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At least 19 records

Energy Efficient Material Processing through Automated Process Monitoring and Controls

Smart manufacturing is bound to play a crucial role in reducing global energy consumption while accelerating economic development. This phenomenon is evident in advanced sensing technology developments, data analytics and machine learning/AI, automated controls, cloud computing, etc. The immediate opportunity for smart manufacturing is to improve the energy efficiency of manufacturing operations through innovations in processes and controls. The manufacturing industry still consumes about 30% of total global energy production, which is significant. This program focused on the recommendation of heterogeneous sensors to monitor the Chemical Vapor Infiltration (CVI) process parameters, states, and key performance indices and utilize cloud computing to sort and analyze the real-time data. Learning through data analytics helps guide the control parameters affecting energy usage. The target process in the program is the CVI process at the Honeywell South Bend facility, which is one of the most energy-intensive manufacturing industries.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Integrating Cyber-Informed Engineering into Process Automation

As organizations increasingly automate their core missions and essential functions to address business risks and enhance efficiency, process automation becomes pivotal. This shift, involving minimal or no manual intervention, significantly impacts an organization's cyber-risk landscape. While automation drives efficiencies, it also introduces new cyber risks if not properly managed. Cyber-Informed Engineering (CIE) provides a proactive framework for managing these digital risks, enhancing cyber-resilience in process automation. This document supports organizations in applying CIE principles to mitigate the cyber risks associated with automation. The outlined approach can be independently implemented to improve any organization’s cyber-resilience, ensuring that the advantages of automation do not result in unaddressed or unmanaged digital risks. It serves as a starting point, offering considerations for integrating CIE principles and practices into organizational processes. CIE is presented as an iterative process, fostering continuous improvement and reinforcing the engineering and operational cultures to manage digital risks effectively. The document is structured as follows: Section 1 provides background on CIE and process automation, and their integration. Section 2 explores the twelve CIE principles in the context of process automation, highlighting key questions, engineering considerations, and implications for digital risk management. Section 3 synthesizes the findings and offers recommendations to advance resilience by design.

42 - ENGINEERING↗

Overview of the Process Automation and Control Group (E-3) [Slides]

Process Automation and Control (E-3) is a part of the Weapons Associate Laboratory Directorate (DDW) which includes Weapons Engineering Directorate (WE) and the Engineering Technology and Design (E) Division. There are three teams: Fabrication and Assembly, Process Controls, and Automation and Robotics. After an overview of the group, information is provided about an internship and how to apply.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Containerless automated processing of intermetallic compounds and composites

An automated containerless processing system has been developed to directionally solidify high temperature materials, intermetallic compounds, and intermetallic/metallic composites. The system incorporates a wide range of ultra-high purity chemical processing conditions. The utilization of image processing for automated control negates the need for temperature measurements for process control. The list of recent systems that have been processed includes Cr, Mo, Mn, Nb, Ni, Ti, V, and Zr containing aluminides. Possible uses of the system, process control approaches, and properties and structures of recently processed intermetallics are reviewed.

Johnson, D. R.↗

Workflow for Process Automation of Soil Gas Results from an Automated Soil Gas-Sampling System for Application in Carbon Storage Projects

Conference presentation at Geoconvention, Calgary, Alberta, Canada, May 12–14, 2025. The Energy & Environmental Research Center (EERC) developed an automated workflow for processing soil gas measurements collected from the automated soil gas-sampling systems deployed across the project site. Raw soil gas measurements are collected from each station every 4 hours and automatically uploaded to a cloud database. The workflow begins by writing code to download the data to a workstation automatically, then the data are published to an online dashboard that visualizes the measurements in time-series plots and a process-based decision-making framework. This automated workflow accelerates the time from data acquisition to decision-making. It supports carbon storage project operators by preparing and delivering a live, standardized dataset for quick analysis and source attribution to provide assurance of containment and overall permit compliance.

02 PETROLEUM↗

Workflow for Process Automation of Soil Gas Results from an Automated Soil Gas-Sampling System for Application in Carbon Storage Projects

Extended abstract for Geoconvention, Calgary, Alberta, Canada, May 12–14, 2025. The Energy & Environmental Research Center (EERC) developed an automated workflow for processing soil gas measurements collected from the automated soil gas-sampling systems deployed across the project site. Raw soil gas measurements are collected from each station every 4 hours and automatically uploaded to a cloud database. The workflow begins by writing code to download the data to a workstation automatically, then the data are published to an online dashboard that visualizes the measurements in time-series plots and a process-based decision-making framework. This automated workflow accelerates the time from data acquisition to decision-making. It supports carbon storage project operators by preparing and delivering a live, standardized dataset for quick analysis and source attribution to provide assurance of containment and overall permit compliance.

02 PETROLEUM↗

In‐mold rheology and automated process control for injection molding of recycled polypropylene

Abstract Manufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock. Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Krantz, Joshua↗

Automated Processing of ISIS Topside Ionograms into Electron Density Profiles

Modeling of the topside ionosphere has for the most part relied on just a few years of data from topside sounder satellites. The widely used Bent et al. (1972) model, for example, is based on only 50,000 Alouette 1 profiles. The International Reference Ionosphere (IRI) (Bilitza, 1990, 2001) uses an analytical description of the graphs and tables provided by Bent et al. (1972). The Alouette 1, 2 and ISIS 1, 2 topside sounder satellites of the sixties and seventies were ahead of their times in terms of the sheer volume of data obtained and in terms of the computer and software requirements for data analysis. As a result, only a small percentage of the collected topside ionograms was converted into electron density profiles. Recently, a NASA-funded data restoration project has undertaken and is continuing the process of digitizing the Alouette/ISIS ionograms from the analog 7-track tapes. Our project involves the automated processing of these digital ionograms into electron density profiles. The project accomplished a set of important goals that will have a major impact on understanding and modeling of the topside ionosphere: (1) The TOPside Ionogram Scaling and True height inversion (TOPIST) software was developed for the automated scaling and inversion of topside ionograms. (2) The TOPIST software was applied to the over 300,000 ISIS-2 topside ionograms that had been digitized in the fkamework of a separate AISRP project (PI: R.F. Benson). (3) The new TOPIST-produced database of global electron density profiles for the topside ionosphere were made publicly available through NASA s National Space Science Data Center (NSSDC) ftp archive at . (4) Earlier Alouette 1,2 and ISIS 1, 2 data sets of electron density profiles from manual scaling of selected sets of ionograms were converted fiom a highly-compressed binary format into a user-friendly ASCII format and made publicly available through nssdcftp.gsfc.nasa.gov. The new database for the topside ionosphere established as a result of this project, has stimulated a multitude of new studies directed towards a better description and prediction of the topside ionosphere. Marinov et al. (2004) developed a new model for the upper ion transition height (Oxygen to Hydrogen and Helium) and Bilitza (2004) deduced a correction term for the I N topside electron density model. Kutiev et al. (2005) used this data to develop a new model for the topside ionosphere scale height (TISH) as a function of month, local time, latitude, longitude and solar flux F10.7. Comparisons by Belehaki et al. (2005) show that TISH is in general agreement with scale heights deduced from ground ionosondes but the model predicts post-midnight and afternoon maxima whereas the ionosonde data show a noon maximum. Webb and Benson (2005) reported on their effort to deduce changes in the plasma temperature and ion composition from changes in the topside electron density profile as recorded by topside sounders. Limitations and possible improvements of the IRI topside model were discussed by Coisson et al. (2005) including also the possible use of the NeQuick model, Our project progressed in close collaboration and coordination with the GSFC team involved in the ISIS digitization effort. The digitization project was highly successful producing a large amount of digital topside ionograms. Several no-cost extensions of the TOPIST project were necessary to keep up with the pace and volume of the digitization effort.

Reinisch, bodo W.↗

Advanced Control Architecture and Sensor Information Development for Process Automation, Optimization, and Imaging of Chemical Looping Systems

The Syngas Chemical Looping (SCL) process developed at The Ohio State University (OSU) uses an iron-based oxygen carrier to convert syngas into high-purity hydrogen while simultaneously capturing carbon dioxide that is readily sequestrable. A 25 kWth sub-pilot unit was successfully demonstrated multiple times on the OSU Clean Coal Research Facility, and a 250 kWth – 3 MWth pilot demonstration unit has been designed and constructed at the National Carbon Capture Center (NCCC) in Wilsonville, Alabama. The focus of this project is to develop multiple technologies to automate the startup and shutdown of chemical looping system. Success of this project will propel the advanced carbon capture method toward commercialization, hence be disruptive to the fossil fuel and power industries. Advanced process automation control architecture and imaging and optimization sensor software were developed for OSU chemical looping process. A high-level controller (HLC) consisting of decision-making and controller-selection logic integrated with sliding mode controllers (SMCs) were developed to perform chemical looping process startup and shutdown. Babcock & Wilcox Power Generation Group’s FocalPoint Optimization System was implemented to optimize the process operating conditions. The process automation controller and optimization information were realized and tested on OSU’s existing sub-pilot chemical looping test unit under atmospheric condition. The implemented control architecture was able to perform the complete process procedure from startup, steady-state reaction operation to shutdown with minimal operator intervention. The controller was also implemented on the pressurized syngas chemical looping (SCL) pilot test unit constructed at the National Carbon Capture Center (NCCC), demonstrating its pressure control capability with a designed transient state trajectory. An electrical capacitance volume tomography (ECVT) sensor device and its software were developed to image the packed moving bed and slugging fluidized bed of oxygen carriers in chemical looping systems at elevated temperatures. The ECVT device constructed was capable of tracking the subtle voidage variance along the moving bed axis as a feature for directly measuring the oxygen carrier particles’ linear velocity. Also, the high temperature ECVT device was used to study the fluidization characteristics of Geldart Group D particles.

08 HYDROGEN↗

Automated Process Planning for Embossing and Functionally Grading Materials via Site-Specific Control in Large-Format Metal-Based Additive Manufacturing

The potential for site-specific, process-parameter control is an attribute of additive manufacturing (AM) that makes it highly attractive as a manufacturing process. The research interest in the functionally grading material properties of numerous AM processes has been high for years. However, one of the issues that slows developmental progress in this area is process planning. It is not uncommon for manual programming methods and bespoke solutions to be utilized for site-specific control efforts. This article presents the development of slicing software that contains a fully automated process planning approach for enabling through-thickness, process-parameter control for a range of AM processes. The technique includes the use of parent and child geometries for controlling the locations of site-specific parameters, which are overlayed onto unmodified toolpaths, i.e., a vector-based planning approach is used in which additional information, such as melt pool size for large-scale metal AM processes, is assigned to the vectors. This technique has the potential for macro- and micro-structural modifications to printed objects. A proof-of-principle experiment is highlighted in which this technique was used to generate dynamic bead geometries that were deposited to induce a novel surface embossing effect, and additional software examples are presented that highlight software support for more complex objects.

36 MATERIALS SCIENCE↗

CFD Process Automation Using Overset Grids

This talk summarizes three applications of the overset grid method for CFD using some level of automated grid generation, flow solution and post-processing. These applications are 2D high-lift airfoil analysis (INS2D code), turbomachinery applications (ROTOR2/3 codes), and subsonic transport wing/body configurations (OVERFLOW code). These examples provide a forum for discussing the advantages and disadvantages of overset gridding for use in an automated CFD process. The goals and benefits of the automation incorporated in each application will be described, as well as the shortcomings of the approaches.

Buning, Pieter G.↗

Development of an automated processing and screening system for the space shuttle orbiter flight test data

One nemesis of the structural dynamist is the tedious task of reviewing large quantities of data. This data, obtained from various types of instrumentation, may be represented by oscillogram records, root-mean-squared (rms) time histories, power spectral densities, shock spectra, 1/3 octave band analyses, and various statistical distributions. In an attempt to reduce the laborious task of manually reviewing all of the space shuttle orbiter wideband frequency-modulated (FM) analog data, an automated processing system was developed to perform the screening process based upon predefined or predicted threshold criteria.

Mccutchen, D. K.↗

Application of the informational reference system OZhUR to the automated processing of data from satellites of the Kosmos series

The structure and potential of the information reference system OZhUR designed for the automated data processing systems of scientific space vehicles (SV) is considered. The system OZhUR ensures control of the extraction phase of processing with respect to a concrete SV and the exchange of data between phases.The practical application of the system OZhUR is exemplified in the construction of a data processing system for satellites of the Cosmos series. As a result of automating the operations of exchange and control, the volume of manual preparation of data is significantly reduced, and there is no longer any need for individual logs which fix the status of data processing. The system Ozhur is included in the automated data processing system Nauka which is realized in language PL-1 in a binary one-address system one-state (BOS OS) electronic computer.

Pokras, V. M.↗

A system of automated processing of deep water hydrological information

An automated system for primary and scientific analysis of deep water hydrological information is presented. Primary processing of the data in this system is carried out on a drifting station, which also calculates the parameters of vertical stability of the sea layers, as well as their depths and altitudes. Methods of processing the raw data are described.

Romantsov, V. A.↗

An automated process sequence using preformed cell contacts and interconnects with a total cost of $0.64 per peak watt in 1986

A process sequence is described which utilizes a preformed metal mesh electrostatically bonded to each cell to provide the front contact. Cells of 12 percent AM1 efficiency have been produced using this scheme. This method also permits access to both contacts on the cell from the back side. In addition, low cost cell interconnection is accomplished using a flexible 'printed circuit' sheet which is ultrasonically bonded to the cell contacts. The complete process sequence as well as automated equipment which also uses ion implantation and pulse annealing is described. The total cost for module fabrication is estimated at $0.64 per peak watt for a 30 MW/year plant.

Armini, A. J.↗

Preliminary Evaluation of an Aviation Safety Thesaurus' Utility for Enhancing Automated Processing of Incident Reports

This document presents a preliminary evaluation the utility of the FAA Safety Analytics Thesaurus (SAT) utility in enhancing automated document processing applications under development at NASA Ames Research Center (ARC). Current development efforts at ARC are described, including overviews of the statistical machine learning techniques that have been investigated. An analysis of opportunities for applying thesaurus knowledge to improving algorithm performance is then presented.

Barrientos, Francesca↗

Pypromice: A Python Package for Processing Automated Weather Station Data

The pypromice Python package is for processing and handling observation datasets from automated weather stations (AWS). It is primarily aimed at users of AWS data from the Geological Survey of Denmark and Greenland (GEUS), which collects and distributes in situ weather station observations to the cryospheric science research community. Functionality in pypromice is primarily handled using two key open-source Python packages, xarray (Hoyer & Hamman, 2017) and pandas (The pandas development team, 2020). A defined processing workflow is included in pypromice for transforming original AWS observations (Level 0, L0) to a usable, CF-convention-compliant dataset (Level 3, L3) (Figure 1). Intermediary processing levels (L1,L2) refer to key stages in the workflow, namely the conversion of variables to physical measurements and variable filtering (L1), cross-variable corrections and user-defined data flagging and fixing (L2), and derived variables (L3). Information regarding the station configuration is needed to perform the processing, such as instrument calibration coefficients and station type (one-boom tripod or two-boom mast station design, for example), which are held in a toml configuration file. Two example configuration files are provided with pypromice , which are also used in the package’s unit tests. More detailed documentation of the AWS design, instrumentation, and processing steps are described in Fausto et al. (2021).

pypromice↗