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DOE OSTI2024

Malcolm Deployment Guide for Solar Power Generation Plants

This guide provides detailed instructions for deploying Malcolm in Solar Power Generation systems. It covers the deployment process, from understanding the network architecture of these systems to configuring network switches and Switched Port Analyzer (SPAN) ports or mirror ports or TAPs. The guide also includes best practices for deploying Hedgehog sensors, another critical component in these systems. Following this guide, users can enhance network visibility, improve their system’s security, and effectively troubleshoot common issues.

14 SOLAR ENERGY↗

NASA NTRS2000

Data Retrieval Algorithms for Validating the Optical Transient Detector and the Lightning Imaging Sensor

A linear algebraic solution is provided for the problem of retrieving the location and time of occurrence of lightning ground strikes from an Advanced Lightning Direction Finder (ALDF) network. The ALDF network measures field strength, magnetic bearing, and arrival time of lightning radio emissions. Solutions for the plane (i.e., no earth curvature) are provided that implement all of these measurements. The accuracy of the retrieval method is tested using computer-simulated datasets, and the relative influence of bearing and arrival time data an the outcome of the final solution is formally demonstrated. The algorithm is sufficiently accurate to validate NASA:s Optical Transient Detector and Lightning Imaging Sensor. A quadratic planar solution that is useful when only three arrival time measurements are available is also introduced. The algebra of the quadratic root results are examined in detail to clarify what portions of the analysis region lead to fundamental ambiguities in sc)iirce location, Complex root results are shown to be associated with the presence of measurement errors when the lightning source lies near an outer sensor baseline of the ALDF network. For arbitrary noncollinear network geometries and in the absence of measurement errors, it is shown that the two quadratic roots are equivalent (no source location ambiguity) on the outer sensor baselines. The accuracy of the quadratic planar method is tested with computer-generated datasets, and the results are generally better than those obtained from the three-station linear planar method when bearing errors are about 2 deg.

Koshak, W. J.↗

DOE OSTI2018

Automatic signal decoding and sensor stability of a 3-electrode mixed-potential sensor for NO x /NH 3 quantification

Sensors to detect mixtures of NO x /NH 3 are needed to monitor emissions of diesel automobiles where a selective catalytic reduction system uses an NH 3 mediated reaction to reduce NO x . We report on the application of a three electrode La 0.8 Sr 0.2 CrO 3 , Au 0.5 Pd 0.5 , Pt mixed potential sensor using yttria-stabilized-zirconia (YSZ) as a solid electrolyte to NO x /NH 3 sensing. Artificial neural networks were used to automatically decode the concentrations of NO x /NH 3 and errors of less than 15% are achieved. The optimal architecture for ANN decoding and the maximum density of training data points are also determined. The stability of the sensor was monitored by electrochemical impedance spectroscopy. The impedance associated with YSZ oxygen ion conduction and the electrochemical reactions at the three-phase interface are tracked for a period of over 100 days.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗

NASA NTRS2004

Optical Calibration Process Developed for Neural-Network-Based Optical Nondestructive Evaluation Method

A completely optical calibration process has been developed at Glenn for calibrating a neural-network-based nondestructive evaluation (NDE) method. The NDE method itself detects very small changes in the characteristic patterns or vibration mode shapes of vibrating structures as discussed in many references. The mode shapes or characteristic patterns are recorded using television or electronic holography and change when a structure experiences, for example, cracking, debonds, or variations in fastener properties. An artificial neural network can be trained to be very sensitive to changes in the mode shapes, but quantifying or calibrating that sensitivity in a consistent, meaningful, and deliverable manner has been challenging. The standard calibration approach has been difficult to implement, where the response to damage of the trained neural network is compared with the responses of vibration-measurement sensors. In particular, the vibration-measurement sensors are intrusive, insufficiently sensitive, and not numerous enough. In response to these difficulties, a completely optical alternative to the standard calibration approach was proposed and tested successfully. Specifically, the vibration mode to be monitored for structural damage was intentionally contaminated with known amounts of another mode, and the response of the trained neural network was measured as a function of the peak-to-peak amplitude of the contaminating mode. The neural network calibration technique essentially uses the vibration mode shapes of the undamaged structure as standards against which the changed mode shapes are compared. The published response of the network can be made nearly independent of the contaminating mode, if enough vibration modes are used to train the net. The sensitivity of the neural network can be adjusted for the environment in which the test is to be conducted. The response of a neural network trained with measured vibration patterns for use on a vibration isolation table in the presence of various sources of laboratory noise is shown. The output of the neural network is called the degradable classification index. The curve was generated by a simultaneous comparison of means, and it shows a peak-to-peak sensitivity of about 100 nm. The following graph uses model generated data from a compressor blade to show that much higher sensitivities are possible when the environment can be controlled better. The peak-to-peak sensitivity here is about 20 nm. The training procedure was modified for the second graph, and the data were subjected to an intensity-dependent transformation called folding. All the measurements for this approach to calibration were optical. The peak-to-peak amplitudes of the vibration modes were measured using heterodyne interferometry, and the modes themselves were recorded using television (electronic) holography.

Decker, Arthur J.↗

DOE OSTI2015

Data Release Report for Source Physics Experiments 2 and 3 (SPE-2 and SPE-3) Nevada National Security Site

The second Source Physics Experiment shot (SPE-2) was conducted in Nevada on October 25, 2011, at 1900:00.011623 Greenwich Mean Time (GMT). The explosive source was 997 kilograms (kg) trinitrotoluene (TNT) equivalent of sensitized heavy ammonium fuel oil (SHANFO) detonated at a depth of 45.7 meters (m). The third Source Physics Experiment shot (SPE-3) was conducted in Nevada on July 24, 2012, at 1800:00.44835 GMT. The explosive source was 905 kg TNT equivalent of SHANFO detonated at a depth of 45.8 m. Both shots were recorded by an extensive set of instrumentation that includes sensors both at near-field (less than 100 m) and far-field (100 m or greater) distances. The near-field instruments consisted of three-component accelerometers deployed in boreholes at 15, 46, and 55 m depths around the shot and a set of single-component vertical accelerometers on the surface. The far-field network was composed of a variety of seismic and acoustic sensors, including short-period geophones, broadband seismometers, three-component accelerometers, and rotational seismometers at distances of 100 m to 25 kilometers. This report coincides with the release of these data for analysts and organizations that are not participants in this program. This report describes the second and third Source Physics Experiment shots and the various types of near-field and far-field data that are available.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2015

Data Release Report for Source Physics Experiments 2 and 3 (SPE-2 and SPE-3) Nevada National Security Site

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Virtual sensing-enabled digital twin framework for real-time monitoring of nuclear systems leveraging deep neural operators

Abstract Real-time monitoring is a foundation of nuclear digital twin technology, crucial for detecting material degradation and maintaining nuclear system integrity. Traditional physical sensor systems face limitations, particularly in measuring critical parameters in hard-to-reach or harsh environments, often resulting in incomplete data coverage. Machine learning-driven virtual sensors offer a transformative solution by complementing physical sensors in monitoring critical degradation indicators. This paper introduces the use of Deep Operator Networks (DeepONet) to predict key thermal-hydraulic parameters in the hot leg of pressurized water reactor. DeepONet acts as a virtual sensor, mapping operational inputs to spatially distributed system behaviors without requiring frequent retraining. Our results show that DeepONet achieves low mean squared and Relative L2 error, making predictions 1400 times faster than traditional CFD simulations . These characteristics enable DeepONet to function as a real-time virtual sensor, synchronizing with the physical system to track degradation conditions and provide insights within the digital twin framework for nuclear systems.

Hossain, Raisa↗

NASA NTRS2004

An Architecture for Intelligent Systems Based on Smart Sensors

Based on requirements for a next-generation rocket test facility, elements of a prototype Intelligent Rocket Test Facility (IRTF) have been implemented. A key component is distributed smart sensor elements integrated using a knowledgeware environment. One of the specific goals is to imbue sensors with the intelligence needed to perform self diagnosis of health and to participate in a hierarchy of health determination at sensor, process, and system levels. The preliminary results provide the basis for future advanced development and validation using rocket test stand facilities at Stennis Space Center (SSC). We have identified issues important to further development of health-enabled networks, which should be of interest to others working with smart sensors and intelligent health management systems.

Schmalzel, John↗

NASA NTRS1989

A design philosophy for multi-layer neural networks with applications to robot control

A system is proposed which receives input information from many sensors that may have diverse scaling, dimension, and data representations. The proposed system tolerates sensory information with faults. The proposed self-adaptive processing technique has great promise in integrating the techniques of artificial intelligence and neural networks in an attempt to build a more intelligent computing environment. The proposed architecture can provide a detailed decision tree based on the input information, information stored in a long-term memory, and the adapted rule-based knowledge. A mathematical model for analysis will be obtained to validate the cited hypotheses. An extensive software program will be developed to simulate a typical example of pattern recognition problem. It is shown that the proposed model displays attention, expectation, spatio-temporal, and predictory behavior which are specific to the human brain. The anticipated results of this research project are: (1) creation of a new dynamic neural network structure, and (2) applications to and comparison with conventional multi-layer neural network structures. The anticipated benefits from this research are vast. The model can be used in a neuro-computer architecture as a building block which can perform complicated, nonlinear, time-varying mapping from a multitude of input excitory classes to an output or decision environment. It can be used for coordinating different sensory inputs and past experience of a dynamic system and actuating signals. The commercial applications of this project can be the creation of a special-purpose neuro-computer hardware which can be used in spatio-temporal pattern recognitions in such areas as air defense systems, e.g., target tracking, and recognition. Potential robotics-related applications are trajectory planning, inverse dynamics computations, hierarchical control, task-oriented control, and collision avoidance.

Vadiee, Nader↗

DOE OSTI2017

Data Release Report for Source Physics Experiment 4Prime (SPE-4Prime) Nevada National Security Site (Revision 1)

The fourth test in the Source Physics Experiment series (SPE-4Prime) was conducted at a granite site in Nevada on May 21, 2015, at 18:35:44.000,003,989 ± 20 nanoseconds Coordinated Universal Time. The explosive source was 69.1 kilograms (kg) (including detonator assembly) of Composition C4 plastic explosive (89.14 kg TNT equivalent) detonated at a depth of 87.2 meters (m). The explosion was recorded by an extensive set of instrumentation that includes sensors both at near-field (less than 100 m) and far-field (100 m or greater) distances. The near-field instruments consisted of three-component accelerometers installed at various depths from 7 to 99 m in boreholes positioned around the source hole, and a set of single-component vertical accelerometers on the surface. The far-field network was composed of a variety of seismic and acoustic sensors, including short-period geophones, broadband seismometers, and three-component accelerometers at distances of 100 m to 25 kilometers. Infrasound data were collected from ground-based sensor arrays at distances out to 5 kilometers. This revised document includes a new Section 3.2.2, which is a discussion of clock timing issues discovered at four far-field stations.

58 GEOSCIENCES↗

DOE OSTI2017

Data Release Report for Source Physics Experiment 4Prime (SPE-4Prime) Nevada National Security Site

58 GEOSCIENCES↗

NASA NTRS2005

An Analysis of Peak Wind Speed Data from Collocated Mechanical and Ultrasonic Anemometers

This study focuses on a comparison of peak wind speeds reported by mechanical and ultrasonic anemometers at Cape Canaveral Air Force Station and Kennedy Space Center (CCAFS/KSC) on the east central coast of Florida and Vandenberg Air Force Base (VAFB) on the central coast of California. The legacy mechanical wind instruments on CCAFS/KSC and VAFB weather towers are being changed from propeller-and-vane (CCAFS/KSC) and cup-and-vane (VAFB) sensors to ultrasonic sensors under the Range Standardization and Automation (RSA) program. The wind tower networks on KSC/CCAFS and VAFB have 41 and 27 towers, respectively. Launch Weather Officers, forecasters, and Range Safety analysts at both locations need to understand the performance of the new wind sensors for a myriad of reasons that include weather warnings, watches, advisories, special ground processing operations, launch pad exposure forecasts, user Launch Commit Criteria (LCC) forecasts and evaluations, and toxic dispersion support. The Legacy sensors measure wind speed and direction mechanically. The ultrasonic RSA sensors have no moving parts. Ultrasonic sensors were originally developed to measure very light winds (Lewis and Dover 2004). The technology has evolved and now ultrasonic sensors provide reliable wind data over a broad range of wind speeds. However, because ultrasonic sensors respond more quickly than mechanical sensors to rapid fluctuations in speed, characteristic of gusty wind conditions, comparisons of data from the two sensor types have shown differences in the statistics of peak wind speeds (Lewis and Dover 2004). The 45th Weather Squadron (45 WS) and the 30 WS requested the Applied Meteorology Unit (AMU) to compare data from RSA and Legacy sensors to determine if there are significant differences in peak wind speed information from the two systems.

Short, David A.↗

DOE OSTI2019

Data Release Report Source Physics Experiments 5 and 6 (SPE-5 and SPE-6), Nevada National Security Site

The fifth Source Physics Experiment test (SPE-5) was conducted in Nevada on April 26, 2016, at 20:49:00 Coordinated Universal Time (UTC). The explosive source was 4,288.7 kilograms (kg) of polymer-bonded explosive (PBXN) –110, equivalent to 5,035 kg of trinitrotoluene (TNT) detonated at a depth of 76.5 meters (m). The sixth Source Physics Experiment test (SPE-6) was conducted in Nevada on October 12, 2016 at 18:36:00 UTC. The explosive source was 1,982.2 kg of PBXC-141, equivalent to 2,240.2 kg of TNT detonated at the depth of 31.4 m. Both tests were recorded by an extensive set of instrumentation that includes sensors both at near-field (less than 100 m) and far-field (100 m or greater) distances. The near-field instruments consisted of three-component accelerometers installed at various depths ranging from 4 to 99 m below ground surface in boreholes positioned around the shot, and a set of single-component vertical accelerometers on the surface. The far-field network was composed of a variety of seismic and acoustic sensors, including short-period geophones, broadband seismometers, and three-component accelerometers at distances of 100 m to 400 kilometers. In addition, both explosions were recorded in a temporary array of 996 geophones arranged in a densely spaced grid pattern (“large N”). This report coincides with the release of these data for analysts and organizations that are not participants in this program. This report describes the fifth and sixth Source Physics Experiment tests and the various types of near-field and far-field data that are available.

58 GEOSCIENCES↗

DOE OSTI2023

Designing an Intrusion Detection for an Adjustable Speed Drive System Controlling a Critical Process

In this article, we address the cyber-security problem of industrial control systems (ICSs) when their sensor measurements may be compromised due to an attacker who has intercepted those measurements via a network. We introduce a general-purpose method “Dynamic Watermarking (DW)” to detect potential cyber-intrusions on speed sensor measurements within industrial control systems, which deploy an adjustable speed drive (ASD) to control a critical process. The DW method is injecting a random private low-amplitude signal with a zero mean Gaussian distribution, “watermark”, into one of the input phase voltages powering the ASD system. The watermark signal propagates through the system including pulse width modulation (PWM) power conversion stage and motor, then ultimately appears in the speed sensor measurements. By deploying two statistical DW tests with two proper thresholds, the system can detect potential cyber-intrusions or unobservable cyber-attacks such as replay attacks and false data injection attacks (FDIA). The DW method tested on a laboratory-scale ASD system experimentally to protect the system against cyber-intrusions. This system, powered by a commercial PWM drive operating at 208 V, 3-phase, and 3.7 kW, served as our experimental platform.

42 ENGINEERING↗

DOE OSTI2023

Retina-inspired narrowband perovskite sensor array for panchromatic imaging

The retina is the essential part of the human visual system that receives light, converts it to neural signal, and transmits to brain for visual recognition. The red, green, and blue (R/G/B) cone retina cells are natural narrowband photodetectors (PDs) sensitive to R/G/B lights. Connecting with these cone cells, a multilayer neuro-network in the retina provides neuromorphic preprocessing before transmitting to brain. Inspired by this sophistication, we develop the narrowband (NB) imaging sensor combining R/G/B perovskite NB sensor array (mimicking the R/G/B photoreceptors) with a neuromorphic algorithm (mimicking the intermediate neural network) for high-fidelity panchromatic imaging. Compared to commercial sensors, we use perovskite “intrinsic” NB PD to exempt the complex optical filter array. In addition, we use an asymmetric device configuration to collect photocurrent without external bias, enabling a power-free photodetection feature. These results display a promising design for efficient and intelligent panchromatic imaging.

42 ENGINEERING↗

NASA NTRS1990

Planning for execution monitoring on a planetary rover

A planetary rover will be traversing largely unknown and often unknowable terrain. In addition to geometric obstacles such as cliffs, rocks, and holes, it may also have to deal with non-geometric hazards such as soft soil and surface breakthroughs which often cannot be detected until rover is in imminent danger. Therefore, the rover must monitor its progress throughout a traverse, making sure to stay on course and to detect and act on any previously unseen hazards. Its onboard planning system must decide what sensors to monitor, what landmarks to take position readings from, and what actions to take if something should go wrong. The planning systems being developed for the Pathfinder Planetary Rover to perform these execution monitoring tasks are discussed. This system includes a network of planners to perform path planning, expectation generation, path analysis, sensor and reaction selection, and resource allocation.

Gat, Erann↗

DOE OSTI2024

A multiscale anisotropic polymer network model coupled with phase field fracture

The study of polymers has continued to gain substantial attention due to their expanding range of applications, spanning essential engineering fields to emerging domains like stretchable electronics, soft robotics, and implantable sensors. These materials exhibit remarkable properties, primarily stemming from their intricate polymer chain network, which, in turn, increases the complexity of precisely modeling their behavior. Especially for modeling elastomers and their fracture behavior, accurately accounting for the deformations of the polymer chains is vital for predicting the rupture in highly stretched chains. Despite the importance, many robust multiscale continuum frameworks for modeling elastomer fracture tend to simplify network deformations by assuming uniform behavior among chains in all directions. Recognizing this limitation, our study proposes a multiscale fracture model that accounts for the anisotropic nature of elastomer network responses. At the microscale, damage in the chains is assumed to be driven by both the chain's entropy and the internal energy due to molecular bond distortions. In order to bridge the stretching in the chains to the macroscale deformation, we employ the maximal advance path constraint network model, inherently accommodating anisotropic network responses. As a result, chains oriented differently can be predicted to exhibit varying stretch and, consequently, different damage levels. To drive macroscale fracture based on damages in these chains, we utilize the micromorphic regularization theory, which involves the introduction of dual local-global damage variables at the macroscale. The macroscale local damage variable is obtained through the homogenization of the chain damage values, resulting in the prediction of an isotropic material response. The macroscale global damage variable is subjected to nonlocal effects and boundary conditions in a thermodynamically consistent phase field continuum formulation. Moreover, the total dissipation in the system is considered to be mainly due to the breaking of the molecular bonds at the microscale. To validate our model, we employ the double-edge notched tensile test as a benchmark, comparing simulation predictions with existing experimental data. Additionally, to enhance our understanding of the fracturing process, we conduct uniaxial tensile experiments on a square film made up of polydimethylsiloxane (PDMS) rubber embedded with a hole and notches and then compare our simulation predictions with the experimental observations. Furthermore, we visualize the evolution of stretch and damage values in chains oriented along different directions to assess the predictive capacity of the model. In conclusion, the results are also compared with another existing model to evaluate the utility of our model in accurately simulating the fracture behavior of rubber-like materials.

42 ENGINEERING↗