data community. It will allow parameter optimization using enhanced formalisms, including experimental effects, that better match complex experimental data. Then those evaluated parameters can immediately be passed off to AMPX to be reconstructed with the exact same cross section model and be put into a data library for subsequent testing using SCALE and the Valid Benchmark suite or other suitable benchmark suites.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Creation of System Validation Platform

The objective of this CRADA between Sandia National Laboratories (SNL) and SunSpec Alliance (SunSpec) was to create a software test platform called the System Validation Platform (SVP) that performs end-to-end certification testing of photovoltaic (PV) inverters, energy storage systems, and other distributed energy resources (DERs). The SVP automates interactions of test equipment (PV and grid simulators), data acquisition systems, and interoperable DERs to certify the devices for advanced grid-support functions and interoperability. To assist electricity grid, operators maintain voltage and frequency, new interconnection requirements in the U.S. and Europe require DERs to have grid-support functions with adjustable settings. Automating the certification process for DER devices impacts the bottom line of NRTLs because they do not need to rely on test engineers running days (or weeks) of experiments to validate the performance of the equipment. These savings can then be passed down to the DER vendors so the certification process becomes less expensive and lowers the barrier to market for PV inverters, charge controllers, and other grid-interconnected equipment. This technology can also be used as a research platform for SNL, other national labs, and universities that would like to run hardware tests with power electronics equipment.

14 SOLAR ENERGY↗

Development and Assessment of CTF for Pin-resolved BWR Modeling

CTF is the modernized and improved version of the subchannel code, COBRA-TF. It has been adopted by the Consortium for Advanced Simulation for Light Water Reactors (CASL) for subchannel analysis applications and thermal hydraulic feedback calculations in the Virtual Environment for Reactor Applications Core Simulator (VERA-CS). CTF is now jointly developed by Oak Ridge National Laboratory and North Carolina State University. Until now, CTF has been used for pressurized water reactor modeling and simulation in CASL, but in the future it will be extended to boiling water reactor designs. This required development activities to integrate the code into the VERA-CS workflow and to make it more ecient for full-core, pin resolved simulations. Additionally, there is a significant emphasis on producing high quality tools that follow a regimented software quality assurance plan in CASL. Part of this plan involves performing validation and verification assessments on the code that are easily repeatable and tied to specific code versions. This work has resulted in the CTF validation and verification matrix being expanded to include several two-phase flow experiments, including the General Electric 3 3 facility and the BWR Full-Size Fine Mesh Bundle Tests (BFBT). Comparisons with both experimental databases is reasonable, but the BFBT analysis reveals a tendency of CTF to overpredict void, especially in the slug flow regime. The execution of these tests is fully automated, analysis is documented in the CTF Validation and Verification manual, and the tests have become part of CASL continuous regression testing system. This paper will summarize these recent developments and some of the two-phase assessments that have been performed on CTF.

Salko, Robert K↗

Advanced control sequences and FDD technology. Just shiny objects, or ready for scale?

Innovations in commercial building control sequences (ASHRAE guideline 36) and fault detection and diagnostics (FDD) technology have the potential to transform existing building operational efficiency by realizing whole-building level savings on the order of 15% and higher. However, several technical and market barriers related to up-front estimation of achievable savings, verifying implementation, and ensuring persistence are slowing down their adoption as a core offering through diverse owner-funded initiatives and rate-payer funded programs. This paper describes a suite of solutions to overcome these barriers to program delivery of advanced HVAC controls integrated with FDD energy management and information system (EMIS) technology. First, the Guideline 36 conformance test offers an automated method to confirm correct sequence implementation by the manufacturer, before field deployment. A successful test of a controller was conducted using a new manufacturer-independent hardware-in-the-loop testbed demonstrating the viability and scalability of this approach. Second, the Guideline 36 energy savings calculator uses modeling paired with high-level user inputs to estimate building-specific savings potential, target cost effective implementation and minimize uncertainty. Initial results indicate the baseline control sequences significantly impact energy savings, however, as much as 50% savings may be possible for the worst-case baseline scenario. Third, a functional specification provides minimum recommended EMIS-FDD capabilities, and best practices to integrate the technology into organizational practice and ensure that advanced control sequences provide persistent savings.

Pritoni, Marco↗