Engineering topics

Glaws, Andrew

Publications and source records attributed to Glaws, Andrew.

At least 19 records

DOE OSTI2025

Graph Neural Networks for Surrogate Modeling of Offshore Floating Platforms

Floating offshore wind turbines (FOWTs) present an significant opportunity to increase renewable energy generation. However, significant challenges remain before FOWTs can be widely commercialized and deployed. In particular, hydrodynamic loading on the platforms can stress the overall structure, damage the mooring systems, and impact power generation. Studying these loads is difficult and often relies on computationally expensive models or experiments. In this work, we explore the use of graph neural networks (GNNs) to construct flexible, data-driven surrogates for hydrodynamic loads on platforms. We leverage the natural graph-like structure of offshore wind platform designs to enable the GNN model to learn to approximate the loads for different wave conditions and structural designs. We demonstrate potential uses for the surrogate by performing parameter sweeps and ridge analysis on the trained model to identify the impacts of different wave and structural features on the loads.

floating offshore wind turbines↗

DOE OSTI2024

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

In this work, we examine the use of high-order tensor decompositions to analyze degradation pathways emerging from accelerated stress testing of silicon photovoltaic (PV) modules. Matrix-based decompositions are powerful tools for studying two-dimensional data arrays and form the foundation of a host of classical data analysis techniques. Tensors are high-order extrapolations of matrices that are able to account for more parameter dimensions, and a variety of tensor decomposition methods have been developed that similarly seek to extend insights from matrix decompositions to higher dimensions. Applying and interpreting tensor decomposition methods to sequences of PV module image data, we seek to uncover and isolate different degradation modes occurring from accelerated stress testing procedures. Further, we consider the contributions of different modes to PV module performance degradations.

data analysis↗

DOE OSTI2024

G2Aero Database of Airfoils - Curated Airfoils

This dataset contains a curated set of 19,164 airfoil shapes from various applications and the data-driven design space of separable shape tensors (PGA space), which can be used as a parameter space for machine-learning applications focused on airfoil shapes. We constructed the airfoil dataset in two main stages. First, we identified 13 baseline airfoils from the NREL 5MW and IEA 15MW reference wind turbines. We reparameterized these shapes using least-squares fits of 8-order CST parametrizations, which involve 18 coefficients. By uniformly perturbing all 18 CST coefficients by +/-20% around each baseline airfoil, we generated 1,000 unique airfoils. Each airfoil was sampled with 1,001 shape landmarks whose x-coordinates followed a cosine distribution along the chord. This process resulted in a total of 13,000 airfoil shapes, each with 1,001 landmarks. In the second phase, we gathered additional airfoils from the extensive BigFoil database, which consolidates data from sources such as the University of Illinois Urbana-Champaign (UIUC) airfoil database, the JavaFoil database, the NACA-TR-824 database, and others. We undertook a thorough pre-processing step to filter out shapes with sparse, noisy, or incomplete data. We also removed airfoils with sharp leading edge and those exceeding our threshold for trailing edge thickness. Additionally, we thinned out the collection of NACA airfoils-- parametric sweeps of NACA airfoils with increasing thickness and camber present in BigFoil database-- by selecting every fourth step in the parameter sweeps. Finally, we regularized the airfoils by reparametrizing them with an 8-order CST parametrization (with 1,001 shape landmarks with x coordinated following cosine distribution along the chord) and removing airfoils with high reconstruction errors. This data pre-processing resulted in a set of 6,164 airfoils. In total, our curated airfoil dataset comprises 19,164 airfoils, each with 1,001 landmarks, and is stored in the curated_airfoils.npz file. Using this curated airfoil dataset, we utilized the separable shape tensors framework to develop a data-driven parameterization of airfoils based on principal geodesic analysis (PGA) of separable shape tensors. This PGA space is provided in PGAspace.npz file.

airfoils↗

DOE OSTI2024

Super Resolution for Renewable Energy Resource Data With Wind From Reanalysis Data (Sup3rWind) and Application to Ukraine [Slides]

In this work we present a novel deep learning-based downscaling method, using generative adversarial networks (GANs), for generating high-resolution wind resource data from ECMWF Reanalysis v5 data (ERA5). We show that by training a GAN model on ERA5, as opposed to coarsened high-resolution data, we achieve results that are competitive with conventional dynamical downscaling. This GAN-based downscaling method additionally reduces computational costs over dynamical downscaling by two orders of magnitude. All GANs are trained on data sampled from CONUS, selected to provide a diverse sampling of terrain conditions, and validated on observational data along with data held out from training. This cross-validation shows low error and high correlations with observations and excellent agreement with hold out data across physical distributions. Our approach is finally used to downscale 30km hourly ERA5 to 2-km 5-minute wind data, for January 2000 through December 2023, at multiple hub heights, over Ukraine, Moldova, and part of Romania. Comparisons against observational data from Meteorological Assimilation Data Ingest System (MADIS) and multiple wind farms show the same level of performance as for CONUS validation. This 24 year data record is the first member of the "super resolution for renewable energy resource data with wind from reanalysis data" dataset (Sup3rWind).

17 WIND ENERGY↗

DOE OSTI2024

Assessment of Accelerated Stress Testing Data for Silicon Photovoltaics Using Tensor Decomposition Methods

The photovoltaic (PV) industry is simultaneously targeting long warranties and new materials/designs for high-energy-yield modules, requiring an advanced methodology to forecast long-term durability of products with un-proven materials combinations. Extended, sequential, and combined stress testing methods are gaining popularity for assessing durability of PV modules/materials beyond the early-stage mortalities. Importantly, multiple degradation mechanisms can proceed simultaneously, and their separate contributions to the overall power loss should ideally be quantified. This work examines the use of data-driven tools towards developing a strategy for faster learning cycles in accelerated stress testing.

accelerated stress testing↗

DOE OSTI2024

Sound at Scale: Characterizing Impacts of Noise Ordinances on the Onshore Wind Energy Technical Potential for the United States

Recent surveys have documented the rapid rise of sound ordinances across state and county jurisdictions, which has become crucial for wind energy siting. However, the lack of information on ordinances and computational challenges in turbine sound modeling create uncertainties regarding how evolving policies may affect resource potential and clean energy objectives. Therefore, we develop an approach to evaluate wind turbine sound profiles at millions of locations across the U.S. and translate them into setback distances for every residential structure. Compared to a baseline reference scenario, we find a 7% reduction in the national wind energy capacity potential when accounting for counties with existing sound ordinances. Additionally, when expanding the surveyed sound ordinances nationwide, we observe a potential loss of 53% of the national wind capacity under the most stringent ordinances, with a disproportionate share of this lost capacity coming from high-quality and low-cost wind resource. This work reveals that neglecting sound ordinances results in a significant overestimation of wind resource potential and highlights the important trade-offs between increased wind energy deployment to meet target decarbonization goals and the social/environmental impacts of this deployment that must be considered.

aeroacoustics↗

DOE OSTI2024

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Abstract Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

17 WIND ENERGY↗

DOE OSTI2024

High-Resolution Meteorology with Climate Change Impacts from Global Climate Model Data Using Generative Machine Learning

As renewable energy generation increases, the impacts of weather and climate on energy generation and demand become critical to the reliability of the energy system. However, these impacts are often overlooked. Global climate models (GCMs) can be used to understand possible changes to our climate, but their coarse resolution makes them difficult to use in energy system modelling. Here we present open-source generative machine learning methods that produce meteorological data at a nominal spatial resolution of 4 km at an hourly frequency based on inputs from 100 km daily-average GCM data. These methods run 40 times faster than traditional downscaling methods and produce data that have high-resolution spatial and temporal attributes similar to historical datasets. We demonstrate that these methods can be used to downscale projected changes in wind, solar and temperature variables across multiple GCMs including projections for more frequent low-wind and high-temperature events in the Eastern United States.

climate change↗

DOE OSTI2024

Advanced Permanent Magnet Generator Topologies Using Multimaterial Shape Optimization and 3D Printing: Preprint

A vast majority of utility-scale wind turbine generators in the United States are dependent on foreign- sourced rare-earth permanent magnets that are vulnerable to supply chain uncertainties. Many small wind original equipment manufacturers are motivated to pursue continuous improvements to the generator design to lower the material and production costs and improve performance by lowering cogging torque and increasing the efficiency. Traditional design and manufacturing offer limited opportunities. In this work, we demonstrate advanced design approaches for a 15-kW baseline wind turbine generator by making use of recent progress in three-dimensional (3D) printing of polymer- bonded magnets and, electrical and structural steel. We explore three methods of magnet parametrization using Bezier curves resulting in symmetric, asymmetric and multimaterial magnet designs. We employ a multiphysics approach combining parametric computer-aided design modeling, finite- element analysis and targeted sampling to identify novel designs with more opportunities for reducing rare-earth material, improving efficiency and minimizing cogging torque. The results show that asymmetric-pole design and multimaterial-pole designs offer a greater opportunity to minimize rare-earth magnet materials by up to 35% with similar performance as the baseline generator, suggesting newer opportunities with design freedom beyond traditional limits of symmetry and as allowed by 3D printing.

Bezier curves↗

DOE OSTI2023

Aerodynamic Sensitivity of a Novel Data-Driven Airfoil Shape Representation Framework

We explore the aerodynamic implications of a novel data-driven separable shape tensor framework used to represent discrete airfoil shapes. In this study, we construct a data-driven parameter space defined by separable shape tensors and informed by tens of thousands of distinct airfoils. We use this design space to generate new airfoil designs to study parametric sensitivities with respect to various aerodynamic responses. We use a HAM2D RANS solver to approximate the lift, drag, and moment coefficients for the generated airfoils at two different angles-of-attack. We analyze the robustness and sensitivities of using the separable shape tensor design space by examining the coverage of the aerodynamic response space, uncovering low-dimensional polynomial ridge approximations, and computing various sensitivity metrics. The results show that the data-driven design space produce significant variation in target aerodynamic quantities and facilitate highly accurate approximations (R^2 > 0.96) of one- and two-dimensional structures in each aerodynamic response. This further reduces the effective dimension to enable simplified design and optimization tasks.

aerodynamics↗

DOE OSTI2023

G2Aero: A Python package for separable shape tensors

G2Aero is a Python package for the design and deformation of discrete planar curves and tubular surfaces using a geometric data-driven approach. G2Aero utilizes a topology of product manifolds: the Grassmannian, $\mathcal{G}$($\mathcal{n}$, 2) - the set of 2-dimensional subspaces in $\mathbb{R}$ $\mathcal{n}$ - and the symmetric positive-definite (SPD) manifold, $\mathcal{S}^{2}_{++}$ - the set of 2x2 SPD matrices. The package provides a novel framework for representing separable deformations to shapes, which consist of stretching, scaling, rotating, and translating - also known as affine deformations - and a set of complementary deformations - which we refer to as undulation-type deformations. We focus on airfoil and blade design applications to emphasize the utility of the methods in an environment where the separation of affine and undulation-type deformations is critical. Notable functionalities of the framework for blade design include: 1) generating novel 2D (airfoil) shapes informed by a database of physically relevant airfoils, 2) building 3D blades by interpolating sequences of 2D airfoil cross-sections, and 3) generating blades with consistent perturbations along the blade span. We discuss the framework and provide examples in the context of wind energy applications, specifically wind turbine blade design. Figure 1 shows the wire frame obtained by interpolating airfoils defining the IEA 15-MW wind turbine blade and applying affine transformations corresponding to twist, chordal scaling, and bending. This, and all other figures in the paper, can be reproduced following examples and referencing supporting documentation provided in the G2Aero package.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Automated Design-for-Reliability of a Power Electronics Module

The design of a power electronics module is a multiphysics problem and involves electrical, thermal, and reliability targets and constraints. Although the electrical and thermal design consider multiple aspects such as materials, geometry, and energy losses, reliability design is often limited to the selection of the attachment materials and electrical interconnect types. In this paper, we incorporate reliability metrics in the design phase by investigating the impact of package geometry on the thermomechanical behavior of the die-attachment material. To this end, we conducted thermal and power cycling simulations of a commercial six-pack power module with silicon carbide devices to compute junction temperature and strain energy density per cycle, respectively. We performed multiple simulations with different geometric dimensions and established a correlation between input features and output variables using subspace-based dimension reduction. The machine learning-based dimension reduction method serves as a surrogate model, which can be employed to identify the optimal module design from a thermal and reliability standpoint.

design-for-reliability↗

DOE OSTI2023

AEflow (Autoencoder fluid flow compression network) [SWR-22-29]

As the size of turbulent flow simulations continues to grow, in situ data compression is becoming increasingly important for visualization, analysis, and restart checkpointing. For these applications, single-pass compression techniques with low computational and communication overhead are crucial. In this paper we present a deep-learning approach to in situ compression using an autoencoder architecture that is customized for three-dimensional turbulent flows and is well suited for contemporary heterogeneous computing resources. The autoencoder is compared against a recently introduced randomized single-pass singular value decomposition (SVD) for three different canonical turbulent flows: decaying homogeneous isotropic turbulence, a Taylor-Green vortex, and turbulent channel flow. Our proposed fully convolutional autoencoder architecture compresses turbulent flow snapshots by a factor of 64 with a single pass, allows for arbitrarily sized input fields, is cheaper to compute than the randomized single-pass SVD for typical simulation sizes, performs well on unseen flow configurations, and has been made publicly available. The results reported here show that the autoencoder dramatically outperforms a randomized single-pass SVD with similar compression ratio and yields comparable performance to a higher-rank decomposition with an order of magnitude less compression in regard to preserving a number of important statistical quantities such as turbulent kinetic energy, enstrophy, and Reynolds stresses.

King, Ryan↗

DOE OSTI2023

Wind Resource Data for Southeast Asia Using a Hybrid Numerical Weather Prediction with Machine Learning Super Resolution Approach

In this work we develop and present a machine learning based downscaling approach using generative adversarial networks (GANs). GANs learn to distinguish the relationships between low-resolution and high-resolution simulations and generate accurate high-resolution output from low-resolution input (Stengel, Glaws, Hettinger, & King, 2020). Low-resolution numerical weather prediction (NWP) simulations at 9-km spatial and 60-minute temporal resolution were executed over Southeast Asia to provide input to the GANs model. GANs for wind, temperature, and pressure were trained on coarsened WIND Toolkit data with a diverse sampling of terrain and meteorological conditions. After training, the NWP simulations over Southeast Asia were enhanced by 3x along each horizontal spatial dimension and 4x along the temporal dimension. This novel downscaling approach generated 15-year high-resolution wind, temperature, and pressure data from January 2007 through December 2021 at multiple hub heights over Southeast Asia at 3-km spatial and 15-minute temporal resolution with a 16x reduction in compute time over standard dynamical downscaling.

17 WIND ENERGY↗

DOE OSTI2023

Accelerated Stress Testing of Perovskite Photovoltaic Modules: Differentiating Degradation Modes with Electroluminescence Imaging

Herein, electroluminescence (EL) and thermal imaging are used to examine p–i–n metal halide perovskite (MHP) photovoltaic (PV) mini-modules (MA0.6FA0.4PbI3, 20 cells, 78 cm2) before and after indoor-accelerated stress testing or outdoor deployment. Distinct spatial patterns in the EL images emerge, which depend on the external stress conditions experienced by the mini-module. Imaging results highlight a distribution of dark speckle features that dominate after UV stress, attributed to widespread interfacial contact degradation. Lateral intensity gradients across cells dominate after thermal cycling (TC) stress, attributed to current crowding near scribe defects. While current–voltage analysis alone does not give full insight on the degradation process, this study shows that distinct degradation modes can be further defined by multimodal electro-optical imaging (i.e., EL combined with photoluminescence and dark lock-in thermography). Neither UV exposure nor TC-accelerated stress testing alone replicates the same degradation signatures observed after outdoor deployment, suggesting that multiple degradation modes occur under concurrent stressors outdoors. Finally, spatial characterization of degradation modes in MHP PV mini-modules before and after accelerated stress testing lays the groundwork for developing targeted accelerated stress testing procedures through comparison with outdoor aging.

14 SOLAR ENERGY↗

DOE OSTI2023

Super-Resolution for Renewable Energy Resource Data with Climate Change Impacts (Sup3rCC)

The Super-Resolution for Renewable Energy Resource Data with Climate Change Impacts (Sup3rCC) data is a collection of 4km hourly wind, solar, temperature, humidity, and pressure fields for the contiguous United States under various climate change scenarios. Sup3rCC is downscaled Global Climate Model (GCM) data. The downscaling process was performed using a generative machine learning approach called sup3r: Super-Resolution for Renewable Energy Resource Data (linked below as "Sup3r GitHub Repo"). The data includes both historical and future weather years, although the historical years represent the historical climate, not the actual historical weather that we experienced. You cannot use Sup3rCC data to study historical weather events, although other sup3r datasets may be intended for this. The Sup3rCC data is intended to help researchers study the impact of climate change on energy systems with high levels of wind and solar capacity. Please note that all climate change data is only a representation of the possible future climate and contains significant uncertainty. Analysis of multiple climate change scenarios and multiple climate models can help quantify this uncertainty.

Array↗

DOE OSTI2023

Virtual Engineering Software Framework for Integrated Biomass Conversion Modeling

This presentation covers the design and implementation of a software tool to systematically connect computational models of unit operations to simulate an integrated process of low-temperature conversion of biomass to fuel. This virtual engineering (VE) software was designed with the overarching goal of connecting unit models written in various programming languages and requiring different computational resources within a single, flexible framework. The models and features currently considered for the VE library include mechanistic models for pretreatment, enzymatic hydrolysis, and aerobic bioreaction; high-fidelity computational fluid dynamics (CFD) simulations for enzymatic hydrolysis and aerobic bioreaction; and the capability to perform techno-economic analyses (TEA) using Aspen Plus, a commercial software package. The CFD models require access to high-performance computing (HPC) resources, so in addition to handling multiple programming languages and interfaces, the VE software must also be capable of interacting with an HPC scheduler to submit, run, and post-process jobs. Using the Python programming language, a new VE software package has been developed that contains functionality to manage the input-output communication between various unit models, schedule simulations to run on NREL's HPC and analyze those results, and interface with existing TEA software workflows. A Jupyter-notebook GUI was also created to solicit user input and provide documentation. In cases where multiple models for a particular unit-operation exist, selection between models is accomplished through a simple checkbox, with the appropriate inputs and outputs being parsed and converted seamlessly in the background. Each operation makes use of a different programming language, but the flow of information from pretreatment to enzymatic hydrolysis to bioreaction is managed with an intuitive, centralized file-communication strategy. In this talk, the programming approach and implementation details of the notebook are presented for multiple possibilities of the conversion process, including a demonstration of the ability to manage HPC resources. Additionally, an example of a sensitivity study of treatment parameters governing the overall conversion outcome is shown which highlights the ease of defining new problems using the VE Notebook workflow and leads into a discussion of ongoing work to enable outer-loop optimization studies.

biofuel↗

DOE OSTI2023

Physics-Driven Convolutional Autoencoder Approach for CFD Data Compressions: Preprint

With the growing size and complexity of turbulent flow models, data compression approaches are of the utmost importance to analyze, visualize, or restart the simulations. Recently, in-situ autoencoder-based compression approaches have been proposed and shown to be effective at producing reduced representations of turbulent flow data. However, these approaches focus solely on training the model using point-wise sample reconstruction losses that do not take advantage of the physical properties of turbulent flows. In this paper, we show that training autoencoders with additional physics-informed regularizations, e.g., enforcing incompressibility and preserving enstrophy, improves the compression model in three ways: (i) the compressed data better conform to known physics for homogeneous isotropic turbulence without negatively impacting point-wise reconstruction quality, (ii) inspection of the gradients of the trained model uncovers changes to the learned compression mapping that can facilitate the use of explainability techniques, and (iii) as a performance byproduct, training losses are shown to converge up to 12x faster than the baseline model.

auto-encoders↗