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DOE OSTI2022

Smart connected worker edge platform for smart manufacturing: Part 1—Architecture and platform design

Abstract The challenge of sustainably producing goods and services for healthy living on a healthy planet requires simultaneous consideration of economic, societal, and environmental dimensions in manufacturing. Enabling technology for data driven manufacturing paradigms like Smart Manufacturing (a.k.a. Industry 4.0) serve as the technological backbone from which sustainable approaches to manufacturing can be implemented. Unfortunately, these technologies are typically associated with broader and deeper factory automation that is often too expensive and complex for the small and medium sized manufacturers (SMMs) that comprise the majority of manufacturing business in the USA and for whom their most valuable asset are the people whose jobs automation while replace. This paper describes an edge intelligent platform to integrate internet‐of‐things technologies with computing hardware, software, computational workflows for machine learning, and data ingestion, enabling SMMs to transition into smart manufacturing paradigms by leveraging the intelligence of their people. The platform leverages consumer grade electronics and sensors (affordable and portable), customized software with open source software packages (accessible), and existing communication network infrastructures (scalable). The software systems are implemented via Kubernetes orchestration of Docker containerization to ensure scalability and programmability. The platform is adaptive via computational workflow engines that produce information from data by processing with low‐cost edge computing devices while efficiently accessing resources of cloud servers as needed. The proposed edge platform connects workers to technological resources that provide computational intelligence (i.e., silicon‐based sensing and computation for data collection and contextualization) to enable decision making at the edge of advanced manufacturing.

Kim, Yoon G.↗

DOE OSTI2021

Computational Fluid Dynamics Simulations to Support Efficiency Improvements in Aluminum Smelting Process

Smelting is broadly described as the extraction of a metal from its ore. In the United States, aluminum is commonly produced by smelting alumina in bauxite using the Hall-Héroult process. Optimization of equipment and processes in conventional smelting is crucial to enhancing process efficiency and productivity, is necessary for improving the techno-economic feasibility, which directly manifests as the growth of the American economy. To achieve optima, insightful data on the multiphysics phenomena that are inherent to the process must be obtained through physical investigation or high-fidelity numerical simulations. The resolution of relevant scales in time and space for smelting operations requires intensive, high-performance computing (HPC) simulations. Hostile operating conditions limit physical data acquisition to specific techniques; therefore, these data do not describe the multiscale interaction of simultaneous effects. Fortunately, in recent decades, significant advancements in computing hardware and computational methods have made the numerical resolution of such a complex process possible. In this study, a high-fidelity simulation of aluminum smelting was performed using an open-source tool, OpenFOAM, which analyzed many parameters characteristic to underlying phenomena. A multiphysics model based on the Eulerian-Eulerian multifluid approach was adopted. This model can resolve critical issues in the electrolytic smelting of aluminum, such as bubbling of carbon dioxide from the anode(s), magnetohydrodynamics from electromagnetic effects, ionic dissolution of the alumina in the electrolyte, and the evolution of thermal profiles. This study provides valuable connectivity for characteristic data that can direct the future designs of efficient smelters. A basic framework to model and simulate the smelting process using OpenFOAM is presented for user modification in keeping with process development. Of relevance to the flow field, a detailed investigation of vortices produced by bubble motion and electromagnetics is discussed, along with their impact on the evolution of thermal profiles. The predictions show small-scale vortices in the clearance between the anode and cathode caused by magnetic forces. Predictions also indicate relatively large-scale vortices in the inter-anode space resulting from carbon dioxide rising through the electrolytic flow field. The formation of vortices at the edges of anodes was shown to direct alumina charged by the feeder to the bottom of the anodes, thus preventing the entrapment of gas bubbles in the periphery of the bottom of the anode. Symmetry was observed in the location of cold spots in the electrolytic mixture in the vicinity of the feeder. Cold spots were also observed in the clearance between the anode and cathode due to the flow’s transmission of unconverted alumina to this region.

36 MATERIALS SCIENCE↗

DOE OSTI2015

Batched matrix computations on hardware accelerators based on GPUs

Scientific applications require solvers that work on many small size problems that are independent from each other. At the same time, the high-end hardware evolves rapidly and becomes ever more throughput-oriented and thus there is an increasing need for an effective approach to develop energy-efficient, high-performance codes for these small matrix problems that we call batched factorizations. The many applications that need this functionality could especially benefit from the use of GPUs, which currently are four to five times more energy efficient than multicore CPUs on important scientific workloads. This study, consequently, describes the development of the most common, one-sided factorizations, Cholesky, LU, and QR, for a set of small dense matrices. The algorithms we present together with their implementations are, by design, inherently parallel. In particular, our approach is based on representing the process as a sequence of batched BLAS routines that are executed entirely on a GPU. Importantly, this is unlike the LAPACK and the hybrid MAGMA factorization algorithms that work under drastically different assumptions of hardware design and efficiency of execution of the various computational kernels involved in the implementation. Thus, our approach is more efficient than what works for a combination of multicore CPUs and GPUs for the problems sizes of interest of the application use cases. The paradigm where upon a single chip (a GPU or a CPU) factorizes a single problem at a time is not at all efficient in our applications’ context. We illustrate all of these claims through a detailed performance analysis. With the help of profiling and tracing tools, we guide our development of batched factorizations to achieve up to two-fold speedup and three-fold better energy efficiency as compared against our highly optimized batched CPU implementations based on MKL library. Finally, the tested system featured two sockets of Intel Sandy Bridge CPUs and we compared with a batched LU factorizations featured in the CUBLAS library for GPUs, we achieve as high as 2.5× speedup on the NVIDIA K40 GPU.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Solver for hardware based computing

Full-AC load flow constitutes a core computation in power system analysis. A performance gain with a hardware implementation of a sparse-linear solver using a Field Programmable Gate Array (FPGA) is achieved by use of a DC network emulation of the power system bus. Analog Behavioral Models (ABMs) are used in an efficient strategy for designing analog emulation engines for large-scale power system computation. A generator model is also developed using analog circuits for load flow emulation for power system analysis to reduce computation time. The generator model includes reconfigurable parameters using operational transconductance amplifiers (OTAs). The circuit module is used with other reconfigurable circuits, i.e., transmission lines and loads.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

All-Electric Nonassociative Learning in Nickel Oxide

Habituation and sensitization represent nonassociative learning mechanisms in both non-neural and neural organisms. They are essential for a range of functions from survival to adaptation in dynamic environments. Design of hardware for neuroinspired computing strives to emulate such features driven by electric bias and can also be incorporated into neural network algorithms. Herein, cellular-like learning in oxygen-deficient NiO x devices is demonstrated. Both habituation learning and sensitization response can be achieved in a single device by simply controlling the magnitude of the electric field. Spontaneous memory relaxations and dynamic redistribution of oxygen vacancies under electric bias enable such learning behavior of NiO x under sequential training. These characteristics in simple device arrays are implemented to learn alphabets as well as demonstrate simulated algorithmic use cases in digit recognition. Transition metal oxides with carefully prepared defect concentrations can be highly sensitive to electronic structure perturbations under moderate electrical stimulus and serve as building blocks for next-generation neuroinspired computing hardware.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Final Technical Report for ARRA Funding

Final technical report of the University of Minnesota experimental high energy physics group for ARRA support. The Cryogenic Dark Matter Experiment (CDMS) used the funds received to construct a new passive shield to protect a high-purity germanium detector located in the Soudan mine in Northern Minnesota from cosmic rays. The BESIII and the CMS groups purchased computing hardware to assemble computer farms for data analysis and to generate large volumes of simulated data for comparison with the data collected.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Improving Gas Reactor Design with Complex Non-Standard Reaction Mechanisms in a Reactive Flow Model

Fluorinated gases are critical to a number of high-technology industries including semiconductor manufacturing and related processes such as flat panel display, LED, and photovoltaic manufacturing. These fluorinated gases have very high global warming potentials (GWPs) and, unfortunately are chemically very stable, in some cases lasting for thousands of years in the atmosphere. For environmental reasons, it is imperative that the release of these gases be minimized, but existing methods to destroy them requires a significant amount of energy. The goal of this project was to develop a more energy efficient method of destroying these high GWP gases using computational fluid dynamics, but the computational requirements are significant. In this project, we bring together resources available at the national labs, including high-performance computing hardware and modern computational methods, in order to explore an industrially important problem with key environmental and economic impact. In this project, we examined the state-of-the-art models for the physical processes involved, and made subtle changes to arrive at alternative formulations considerably better suited for computation and study. We examined several representative scenarios and developed a set of analyses techniques and tools that could be used to explore the systems in much greater detail. This exploratory project has demonstrated to ALZETA that HPC can indeed provide a unique view into their complex engineering problem - one that is simply inaccessible by any other means. The tools allow us to explore the details of the chemical process, and allow one to construct "what-if" scenarios to address shortcomings of the physical device in its current operating modes. However, as with many sources of completely new information, many new questions are illuminated with this capability. It will take considerable time, effort and experience before we learn to probe the solutions, pose operating scenarios and confirm modifications to the device that lead to real engineering advances.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Quantum Computing for Energy-Related Applications

Growing interest in quantum computing and simulations have created opportunities for its deployment to improve processes pertaining to energy production, distribution, and consumption. While quantum computing is considered as a paradigm shift in our basic understanding of physical computation, effective implementation of quantum computing in energy applications also depends on progress and development in the dimensions of both quantum computing hardware and quantum computing algorithms. To fully address the status and future challenges of quantum information science (QIS) applied within the energy sector, in this presentation, we firstly summarize recent advancements on the applications of quantum computing to energy infrastructure and materials, complex energy system processes, advanced manufacturing, and energy system security. Then, we will demonstrate the results of quantum computing both on a simulator and a quantum device accessing from OLCF. Our first example is to use the variational quantum eigensolver (VQE) with a unitary coupled cluster with singles and doubles (UCCSD) ansatz to simulate a series of LixHyq molecules (q=-1, 0, +1). The obtained results showed that the quantum computing VQE-UCCSD is comparable to classical CCSD for small systems like LiH with respect to full configuration interaction (FCI). Targeting on CO2 capture application, our second example is to use VQE to quantify molecular vibrational energies and reaction pathways between CO2 and a simplified amine-based solvent model—NH3 to form H2NCOOH. This research showcases quantum computing applications in the study of CO2 capture reactions.

Duan, Yuhua↗

DOE OSTI2024

Fault localization in a microfabricated surface ion trap using diamond nitrogen-vacancy center magnetometry

Here, as quantum computing hardware becomes more complex with ongoing design innovations and growing capabilities, the quantum computing community needs increasingly powerful techniques for fabrication failure root-cause analysis. This is especially true for trapped-ion quantum computing. As trapped-ion quantum computing aims to scale to thousands of ions, the electrode numbers are growing to several hundred, with likely integrated photonic components also adding to the electrical and fabrication complexity, making faults even harder to locate. In this work, we used a high-resolution quantum magnetic imaging technique, based on nitrogen-vacancy centers in diamond, to investigate short-circuit faults in an ion trap chip. We imaged currents from these short-circuit faults to ground and compared them to intentionally created faults, finding that the root cause of the faults was failures in the on-chip trench capacitors. This work, where we exploited the performance advantages of a quantum magnetic sensing technique to troubleshoot a piece of quantum computing hardware, is a unique example of the evolving synergy between emerging quantum technologies to achieve capabilities that were previously inaccessible.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

Implementation of a Particle Accelerator Beam Dynamics Code on Multi-Node GPUs

Particle accelerators play an important role in a wide range of scientific discoveries and industrial applications. The self-consistent multi-particle simulation based on the particle-in-cell (PIC) method has been used to study charged particle beam dynamics inside those accelerators. However, the PIC simulation is time-consuming and needs to use modern parallel computers for high-resolution applications. In this paper, we implemented a parallel beam dynamics PIC code on multi-node hybrid architecture computers with multiple Graphics Processing Units (GPUs). We used two methods to parallelize the PIC code on multiple GPUs and observed that the replication method is a better choice for moderate problem size and current computer hardware while the domain decomposition method might be a better choice for large problem size and more advanced computer hardware that allows direct communications among multiple GPUs. Using the multi-node hybrid architectures at Oak Ridge Leadership Computing Facility (OLCF), the optimized GPU PIC code achieves a reasonable parallel performance and scales up to 64 GPUs with 16 million particles.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Multichannel Analysis of Surface Waves Accelerated (MASWAccelerated): Software for efficient surface wave inversion using MPI and GPUs

Multichannel Analysis of Surface Waves (MASW) is a technique frequently used in geotechnical engineering and engineering geophysics to infer 1D layered models of seismic shear wave velocities in the top tens to hundreds of meters of the subsurface. We aim to accelerate MASW calculations by capitalizing on modern computer hardware available in the workstations of most engineers: multiple cores and graphics processing units (GPUs). We propose new parallel and GPU accelerated algorithms for computing 1D MASW inversion, and provide software implementations in C using Message Passing Interface (MPI) and CUDA. These algorithms take advantage of sparsity that arises in the problem, and the work balance between processes considers typical data trends. We compare our methods to an existing open source Matlab MASW tool. Our serial C implementation achieves a 2x speedup over the Matlab software, and we continue to see improvements by parallelizing the problem with MPI. Here we see nearly perfect strong and weak scaling for uniform data, and improve strong scaling for realistic data by repartitioning the problem to process mapping. By utilizing GPUs available on most modern workstations, we observe an additional 1.3x speedup over the serial C implementation on the first use of the method. We typically repeatedly evaluate theoretical dispersion curves as part of an optimization procedure, and on the GPU the kernel can be cached for faster reuse on later runs. We observe a 3.2x speedup on the cached GPU runs compared to the serial C runs. This work is the first open-source parallel or GPU-accelerated software tool for MASW imaging, and should enable geotechnical engineers to fully utilize all computer hardware at their disposal.

58 GEOSCIENCES↗

DOE OSTI2026

Classical combinatorial optimization scaling for random Ising models on 2D heavy-hex graphs

Motivated by near term quantum computing hardware limitations, combinatorial optimization problems that can be addressed by current quantum algorithms and noisy hardware with little or no overhead are used to probe capabilities of quantum algorithms such as the quantum approximate optimization algorithm. In this study, a specific class of near term quantum computing hardware defined combinatorial optimization problems, Ising models on heavy-hex graphs both with and without geometrically local cubic terms, are examined for their classical computational hardness via empirical computation time scaling quantification. Specifically the time-to-solution (TTS) metric using the classical heuristic simulated annealing is measured for finding optimal variable assignments (ground states), as well as the time required for the optimization software Gurobi to find an optimal variable assignment. Because of the sparsity of these Ising models, the classical algorithms are able to find optimal solutions efficiently even for large instances (i.e. 100 000 spin variables). The Ising models both with and without geometrically local cubic terms exhibit average-case linear-time or weakly quadratic scaling when solved exactly using Gurobi, and the Ising models with no cubic terms show evidence of exponential-time TTS scaling when sampled using simulated annealing. These findings point to the necessity of developing and testing more complex, namely more densely connected, optimization problems in order for quantum computing to ever have a practical advantage over classical computing. Our results are another illustration that different classical algorithms can indeed have exponentially different running times, thus making the identification of the best practical classical technique important in any quantum computing vs. classical computing comparison.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2015

Reproduction of the Yucca Mountain Project TSPA-LA Model Runs using TSPA Computing Systems

Sandia National Laboratories (SNL) conducted an evaluation of total system performance assessment (TSPA) related computing systems for the previously considered Yucca Mountain Project (YMP). This was done to maintain the operational readiness of the computing infrastructure (computer hardware and software) and knowledge capability for total system performance assessment (TSPA) type analysis, as directed by the National Nuclear Security Administration (NNSA), DOE 2010. This work is a continuation of the ongoing readiness evaluation reported in Lee and Hadgu (2014). The current work examined main components of the computing system identified in the previous work (Lee and Hadgu, 2014) to ensure the operational readiness of the TSPA-LA model capability on the server cluster. The TSPA computing hardware and storage system were replaced in late 2014 to maintain core capability and improve computation efficiency. One floating license of GoldSim Version 9.60.300 was installed on the upgraded cluster head node, and its distributed processing capability was mapped on the cluster processors. Other supporting software was tested and installed to support the TSPA-type analysis on the server cluster. All the TSPA-LA modeling cases were tested and verified for the model reproducibility on the upgraded 2014 server cluster (CL2014). All test runs were executed on multiple processors on the server cluster utilizing the GoldSim distributed processing capability, and all runs completed successfully. The model reproducibility verification was evaluated by two approaches: numerical value comparison and graphical comparison. The analysis demonstrated an excellent reproducibility of the TSPA-LA model runs on the upgraded server cluster. The 2014 server cluster and supporting software systems are fully operational to support TSPA- LA type analysis.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Reproduction of the Yucca Mountain Project TSPA-LA Model Runs using TSPA Computing Systems

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Adaptive Mesh Refinement Simulations for Turbulent Reacting Flow

With the increased availability of exascale computing hardware, detailed simulations of realistic devices can be performed at practically relevant time and length scales. Insights into the multiscale driving mechanisms in compressible reacting flow systems with complex geometry, such as combustors, can be used for design optimization and technology improvements. However, to effectively perform these simulations, advanced numerical algorithms must be used to maintain solution accuracy without incurring undue computational costs. PeleC, part of the Pele suite of codes, leverages block-structured adaptive mesh refinement (AMR) through the AMReX library to capture fine-scale flow features in compressible reacting flows. In this talk, we discuss recent improvements to the numerical algorithms, particularly in regard to describing flows at complex boundary structures, and PeleC's performance on exascale computing hardware. We will demonstrate that PeleC is well-suited for modern, extreme-scale, heterogenous compute platforms.

combustion↗

DOE OSTI2016

Reproduction of the Yucca Mountain Project TSPA-LA Uncertainty and Sensitivity Analyses and Preliminary Upgrade of Models

Sandia National Laboratories (SNL) continued evaluation of total system performance assessment (TSPA) computing systems for the previously considered Yucca Mountain Project (YMP). This was done to maintain the operational readiness of the computing infrastructure (computer hardware and software) and knowledge capability for total system performance assessment (TSPA) type analysis, as directed by the National Nuclear Security Administration (NNSA), DOE 2010. This work is a continuation of the ongoing readiness evaluation reported in Lee and Hadgu (2014) and Hadgu et al. (2015). The TSPA computing hardware (CL2014) and storage system described in Hadgu et al. (2015) were used for the current analysis. One floating license of GoldSim with Versions 9.60.300, 10.5 and 11.1.6 was installed on the cluster head node, and its distributed processing capability was mapped on the cluster processors. Other supporting software were tested and installed to support the TSPA-type analysis on the server cluster. The current tasks included verification of the TSPA-LA uncertainty and sensitivity analyses, and preliminary upgrade of the TSPA-LA from Version 9.60.300 to the latest version 11.1. All the TSPA-LA uncertainty and sensitivity analyses modeling cases were successfully tested and verified for the model reproducibility on the upgraded 2014 server cluster (CL2014). The uncertainty and sensitivity analyses used TSPA-LA modeling cases output generated in FY15 based on GoldSim Version 9.60.300 documented in Hadgu et al. (2015). The model upgrade task successfully converted the Nominal Modeling case to GoldSim Version 11.1. Upgrade of the remaining of the modeling cases and distributed processing tasks will continue. The 2014 server cluster and supporting software systems are fully operational to support TSPA-LA type analysis.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

FY17 Status Report on the Computing Systems for the Yucca Mountain Project TSPA-LA Models.

Sandia National Laboratories (SNL) continued evaluation of total system performance assessment (TSPA) computing systems for the previously considered Yucca Mountain Project (YMP). This was done to maintain the operational readiness of the computing infrastructure (computer hardware and software) and knowledge capability for total system performance assessment (TSPA) type analysis, as directed by the National Nuclear Security Administration (NNSA), DOE 2010. This work is a continuation of the ongoing readiness evaluation reported in Lee and Hadgu (2014), Hadgu et al. (2015) and Hadgu and Appel (2016). The TSPA computing hardware (CL2014) and storage system described in Hadgu et al. (2015) were used for the current analysis. One floating license of GoldSim with Versions 9.60.300, 10.5, 11.1 and 12.0 was installed on the cluster head node, and its distributed processing capability was mapped on the cluster processors. Other supporting software were tested and installed to support the TSPA- type analysis on the server cluster. The current tasks included preliminary upgrade of the TSPA-LA from Version 9.60.300 to the latest version 12.0 and address DLL-related issues observed in the FY16 work. The model upgrade task successfully converted the Nominal Modeling case to GoldSim Versions 11.1/12. Conversions of the rest of the TSPA models were also attempted but program and operational difficulties precluded this. Upgrade of the remaining of the modeling cases and distributed processing tasks is expected to continue. The 2014 server cluster and supporting software systems are fully operational to support TSPA-LA type analysis.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

FY 18 Status Report on the Computing Systems for the Yucca Mountain Project TSPA-LA Models and Inventory of Software used for Process Models

Sandia National Laboratories (SNL) continued evaluation of total system performance assessment (TSPA) computing systems for the previously considered Yucca Mountain Project (YMP). This was done to maintain the operational readiness of the computing infrastructure (computer hardware and software) and knowledge capability for total system performance assessment (TSPA) type analysis, as directed by the National Nuclear Security Administration (NNSA), DOE 2010. This work is a continuation of the ongoing readiness evaluation reported in Lee and Hadgu (2014), Hadgu et al. (2015) and Hadgu and Appel (2016), and Hadgu et al. (2017). The TSPA computing hardware (2014 server cluster -CL2014) and storage system described in Hadgu et al. (2015) were used for the current analysis. One floating license of Gold Sim with Versions 9.60.300, 10.5, 11.1 and 12.0 was installed on the cluster head node, and its distributed processing capability was mapped on the cluster processors. Other supporting software were tested and installed to support the TSPA-type analysis on the server cluster. The FY18 task included developing an inventory of software used for the Yucca Mountain Project process models and preliminary assessment of status of the software; enhancing security of the cluster and setting a backup system. The 2014 server cluster and supporting software systems are fully operational to support TSPA-LA type analysis.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗