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Results for “closed loop controls”

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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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Evaluation of automated stability testing in machining through closed-loop control and Bayesian machine learning

Here, this paper describes a system for automated identification of the optimal stable cutting parameters in milling through Bayesian machine learning and closed-loop control. The closed-loop control system consists of a process monitoring architecture, an analysis framework, and a feedback mechanism. The analysis framework consists of a Bayesian machine learning algorithm that learns a stability map given test results. The learned stability map is used to select parameters for stability testing using an expected improvement in the material removal rate criterion. The test parameters are communicated to the machine controller to complete the test cut through a feedback mechanism. The test cuts were monitored using an audio signal; the stability of the test cut was determined by analyzing the frequency content of the audio signal. The test result was fed back to the Bayesian learning algorithm to complete the loop. Experimental results demonstrate that the system can identify the optimal stable parameters without information about the cutting force model or the structural dynamics. The system provides a low-cost method for optimal stable parameter identification in an industrial environment.

Chatter↗
DOE OSTI2022

Closed-loop control of meltpool temperature in directed energy deposition

The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that closed-loop processed parts had a volume percent porosity ranging from 0.036% to 0.043%. In comparison, open-loop processed parts had a larger variation in volume percent porosity ranging from 0.032% to 0.068%. Further, parts built with closed-loop processing depicted consistent dendritic microstructure. By contrast, parts built with open-loop processing showed microstructure heterogeneity with the presence of both dendritic and planar grains, which in turn translated to large variation in microhardness

36 MATERIALS SCIENCE↗
DOE OSTI2025

Hot, Cold, or Just Right? Using a Wide-View Infrared Biometric Sensor to Improve Occupant Comfort and Reduce Overcooling in Buildings via Closed-loop Control (CRADA Final Report)

This research adds to the understanding of building energy management by fundamentally challenging the long-standing paradigm of controlling an environmental parameter—air temperature—and assuming occupant comfort will follow. The project developed and demonstrated a novel approach that directly senses physiological indicators of human comfort to enable closedloop, human-centric control of heating, ventilation, and air conditioning (HVAC) systems. This work shifts the focus from open-loop environmental control to a closed-loop system that prioritizes the occupants' actual thermal state. The primary benefit to the public is the potential for a simultaneous improvement in the quality of indoor environments, where people spend most of their time, and a significant reduction in national energy consumption. Overcooling, or the overuse of cooling energy in a way that discomforts occupants, wastes approximately 0.5 Quads of primary energy annually in U.S. commercial buildings and creates unproductive indoor environments.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Modelling a Heaving Point-Absorber with a Closed-Loop Control System Using the DualSPHysics Code

The present work addresses the need for an efficient, versatile, accurate and open-source numerical tool to be used during the design stage of wave energy converters (WECs). The device considered here is the heaving point-absorber developed and tested by Sandia National Laboratories. The smoothed particle hydrodynamics (SPH) method, as implemented in DualSPHysics, is proposed since its meshless approach presents some important advantages when simulating floating devices. The dynamics of the power take-off system are also modelled by coupling DualSPHysics with the multi-physics library Project Chrono. A satisfactory matching between experimental and numerical results is obtained for: (i) the heave response of the device when forced via its actuator; (ii) the vertical forces acting on the fixed device under regular waves and; (iii) the heave response of the WEC under the action of both regular waves and the actuator force. This proves the ability of the numerical approach proposed to simulate accurately the fluid–structure interaction along with the WEC’s closed-loop control system. In addition, radiation models built from the experimental and WAMIT results are compared with DualSPHysics by plotting the intrinsic impedance in the frequency domain, showing that the SPH method can be also employed for system identification.

42 ENGINEERING↗
DOE OSTI2024

Hot, cold, or just right? An infrared biometric sensor to improve occupant comfort and reduce overcooling in buildings via closed-loop control

To improve occupant comfort and save energy in buildings, we have developed a closed-loop air conditioning (AC) sensor-controller that predicts occupant thermal sensation from the thermographic measurement of skin temperature distribution, then uses this information to reduce overcooling (cooling-energy overuse that discomforts occupants) by regulating AC output. Taking measures to protect privacy, it combines thermal-infrared (TIR) and color (visible spectrum) cameras with machine vision to measure the skin-surface temperature profile. Since the human thermoregulation system uses skin blood flow to maintain thermoneutrality, the distribution of skin temperature can be used to predict warm, neutral, and cool thermal states. We conducted a series of human-subject thermal-sensation trials in cold-to-hot environments, measuring skin temperatures and recording thermal sensation votes. We then trained random-forest classification machine-learning models (classifiers) to estimate thermal sensation from skin temperatures or skin-temperature differences. The estimated thermal sensation was input to a proportional integral (PI) control algorithm for the AC, targeting a sensation level between neutral and warm. Our sensor-controller includes a sensor assembly, server software, and client software. The server software orients the cameras and transmits images to the client software, which in turn assesses occupant skin temperature distribution, estimates occupant thermal sensation, and controls AC operation. A demonstration conducted in a conference room in an office building near Houston, TX showed that our system reduced overcooling, decreasing AC load by 42% when the room was occupied while improving occupant comfort (fraction of “comfortable” votes) by 15 percentage points.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Closed-Loop Control of Active Nematic Flows

Stabilizing and shaping autonomous flows of active fluids is a fundamental challenge and a prerequisite for applications. We embed a light-responsive microtubule-based nematic in a proportional-integral control loop that adjusts the applied light intensity in response to real-time measurements of the spatially averaged flow speed. The self-regulating hardware-software-wetware system maintains a target flow speed against external or internal perturbations, including protein aging and aggregation, sample-to-sample variability, and temperature variation. Varying the controller’s gains reveals antagonistic roles between feedback and intrinsic processes, leading to nontrivial dynamics observed in fluctuation spectra. In particular, oscillations emerge from the interplay between the controller, motor binding kinetics, and active hydrodynamic relaxation. Accounting for the underlying binding timescale, our coarse-grained model and nematohydrodynamics simulations corroborate these observations. This work provides insight into the coupled dynamics of controlled active matter, laying the foundation for spatiotemporal patterning of active stress to generate and stabilize new dynamical configurations.

Active nematics↗
DOE OSTI2025

Closed-loop control of active nematic flows

Stabilizing and shaping autonomous flows of active fluids is a fundamental challenge and a prerequisite for applications. We embed a light-responsive microtubule-based nematic in a proportional-integral control loop that adjusts the applied light intensity in response to real-time measurements of the spatially averaged flow speed. The self-regulating hardware/software/wetware system maintains a target flow speed against external or internal perturbations, including protein aging and aggregation, sample-to-sample variability, and temperature variation. Varying the controller’s gains reveals antagonistic roles between feedback and intrinsic processes, leading to nontrivial dynamics observed in fluctuation spectra. In particular, oscillations emerge from the interplay between the controller, motor binding kinetics, and active hydrodynamic relaxation. Accounting for the underlying binding timescale, our coarse-grained model and nematohydrodynamics simulations corroborate these observations. This work provides insight into the coupled dynamics of controlled active matter, laying the foundation for spatiotemporal patterning of active stress to generate and stabilize new dynamical configurations.

Nishiyama, Katsu [Brandeis Univ., Waltham, MA (Uni↗
DOE OSTI2023

Apparatus and methods of detecting transient discharge modes and/or closed loop control of pulsed systems and method employing same

A system and method for differentiating between different modes of pulsed electrical discharges via of an amplitude to time (ATC) conversion circuit is described. A bipolar ATC circuit is used to add together the positive and negative portions of an attenuated and filtered signal derived either from the voltage or current of a pulse. Alternatively, a unipolar ATC circuit may be employed. The resulting processed signal is compared against a reference voltage to generate an output signal that is active for the amount of time that the processed signal exceeds the reference voltage. Discharge mode is determined based on three factors: did a pulse occur, if a pulse occurred when did the pulse start relative to the original pulse event, and what is the duty cycle of the pulse. Subsequent pulse generated may be controlled accordingly.

Fitzpatrick, Joseph F.↗
DOE OSTI2023

Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements

Aerosol jet printing is a compelling noncontact, digital manufacturing technology for flexible, hybrid, and conformal electronics, but batch‐to‐batch variability and process drift inhibit systematic study and translation to production environments. Emerging measurement techniques for the aerosol volume fraction, a key parameter governing deposition rate, have shown promise for real‐time response, including a recent demonstration of human‐in‐the‐loop control. By integrating improved light scattering measurements with custom software, a robust environment for real‐time monitoring is established and fully automated closed‐loop control over the deposition rate during printing is enabled. The physical basis for scattering measurements as a feedback source is examined and the quantitative insight this provides for ink development and fundamental process studies is highlighted. Three candidate process variables for closed‐loop control, namely the atomizer voltage, carrier gas flow rate, and print speed, are then evaluated. The atomizer voltage demonstrates the best extended duration validity because it addresses atomization variability directly, but carrier gas flow rate and print speed provide faster and more deterministic responses. This methodology is then demonstrated for electrical properties using a silver nanoparticle ink, maintaining 98% of printed patterns within 10% of the mean resistance value over 3 h of printing.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Hardware-in-Loop Modules for Testing Automated Ventilator Controllers

Automated ventilator controllers have the potential to simplify oxygen and carbon dioxide management for trauma. In the pre-hospital or military medicine environment, trauma care can be required for prolonged periods by personnel with limited ventilator management training. As such, there is a need for closed-loop control systems that can adapt ventilator management to a complex, ever-changing medical environment. Here, we present a novel hardware-in-loop test platform for the independent troubleshooting and evaluation of oxygen and carbon dioxide automated ventilator management capabilities. The oxygen management system provides an analogue blood oxygen signal that is responsive to the fraction of inspired oxygen and the peak inspiratory pressure ventilator settings. A tested oxygenation controller successfully reached the target oxygen saturation within 5 min. The carbon dioxide removal system integrates with commercial ventilator technology and mimics carbon dioxide generation, lung compliance, and airway resistance while providing an end-tidal carbon dioxide level that is responsive to changes in the tidal volume and respiratory rate settings. A test mechanical ventilator controller was able to regulate EtCO2 regardless of the starting value within 10 min. This highlights the system’s functionality and provides proof-of-concept demonstrations for how the hardware-in-loop test platforms can be used for evaluating closed-loop controller technologies.

Berard, David (ORCID:0000000322863846)↗
DOE OSTI2023

In-Situ Detection and Prediction of WAAM Cross Feature Geometry

Abstract Wire arc additive manufacturing (WAAM) is increasingly used by manufacturers due to its relatively low cost and high deposition rate compared to other metal AM methods, but the parts produced by WAAM can be subject to localized variations in part quality. One such variation is the cross-feature defect, whereby a localized part height increase occurs due to the crossing of deposition toolpaths. Mitigation of this defect is typically achieved using manual path planning strategies, but closed-loop control is underutilized. Since the nature of this defect and of the WAAM process is such that the previous layer’s geometry influences that of the subsequent layer’s, the cross-feature defect geometry changes throughout the deposition. Therefore, any closed-loop control strategy will need to incorporate the dynamic trait of this defect. The present work seeks to implement an in-situ process modeling approach where a regression model can be continuously updated to predict the defect geometry of the subsequent deposition layer based on the historical process data. Several multi-layer cross-feature geometries are deposited and current, voltage, and optical camera data is taken for each layer. The resulting cross-feature geometries are characterized using 3D scanning and the performance and accuracy of the in-situ modeling approach is evaluated.

Thien, Austen↗
DOE OSTI2025

Digital twin framework for PIP-II linac: AI-driven multi-scale modeling from ion source to 800 MeV

The PIP-II superconducting linac at Fermilab is designed to deliver multi-megawatt proton beams for neutrino physics and other high-intensity applications. To expedite commissioning and enhance operational reliability, we have developed an EPICS-based data flow framework that seamlessly integrates digital twins (DT) with physical twins (PT). These digital twins comprise high-fidelity beam dynamics models or data-driven surrogate models connected to their physical counterparts through real-time diagnostics and advanced machine-learning algorithms.Central to this framework is Linac_Gen, an accelerated simulation tool that incorporates convolutional neural networks, random forests, and genetic algorithms to provide up to a tenfold speedup in optimizing the accelerator geometry model. An EPICS translator layer ensures interoperability by efficiently mapping lattice parameters across diverse simulation platforms.Our EPICS-based framework supports multiple operational modes—monitoring, passive learning, closed-loop control, and online learning—covering the entire machine lifecycle. By leveraging HPC resources and multi-objective optimization techniques, the digital twin enables adaptive trajectory correction, real-time fault detection, and predictive modeling of beam stability. This comprehensive approach paves the way for robust, high-intensity operation and data-driven accelerator R&D at Fermilab.

Pathak, Abhishek [Fermilab]↗
DOE OSTI2020

Online Control of Process Variance Using Feedback

For many stochastic control problem formulations, design objectives typically include constraining the covariance of the outputs of the system. Recent engineering challenges have demonstrated an interest in controlling system output covariances to a setpoint. However, open-loop control of system output covariance can be exceptionally challenging when the system has significant plant uncertainties. This paper explores closed-loop control of the system’s output covariance using a windowed variance function. The stochastic nature of the windowed variance feedback means that root locus and other classical control design techniques cannot be immediately used. Expected value analysis is used to generate transfer functions for the average response of such systems, and the results are used to design controllers. Stochastic simulations are presented to verify the analytical results and make other observations concerning closed-loop variance control.

Bieniek, Mitchell↗
DOE OSTI2022

Machine Learning-based Cyber-Physical Anomaly Detection in Wide Area Voltage Control Systems

Wide-area voltage control systems (WAVCS) are widely deployed in power grid to improve the voltage stability in transmission system using Flexible AC Transmission System (FACTS) devices. The WAVCS relies on wide-area measurement and control signals for closed-loop control of FACTS devices to improve the transient voltage stability in power grid in real-time. Since the WAVCS utilizes a cyber-layer communication during its normal operation, they are susceptible to cyber attacks from adversaries which can lead to a voltage collapse if the attacks go undetected and unmitigated. This paper proposes a supervised machine learning (ML)-based anomaly detection algorithm for detecting various stealthy cyber attacks in the context of WAVCS cybersecurity. In particular, a fuzzy logic-based wide-area controller, as proposed by the Bonneville Power Administration (BPA), is implemented on the Kundur’s four machine two-area system that is integrated with a static var compensator (SVC) to improve voltage profile on sensitive buses. Later, different types of data integrity attacks, including pulse and ramp attacks, are considered on the wide-area measurement and control signals to analyze the performance of the proposed anomaly detector. Our experimental evaluation shows a promising performance with a high true-positive rate (more than 99%) and low false-negative rate (less than 1%) while exhibiting a small prediction time.

24 POWER TRANSMISSION AND DISTRIBUTION↗