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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

ORBITaL-Net: A labeled training library for large-scale building feature extraction

Over the course of several years, nearly 1.5 million building outlines have been created from approximately 128,000 training tiles covering roughly 7,000 km 2 of very high-resolution multispectral overhead imagery, primarily dated between 2010 and 2020. This dataset, dubbed the Oak Ridge Building Image and TrAining Label Net (ORBITaL-Net), is designed for machine learning applications and is global in scope, with samples drawn from 72 countries across North America, South America, Africa, Europe, and Asia. ORBITaL-Net captures a great diversity in geographic setting, structural characteristics, land use (urban and rural), terrain, and imagery conditions. While the labeled building outlines are themselves valuable, the dataset’s true strength lies in the pairing of these labels with corresponding reference imagery, which is being released for open source use. Similar to SpaceNet and Replicable AI For Microplanning (ramp), this building outline dataset will allow the larger computer vision community from academia, government, and industry the opportunity to develop robust, scalable, and generalizable geospatial machine learning techniques. Unlike SpaceNet and ramp, which offer high resolution labels and imagery primarily for large urban cities, ORBITaL-Net is not focused on training samples from heavily populated areas but instead aims to capture the innate variability of conditions present in both the physical environment and imagery collections.

Geography↗
DOE OSTI2023

Bayesian, Multifidelity Operator Learning for Complex Engineering Systems–A Position Paper

Abstract Deep learning has significantly improved the state-of-the-art in computer vision and natural language processing, and holds great potential to design effective tools for predicting and simulating complex engineering systems. In particular, scientific machine learning seeks to apply the power of deep learning to scientific and engineering tasks, with operator learning (OL) emerging as a particularly effective tool. OL can approximate nonlinear operators arising in complex engineering systems, making it useful for simulating, designing, and controlling those systems. In this position paper, we provide a comprehensive overview of OL, including its potential applications to complex engineering domains. We cover three variations of OL approaches: deterministic OL for modeling nonautonomous systems, OL with uncertainty quantification (UQ) capabilities, and multifidelity OL. For each variation, we discuss drawbacks and potential applications to engineering, in addition to providing a detailed explanation. We also highlight how multifidelity OL approaches with UQ capabilities can be used to design, optimize, and control engineering systems. Finally, we outline some potential challenges for OL within the engineering domain.

Computer Science↗
DOE OSTI2023

DeepPatent2: A Large-Scale Benchmarking Corpus for Technical Drawing Understanding

Abstract Recent advances in computer vision (CV) and natural language processing have been driven by exploiting big data on practical applications. However, these research fields are still limited by the sheer volume, versatility, and diversity of the available datasets. CV tasks, such as image captioning, which has primarily been carried out on natural images, still struggle to produce accurate and meaningful captions on sketched images often included in scientific and technical documents. The advancement of other tasks such as 3D reconstruction from 2D images requires larger datasets with multiple viewpoints. We introduce DeepPatent2, a large-scale dataset, providing more than 2.7 million technical drawings with 132,890 object names and 22,394 viewpoints extracted from 14 years of US design patent documents. We demonstrate the usefulness of DeepPatent2 with conceptual captioning. We further provide the potential usefulness of our dataset to facilitate other research areas such as 3D image reconstruction and image retrieval.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Making Invisible Visible: Data-Driven Seismic Inversion With Spatio-Temporally Constrained Data Augmentation

Deep learning and data-driven approaches have shown great potential in scientific domains. The promise of data-driven techniques relies on the availability of a large volume of high-quality training datasets. Due to the high cost of obtaining data through expensive physical experiments, instruments, and simulations, data augmentation techniques for scientific applications have emerged as a new direction for obtaining scientific data recently. However, existing data augmentation techniques originating from computer vision yield physically unacceptable data samples that are not helpful for the domain problems that we are interested in. In this article, we develop new data augmentation techniques based on convolutional neural networks. Specifically, our generative models leverage different physics knowledge (such as governing equations, observable perception, and physics phenomena) to improve the quality of the synthetic data. To validate the effectiveness of our data augmentation techniques, we apply them to solve a subsurface seismic full-waveform inversion using simulated CO 2 leakage data. Our interest is to invert for subsurface velocity models associated with very small CO 2 leakage. We validate the performance of our methods using comprehensive numerical tests. Here via comparison and analysis, we show that data-driven seismic imaging can be significantly enhanced by using our data augmentation techniques. Particularly, the imaging quality has been improved by 15% in test scenarios of general-sized leakage and 17% in small-sized leakage when using an augmented training set obtained with our techniques.

58 GEOSCIENCES↗
DOE OSTI2026

Illuminating the Material World: Autonomous Microscopy to Understand Order, Disorder, and Everything In Between

Artificial intelligence (AI) holds immense promise for revolutionizing microscopy, yet its widespread adoption has been hindered by challenges ranging from user inexperience to limited model transferability and difficulties in operationalizing machine learning. This presentation showcases our approach to developing practical autonomy for materials discovery, aiming to accelerate the integration of AI into everyday microscopy workflows. As shown in Fig. 1, I will focus on three key areas: understanding order-disorder transitions, quantifying point defects, and achieving truly device-scale microscopy. First, I will demonstrate the power of multi-modal knowledge graphs for integrating diverse microscopy data. By combining imaging, spectroscopy, and diffraction data, these graphs provide a holistic view of material behavior, capturing the intricate relationships between different modalities [1,2]. I will present a case study on how these models illuminate the structural and chemical changes associated with irradiation in oxide thin films, revealing critical insights for designing materials for extreme environments like spaceflight and nuclear energy. Specifically, I will show how multi-modal analysis clarifies the evolution of order-disorder transitions under irradiation, a key factor influencing material performance in these applications. Next, I will address the challenge of quantifying point defects in 2D materials. We demonstrate the application of computer vision and transfer learning to accurately identify and classify various defect types, such as vacancies and substitutional atoms, and to quantify their concentrations. This information is crucial for understanding and tailoring the properties of 2D materials for applications in electronics, optoelectronics, and catalysis. For example, I will show how our models can characterize the topological distribution of point defects in MXene transition metal carbides, providing valuable insights for optimizing their performance in energy storage and separation science. Finally, I will discuss our progress toward autonomous device-scale microscopy [3,4]. We are fundamentally redesigning electron microscopes around the principles of machine reasoning, enabling automation beyond basic tasks like sample navigation and data acquisition to include sophisticated experimental design. This approach paves the way for truly reproducible and massively scaled analysis campaigns. I will emphasize the importance of autonomous microscopy platforms for high-throughput materials discovery and characterization, facilitating the rapid screening of materials for a broad range of applications and accelerating the development of next-generation technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

HDBind: encoding of molecular structure with hyperdimensional binary representations

Traditional methods for identifying “hit” molecules from a large collection of potential drug-like candidates rely on biophysical theory to compute approximations to the Gibbs free energy of the binding interaction between the drug and its protein target. These approaches have a significant limitation in that they require exceptional computing capabilities for even relatively small collections of molecules. Increasingly large and complex state-of-the-art deep learning approaches have gained popularity with the promise to improve the productivity of drug design, notorious for its numerous failures. However, as deep learning models increase in their size and complexity, their acceleration at the hardware level becomes more challenging. Hyperdimensional Computing (HDC) has recently gained attention in the computer hardware community due to its algorithmic simplicity relative to deep learning approaches. The HDC learning paradigm, which represents data with high-dimension binary vectors, allows the use of low-precision binary vector arithmetic to create models of the data that can be learned without the need for the gradient-based optimization required in many conventional machine learning and deep learning methods. This algorithmic simplicity allows for acceleration in hardware that has been previously demonstrated in a range of application areas (computer vision, bioinformatics, mass spectrometery, remote sensing, edge devices, etc.). To the best of our knowledge, our work is the first to consider HDC for the task of fast and efficient screening of modern drug-like compound libraries. We also propose the first HDC graph-based encoding methods for molecular data, demonstrating consistent and substantial improvement over previous work. We compare our approaches to alternative approaches on the well-studied MoleculeNet dataset and the recently proposed LIT-PCBA dataset derived from high quality PubChem assays. We demonstrate our methods on multiple target hardware platforms, including Graphics Processing Units (GPUs) and Field Programmable Gate Arrays (FPGAs), showing at least an order of magnitude improvement in energy efficiency versus even our smallest neural network baseline model with a single hidden layer. Our work thus motivates further investigation into molecular representation learning to develop ultra-efficient pre-screening tools. We make our code publicly available at https://github.com/LLNL/hdbind.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Coarse-to-fine Task-driven Inpainting for Geoscience Images

The processing and recognition of geoscience images have wide applications. Most of existing researches focus on understanding the high-quality geoscience images by assuming that all the images are clear. However, in many real-world cases, the geoscience images might contain occlusions during the image acquisition. This problem actually implies the image inpainting problem in computer vision and multimedia. As far as we know, all the existing image inpainting algorithms learn to repair the occluded regions for a better visualization quality, they are excellent for natural images but not good enough for geoscience images, and they never consider the following geoscience task when developing inpainting methods. Here, this paper aims to repair the occluded regions for a better geoscience task performance and advanced visualization quality simultaneously, without changing the current deployed deep learning based geoscience models. Because of the complex context of geoscience images, we propose a coarse-to-fine encoder-decoder network with the help of designed coarse-to-fine adversarial context discriminators to reconstruct the occluded image regions. Due to the limited data of geoscience images, we propose a MaskMix based data augmentation method, which augments inpainting masks instead of augmenting original images, to exploit the limited geoscience image data. The experimental results on three public geoscience datasets for remote sensing scene recognition, cross-view geolocation and semantic segmentation tasks respectively show the effectiveness and accuracy of the proposed method. The code is available at: https://github.com/HMS97/Task-driven-Inpainting.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Automated, Unmanned Detection and Quantification of Fugitive Methane Emissions

Compressor stations used to move natural gas are one of the largest sources of fugitive methane emissions in the midstream sector, accounting for approximately 50% of all fugitive emissions (Zimmerle et al., 2015). This problem is most widespread at reciprocating compressors (Subramanian et al., 2015) where faulty seals are a key contributor to methane emissions (Johnson et al., 2015). As such, there is a significant need for a robust technology that could provide an early indication of an unexpected emission. Equally important, the technology needs to be able to account for biogenic versus anthropogenic sources of methane. One means of indirectly making this determination, is to leverage optical technologies that can autonomously pinpoint the source of such leaks. This presentation discusses recent work funded by the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL), focused on the development of an innovative remote sensing technology that can reliably and autonomously detect fugitive methane emissions in near real-time, using computer vision and deep learning. The technology called the Smart Methane Leak Detection (SLED/M) system was initially developed to monitor facilities such as compressor stations in a stationary, pan-tilt-zoom configuration. The system has recently been adapted to monitor facilities from an unmanned aerial system (UAS). The speed and maneuverability of UAS platforms are attractive to leak detection and repair program operators, but introduce several challenges. Many existing methane detection algorithms rely on mostly static backgrounds becoming unusable with motion. In addition, top-down views of fugitive methane emissions present differently in Optical Gas Imagers (OGI) compared to looking across the plume. Our work has focused on overcoming these challenges, enhancing the operators ability to detect methane emissions, and pinpoint their sources. Another recent adaptation to SLED/M is the ability to quantify methane emissions using passive sensors (OGI, thermal camera), environmental conditions, plume modeling, and deep learning. SLED/M advances the state-of-the-art for methane emission detection and quantification by focusing on three key critical criteria for effective methane emission mitigation: (1) autonomy (no need for a human to be in the loop), (2) high reliability (low false alarm rates), and (3) real-time performance. Results from this work will be presented.

03 NATURAL GAS↗
DOE OSTI2025

Artificial Intelligence-Enhanced CMIP6 Climate Projections Across the Conterminous United States

This dataset comprises high-resolution climate projections at 1/24 degree grid (~4km) over the conterminous United States (CONUS) based on ten Global Climate Models (GCMs) that are part of the Coupled Models Intercomparison Project phase 6 (CMIP6). The CMIP6 GCMs are downscaled using two artificial intelligence (AI) techniques, primarily based on the computer vision approach called super-resolution. We train two separate networks: super-resolution convolutional neural network (SRCNN) and super-resolution generative adversarial network (SRGAN). The networks are trained using Daymet observations, originally available at a 1 km resolution. For training purposes, the Daymet data is interpolated to 1/24 degree (~4km), 0.25 degree and 1 degree, which serve as high, intermediate and low-resolution inputs respectively. For each of the SRCNN and SRGAN network, we use a two-step resolution enhancement, the first step generates 4x refinement from 1 degree to 0.25 degree and the second step generates 6x refinement from 0.25 degree to 1/24 degree (~4km). We downscale daily scale precipitation, maximum temperature and minimum temperature for the six CMIP6 GCMs for 1980 to 2019 in the historical period and 2020 to 2059 in the near-term future under the shared socioeconomic pathway 585 and 245 (SSP585 and SSP245) emission scenarios. We also perform double bias-correction with Daymet observations using a quantile mapping approach, first for GCMs prior to making predictions at 1 degree grid and second after making final predictions at ~4km.

13 HYDRO ENERGY↗
DOE OSTI2021

How AI Predicts the Untrained and Unseen

Focus Area: Model predictability improvements (Primary); Data optimization (secondary); Data complexity insights (secondary). The Scientific Challenge: If we believe that a future under extreme conditions will look very differently from today, we can likely agree that ML/AI models trained on past and present datasets will not be adequate to make reliable predictions into the future. This is true for water cycling, as well as biogeochemistry and other Earth system components and behaviors. Additionally, ML/AI models are inherently non-physical. Despite the flourishing success of ML/AI in many applications, such as computer vision, natural language process, and gaming, even the most sophisticated AI models don’t understand the very basic physical laws. Therefore, a natural question is: Can we trust ML/AI based predictions of Earth system behaviors that are fundamentally driven by physical laws? So, are physics models with meticulous process representation a better choice? Not exactly. Physical models, when firmly rooted in first principles, work great at predicting behaviors of systems with a well-defined set of boundary conditions and variables. However, as a complex system, the number of parameters and the degree of complexity and dynamics in processes, coupling, and scale dependent emergent behaviors make the Earth system behaviors very challenging to predict with physical models composed of deterministic laws. In addition, due to the lack of fundamental understandings, physical models often implement empirical correlations derived from observations with biases from locality of data generation. Because correlation is not necessarily causation or comply with first principles, scaling of model predictions beyond locality is often invalid. Beyond the limitation of models, physics or AI, our knowledge of the Earth system is limited by the lack of observational technologies and resources. Insufficient data density, dimensionality and diversity only offer a sliced (or projected) view of the Earth system, e.g. Plato’s Cave analogy, limiting our capability to better understand and represent fundamental processes in models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Iterative self-organizing SCEne-LEvel sampling (ISOSCELES) for large-scale building extraction

Convolutional neural networks (CNN) provide state-of-the-art performance in many computer vision tasks, including those related to remote-sensing image analysis. Successfully training a CNN to generalize well to unseen data, however, requires training on samples that represent the full distribution of variation of both the target classes and their surrounding contexts. With remote sensing data, acquiring a sufficiently representative training set is a challenge due to both the inherent multi-modal variability of satellite or aerial imagery and the general high cost of labeling data. To address this challenge, we have developed ISOSCELES, an Iterative Self-Organizing SCEne LEvel Sampling method for hierarchical sampling of large image sets. Using affinity propagation, ISOSCELES automates the selection of highly representative training images. Compared to random sampling or using available reference data, the distribution of the training is principally data driven, reducing the chance of oversampling uninformative areas or undersampling informative ones. In comparison to manual sample selection by an analyst, ISOSCELES exploits descriptive features, spectral and/or textural, and eliminates human bias in sample selection. Using a hierarchical sampling approach, ISOSCELES can obtain a training set that reflects both between-scene variability, such as in viewing angle and time of day, and within-scene variability at the level of individual training samples. We verify the method by demonstrating its superiority to stratified random sampling in the challenging task of adapting a pre-trained model to a new image and spatial domain for country-scale building extraction. Using a pair of hand-labeled training sets comprising 1,987 sample image chips, a total of 496,000,000 individually labeled pixels, we show, across three distinct model architectures, an increase in accuracy, as measured by F1-score, of 2.2–4.2%.

42 ENGINEERING↗
DOE OSTI2021

Open Data and Deep Semantic Segmentation for Automated Extraction of Building Footprints

Advances in machine learning and computer vision, combined with increased access to unstructured data (e.g., images and text), have created an opportunity for automated extraction of building characteristics, cost-effectively, and at scale. These characteristics are relevant to a variety of urban and energy applications, yet are time consuming and costly to acquire with today’s manual methods. Several recent research studies have shown that in comparison to more traditional methods that are based on features engineering approach, an end-to-end learning approach based on deep learning algorithms significantly improved the accuracy of automatic building footprint extraction from remote sensing images. However, these studies used limited benchmark datasets that have been carefully curated and labeled. How the accuracy of these deep learning-based approach holds when using less curated training data has not received enough attention. The aim of this work is to leverage the openly available data to automatically generate a larger training dataset with more variability in term of regions and type of cities, which can be used to build more accurate deep learning models. In contrast to most benchmark datasets, the gathered data have not been manually curated. Thus, the training dataset is not perfectly clean in terms of remote sensing images exactly matching the ground truth building’s foot-print. A workflow that includes data pre-processing, deep learning semantic segmentation modeling, and results post-processing is introduced and applied to a dataset that include remote sensing images from 15 cities and five counties from various region of the USA, which include 8,607,677 buildings. The accuracy of the proposed approach was measured on an out of sample testing dataset corresponding to 364,000 buildings from three USA cities. The results favorably compared to those obtained from Microsoft’s recently released US building footprint dataset.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Open data sets for assessing photovoltaic system reliability

Photovoltaic (PV) systems have become a cornerstone of renewable energy strategies, particularly due to the significant reduction in solar power costs over the past decade. However, the long-term reliability of PV installations presents a persistent challenge, requiring the development of advanced monitoring and predictive maintenance strategies. A wide range of data types is used to evaluate the health of PV systems, including environmental conditions, electrical performance, and inspection imagery. These data enable methodologies such as machine learning (ML) models for lifetime prediction and computer vision techniques for defect detection. However, the acquisition of high-quality and comprehensive data is difficult, particularly in terms of long-term consistency and data variety. Publicly available data sets serve as valuable resources for addressing these challenges, but they often suffer from fragmentation and are difficult to access. This paper presents a comprehensive review of existing open-source data sets related to PV degradation, analyzing their features, functionalities, and potential applications. We categorize these data sets based on the specific aspects of PV system information they cover, such as environmental conditions, operational monitoring, image inspection and module materials, and propose relevant tools and ML models for processing them. In addition, we propose practices for future data collection and usage, while also discussing potential directions in data-driven research. Our aim is to enhance data utilization and publication among researchers and industry professionals, promoting a deeper understanding of the role of data in enhancing the performance and durability of PV systems.

14 SOLAR ENERGY↗
DOE OSTI2025

AI-powered municipal solid waste management: a comprehensive review from generation to utilization

The accumulation of municipal solid waste (MSW) continues to rise due to burgeoning population, rapid global urbanization and economic growth, intensifying ecological concerns associated with landfills and greenhouse gas (GHG) emissions. Over the past 2 decades, global waste generation has surged by 50%, with one-third remaining uncollected and about 70% sent to landfills. This review examines the critical role of integrating emerging technologies, such as advanced sensors and artificial intelligence (AI), into end-to-end MSW management to alleviate landfill burdens. The suitability of various AI tools for different stages of MSW management is assessed, alongside the deployment of advanced sensors including hyperspectral cameras, computer vision systems, and internet of things (IoT) devices for material identification. Applications of genetic algorithms and reinforcement learning for optimizing collection routes, reducing costs, and lowering emissions are highlighted. Life cycle assessment (LCA) across all stages of MSW management is also reviewed, along with future trends in leveraging generative AI, natural language processing (NLP), and agent-based AI systems to analyze waste generation patterns and public sentiment. Efficient collection and handling can be enhanced through route optimization with geographic information systems and real-time bin-level monitoring. Furthermore, sensor-embedded, real-time object detection systems paired with robotics enable material characterization and automated sorting, thereby lowering costs and diverting waste from landfills into value-added products for diverse industrial sectors including packaging, chemicals, textiles, metals and glass, transportation, and electronics industries. Without intervention, global waste is projected to reach 4.54 billion tons by 2050, contributing direct economic costs of $\$$400 billion and roughly 2.38 billion tons of CO 2 -equivalent emissions annually. This review demonstrates how AI-driven, end-to-end solutions for MSW management can mitigate economic and environmental challenges, while directly supporting the United Nations Sustainable Development (UNDP) goals related to innovation and infrastructure (SDG 9), sustainable cities (SDG 11), responsible consumption and production (SDG 12), and climate action (SDG 13).

09 BIOMASS FUELS↗
DOE OSTI2022

Using dorsal surface for individual identification of dairy calves through 3D deep learning algorithms

Advances in machine learning techniques have allowed the development of computer vision systems (CVS) that can accurately predict several phenotypes of interest for livestock operations. In this context, 3D images taken from a top-down view are particularly useful for estimating body condition score, growth development, and body biometrics in cattle. Frequently, such CVS rely on identification (ID) systems, such as electronic tags, as a way to match animal ID and the predicted phenotype. However, the same 3D images used to predict body weight and other animal biometrics could be adopted for animal recognition as well. Such alternative would optimize CVS to recognize animal ID and monitor growth development simultaneously while leveraging the same hardware infrastructure. Furthermore, this strategy could be used to recognize animals with similar color patterns. Nonetheless, growing animals are continuously changing body shape, which could limit its use as an invariant feature for pattern recognition. Thus, the objectives of this study were: (1) to compare algorithms for different 3D object representations to identify individual animals; and (2) to evaluate how short-term changes in body shape due to animal growth affect the predictive performance of these algorithms. For objective 1, the algorithms were trained (n = 4,558) and tested (n = 1,139) using images from 38 Holstein calves. For objective 2, we designed three different experiments using images (n = 2,347) from five Holstein calves taken over six weeks during their growing period, always training and testing on different weeks. Each experiment evaluated how changing a different parameter of the image capturing procedure affected the predictive ability of the trained algorithms. In the first experiment, we varied the total number of images per animal in the training set; in the second experiment, we varied the number of weeks while keeping a fixed number of images in the training set; and in the third experiment, we skipped weeks between images in the training and test sets. The F 1 score for objective (1) was up to 0.804 when testing with the last frames of each video, and up to 0.959 when using random frames for testing. For objective (2), the F 1 score was up to 0.947 for the first experiment when using 130 images per animal; up to 0.979 for the second experiment when using all five weeks; and up to 0.917 when not skipping weeks between training and testing. In conclusion, these results show that deep learning algorithms can be used to identify individual animals through their dorsal area 3D surfaces, and, from our experiments using calves in their growing period, that they are robust enough to account for changes in body shape and size, making them a promising tool for animal recognition during growth.

3D neural networks↗
DOE OSTI2022

Exploring Physics of Ferroelectric Domain Walls in Real Time: Deep Learning Enabled Scanning Probe Microscopy

The functionality of ferroelastic domain walls in ferroelectric materials is explored in real-time via the in situ implementation of computer vision algorithms in scanning probe microscopy (SPM) experiment. The robust deep convolutional neural network (DCNN) is implemented based on a deep residual learning framework (Res) and holistically nested edge detection (Hed), and ensembled to minimize the out-of-distribution drift effects. The DCNN is implemented for real-time operations on SPM, converting the data stream into the semantically segmented image of domain walls and the corresponding uncertainty. Further the pre-defined experimental workflows perform piezoresponse spectroscopy measurement on thus discovered domain walls, and alternating high- and low-polarization dynamic (out-of-plane) ferroelastic domain walls in a PbTiO 3 (PTO) thin film and high polarization dynamic (out-of-plane) at short ferroelastic walls (compared with long ferroelastic walls) in a lead zirconate titanate (PZT) thin film is reported. This work establishes the framework for real-time DCNN analysis of data streams in scanning probe and other microscopies and highlights the role of out-of-distribution effects and strategies to ameliorate them in real time analytics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Automation for Electric Vehicle Battery Pack Disassembly

Battery‐electric vehicles (EVs) are growing exponentially. The demand for these batteries is expected to increase sevenfold by 2035. The EV batteries reach their end of life when the capacity fades to 70%–80% of new, with some being removed from the primary applications with even lower levels of degradation. These batteries can be used in less demanding applications. The disassembly process is currently manual, slow, unsafe, and expensive. Automation is needed to increase the throughput. EV battery packs feature various continually changing designs and form factors, which limit the usefulness of deterministically programmed robotic solutions. The conceptual robotic disassembly of EV batteries has attracted the attention of researchers. However, while many approaches have been proposed, practical implementations are lacking. Here, we review proposed concepts for EV battery disassembly and describe the selected approach, with elements of partial solutions validated in a laboratory setting, including the selection of commercial solutions, the development of custom end effectors, and methodologies for detection, localization, and classification of fasteners. The computer vision tasks employed an overhead 2D camera to detect the type of battery pack and approximate localization of fasteners, and a 3D camera mounted on the robotic arm for precise localization (position and tilt) and classification.

Islam, Abu [Rochester Inst. of Technology, Rochest↗
DOE OSTI2025

Contaminant Investigation and Pre‐Processing Opportunities for Textile‐To‐Textile Recycling

Millions of metric tons of textiles are landfilled or incinerated each year in the United States, with less than 1% of textiles recycled into new clothing or fabrics. To counter this trend, a growing number of companies and researchers are exploring how a circular economy can be applied to support textile‐to‐textile recycling. A significant barrier they face comes down to quickly and efficiently extracting pure feedstock material from post‐consumer garments that feature a mix of natural and synthetic fibers. Textile recyclers prefer pure feedstocks, as working with mixed sources typically means lower throughput, higher risk of equipment failure, and diminished business margins. To facilitate a circular economy for textiles, methods, and technologies are needed that can efficiently separate out materials and contaminants from end‐of‐life textiles to increase the flow of pure feedstocks to recyclers. This paper summarizes findings from interviews with a cross section of textile recyclers and from a review of literature to define basic feedstock requirements. In addition to our qualitative research, we deconstruct a bale of post‐consumer textiles and analyze them using computer‐vision imaging, Fourier transform infrared spectroscopy (FTIR), and machine learning. The resulting data are used to set system‐level design inputs for an automated contaminant removal system to process post‐consumer clothing into appropriate feedstocks for recycling. To set the system's levels for automated real‐time near‐infrared analysis, we identify the minimum percentage of primary material that any single garment in a load of used clothing must contain for the average of the full output stream to meet the target purity levels of recyclers. Here, the envisioned automated system can also address undesirable trace materials that might contaminate the processed stream by using imaging cameras coupled with artificial intelligence to identify sections of clothing for de‐trimming. Proof‐of‐concept machine learning algorithms are evaluated to locate and identify trims or garment areas with hidden contaminant materials. Integrating these methods into automated textile cutting systems can provide a cost‐effective means for increasing feedstock purity from used clothing, which can advance circularity for textiles by helping recyclers to reach production volumes and quality targets that were not possible solely with manual dismantling operations.

Parsons, Ryan [Rochester Institute of Technology, ↗