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Results for “network closed-loop control”

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 OSTI2023

Model Predictive Control for Urban Traffic Signals with Stability Guarantees

Traditional traffic signal control focuses more on the optimization aspects whereas the stability and robustness of the closed-loop system are less studied. This paper aims to establish the stability properties of traffic signal control systems through the analysis of a practical model predictive control (MPC) scheme, which models the traffic network with the conservation of vehicles based on a store-and forward model and attempts to balance the traffic densities. More precisely, this scheme guarantees the exponential stability of the closed-loop system under state and input constraints when the inflow is feasible and traffic demand can be fully accessed. Practical exponential stability is achieved in case of small uncertain traffic demand by a modification of the previous scheme. Simulation results of a small-scale traffic network validate the theoretical analysis.

ADVANCED PROPULSION SYSTEMS,MATHEMATICS AND COMPUT↗
DOE OSTI2024

Isolating Signatures of Cyberattacks under Stressed Grid Conditions

In a controlled cyber-physical network, such as a power grid, any malicious data injection in the sensor measurements can lead to widespread impact due to the actions of the closed-loop controllers. While fast identification of the attack signatures is imperative for reliable operations, it is challenging to do so in a large dynamical network with tightly coupled nodes. A particularly challenging scenario arises when the cyberattacks are strategically launched during a grid stress condition, caused by non-malicious physical disturbances.

Ghosh, Sanchita [BATTELLE (PACIFIC NW LAB)]↗
DOE OSTI2023

Deployment of Dynamic Neural Network Optimization to Minimize Heat Rate During Ramping for Coal Power Plants (Final Technical Report)

Much success was achieved throughout the course of this project. A successful implementation of Dynamic Neural Network Optimization (D-NNO) was coupled with Adaptive Predictive Controls (APC) and a novel hardware installation comprised of an advanced sensor network (ASN) measuring mass-weighted averages of flue gas constituents above the horizontal superheater of a coal-fired utility boiler. From 2019 through 2023 (including an extension due to COVID delays), the team was able to prototype, evaluate, deploy, iterate, and ultimately finalize an advanced closed-loop control D-NNO system which demonstrated the ability to: •improve unit efficiency ~2.0% relative to unoptimized operation (represented as total fuel fired per MWh generated) •improve unit NOx emission rates 10%+ beyond static optimization baselines •improve unit temperature stability as much as 58% and on average 12% •improve operating load stability as much as 35% The culmination of this project has generated an advanced methodology of deploying specially designed recurrent neural networks (long short-term memory, gated recurrent unit, encoder-decoder networks, transformers, etc.), customized trajectory planning and closed-loop optimization modules capable of adapting to live electric grid responses and demands, self-tuning and adaptive expert controls constantly adjusting prediction parameters to real-time unit behavior, and a hardware/software package able to reliably calculate net unit heat rate (NUHR) in real-time using flue gas constituents, machine learning, and known combustion relationships. Through this real-time NUHR value, immediate feedback on system adjustments relative to operating efficiency was available, allowing for rapid improvements to system performance. In addition to development and deployment of the advanced D-NNO system, the approach methodology has been readily commercialized through the project platform Griffin Open Systems, LLC, the D-NNO software platform host. Similar methodologies to those developed by this project have already been deployed at 5 other units across the United States, with another 6 implementations scheduled, and more expected. Over the course of the project, multiple academic papers were submitted and accepted for publication within esteemed academic journals, and PhD students were trained and graduated, as well as undergraduate students becoming involved and participating to project objectives.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Chapter 7: Learning Stable Local Volt/Var Controllers in Distribution Grids

This chapter describes a framework to synthesize provably stable local Volt/Var controllers for distributed energy resources (DERs) in power distribution grids (DGs). The goal is to control the reactive power injections of DERs to improve the system performance as quantified by a generic optimal reactive power flow (ORPF) problem. To achieve this, we jointly design for each DER the control function, which prescribes the reactive power update rule, and the equilibrium function, which approximates the ORPF solutions from local measurements of voltages and powers. We provide conditions on the equilibrium functions and the control parameters ensuring the stability of the closed-loop system. In particular, we discuss the trade-offs between each set of conditions accounting for practical considerations, like fully exploiting the DERs' generation capabilities and reducing the optimality gap. These conditions are then translated into learning constraints on the neural networks' parameters that are enforced in the training phase. We validate our framework with numerical simulations on the IEEE 37-bus network and through a comparison with an optimized version of standard piece wise linear control rules.

closed-loop asymptotic stability↗
DOE OSTI2022

Dynamic machine learning-based optimization algorithm to improve boiler efficiency

With decreasing computational costs, improvement in algorithms, and the aggregation of large industrial and commercial datasets, machine learning is becoming a ubiquitous tool for process and business innovations. Machine learning is still lacking applications in the field of dynamic optimization for real-time control. This work presents a novel framework for performing constrained dynamic optimization using a recurrent neural network model combined with a metaheuristic optimizer. The framework is designed to augment an existing control system and is purely data-driven, like most industrial Model Predictive Control applications. Several recurrent neural network models are compared as well as several metaheuristic optimizers. Hyperparameters and optimizer parameters are tuned with parameter sweeps, and the resulting values are reported. Further, the best parameters for each optimizer and model combination are demonstrated in closed-loop control of a dynamic simulation, and several recommendations are made for generalizing this framework to other systems. Up to 0.953% improvement is realized over the non-optimized case for a simulated coal-fired boiler. While this is not a large improvement in percentage, the total economic impact is $991,000 per year, and this study builds a foundation for future machine learning with dynamic optimization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Optimisation of the Kaplan hydropower system via PID 2 and digital twin

Here, this paper proposes a proportional–integral-double–derivative (PID 2 ) optimisation method for the Kaplan hydropower system by building a digital twin. The study first uses one multilayer perceptron (MLP) to model the hydroturbine dynamic and then adopts three connected MLPs to model the generator dynamic, both in an open-loop fashion. Inspired by stochastic distribution control (SDC) theory, we regard the training of the turbine's neural network model as a process control problem, and we propose minimising entropy loss to update the network parameters. The next step is to build the digital twin by connecting the neural network models with a PID 2 controller and a lead-lag exciter and run the whole model in a closed-loop fashion. After that, a binary search approach is applied to optimise the PID 2 parameters based on the obtained digital twin model. The simulation results show that the proposed method can reduce the mean square tracking error by more than 90%. Furthermore, the method is extended to jointly optimise the PID 2 controller and excitation system gains through multiobjective optimisation, leveraging Pareto frontier analysis to balance active power and voltage tracking performance. Simulation results confirm the effectiveness of the proposed method, achieving a 83.46% reduction in relative mean square error of active power, a 47.13% reduction in terminal voltage tracking error, and an 82.78% improvement in the overall scalarized objective.

Hydropower system↗
DOE OSTI2024

Effects of input gradient regularization on neural networks time-series forecasting of thermal power systems

This study proposes using neural networks, specifically gated recurrent unit (GRU), long-short-term memory (LSTM), and transformer networks, to improve control strategies in a 450 MW coal-fired power plant. However, neural networks face issues of becoming overly dependent on just a few variables to make predictions, which negatively impacts control decisions that rely on the model to determine the value of all manipulated variables. The paper introduces regularization techniques, including noise injection and input gradient regularization, during the training phase. Here, the work presents novel contributions in adapting neural networks to control industrial systems and applying regularization techniques from computer vision to industrial process control. Results demonstrate the effectiveness of input gradient regularization in reducing model dependence on subsets of variables, emphasizing the balance between fidelity and controllability. Further exploration is recommended, including the development of recurrent transformers, closed-loop control testing, and a sensitivity analysis on computer models to provide further insight.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2023

Machine Learning-Based Model Predictive Control of Two-Time-Scale Systems

In this study, we present a general form of nonlinear two-time-scale systems, where singular perturbation analysis is used to separate the dynamics of the slow and fast subsystems. Machine learning techniques are utilized to approximate the dynamics of both subsystems. Specifically, a recurrent neural network (RNN) and a feedforward neural network (FNN) are used to predict the slow and fast state vectors, respectively. Moreover, we investigate the generalization error bounds for these machine learning models approximating the dynamics of two-time-scale systems. Next, under the assumption that the fast states are asymptotically stable, our focus shifts toward designing a Lyapunov-based model predictive control (LMPC) scheme that exclusively employs the RNN to predict the dynamics of the slow states. Additionally, we derive sufficient conditions to guarantee the closed-loop stability of the system under the sample-and-hold implementation of the controller. A nonlinear chemical process example is used to demonstrate the theory. In particular, two RNN models are constructed: one to model the full two-time-scale system and the other to predict solely the slow state vector. Both models are integrated within the LMPC scheme, and we compare their closed-loop performance while assessing the computational time required to execute the LMPC optimization problem.

97 MATHEMATICS AND COMPUTING↗
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 OSTI2022

Life Cycle Assessment for Closed-Loop Pumped Hydropower Energy Storage in the United States

The federal government has initiated an aggressive set of policies to achieve a net-zero carbon emission goal for the electricity sector by 2050. As a result, rapid growth in deployment of renewable energy technologies is expected. Most commercially mature technologies are temporally variable and do not provide grid inertia, while renewable technologies with high projected deployment have intermittent generation methods. Energy storage technologies are needed to both dispatch power on-demand and help provide the needed grid inertia. Pumped storage hydro (PSH) is a well-established technology that has gained renewed interest in recent years offering energy-balancing, grid stability, control of electrical network frequency, and large-scale storage capacity. For widespread adoption of PSH, more information is needed regarding its current life cycle environmental impacts. The objective of this study is to perform a full life cycle assessment (LCA) of new closed-loop PSH in the U.S. The functional unit for this study is 1 kWh of electrical power delivered to the grid and the base case project lifetime is 80 years. The life cycle inventory for this project accounts for all material and energy flows associated with the green-field construction, operation, maintenance, and decommissioning of a closed-loop PSH plant in the U.S. Collected data represents a range of potential PSH specifications and geographic locations coming from all prospective closed-loop PSH installations in the U.S. with data available. In addition, existing PSH installations are used to provide assumptions for inventory inputs. Results presented will include the global warming potential (GWP IPCC 100a) and Energy Return on Investment (EROI) from our base case (average PSH installation) as well as from scenario analyses and model sensitivity. These results will be compared to the impacts from existing PSH sites and alternate storage technologies. Methods align with the assumptions and guidelines put in place by previous PSH LCAs to ensure an accurate comparison with the results from this report.

ENERGY PLANNING, POLICY, AND ECONOMY,HYDRO ENERGY↗
DOE OSTI2023

Machine learning-based ethylene and carbon monoxide estimation, real-time optimization, and multivariable feedback control of an experimental electrochemical reactor

Electrochemical reduction of CO 2 gas is a novel CO 2 utilization technique that has the potential to mitigate the global climate crisis caused by anthropogenic CO 2 emissions, and enable the large-scale storage of energy generated from renewable sources in the form of carbon-based chemicals and fuels. However, due to the complexity of the electrochemical reactions, the explicit first-principles models for CO2 reduction are not available yet, and there has been a limited effort to develop process modeling, optimization and control of CO 2 electrochemical reactors. To this end, a rotating cylinder electrode (RCE) reactor has been constructed at UCLA to understand the mass transfer and reaction kinetics effects separately on the productivity. In the RCE reactor, the applied potential strongly influences the reaction energetics and the electrode rotation speed affects the hydrodynamic boundary layer and modifies the film mass transfer coefficient, which involves convective and diffusive transport. Further, the present work aims to develop a multi-input multi-output (MIMO) control scheme for the RCE reactor that integrates techniques from artificial and recurrent neural network modeling, nonlinear optimization, and process controller design. Specifically, production rates of two products from the experimental reactor, ethylene and carbon monoxide, are controlled by manipulating two inputs, applied potential and catalyst rotation speed. Process dynamics and controllability are analyzed, a feedback control strategy is designed and the controllers are tuned accordingly. The experimental electrochemical cell is employed to gather data for process modeling and implement the multivariable control system. Finally, the experimental results are presented which demonstrate excellent closed-loop performance by the control system and regulation of the outputs at three different set-points including an economically-optimal set-point.

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

Time-Varying Output Delay Compensation-A Model-Free Approach and its Application on Cooperative On-Ramp Merging

This paper presents a model-free approach to compensate for time-varying output delay in networked control systems. The proposed architecture combines a model-free observer and the Smith predictor. The model-free observer estimates the current state while handling modeling errors and uncertainties of the system. The Smith predictor moves the effect of time delay outside the control closed-loop using the estimated delayed output and the actual output of the plant. The proposed method is applied to a cooperative on-ramp merging problem. First, an ultra-local model predictive control is implemented to provide a computationally efficient online speed planner agnostic to the vehicle dynamics. After that, a model-free observer is designed to estimate the current state. Finally, the proposed architecture is tested against a time-varying output delay with an upper bound of 200 milliseconds. The results demonstrate the effectiveness of the proposed method with improved tracking of intervehicle distance.

Waleed khan, Muhammad [The University of Texas at ↗
DOE OSTI2023

Redox-enabled electronic interrogation and feedback control of hierarchical and networked biological systems

Abstract Microelectronic devices can directly communicate with biology, as electronic information can be transmitted via redox reactions within biological systems. By engineering biology’s native redox networks, we enable electronic interrogation and control of biological systems at several hierarchical levels: proteins, cells, and cell consortia. First, electro-biofabrication facilitates on-device biological component assembly. Then, electrode-actuated redox data transmission and redox-linked synthetic biology allows programming of enzyme activity and closed-loop electrogenetic control of cellular function. Specifically, horseradish peroxidase is assembled onto interdigitated electrodes where electrode-generated hydrogen peroxide controls its activity. E. coli ’s stress response regulon, oxyRS , is rewired to enable algorithm-based feedback control of gene expression, including an eCRISPR module that switches cell-cell quorum sensing communication from one autoinducer to another—creating an electronically controlled ‘bilingual’ cell. Then, these disparate redox-guided devices are wirelessly connected, enabling real-time communication and user-based control. We suggest these methodologies will help us to better understand and develop sophisticated control for biology.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Physics-informed machine learning modeling for predictive control using noisy data

Due to the occurrence of over-fitting at the learning phase, the modeling of chemical processes via artificial neural networks (ANN) by using corrupted data (i.e., noisy data) is an ongoing challenge. Therefore, this work investigates the effect of both Gaussian and non-Gaussian noise on the performance of process-structure based recurrent neural networks (RNN) models, which take the form of partially-connected RNN models in this work, that are used to approximate a class of multi-input-multi-outputs nonlinear systems. Furthermore, two different techniques, specifically Monte Carlo dropout and co-teaching, are utilized in the development of partially-connected RNN models. Here, these two techniques are employed to reduce the over-fitting in ANNs when noisy data is used in the training process and, hence, to improve the open-loop accuracy as well as the closed-loop performance under a Lyapunov-based model predictive controller (MPC). Aspen Plus Dynamics, a well-known high-fidelity process simulator, is used to simulate a large-scale chemical process application in order to demonstrate the anticipated improvements in both open-loop approximation and closed-loop controller performance in the presence of Gaussian and non-Gaussian noise in the data set using physics-informed RNNs.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Machine learning modeling and model predictive control of a closed-circuit reverse osmosis system

Closed-circuit reverse osmosis (CCRO) offers a flexible and energy-efficient alternative to conventional reverse osmosis by operating in a semi-batch mode that recycles brine, enabling higher recovery rates and reduced specific energy consumption (SEC). However, developing accurate, system-level dynamic models for CCRO remains challenging due to its nonlinear, multi-phase operation and sensitivity to variable feed water conditions. Traditional modeling approaches, such as NARMAX (nonlinear autoregressive moving average with exogenous inputs), often struggle to generalize across varying inlet feed concentrations, necessitating frequent parameter re-estimation and limiting their utility for real-time control applications. To address these limitations, we developed a long short-term memory (LSTM) neural network model trained on an extensive experimental data set from a CCRO pilot plant. The model accepts three inputs, feed flow rate, recirculation flow rate, and initial feed conductivity, and predicts three key outputs: reject conductivity, feed pump power draw, and recirculation pump power draw. We validated the LSTM model against experimental data, demonstrating its ability to distinguish between different feed conductivities and adapt to variable flow rates. Subsequently, we incorporated the LSTM model within a nonlinear model predictive control (MPC) scheme and conducted closed-loop simulations to optimize the integrated SEC (iSEC). In conclusion, the results project up to a 6% reduction in iSEC by using MPC to optimize performance over the entire experiment duration, without requiring any random excitation for data collection or parameter re-estimation.

Desalination↗
DOE OSTI2026

CONTROL AND DATA ACQUISITION IN A CYBER-PHYSICAL MIDSTREAM TESTBED

This thesis presents the development of a laboratory-scale cyber–physical midstream pipeline testbed designed to address this gap and support research in industrial control systems security. The platform integrates pumps, valves, sensors, programmable logic controllers (PLCs), and a human–machine interface (HMI) to emulate the monitoring and control architecture of real pipeline operations. The physical process is implemented as a closed-loop liquid circulation system designed to replicate flow behavior characteristic of midstream pipeline infrastructure. The testbed enables real-time data acquisition of key process variables, including flow rate and pressure facilitating the generation of datasets representative of normal pipeline operation. A threat model encompassing common ICS attack vectors was developed, including sensor spoofing, command injection, false data injection, denial-of-service attacks, and relay manipulation. Multiple attack scenarios were implemented and evaluated to demonstrate how cyber intrusions targeting sensors, actuators, networks, and software propagate into measurable physical consequences in pipeline flow and pressure. The developed platform serves as a practical, cost-effective environment for experimentation, education, and future cybersecurity research in midstream pipeline systems.

42 ENGINEERING↗
DOE OSTI2025

Stability Analysis of Parallel Connected Bidirectional WPT System

This paper presents a stability analysis of parallel-connected bi-directional series-series resonant network wireless power transfer (WPT), optimized for Electric Vehicle (EV) charging and vehicle-to-grid (V2G) applications. The study addresses critical stability challenges in systems integrated with diverse distributed energy resources (DERs), including photovoltaics, fuel cells, wind turbines, energy storage systems, and the AC grid. The stability of such integrated DC grid systems is paramount for ensuring reliable operation, particularly under varying power flow conditions and dynamic interactions between parallel WPT systems. The analysis included system impedance characterization, state-space modeling, and open and closed-loop stability evaluations. The results demonstrated that the integration of a robust control architecture effectively mitigates instability risks and supports scalable, efficient operation. This work underscores the converter's adaptability and its potential for large-scale deployment in wireless EV charging infrastructures and integrated DC grid systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗