Artificial intelligence for digital twins in energy systems and turbomachinery: development of machine learning frameworks for design, optimization and maintenance

The expression Industry4.0 identifies a new industrial paradigm that includes the development of Cyber-Physical Systems (CPS) and Digital Twins promoting the use of Big-Data, Internet of Things (IoT) and Artificial Intelligence (AI) tools. Digital Twins aims to build a dynamic environment in which, with the help of vertical, horizontal and end-to-end integration among industrial processes, smart technologies can communicate and exchange data to analyze and solve production problems, increase productivity and provide cost, time and energy savings. Specifically in the energy systems field, the introduction of AI technologies can lead to significant improvements in both machine design and optimization and maintenance procedures. Over the past decade, data from engineering processes have grown in scale. In fact, the use of more technologically sophisticated sensors and the increase in available computing power have enabled both experimental measurements and highresolution numerical simulations, making available an enormous amount of data on the performance of energy systems. Therefore, to build a Digital Twin model capable of exploring these unorganized data pools collected from massive and heterogeneous resources, new Artificial Intelligence and Machine Learning strategies need to be developed. In light of the exponential growth in the use of smart technologies in manufacturing processes, this thesis aims at enhancing traditional approaches to the design, analysis, and optimization phases of turbomachinery and energy systems, which today are still predominantly based on empirical procedures or computationally intensive CFD-based optimizations. This improvement is made possible by the implementation of Digital Twins models, which, being based primarily on the use of Machine Learning that exploits performance Big-Data collected from energy systems, are acknowledged as crucial technologies to remain competitive in the dynamic energy production landscape. The introduction of Digital Twin models changes the overall structure of design and maintenance approaches and results in modern support tools that facilitate real-time informed decision making. In addition, the introduction of supervised learning algorithms facilitates the exploration of the design space by providing easy-to-run analytical models, which can also be used as cost functions in multi-objective optimization problems, avoiding the need for time-consuming numerical simulations or experimental campaings. Unsupervised learning methods can be applied, for example, to extract new insights from turbomachinery performance data and improve designers’ understanding of blade-flow interaction. Alternatively, Artificial Intelligence frameworks can be developed for Condition-Based Maintenance, allowing the transition from preventive to predictive maintenance. This thesis can be conceptually divided into two parts. The first reviews the state of the art of Cyber-Physical Systems and Digital Twins, highlighting the crucial role of Artificial Intelligence in supporting informed decision making during the design, optimization, and maintenance phases of energy systems. The second part covers the development of Machine Learning strategies to improve the classical approach to turbomachinery design and maintenance strategies for energy systems by exploiting data from numerical simulations, experimental campaigns, and sensor datasets (SCADA). The different Machine Learning approaches adopted include clustering algorithms, regression algorithms and dimensionality reduction techniques: Autoencoder and Principal Component Analysis. A first work shows the potential of unsupervised learning approaches (clustering algorithms) in exploring a Design of Experiment of 76 numerical simulations for turbomachinery design purposes. The second work takes advantage of a nonsequential experimental dataset, measured on a rotating turbine rig characterized by 48 blades divided into 7 sectors that share the same baseline rotor geometry but have different tip designs, to infer and dissect the causal relationship among different tip geometries and unsteady aero-thermodynamic performance via a novel Machine-Learning procedure based on dimensionality reduction techniques. The last application proposes a new anomaly detection framework for gensets in DH networks, based on SCADA data that exploits and compares the performance of regression algorithms such as XGBoost and Multi-layer Perceptron

Development of a data-driven model for turbulent heat transfer in turbomachinery

Machine Learning (ML) algorithms have become popular in many fields, including applications related to turbomachinery and heat transfer. The key properties of ML are the capability to partially tackle the problem of slowing down of Moore’s law and to dig-out correlations within large datasets like those available on turbomachinery. Data come from experiments and simulations with different degree of accuracy, according to the test-rig or the CFD approach. When dealing with modelling of turbulent flows in turbomachinery there is a constant trade-off between accuracy and computational costs, but starting from the large amount of data on turbomachinery performance, with ML it is possible to train a learner to correct and improve CFD. The aim of this work is to investigate an innovative data-driven approach that could lead to a significant improvement in the analysis of heat transfer in turbulent flows. The effects of Reynolds number and wall temperature on heat transfer for a double forward-facing step with two squared obstacles were investigated by numerical simulations carried out in OpenFOAM. Then a machine-learnt model was derived using a regression algorithm. The results of regressor showed that a data-driven approach can effectively predict results of the RANS model

Cascade With Sinusoidal Leading Edges: Identification And Quantification of Deflection With Unsupervised Machine Learning.

One of the key issues in turbomachinery design is the identification of loss mechanisms and their quantification, both during preliminary design and in all subsequent optimization loops. Over the years, many correlations have been proposed, accounting for different dissipative mechanisms that occur in blade-to-blade passages, such as the development of boundary layers, turbulent wake mixing, shockwaves, and secondary flows or off-design incidence. In recent years, the fan industry started the production of more complex rotor geometries, characterized by sinusoidal leading and trailing edges, mostly to extend stall margin and to reduce noise emissions. Literature still lacks a quantification of the losses introduced by the secondary motions released by serrated leading-edges. In this paper we investigate a design of experiments that entails 76 cases of a 3D flow cascade with NACA 4digit profiles with sinusoidal leading edges to measure losses according to the Lieblein’s approach. The flow field simulated with RANS strategy was investigated using an unsupervised machine learning strategy to classify and isolate the turbulent wake downstream of the cascade with a combination of Principal Component Analysis and Gaussian Mixture clustering. Then a gradient boosting regressor was used to derive the correlation between input parameters and cascade deflectio

A Machine-Learnt Wall Function for Rotating Diffusers

Data-driven tools and techniques have proved their effectiveness in many engineering applications. Machine-learning has gradually become a paradigm to explore innovative designs in turbomachinery. However, industrial Computational Fluid Dynamics (CFD) experts are still reluctant to embed similar approaches in standard practice and very few solutions have been proposed so far. The aim of the work is to prove that standard wall treatments can obtain serious benefits from machine-learning modelling. Turbomachinery flow modeling lives in a constant compromise between accuracy and the computational costs of numerical simulations. One of the key factors of process is defining a proper wall treatment. Many works point out how insufficient resolutions of boundary layers may lead to incorrect predictions of turbomachinery performances. Wall functions are universally exploited to replicate the physics of boundary layers where grid resolution does not suffice. Widespread wall functions were derived by the observation of a few canonical flows, further expressed as a simple polynomial of Reynolds number and turbulent kinetic energy. Despite their popularity, these functions are frequently applied in flows where the ground assumptions cease to be true, such as rotating passages or swirled flows. In these flows, the mathematical formulations of wall functions do not account for the distortion on the boundary layer due to the combined action of centrifugal and Coriolis forces. Here we will derive a wall function for rotating passages, through means of machine-learning. The algorithm is directly implemented in the N-S equations solver. Cross-validation results show that the machine-learnt wall treatment is able to effectively correct the turbulent kinetic energy field near the solid walls, without impairing the accuracy of the RANS turbulence model in any way

Condition-Based Maintenance of Gensets in District Heating Using Unsupervised Normal Behavior Models Applied on SCADA Data

Increasing interest in natural gas-fired gensets is motivated by District Heating (DH) network applications, especially in urban areas. Even if they represent customary solutions, when used in DH, duty regimes are driven by network thermal energy demands resulting in discontinuous operation, which affects their remaining useful life. As such, the attention on effective condition-based maintenance has gained momentum. In this paper, a novel unsupervised anomaly detection framework is proposed for gensets in DH networks based on Supervisory Control And Data Acquisition (SCADA) data. The framework relies on multivariate Machine-Learning (ML) regression models trained with a Leave-One-Out Cross-Validation method. Model residuals generated during the testing phase are then post-processed with a sliding threshold approach based on a rolling average. This methodology is tested against nine major failures that occurred on the gas genset installed in the Aosta DH plant in Italy. The results show that the proposed framework successfully detects anomalies and anticipates SCADA alarms related to unscheduled downtime

Mechanically stacked, two-terminal graphene-based perovskite/silicon tandem solar cell with efficiency over 26%

Perovskite/silicon tandem solar cells represent an attractive pathway to upgrade the market-leading crystalline silicon technology beyond its theoretical limit. Two-terminal architectures result in reduced plant costs compared to four-terminal ones. However, it is challenging to monolithically process perovskite solar cells directly onto the micrometer-sized texturing on the front surface of record-high efficiency amorphous/crystalline silicon heterojunction cells, which limits both high-temperature and solution processing of the top cells. To tackle these hurdles, we present a mechanically stacked two-terminal perovskite/silicon tandem solar cell, with the sub-cells independently fabricated, optimized, and subsequently coupled by contacting the back electrode of the mesoscopic perovskite top cell with the texturized and metalized front contact of the silicon bottom cell. By minimizing optical losses, as achieved by engineering the hole selective layer/rear contact structure, and using a graphene-doped mesoporous electron selective layer for the perovskite top cell, the champion tandem device demonstrates a 26.3% efficiency (25.9% stabilized) over an active area of 1.43 cm2

AISF position paper on HCV in immunocompromised patients

This report summarizes the clinical features and the indications for treating HCV infection in immunocompromised and transplanted patients in the Direct Acting Antiviral drugs era