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DOE OSTI2022

A Boundary Topology Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing

Minimizing the mass in electric machines while maintaining superior performance has become a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization for light-weighting electric machines using traditional approaches typically explore a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods like cell-based density approaches suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the IEA-15MW radial flux direct-drive wind turbine generator. The free-from boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with upto 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2022

A New Shape Optimization Approach for Lightweighting Electric Machines Inspired by Additive Manufacturing: Preprint

Minimizing the mass in electric machines while maintaining superior performance is a new requirement for the advancement of drivetrains used in wind energy and electric mobility. Topology optimization (TO) for lightweighting electric machines using traditional approaches typically explores a restricted design space allowed by standard parametrizable geometry and manufacturing, while advanced methods, such as cell-based density approaches, suffer from a lack of robust manufacturability constraints during the optimization process. To overcome these drawbacks, we explore a grid-independent, boundary TO where the outer shape of the magnet is parameterized using Bezier curves. We conduct a design of experiments (DOE) to study the effect of different magnet shapes on machine performance by varying the control points on the Bezier curves. A machine-learning-based surrogate model is constructed using the data from the DOE to quantify the relationship between the control points, air-gap torque, and mass. The control points are then optimized to maximize the torque density. The approach is used for minimizing electrical steel mass in the International Energy Agency (IEA) 15-MW radial flux direct-drive wind turbine generator. The free-form boundary TO resulted in smooth and concise shapes that can be easily additively manufactured with up to a 20-ton reduction in electrical steel mass.

additive manufacturing↗

DOE OSTI2023

Self-supervised learning of spatiotemporal thermal signatures in additive manufacturing using reduced order physics models and transformers

Microstructure control via additive manufacturing has enormous potential as manufacturers, materials scientists, and designers alike seek to exploit novel fabrication technologies to improve component performance. Recent works have demonstrated the feasibility of producing materials with controlled microstructures across various length scales. However, the experimental approach towards exploring the process-structure space can be laborious and costly. This is particularly true if also considering scan pattern optimization which is well suited for processes such as powder bed fusion electron beam melting. In this work we propose an approach for encoding additive manufacturing layer-wise thermal response signatures using self-supervised representation learning. Thermal simulations from a reduced order model are utilized to estimate the spatiotemporal response during printing. A machine learning framework, using video-transformers, is utilized to efficiently distill spatiotemporal patterns into a compact latent space representation. This latent state representation encodes the relevant physics which is then utilized to establish a data-driven process-structure model for an additively manufactured Ni-based superalloy. In conclusion, the proposed methodology could potentially be used towards in-situ process monitoring, scan pattern experimental design, and component qualification.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Controlling $H_{3}^{+}$ Formation From Ethane Using Shaped Ultrafast Laser Pulses

An adaptive learning algorithm coupled with 3D momentum-based feedback is used to identify intense laser pulse shapes that control $H_{3}^{+}$ formation from ethane. Specifically, we controlled the ratio of D 2 H + to $D_{3}^{+}$ produced from the D 3 C-CH 3 isotopologue of ethane, which selects between trihydrogen cations formed from atoms on one or both sides of ethane. We are able to modify the D 2 H + :$D_{3}^{+}$ ratio by a factor of up to three. In addition, two-dimensional scans of linear chirp and third-order dispersion are conducted for a few fourth-order dispersion values while the D 2 H + and $D_{3}^{+}$ production rates are monitored. The optimized pulse is observed to influence the yield, kinetic energy release, and angular distribution of the D 2 H + ions while the $D_{3}^{+}$ ion dynamics remain relatively stable. We subsequently conducted COLTRIMS experiments on C 2 D 6 to complement the velocity map imaging data obtained during the control experiments and measured the branching ratio of two-body double ionization. Two-body $D_{3}^{+}$ + $C_{2}D_{3}^{+}$ is the dominant final channel containing $D_{3}^{+}$ ions, although the three-body D + $D_{3}^{+}$ + $C_{2}D_{2}^{+}$ final state is also observed.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2022

Multi-fidelity information fusion with concatenated neural networks

Recently, computational modeling has shifted towards the use of statistical inference, deep learning, and other data-driven modeling frameworks. Although this shift in modeling holds promise in many applications like design optimization and real-time control by lowering the computational burden, training deep learning models needs a huge amount of data. This big data is not always available for scientific problems and leads to poorly generalizable data-driven models. This gap can be furnished by leveraging information from physics-based models. Exploiting prior knowledge about the problem at hand, this study puts forth a physics-guided machine learning (PGML) approach to build more tailored, effective, and efficient surrogate models. For our analysis, without losing its generalizability and modularity, we focus on the development of predictive models for laminar and turbulent boundary layer flows. In particular, we combine the self-similarity solution and power-law velocity profile (low-fidelity models) with the noisy data obtained either from experiments or computational fluid dynamics simulations (high-fidelity models) through a concatenated neural network. We illustrate how the knowledge from these simplified models results in reducing uncertainties associated with deep learning models applied to boundary layer flow prediction problems. The proposed multi-fidelity information fusion framework produces physically consistent models that attempt to achieve better generalization than data-driven models obtained purely based on data. While we demonstrate our framework for a problem relevant to fluid mechanics, its workflow and principles can be adopted for many scientific problems where empirical, analytical, or simplified models are prevalent. In line with grand demands in novel PGML principles, this work builds a bridge between extensive physics-based theories and data-driven modeling paradigms and paves the way for using hybrid physics and machine learning modeling approaches for next-generation digital twin technologies.

42 ENGINEERING↗

DOE OSTI2024

Third-integer Resonant Extraction Regulation System for Mu2e

A third-integer resonant slow extraction system is being developed for Fermilab's Delivery Ring to deliver protons to the upcoming Mu2e experiment. The timescale of the extraction (or spill) duration is 43 milliseconds, which is extremely short and unprecedented. Additionally, the experiment's strict and challenging requirements on the quality of the spill at this time scale has led to the development of a new Spill Regulation System (SRS) design. The SRS primarily consists of three components - slow regulation, fast regulation, and harmonic content suppressor. Contributions to the first two components of the SRS, i.e., Slow Regulation and Fast Regulation subsystems, will be presented in which new adaptive learning algorithm schemes for the slow regulation of the spill -- validated using particle tracking simulations -- shall be described. In addition to these novel methods for the enhancement of the spill regulation system, results of employing Machine Learning in enhancing the performance of the resonant extraction are also presented. At the forefront of applying ML techniques to solve non-linear accelerator control problems, this work includes optimizing the PID gains as well as the replacement of the traditional PID controller using Recurrent Neural Networks and Gated Recurrent Unit (GRU) ML models to achieve efficiencies greater than a PID controller. Cutting-edge on-going Reinforcement Learning efforts, including an actor-critic family of learning algorithms, to regulate the spill rate will be reviewed, as well as present analytical calculations pertaining the transit time of particles in a third-integer resonant extraction. Detailed numerical investigations and validations of such calculations, the model of which could be exported and reliably used in future analytical modeling of any resonant extraction, are discussed.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Outlook towards deployable continual learning for particle accelerators

Particle accelerators are high power complex machines. To ensure uninterrupted operation of these machines, thousands of pieces of equipment need to be synchronized, which requires addressing many challenges including design, optimization and control, anomaly detection and machine protection. With recent advancements, machine learning (ML) holds promise to assist in more advance prognostics, optimization, and control. While ML based solutions have been developed for several applications in particle accelerators, only few have reached deployment and even fewer to long term usage, due to particle accelerator data distribution drifts caused by changes in both measurable and non-measurable parameters. In this paper, we identify some of the key areas within particle accelerators where continual learning can allow maintenance of ML model performance with distribution drifts. Particularly, we first discuss existing applications of ML in particle accelerators, and their limitations due to distribution drift. Next, we review existing continual learning techniques and investigate their potential applications to address data distribution drifts in accelerators. By identifying the opportunities and challenges in applying continual learning, this paper seeks to open up the new field and inspire more research efforts towards deployable continual learning for particle accelerators.

43 PARTICLE ACCELERATORS↗

DOE OSTI2019

UX Focused Development Work During Recent ORNL EPICS-Based Instrument Control System Upgrade Projects

The importance of usability and easy-to-use user interfaces (UI) have been recognized across many domains. However, the user-friendliness of scientific experiment control systems often lags behind industry standards in the flourishing user experience (UX) field. Scientific control systems can certainly benefit from these new UX research methods and approaches. Recent instrument control system upgrade projects at the SNS and HFIR facilities at Oak Ridge National Laboratory demonstrate the effectiveness of UX focused development work, and further reveal the need for more utilization of such techniques coming from the UX field. The ongoing control system upgrades are targeting the key facility-level priority of higher scientific productivity, and UX is one of the important tools to help us achieve this priority. We will highlight research methods and practices, introduce our findings and deliverables, and share challenges and lessons learned in applying UX methods to scientific control systems.

Yao, Marie Xingxing↗

DOE OSTI2021

Learning Sequential Distribution System Restoration via Graph-Reinforcement Learning

We report a distribution service restoration algorithm as a fundamental resilient paradigm for system operators provides an optimally coordinated, resilient solution to enhance the restoration performance. The restoration problem is formulated to coordinate distribution generators and controllable switches optimally. A model-based control scheme is usually designed to solve this problem, relying on a precise model and resulting in low scalability. To tackle these limitations, this work proposes a graph-reinforcement learning framework for the restoration problem. We link the power system topology with a graph convolutional network, which captures the complex mechanism of network restoration in power networks and understands the mutual interactions among controllable devices. Latent features over graphical power networks produced by graph convolutional layers are exploited to learn the control policy for network restoration using deep reinforcement learning. The solution scalability is guaranteed by modeling distributed generators as agents in a multi-agent environment and a proper pre-training paradigm. Comparative studies on IEEE 123-node and 8500-node test systems demonstrate the performance of the proposed solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Insights and Impacts of Credentials: Energy Auditor, Quality Control Inspector, and Certification Updates

Join this session to learn about recent and upcoming Home Energy Professional credential and resource updates from the National Renewable Laboratory (NREL) in support of the U.S. Department of Energy's Weatherization Assistance Program (WAP). NREL staff will provide an in-depth overview of improvements to the EA and QCI certification schemes. Be prepared to provide feedback and share new ideas in pursuit of continuous improvement within WAP. These certifications are critical to ensuring the highest standards of quality, safety, and efficiency within the Weatherization Assistance Program, helping to elevate the skills of professionals and drive the program's overall success.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2011

2011 Quantum Control of Light & Matter Gordon Research Conference (July 31-August 5, 2011, Mount Holyoke College, South Hadley, MA)

Quantum control of light and matter is the quest to steer a physical process to a desirable outcome, employing constructive and destructive interference. Three basic questions address feasibility of quantum control: (1) The problem of controllability, does a control field exist for a preset initial and target state; (2) Synthesis, constructively finding the field that leads to the target; and (3) Optimal Control Theory - optimizing the field that carries out this task. These continue to be the fundamental theoretical questions to be addressed in the conference. How to realize control fields in the laboratory is an ongoing challenge. This task is very diverse viewing the emergence of control scenarios ranging from attoseconds to microseconds. How do the experimental observations reflect on the theoretical framework? The typical arena of quantum control is an open environment where much of the control is indirect. How are control scenarios realized in dissipative open systems? Can new control opportunities emerge? Can one null decoherence effects? An ideal setting for control is ultracold matter. The initial and final state can be defined more precisely. Coherent control unifies many fields of physical science. A lesson learned in one field can reflect on another. Currently quantum information processing has emerged as a primary target of control where the key issue is controlling quantum gate operation. Modern nonlinear spectroscopy has emerged as another primary field. The challenge is to unravel the dynamics of molecular systems undergoing strong interactions with the environment. Quantum optics where non-classical fields are to be generated and employed. Finally, coherent control is the basis for quantum engineering. These issues will be under the limelight of the Gordon conference on Quantum Control of Light and Matter.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2015

TU-B-304-01: The Aftermath of TG-142

Although published in 2009, the AAPM TG-142 report on accelerator quality assurance still proves a challenge for full clinical implementation. The choice of methodologies to satisfy TG-142 requirements is critical to a successful application. Understanding the philosophy of TG-142 can help in creating an institution-specific QA practice that is both efficient and effective. The concept of maintaining commissioned beam profiles is still found confusing. The physicist must also consider technologies not covered by TG-142 (i.e. arc therapy techniques). On the horizon is TG-198 report on implementing TG-142. Although the community still lacks a final TG-100 report, performing a failure-mode -and-effects analysis and statistical process control analysis to determine the institution-specific clinical impact of each TG-142 test may be useful for identifying trends for pro-active surveillance. Learning Objectives: To better understand the confusing and controversial aspects of TG-142. To understand what is still missing from TG-142 and how to account for these tests in clinical practice To describe which QA tests in TG-142 yield the largest potential clinical result if not discovered.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

TU-B-304-02: Quantitative FMEA of TG-142

60 APPLIED LIFE SCIENCES↗

DOE OSTI2015

TU-B-304-00: The Aftermath of TG-142

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Exploring far-from-equilibrium ultrafast polarization control in ferroelectric oxides with excited-state neural network quantum molecular dynamics

Ferroelectric materials exhibit a rich range of complex polar topologies, but their study under far-from-equilibrium optical excitation has been largely unexplored because of the difficulty in modeling the multiple spatiotemporal scales involved quantum-mechanically. To study optical excitation at spatiotemporal scales where these topologies emerge, we have performed multiscale excited-state neural network quantum molecular dynamics simulations that integrate quantum-mechanical description of electronic excitation and billion-atom machine learning molecular dynamics to describe ultrafast polarization control in an archetypal ferroelectric oxide, lead titanate. Far-from-equilibrium quantum simulations reveal a marked photo-induced change in the electronic energy landscape and resulting cross-over from ferroelectric to octahedral tilting topological dynamics within picoseconds. The coupling and frustration of these dynamics, in turn, create topological defects in the form of polar strings. The demonstrated nexus of multiscale quantum simulation and machine learning will boost not only the emerging field of ferroelectric topotronics but also broader optoelectronic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Online Learning of Effective Turbine Wind Speed in Wind Farms

To develop better wind farm controllers that can meet more complex objectives, methods of modeling the wind turbine wakes at low computational expense are needed. Gaussian process (GP) regression offers a computationally inexpensive framework for learning complex functions from noisy measurements with very few datapoints. In this work, an online learning approach is presented to learn the rotor-averaged wind velocity at downstream wind turbines with GPs, using the available datastream of wind field measurements and wind turbine control set-points. This framework can readily be integrated into model-based controls methods because the model a) is updated online at low computational expense, b) assumes a mathematically favorable Gaussian form, and c) explicitly quantifies the stochastic nature of the wake field so that the trade-off between exploration and exploitation, and the uncertainty in the prediction, can be utilized. We show that a GP-learned model can match true values with errors within 0.5% on average, with as few as 5 training data points.

Gaussian process↗

DOE OSTI2014

Field Test Results of Using a Nacelle-Mounted Lidar for Improving Wind Energy Capture by Reducing Yaw Misalignment (Presentation)

Presented at the Nordic Wind Power Conference on November 5, 2014. This presentation describes field-test campaigns performed at the National Wind Technology Center in which lidar technology was used to improve the yaw alignment of the Controls Advanced Research Turbine (CART) 2 and CART3 wind turbines. The campaigns demonstrated that whether by learning a correction function to the nacelle vane, or by controlling yaw directly with the lidar signal, a significant improvement in power capture was demonstrated.

17 WIND ENERGY↗

DOE OSTI2025

Performance Evaluation of Intelligent Solar Control Software Through Hardware-in-the-Loop (CRADA Final Report)

Recent research has highlighted the potential for solar to act as a zero-marginal-cost and zero-emission flexibility resource on the bulk power system when operated with advanced control systems. To increase the performance of these systems, leading technologies, including machine learning (ML) and hierarchical inverter set point allocation, have been developed by Latimer Controls, Inc. to estimate the headroom of large PV plants for grid operation and control; however, these technologies lack comprehensive validation under real-world application scenarios. Latimer Controls, Inc. received two voucher awards for research at a national laboratory from the Department of Energy American Made Solar Prize Round 6. The National Renewable Energy Laboratory (NREL) was selected to collaborate with Latimer staff to conduct a performance evaluation of Latimer PV control software. The NREL team will develop a hardware-in-the-loop (HIL) testbed to perform testing and validation of the Latimer PV control technology in a de-risked yet realistic testbed environment. Latimer and NREL worked together to analyze the test data, draw conclusions from the results, and disseminate the resulting scientific findings. In this CRADA work, we propose to test and validate the real-world application of the Latimer Control solution in an HIL environment. We evaluate the performance of different flexible solar technologies in responding to automatic generation control signals in a closed-loop fashion. In particular, a data-driven potential high limit (PHL) estimation is developed for large solar plants to accurately estimate their headroom so that they have fast and short-time regulation and control capability to participate in grid services and respond to grid signals in real time (e.g., AGC). This PHL estimation algorithm is embedded in a hardware power plant controller (PPC) and tested with an IEEE-39 bus system model developed in RTDS. To account for the varying cloud conditions and diverse inverter dispatches, we developed a 135-MW PV plant with detailed modeling of 27 individual PV modules and inverters using RTDS. The real-world communications used in such big plants, such as ModBus TCP/IP for inverter level and DNP3 for plant level, were developed to emulate the real-world applications in big PV plants. The ML-based PHL estimation method is tested under nine separate weather scenarios against the ‘reference-control’ solution, hereafter referred to as the baseline solution. The baseline method reserves a subset of inverters (reference group) to operate at their PHL at all times and dispatches only the remaining inverters (control group) at curtailed levels to fulfill the flexibility need. Despite being successfully piloted by NREL in California in 2017 and Chile in 2020, there exist two gaps in the state of the art to fully unlock the flexibility of PV plants: a. There is a trade-off between the PHL estimation accuracy and the flexibility range. b. There lacks granularity in the PHL estimation to capture the variation across inverters. The Latimer solution seeks to address these gaps by applying machine learning methods to improve PHL estimation accuracy while accounting for variability at every inverter. Performance metrics were taken from the 2023 Georgia Power CARES utility-scale RFP. The results demonstrate that the ML-based approach outperforms the traditional baseline method in PHL estimation accuracy for 7 of 9 scenarios. The average PHL error across the nine scenarios was 7.40% for the ML-based method, 2.06% less than the 9.46% PHL error average across scenarios that was exhibited by the baseline method. Additionally, the PHL error was below 5% for at least 95% of the testing interval for 3 of 9 tested intervals with the ML approach, whereas it did not achieve this metric for any of the baseline tests. Overall, simulation results indicate the superior performance of an ML-based approach compared to the conventional baseline reference-control approach, showcasing its potential to support grid stability and operational efficiency. This laboratory HIL testing using real PPC, representative power system simulation models in real-time with detailed PV plant and inverter models, and real-world communication protocols gives us confidence that this machine learning based PHL estimation algorithm works well in the hardware PPC and therefore de-risks future field commissioning. The end goal of this project is to advance grid technology to address the grid operation challenges brought by solar plant’s variability and uncertainties in power generation.

14 SOLAR ENERGY↗