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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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Integrating Machine-learning-assisted Computer Vision with RICH System

Developments in artificial intelligence have vastly expanded the capabilities of robots. Currently, the Spallation Neutron Source (SNS) beamlines at Oak Ridge National Lab (ORNL) have robotic sample loaders to increase the efficiency of running experiments. However, they require retraining if anything about the situation changes, e.g., where the samples are, and cannot notice if errors occur. So, the viability of using computer vision and machine learning to enhance these sample loaders’ functionality was investigated. In this project, the RICH system with a Dobot CR3 6-axis robot present at the VULCAN beamline assisted by an Intel Realsense D435i camera, a unique camera that enables convenient translation of 2D pixel coordinates to 3D world points, was programmed to load ceramic crucibles into a thermogravimetric analyzer (TGA) furnace. An algorithm was constructed in Python with three major phases planned: (1) obtaining a sample, (2) moving it to the target location, and then (3) bringing the sample back to its original location once the experiment finished. In the first phase, the algorithm would dynamically detect sample locations using ArUco markers to recognize the samples’ general location and a custom-trained yolov5 object detection model to locate the crucibles’ centers. Afterward, the robot would be directed to pick up samples based on the crucibles’ calculated positions. In the second phase, the robot would move the sample to a secondary point, reorient its grip, and place the sample at the target location. In the final phase, the robot would determine whether the sample was intact and would bring it back to its original place if it was or raise an alarm. Using this algorithm, the robot was able to pick up different types of crucibles at varying positions. These results indicate that integrating machine-learning-assisted computer vision with robotic sample loaders can result in effective autonomous detection of samples.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Lab-Scale Cable-Driven Parallel Robot Prototype for Automated Prefabricated Component Manipulation

This paper presents the design and evaluation of a lab-scale cable-driven parallel robot (CDPR) developed as a flexible platform for automated installation of prefabricated components onto exterior building envelopes. Traditional manual installation methods for prefabricated components, which depend on scaffolding, cranes, cherry pickers, and verbal coordination, are not only labor-intensive and error-prone but also face significant limitations in dense urban environments due to site access constraints. To address these challenges, we developed a lab-scale CDPR platform capable of autonomously transporting building envelope components from a designated pickup zone to their target installation location, minimizing the need for human intervention. This study describes the system’s mechanical design, actuation architecture, real-time feedback system, and control strategy of the CDPR, and evaluates its performance in a laboratory environment. The robot’s actuation system uses torque control for end-effector manipulation. The robot’s real-time pose feedback comes from a construction-grade total station and a wireless inertial measurement unit (IMU), which together support precise end-effector control. Experimental results demonstrate the successful integration of the hardware, sensing, state estimation, and control subsystems. Preliminary tests showed that our lab-scale prototype can position the end effector with an error of less than 3 mm, which is a level of precision not previously achieved by existing CDPRs in construction applications. The key findings are twofold: (1) torque-only control is necessary but not sufficient for minimizing final pose error, and (2) incorporating real-time pose feedback can achieve the desired placement accuracy.

Liu, Yifang [Oak Ridge National Laboratory (ORNL),↗
DOE OSTI2026

Design and Integration of a Compact Mobile Outdoor Soil Sampling Agricultural Robot

The lack of feedback on soil management for crop systems necessitates the collection of soil samples to derive insights into prevailing soil conditions. Achieving an accurate model of these plantations requires a substantial number of soil samples, which is a labor-intensive process that can suffer from inconsistencies in both the methodology of collection and the locations from which samples are gathered. In addition, the close spacing of crop rows constrains the maneuverability of mobile agricultural equipment during sample collection. This article proposes the use of agricultural robotics to facilitate the acquisition of composite soil samples with minimal human intervention, allowing for precise data collection for a Populus plant system. More specifically, this article presents a case study on the design and construction of a compact agricultural robot for soil sample collection. The performance of the robot, including its soil collection efficacy, maneuverability, and positional accuracy, is evaluated.

42 ENGINEERING↗
DOE OSTI2025

The Cost of Scaling Up in Large-Format Additive Manufacturing

Additive manufacturing (AM) of large objects has, over the last decade, required the scaling of existing material extrusion processes. The current generation of large-scale printers are primarily gantry robots with high-throughput extrusion systems. With workspaces approaching 50 m 3 , these printers have pushed the boundaries of achievable print volume while allowing the utilization of low-cost feedstocks, such as cementitious materials and polymer pellets, like those used in injection molding. Continued workspace expansion requires an examination of the inherent trade-offs, which impact capital and operational costs. Here, in this work, the authors examine these trade-offs to determine fundamental scaling laws for existing system architectures, survey the state of the art for alternative system configurations, and pose recommendations for future system designers to continue the evolution of large-scale AM systems.

3D printing↗
DOE OSTI2023

Colloidal State Machines as Smart Tracers for Chemical Reactor Analysis

A widely utilized tool in reactor analysis is passive tracers that report the residence time distribution, allowing estimation of the conversion and other properties of the system. Recently, advances in microrobotics have introduced powered and functional entities with sizes comparable to some traditional tracers. This has motivated the concept of Smart Tracers that could record the local chemical concentrations, temperature, or other conditions as they progress through reactors. Herein, the design constraints and advantages of Smart Tracers by simulating their operation in a laminar flow reactor model conducting chemical reactions of various orders are analyzed. It is noted that far fewer particles are necessary to completely map even the most complex concentration gradients compared with their conventional counterparts. Design criteria explored herein include sampling frequency, memory storage capacity, and ensemble number necessary to achieve the required accuracy to inform a reactor model. Cases of severe particle diffusion and sensor noise appear to bind the functional upper limit of such probes and require consideration for future design. The results of the study provide a starting framework for applying the new technology of microrobotics to the broad and impactful set of problems classified as chemical reactor analysis.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Development of a Web-Based Graphical User Interface for Fermilab Robots

This project provides the students/faculty team with the unique opportunity to work with several robots. Additionally, the student team will be able to learn from the experience of the Robotics Initiative members who have a wide variety of technical backgrounds outside of software development. Working with an interdisciplinary group to solve a complex problem that is unique to our facility, is a valuable experience that the lab can provide. This project aligns with the ACORN projects R&D efforts regarding the integration of robotics status/control with the accelerator control system.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Testing, Calibration, and UxS Integration of the Kromek GR1 Plus CZT Gamma Spectrometer

Collecting radiation measurements can be a hazardous task, especially in the presence of highly active sources. Various scenarios necessitate source search, classification, and quantification, often with limited or no a priori information. Activities such as disaster mitigation, emergency response, environmental monitoring, and site remediation may involve dangerous radioactive sources. In these situations, there is a pressing need for remote monitoring capabilities that protect human operators from potential harm and enhance adherence to the principle of “As Low as Reasonably Achievable” (ALARA) for radiation doses. The first step toward achieving remote radiation measurement capabilities is the remote operation of a radiation sensor. Once this milestone is reached, the next challenge is to integrate this remote sensing capability into suitable actuation agents, collectively referred to as uncrewed systems (UxS). These systems include familiar platforms such as robotic quadrupeds, aerial multirotor vehicles, and ground vehicles, any of which may be teleoperated, act autonomously, or utilize a combination of both. A critical factor in achieving remote radiation sensing is the availability of data from the appropriate sensor. Many commercially available radiation sensors have closed-source documentation for their communication protocols. Typical end-user products are often self-contained, handheld devices designed for manual measurement scenarios. While there are commercial off-the-shelf (COTS) integrations of radiation sensors with UxS available for purchase, these solutions are typically tailored for specific use cases and may not meet the requirements of different applications. This paper discusses efforts to remotely acquire radiation measurements from a small form-factor CZT gamma spectrometer. Sandia National Laboratories has successfully demonstrated the initial capability to integrate low size, weight, and power (SWaP) gamma spectroscopy into various UxS, alongside co-located GPS data logging and sensor calibration and qualification. With remote gamma spectroscopy achieved, the stage is set for UxS integration of this capability.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

Automated Systems for Solvent Extraction

An automated solvent extraction system for the eventual handling of radioactive materials has been designed and procured for rapid, efficient and safe liquid-liquid extraction processes. This system will be configured to carry out liquid-liquid separations from beginning to end, automating tedious and time-consuming tasks such as organic/aqueous phase prep, pH checks, phase separation, and metal ion analysis. The system features advanced liquid handling capabilities, a robotic arm for precise sample transfer, and sophisticated analytical tools including UV-VIS spectrophotometry for real-time monitoring. Additionally, it incorporates automated capping of vials, vortex mixing, and centrifugation to ensure thorough mixing and phase separation. This report provides an overview of the system and general capabilities as well as initial efforts to develop an automated workflow for liquid-liquid separations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2020

Advancing Fusion with Machine Learning Research Needs Workshop Report

Abstract Machine learning and artificial intelligence (ML/AI) methods have been used successfully in recent years to solve problems in many areas, including image recognition, unsupervised and supervised classification, game-playing, system identification and prediction, and autonomous vehicle control. Data-driven machine learning methods have also been applied to fusion energy research for over 2 decades, including significant advances in the areas of disruption prediction, surrogate model generation, and experimental planning. The advent of powerful and dedicated computers specialized for large-scale parallel computation, as well as advances in statistical inference algorithms, have greatly enhanced the capabilities of these computational approaches to extract scientific knowledge and bridge gaps between theoretical models and practical implementations. Large-scale commercial success of various ML/AI applications in recent years, including robotics, industrial processes, online image recognition, financial system prediction, and autonomous vehicles, have further demonstrated the potential for data-driven methods to produce dramatic transformations in many fields. These advances, along with the urgency of need to bridge key gaps in knowledge for design and operation of reactors such as ITER, have driven planned expansion of efforts in ML/AI within the US government and around the world. The Department of Energy (DOE) Office of Science programs in Fusion Energy Sciences (FES) and Advanced Scientific Computing Research (ASCR) have organized several activities to identify best strategies and approaches for applying ML/AI methods to fusion energy research. This paper describes the results of a joint FES/ASCR DOE-sponsored Research Needs Workshop on Advancing Fusion with Machine Learning, held April 30–May 2, 2019, in Gaithersburg, MD (full report available at https://science.osti.gov/-/media/fes/pdf/workshop-reports/FES_ASCR_Machine_Learning_Report.pdf ). The workshop drew on broad representation from both FES and ASCR scientific communities, and identified seven Priority Research Opportunities (PRO’s) with high potential for advancing fusion energy. In addition to the PRO topics themselves, the workshop identified research guidelines to maximize the effectiveness of ML/AI methods in fusion energy science, which include focusing on uncertainty quantification, methods for quantifying regions of validity of models and algorithms, and applying highly integrated teams of ML/AI mathematicians, computer scientists, and fusion energy scientists with domain expertise in the relevant areas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Chemically controlled shape-morphing of elastic sheets

Two-dimensional responsive materials that change shape into complex three-dimensional structures are valuable for creating systems ranging from wearable electronics to soft robotics. Typically, the final 3D structure is unique and predetermined through the materials’ processing. Here, we use theory and simulation to devise a distinctive approach for driving shape changes of 2D elastic sheets in fluid-filled microchambers. The sheets are coated with catalyst to generate controllable fluid flows, which transform the sheets into complex 3D shapes. A given shape can be achieved by patterning the arrangement of the catalytic domains on the sheet and introducing the appropriate reactant to initiate a specific catalytic reaction. Moreover, a single sheet that encompasses multiple catalytic domains can be transformed into a variety of 3D shapes through the addition of one or more reactants. Materials systems that morph on-demand into a variety of distinct structures can simplify manufacturing processes and broaden the utility of soft materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A nuclear power plant digital twin for developing robot navigation and interaction

As robot technologies are rapidly improving, an increasing number of new ideas on utilizing robots for automated operation and maintenance tasks in nuclear power plants (NPPs) are being studied. However, due to safety concerns, researchers hardly found opportunities to test their new robot solutions on physical NPPs. In that sense, an efficient and realistic simulation environment plays a vital role in the development of automation systems for an NPP. In this paper, we propose the design of a 3D digital twin system capable of simulating NPP in real-time. This system obtains the data from a full-scope NPP simulator to reproduce the operating conditions of the plant. In addition, a scenario of a team of robots performing inspection tasks like temperature and pressure measurements will highlight its usability. This system enables development of intelligent robot swarms to deploy for inspection and maintenance purposes. It will positively impact autonomous control and operations for many types of reactors by reducing uncertainty in autonomous control and providing the tools necessary for remote intervention.

Energy & Fuels↗
DOE OSTI2020

Extremum seeking for optimal control problems with unknown time-varying systems and unknown objective functions

We consider the problem of optimal feedback control of an unknown, noisy, time-varying, dynamic system that is initialized repeatedly. Examples include a robotic manipulator which must perform the same motion, such as assisting a human, repeatedly and accelerating cavities in particle accelerators which are turned on for a fraction of a second with given initial conditions and vary slowly due to temperature fluctuations. In this paper, we present an approach that applies to systems of practical interest. The method presented here is model independent; does not require knowledge of the objective function; is robust to measurement noise; is applicable for any set of initial conditions; is applicable to simultaneously controlling an arbitrary number of parameters; and may be implemented with a broad range of continuous or discontinuous functions such as sine or square waves. For systems with convex cost functions we prove that our algorithm will produce controllers that approach the minimal cost. For linear systems we reproduce the cost minimizing linear quadratic regulator optimal controller that could have been designed analytically had the system and cost function been known. We demonstrate the effectiveness of the algorithm with simulation studies of noisy and time-varying systems.

42 ENGINEERING↗
DOE OSTI2021

Robotic sample changers for macromolecular X-ray crystallography and biological small-angle X-ray scattering at the National Synchrotron Light Source II

In this work, we present two robotic sample changers integrated into the experimental stations for the macromolecular crystallography (MX) beamlines AMX and FMX, and the biological small-angle scattering (bioSAXS) beamline LiX. They enable fully automated unattended data collection and remote access to the beamlines. The system designs incorporate high-throughput, versatility, high-capacity, resource sharing and robustness. All systems are centered around a six-axis industrial robotic arm coupled with a force torque sensor and in-house end effectors (grippers). They have the same software architecture and the facility standard EPICS-based BEAST alarm system. The MX system is compatible with SPINE bases and Unipucks. It comprises a liquid nitrogen dewar holding 384 samples (24 Unipucks) and a stay-cold gripper, and utilizes machine vision software to track the sample during operations and to calculate the final mount position on the goniometer. The bioSAXS system has an in-house engineered sample storage unit that can hold up to 360 samples (20 sample holders) which keeps samples at a user-set temperature (277 K to 300 K). The MX systems were deployed in early 2017 and the bioSAXS system in early 2019.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Modular Autonomous Experimentation for Biological Applications (Full Report)

The Modular Autonomous Research System (MARS) was developed to address the pressing need for faster, more reliable, and more adaptable scientific discovery. Traditional experimentation is limited by manual labor, long cycle times, and fragmented data streams, which constrain the ability to explore complex chemical and materials design spaces. To overcome these limitations, we created an integrated, modular platform that combines laboratory robotics, diverse measurement instruments, and a central data infrastructure with artificial intelligence–driven decision-making. The system links liquid handling robots, robotic arms, and optical plate readers into a closed loop where experiments are executed automatically, data is analyzed in real time, and subsequent experimental conditions are adaptively chosen to maximize information gain. Over the course of the project, MARS was validated on two primary test cases—spectroscopic metal–ligand binding assays and peptide-directed mineralization—which highlighted the system’s ability to handle uncertainty and variability in experimental measurements. To further demonstrate modularity and extensibility, we also established additional testbeds in electrochemistry for catalyst discovery and electrolyte formulation for advanced batteries. The results show that MARS can reliably conduct autonomous campaigns with minimal human intervention, adapt to distinct scientific domains, and provide a scalable model for future self-driving laboratories. This work establishes new capabilities for modular, uncertainty-aware automation and directly supports the need for advanced, data-driven research platforms capable of accelerating discovery across a wide range of scientific and national security missions.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Mechanical rolling and annealing of wire-arc additively manufactured stainless steel plates

Thin walls of 304L stainless steel were fabricated by wire-arc additive manufacturing (WAAM) followed by post build thermomechanical processing to modify the as built microstructure and properties. The walls were made using a high-deposition-rate robotically controlled gas-metal arc welding system and were characterized using optical microscopy and tensile tested for mechanical properties. Post processing consisted of mechanical rolling the walls to 25% and 40% strains, followed by annealing at 1050°C to demonstrate a wide range of properties. Results show that WAAM can be used to build custom sized semi-finished parts or blanks that can later be thermomechanically processed to increase strength and ductility through recrystallization of the as built microstructure, and/or processed into desired shapes with improved mechanical properties.

304L stainless steel↗
DOE OSTI2023

Automated recovery of rare earth permanent magnets from electric machines

A method for the automated recovery of rare earth permanent magnets from electric machines are provided. The method includes identifying electric machines in a mixed product stream for performing a unique robotic disassembly routine. Electric machines that are not identified are diverted to a robot training station, during which time the system and the method include implementing a suitable disassembly routine. A conveyor delivers the remaining electric machines to a rotary platform having multiple stations for the simultaneous disassembly of multiple electric machines. Permanent magnets are removed from the electric machines and are then sorted for recycling operations.

McIntyre, Timothy J.↗