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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 OSTI2020

Dynamic Performance Enhancement for Nonlinear Stochastic Systems Using RBF Driven Nonlinear Compensation with Extended Kalman Filter

In this paper, a novel hybrid control method is proposed to enhance the control performance of the PI based control system for a class of nonlinear and non-Gaussian stochastic dynamic processes with unmeasurable states. Firstly, to enhance the tracking performance of the PI controller where the PI parameters are fixed in many actual control systems, the compensative signal is formed using the extended Kalman filter(EKF) based state estimator and driven by the radial basis function (RBF) neural network based compensator. In addition, the weights of RBF is trained to minimize the entropy criterion of tracking error as the process is subjected to non-Gaussian disturbances. Meanwhile, since the precise statistical property of noises is hard to obtain for many industrial processes, the kernel density estimation (KDE) technique is employed in this paper to estimate the entropy. The convergence of RBF network is discussed and the stability of the resulted closed-loop hybrid control system is analyzed in mean square sense. Finally, a numerical example and a practical system testing are given to illustrate the effectiveness of the proposed control method.

stochastic systems, PI Controller, Entropy, Extend↗
DOE OSTI2021

OPERATING EXPERIENCE AND ITS RELATIONSHIP TO EMBEDDED DIGITAL DEVICES IN SAFETY SYSTEMS

Interest in embedded digital devices (EDDs) for monitoring and providing control of components is increasing and the added functionality digital brings such as diagnostics, displays, control functions is welcomed in both the nuclear and other industries. As a result, pure analog-based components continue to disappear from the industrial I&C marketplace. Equipment with EDDs, also known by related terms such as smart devices, intelligent devices, and digital devices of limited functionality, can include sensors, breakers, priority logic modules, time delay relays, pumps, valve actuators, motor control centers, and uninterruptible power supplies. Not only is equipment consisting of analog and older digital technology being replaced with commercial grade products containing EDDs, but EDDs can also be retrofitted to work with existing components. EDDs may be installed physically within a component, such as in a relay. There are also external devices that some would not consider an EDD, but that operate in almost all technical ways identically to one internal to a component such as in a valve controller. In fact, the digital portions may be located hundreds of feet from the actual component.Due to the potential of being used in an identical manner and without alteration from their application in other industries, operating experience (OpE) for EDDs may be much more applicable than in the case of other more system level devices. Clear separation and independence of functionality provided with EDDs may also allow greater applicability of existing OpE from industry for changes that can be shown not to affect its safety function. However, OpE also demonstrates issues with different conditions between other industries and nuclear power plants, such as issues with undeclared changes or undeclared digital devices and the new failure modes they may introduce, issues with the reporting of OpE in industry, and a lack of transparency into OpE for EDDs.Understanding and addressing these issues will be key in the future use of EDDs in nuclear power plants, but failure rate data is difficult to obtain for EDDs, and lessons learned from the use of EDDs are difficult to collect and identify.Key words: embedded digital device, smart device, operating experience, failure modes

Muhlheim, Michael↗
DOE OSTI2024

A High-Fidelity Electromagnetic Transient Model of Inverter-based Resources Integrated to an IEEE-9 Bus System for Benchmarking Studies

An inverter-based resource (IBR) is a source of electricity that is asynchronously connected to the electrical grid via an electronic power converter. These power sources lack the intrinsic behaviors of the standard power plants, presenting specific challenges to system stability. These power sources lack the intrinsic behaviors of the standards power plants and their features are almost entirely defined by the control strategy used on them, presenting specific challenges to system stability as their penetration increases into the already fragile Bulk Power System (BPS). Utilizing renewable energy has a great upside but the electrical industry needs to understand the requirements like performing electromagnetic transient (EMT) simulation studies in planning and/or in interconnection studies. This paper presents the development of a high-fidelity EMT model based on commercial equipment and field parameters, which at the same time aims to study the increasing penetration of IBRs and their impact on the actual BPS. The open-source EMT model developed will be a benchmarking example that can be used to evaluate algorithms in the power grid (including evaluating grid-forming controls, power system monitoring and operation, etc.).

Martinez Montejano, Misael↗
DOE OSTI2024

7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process

Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.

Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗
DOE OSTI2022

Introducing the 9500 Node Distribution Test System to Support Advanced Power Applications: An Operations-Focused Approach

The 9500 Node Test System is a representative section of distribution power system model developed as a part of the GridAPPS-D™ project, an effort funded by DOE as a part of the Grid Modernization Lab Consortium (GMLC) program. The test system was developed to fulfill a growing need to represent the rapidly evolving state of electric distribution systems by combining elements of legacy infrastructure systems, modern feeder topologies, and an anticipated future with smart grid technologies. It also provides a network model capable of supporting the simulation of operational scenarios such as the ones in a utility distribution control center. This test system allows the evaluation of the performance of advanced power applications in real-time, such as one that simulates the operations of an Advanced Distribution Management Systems (ADMS), Distributed Energy Resource Management Systems (DERMS), etc. in a Distribution control center. This model is an extension of the widely used IEEE 8500 Node Test Feeder and is currently being validated to become an IEEE test case to help increase adoption and widespread usage among both academia and industry. It is a full-size model representative of a section of a utility’s distribution system with multiple feeders fed from different substations. The model includes multiple distribution circuits, a sub-transmission system, multiple substations, behind the meter customer rooftop photovoltaics (PV), and multiple utility-scale distributed energy resources. To enable accurate simulations of operational scenarios, the 9500 Node Test System is designed to support procedure-based operations, with the ability to realistically demonstrate switching operations, feeder reconfiguration, adjustment of volt-var control equipment, dispatch of distributed generation, and response to planned and unplanned outages. The 9500 Node Test System includes three radial distribution feeders with 12.3 MVA of average load, consisting of both medium voltage and low voltage equipment each supplied by a different distribution substation. The three distribution feeders are connected to each other through Normally-Open switches which can be closed when needed to simulate restoration scenarios due to a fault. One feeder represents today’s grid with low penetration of customer-side renewables. The second represents a potential future grid with microgrids and 100% renewable penetration. The third has no customer generation resources, a district steam plant, and a utility-scale solar farm. The three diverse circuits were created to allow the simulation of both today’s situation as well as potential future scenarios. All three feeders have customers connected by low-voltage secondary triplex lines. This test system meets all requirements outlined in the report for creating a simulation environment that would enable discussion between key technical stakeholders as well as having the potential to accelerate operational application development and their subsequent testing and integration. The new model is a possible representation of what we believe the distribution grid may look like in the future: a high penetration of renewables, reconfigurable radial and mesh topology, numerous DERs, islanded microgrids, and significantly increased data and measurement density. The system supports both the solution of existing and newer algorithms but also enables the evaluation of applications in a realistic operational environment defined by task oriented procedural steps that represent the interaction between the control center operator and field personnel.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Investigation of Multiple Data Streams for Gearbox Bearing Fault Prediction Through Machine-Learning Models

Operations and maintenance (O&M) cost of wind plant accounts up to 30% of total energy cost, which can be reduced through continuous monitoring and successfully detecting incipient wind turbine failures. To accomplish this, condition monitoring and predictive maintenance systems are being implemented in wind industry to support O&M decision making. A wide range of approaches for condition monitoring and fault prediction have been developed. These approaches generally use historical data of wind turbines collected by Supervisory Control and Data Acquisition (SCADA) system to identify patterns that lead to failure. These SCADA data show the overall condition of a wind turbine and can be leveraged to detect when the turbine's performance is degrading and to identify if a fault is developing. However, it becomes challenging to predict the failure of a specific wind turbine gearbox bearing, because the SCADA data are often not directly linked to the component. To bridge the gap, we have investigated features calculated from SCADA data using physics-based models and the gearbox design over the years. The damaged metric we used in the physics domain is frictional energy. Combining these physics domain variables with SCADA data as inputs to various machine learning models for gearbox bearing fault prediction, we have demonstrated the benefits of leveraging both physics and data domain models. It was an attempt to improve frictional-energy-based damage metric by adding data domain inputs, as we had learned that the frictional-energy-based damage metric alone is not sufficient to single out failed bearings from healthy. As condition monitoring data (either vibration or oil debris data) has become available at more and more wind plants, we would like to evaluate whether by adding the condition monitoring data can help further improve the performance of frictional-energy-based damage metric for gearbox bearing fault prediction. Both cases by modeling through various machine learning algorithms are discussed in this study along with some observations.

fault prediction↗
DOE OSTI2020

Putting Our Industry's Data to Work: A Case Study of Large-Scale Data Aggregation: Preprint

With increasing deployment of Advanced Metering Infrastructure (AMI), Building Automation System (BAS) controls, Internet of Things (IoT) network devices, and data-driven evaluation, measurement, and verification studies, the building sector is currently generating a staggering amount of energy-related data. In the right hands, these data sets can contribute to increased comfort and energy savings for building occupants and a more reliable electrical grid; however, due to a combination of factors, including significant privacy concerns, much of the data that are presently generated and stored are not used outside of basic operational applications. In the past year, our team has dedicated over 2,000 person-hours to accessing building energy data for a project funded by the U.S. Department of Energy (DOE) Building Technologies Office. We sought whole-building or end-use (e.g., lighting) timeseries data at the individual-building or equipment level where possible or aggregated information, such as timeseries averages and quartiles by building type (e.g., office, retail, hospital), where sharing individual building information was not an option. We are additionally working with IoT and BAS data sets to derive information important to the project. We have assembled an extensive data set that will enable the development of publicly available end-use load profiles to benefit the U.S. building and electricity industries. Here we present an overview of the data set that we have assembled to date, the motivators and approaches that got us here, and the lessons we learned through our efforts. We also discuss work underway that presents additional options for future data access.

building energy data↗
DOE OSTI2022

Real-time Distribution Simulation and Application Development for Power Systems Education

To help bridge the gap between traditional power system engineering instruction and emerging industry needs, a new set of classroom and research tools are needed. Real-time simulation tools emulating power system control room software present an opportunity to introduce students to the array of operational considerations, technical challenges, and decision-making associated with power system operations. The GridAPPS-D platform is proposed to support coursework and academic research as it provides an open-source platform for simulation, application development, and software integration. The GridAPPS-D platform, simulation capabilities, development environment, and interactive training are discussed in the context of lessons-learned from implementation for undergraduate and graduate students in the US and India. A series of potential GridAPPS-D supported academic capabilities are introduced.

Active distribution networks, open educational res↗
DOE OSTI2022

Stress-Controlled Creep–Fatigue of an Advanced Austenitic Stainless Steel at Elevated Temperatures

Creep–fatigue interaction occurs in many structural components of high-temperature systems operating under cyclic and steady-state service conditions, such as in nuclear power plants, aerospace, naval, and other industrial applications. Thus, understanding micromechanisms governing high-temperature creep–fatigue behavior is essential for safety and design considerations. In this work, stress-controlled creep–fatigue tests of advanced austenitic stainless steel (Alloy 709) were performed at a 400 MPa stress range and 750 °C with tensile hold times of 0, 60, 600, 1800, and 3600 s, followed by microstructural examinations. The creep–fatigue lifetime of the Alloy 709 was found to decrease with increasing hold time until reaching a saturation level where the number of cycles to failure did not exhibit a significant decrease. Softening behavior was observed at the beginning of the test, possibly due to the recovery of entangled dislocations and de-twining. In addition, hysteresis loops showed ratcheting behavior, although the mean stress was zero during creep–fatigue cycling, which was attributed to activity of partial dislocations. Microstructural examination of the fracture surfaces showed that fatigue failure dominated at small hold times where the cracks initiated at the surface of the sample. Larger creep cracks were found for longer hold times with a lower probability of dimpled cavities, indicating the dominance of creep deformation. The results were compared with other commonly used stainless steels, and plausible reasons for the observed responses were described.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

CRADA Final Report: CRADA Number NFE-24-10036 with ThermaMatrix, Inc.

ThermaMatrix, Inc provides novel vision inspection solutions for a wide range of manufacturers and industries, providing and implementing the leading technologies for nondestructive inspection (NDI) and material characterization. Many other inspection solutions are either not adequate or are not approachable due to implementation barriers needing expert level operators, excessive inspection time, and high cost. ThermaMatrix’s advanced vision inspection technology addresses all of these limitations. The Lab Embedded Entrepreneurial Program (LEEP) opportunity by the Department of Energy (DOE) allows small-business start-ups to leverage national laboratory capabilities and skilled scientists to rapidly develop their technology that aligns with DOE goals. ThermaMatrix, Inc. was positioned in the Innovation Crossroads program at Oak Ridge National Laboratory to further develop the novel Watson Vision Inspection System to support manufacturing quality control efforts. The research goals were (1) explore fundamental parameters that would improve preexisting capabilities, (2) full-scale industrial setup for demonstration, and (3) capability testing and verification. Manufacturing is demanding more NDI implementation to support their quality control needs, which this technology development would support.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Case Study of Luminaire-Level Lighting Control: Lighting the Northwest Energy Efficiency Alliance (NEEA) Office in Portland, OR

What happens when advanced lighting and control systems are installed in the real world? Are the advantages and energy savings realized? By observing the design, installation, commissioning, and ongoing use of connected lighting systems in real-world settings, it is possible to identify the strengths, challenges, and points of human-technology interaction that may be new or unfamiliar to those responsible for implementing or maintaining the lighting system. Ultimately, understanding and experiencing each stakeholder’s interaction with the technology can allow the research team to synthesize feedback for manufacturers, improve industry understanding of the technology, and increase adoption. The Northwest Energy Efficiency Alliance (NEEA) office in Portland, OR, is a single-floor installation that puts tunable-white, interoperability, and luminaire-level advanced control capabilities to the test. Compared to simpler, “out-of-the-box” systems that minimize field-adjustable settings, the system utilized in this space allowed for granular field adjustments which required the system specifier, client, and programming agent to make additional decisions regarding system operation while the system was being programmed. This report communicates the observational findings from the installation, programming, and ongoing operation of an advanced office LLLC system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Digital Twin Technology (“Morpheus”) for Optimized Building Operations [SWR-22-74]

The electrification of buildings is an important step to reducing greenhouse gas emissions across all industries. The management of increasingly electrified buildings is a complex pursuit, and there remains a need for cost-effective software capable of handling the computational burden required of such complexity. Through a partnership with Dallas Fort Worth (DFW) Airport, researchers at NREL have developed a digital twin modeling framework to optimize building operations, called Morpheus. Pairing predictive control with automatic fault detection and diagnostics, Morpheus decreases energy expenditures, costs, and faults for large facilities. Additionally, Morpheus employs artificial intelligence to continuously improve its performance using information provided by sensor systems, human experts with deep industry domain knowledge, and even from other similar machines or fleets of machines. Coupling this novel energy-management software with other digital twins, such as NREL’s Athena software for mobility operations, enables robust decision-making for asset and space management. The implementation of Morpheus at DFW has resulted in significantly improved HVAC system operations and reduced both peak power and overall energy consumption. This enhanced functionality comes at a more affordable price than previously developed digital twins and can be customized for other facilities’ geometries to provide optimal, individualized control of a facility’s energy consumption.

Chinde, Venkatesh↗
DOE OSTI2025

Unsupervised anomaly clustering via offset alignment in multivariate grid sensing data

Modern industries increasingly rely on multi-sensor technologies to acquire complex, high-dimensional data streams, enabling advanced monitoring and control systems. One critical application is online anomaly detection in electrical smart grids, where multivariate and multimodal sensing technologies play a vital role. However, detecting anomalies in such time-series data is challenging due to their inherent temporal dependencies and stochastic behavior. Traditional approaches based on supervised and semi-supervised learning methods depend on labeled datasets, which are often unavailable in real-world scenarios. While unsupervised methods have emerged as promising alternatives, these methods are highly susceptible to noise and outliers commonly present in sensing applications. Furthermore, deep learning-based anomaly detection methods, despite their performance, are often criticized for their black-box nature, limiting their applicability in safety-critical and online environments where interpretability and explainability are paramount. In this work, we propose an unsupervised anomaly clustering method leveraging a cyclic alignment-based offset detection algorithm for multivariate time-series signals. The proposed method is applied to multivariate data collected from vibrational, voltage, and magnetic field sensors deployed in a local grid substation. Our results demonstrate the robustness of the algorithm in accurately clustering various anomalies/events across different sensing modalities. Additionally, we compare the effectiveness of the proposed approach against a simple pattern-based anomaly detection method, which performs well for univariate data but fails to generalize to multivariate and multimodal time-series data.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2021

Event-Based Analysis of Solar Power Distribution Feeder Using Micro-PMU Measurements

Solar distribution feeders are commonly used in solar farms that are integrated into distribution substations. In this paper, we focus on a real-world solar distribution feeder and conduct an event-based analysis by using micro-PMU measurements. The solar distribution feeder of interest is a behind-the-meter solar farm with a generation capacity of over 4 MW that has about 200 low-voltage distributed photovoltaic (PV) inverters. The event-based analysis in this study seeks to address the following practical matters. First, we conduct event detection by using an unsupervised machine learning approach. For each event, we determine the event’s source region by an impedancebased analysis, coupled with a descriptive analytic method. We segregate the events that are caused by the solar farm, i.e., locallyinduced events, versus the events that are initiated in the grid, i.e., grid-induced events, which caused a response by the solar farm. Second, for the locally-induced events, we examine the impact of solar production level and other significant parameters to make statistical conclusions. Third, for the grid-induced events, we characterize the response of the solar farm; and make comparisons with the response of an auxiliary neighboring feeder to the same events. Fourth, we scrutinize multiple specific events; such as by revealing the dynamics to the control system of the solar distribution feeder. The results and discoveries in this study are informative to utilities and solar power industry.

14 SOLAR ENERGY↗
DOE OSTI2021

Chapter 22: Compressed Air Evaluation Protocol. The Uniform Methods Project: Methods for Determining Energy Efficiency Savings for Specific Measures (September 2011 - August 2020)

Compressed-air systems are used widely throughout industry for many operations, including pneumatic tools, packaging and automation equipment, conveyors, and other industrial process operations. Compressed-air systems are defined as a group of subsystems composed of air compressors, air treatment equipment, controls, piping, pneumatic tools, pneumatically powered machinery, and process applications using compressed air. A compressed-air system has three primary functional subsystems: supply, distribution, and demand. Air compressors are the primary energy consumers in a compressed-air system and are the primary focus of this protocol. The two compressed-air energy efficiency measures specifically addressed in this protocol are: high-efficiency/variable speed drive (VSD) compressor replacing modulating, load/unload, or constant-speed compressor; compressed-air leak survey and repairs. This protocol provides direction on how to reliably verify savings from these two measures using a consistent approach for each.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Demonstrate FARM supervisory capabilities for a thermal energy storage problem for the DETAIL facility: IES Simulation Ecosystem Control System Development

The goal of the power dispatch problem for an Integrated Energy System (IES) is to adjust the power output and the heat flow of each component to maximize the profitability of the whole unit. Facilities that can integrate real-time digital signals, mock nuclear power, thermal energy storage and industrial heat use via high-temperature electrolysis were constructed at INL to support the research activities. The Dynamic Energy Technology and Integration Laboratory (DETAIL) houses the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET) and the Thermal Energy Distribution System (TEDS). In this report, the hierarchical control system architecture proposed in June 2023 milestone for the flexible operation of DETAIL facility is finalized and demonstrated. A brief description of the components and the corresponding Dymola models from the HYRBID repository is first provided. Then, the current control strategy is presented. In particular, the approach for generating the set-point trajectories to be fed to the PI controllers is analyzed, and its limits were identified. To preserve safe operation over both long-time and real-time horizons, the integration of a Supervisory Control layer embedding a modified version of FARM (Feasible Actuator Range Modifier) module is proposed. FARM is a component of the RAVEN-based FORCE framework designed to support HERON module at optimizing the operation of IES units. The proposed control system for DETAIL foresees FARM to be applied twice, i.e., the original version (“FARM-Validator”) aiding the solution of the power dispatch problem, and a modified version (“FARM-Supervisory”) coordinating the PID controllers. Despite the kernel of the two modules is the same, their tasks are quite different. The former intervenes at the beginning of each hour to prevent constraint violations over long time periods, the latter addresses real-time control tasks and monitors the response of constrained variables at a much finer time resolution. A tentative procedure for training the embedded Digital Twins with the experimental data is also proposed. Finally, the capabilities of the designed architecture and the impact of the added Supervisory Control layer are demonstrated by simulating a representative power dispatch scenario.

25 ENERGY STORAGE↗
DOE OSTI2023

Grid Optimization Competition on Synthetic and Industrial Power Systems

This paper summarizes a grid optimization (GO) competition effort in the United States to find the best solution strategies for up to interconnect-scale power system networks with around 32,000 buses. The optimization problem is a mixedinteger, non-convex non-linear problem, (MINLP) and includes discrete variables such as unit commitment and line switching, control settings (transformer taps and phase shifters with impedance correction tables), and bus shunts. The case study includes six actual industry grids as well as 16 realistic synthetic grids created by three different dataset teams. The winners are selected and ranked based on scoring criteria, which consider the solution quality (such as objective functions) within time limits. Nine winner teams are selected from 26 competitor teams. The results achieved by different teams are described and the performance of different algorithms on synthetic grids and actual industry grids are compared and analyzed.

mixed-integer non-linear programming↗