Physics-based Digital Twins for Integrated Thermal Energy Systems Using Active Learning
Authors: Umme Mahbuba Nabila, Paul Seurin, Linyu Lin, Majdi I. Radaideh
Organizations: Department of Nuclear Engineering and Radiological Sciences, University of Michigan, Ann Arbor, MI 48109, United States · Nuclear Science & Technology Division, Idaho National Laboratory, Idaho Falls, ID 83415, United States · Department of Computer Science and Engineering, University of Michigan, Ann Arbor, MI 48109, United States
Real-time supervisory control of thermal energy distribution systems requires digital twins that are accurate, interpretable, and uncertainty-aware, yet remain data and computationally efficient. High-fidelity simulations alone are costly, while purely data-driven surrogates often lack robustness. To address these challenges, this work proposes an active learning (AL) framework that couples system-level Modelica simulations with four simpler physics-informed and data-driven surrogate modeling approaches: deterministic Sparse Identification of Nonlinear Dynamics with Control (SINDyC), its probabilistic multivariate-Gaussian extension (MvG-SINDyC), feedforward neural network (FNN), and gated recurrent unit (GRU) network. Tailored to each surrogate, model-specific AL query strategies are employed, including Mahalanobis-distance sampling in coefficient space for MvG-SINDyC and error-based sampling in prediction space for SINDyC, FNN, and GRU, allowing the learning process to prioritize dynamically informative trajectories. The proposed approach is demonstrated on the glycol heat exchanger (GHX) subsystem of the Thermal Energy Distribution System (TEDS) at Idaho National Laboratory. Across key GHX outputs--the bypass mass flow rate m˙GHX and heat transfer rate QGHX-the AL framework achieves comparable predictive accuracy using as few as one-fifth of the simulation trajectories required by random sampling. Among the evaluated surrogates, the GRU achieves the highest predictive fidelity, while SINDyC remains the most computationally efficient and interpretable. The probabilistic MvG-SINDyC surrogate further enables uncertainty quantification and exhibits the largest computational gains under AL.
Digital Twins rely on surrogate models to mirror physical systems in real time, yet these models can degrade as operating conditions evolve, a phenomenon known as concept drift. Maintaining surrogate fidelity under drift, particularly when models must also capture aleatoric uncertainty, remains an open challenge. Existing adaptive frameworks lack principled mechanisms for detecting when updates are needed, for efficiently adapting models from limited streaming data, and for certifying that updates genuinely improve predictive performance. Here we present an adaptive Digital Twin framework that integrates a Fisher score--based multivariate drift detector, Low-Rank Adaptation (LoRA) for parameter-efficient continual learning, and a Mann--Whitney U test for online statistical validation. The framework monitors surrogate-model confidence via Fisher score vectors, triggers targeted fine-tuning of fewer than 1% of model parameters upon drift detection, and statistically certifies predictive improvement before deploying the updated surrogate. Applied to a stochastic linear system and a directed energy deposition additive manufacturing process as case studies, the framework successfully detects distributional shifts with short delays and restores both predictive accuracy and uncertainty quantification under abrupt and incremental drift. These results establish a statistically rigorous and computationally tractable pathway for sustaining the trustworthiness of neural-network--based Digital Twins throughout their operational life cycle.
Artificial-intelligence surrogates can support second-by-second thermal-hydraulic forecasting, but models selected and frozen offline may become condition-locked once deployed outside their pretraining envelope. This study develops a guarded continual-adaptation framework for experimental thermal-hydraulic loop data in which role-separated agents - Monitor, Diagnosis, Adaptation, Safety-Auditor, and Orchestrator - diagnose error signatures, prioritize candidate model families, and review promotions, while deterministic champion-challenger gates and background shadow learning retain final authority over model replacement. Seven surrogate families were screened by blocked three-fold cross-validation, and a temporal Fourier neural operator was selected as the initial champion for 60-s-history-to-10-s-trajectory forecasting on two held-out transients, with three seeds per adaptive mode. Static deployment gave a channel-averaged MAE of 7.06 and a 56.8% warning-exceedance ratio; rule-based adaptation reduced MAE to 6.54, whereas shadow refresh alone remained close to Static. The MA-Full mode, in which the role-separated multi-agent council reviews every evaluated stream step, achieved the lowest mean error, 5.72, and 35.8% exceedance, corresponding to a 19.0% improvement over Static. Paired bootstrap intervals against Static excluded zero, although intervals among adaptive modes overlapped and the six paired units limit broad statistical claims. Validated promotions from the neural operator to Transformer and graph neural network indicate that logged, gate-controlled adaptation can support auditable surrogate evolution while deterministic gates retain deployment authority.
Surrogate models are central to scientific machine learning, where they enable fast prediction, simulation, inference, and control for complex physical systems. For time-dependent problems, however, accurate interpolation of training trajectories is not sufficient: reliable surrogates should also respect the conservation laws, invariants, admissibility conditions, and dissipative structures that give those trajectories physical meaning. We introduce Physics-conforming Latent Twins, a framework for learning latent surrogate solution operators whose dynamics satisfy selected physical principles by design. The method builds on the Latent Twin formulation by jointly learning an encoder, a decoder, and a latent flow map between arbitrary time-indexed states, while constraining the latent dynamics to preserve or dissipate prescribed structural quantities. We develop a constraint-transfer viewpoint that connects physical structure in the original state space with compatible constraints in latent space, and prove structure-preservation bounds showing how latent enforcement improves control of physical defects after decoding. We also derive algebraic conditions for latent flow maps that preserve linear and quadratic invariants or enforce dissipative inequalities. Numerical experiments on representative ODE and PDE benchmarks demonstrate improved constraint satisfaction, structural fidelity, and qualitative long-time behavior while maintaining accurate surrogate prediction.