Physics-guided machine learning for saturation control across variable hydraulic conditions in heap leaching

This paper presents a data-driven method for modeling the pressure response of a hydraulic clutch control circuit. The system consists of a variable-force solenoid, accumulator, pressure regulator valve, and latch valve, and exhibits nonlinear behavior caused by hysteresis, latch transitions, and actuator dynamics. A baseline model using commanded current variables captured the general pressure response but failed to represent hysteresis and latch behavior accurately. The input vector was therefore extended with current derivative information, and several classifiers were tested to separate latch-related operating regimes before fitting Gaussian Process regression models to the resulting partitions. Nonlinear SVC and gradient boosting produced the highest latch-classification accuracy, and nonlinear SVC was selected for the final local-regression pipeline. The proposed approach was evaluated on unseen ramp-rate data and compared against a physics-based Amesim model. The machine-learning model reproduced the measured pressure response and hysteresis behavior more accurately than the physics-based simulation for the tested operating conditions. These results suggest that machine-learning plant models can complement physics-based hydraulic models during hardware development and controller calibration when representative test-stand data are available.

This article presents a cross-dataset evaluation of learned native-cell surrogate models for solver-consistent water-surface elevation (WSE) prediction in HEC-RAS 2D. To avoid raster remapping error and information-access confounding, surrogates are evaluated directly on the original nonuniform computational cells under an explicit policy that separates static project inputs, current hydraulic state, project-input forcing, calibration-derived quantities, and future solver-output targets. We introduce the Learned Response-Field Inertia Operator (LRFIO), a no-forcing, increment-based learned surrogate that calibrates an inertial response operator from solved HEC-RAS trajectories and deploys the retained operator through closed-form native-cell rollout. LRFIO evaluates a base-case-first response hierarchy consisting of persistence, global calibrated inertia, and segmented response-field inertia. Segmentation, residual correction, and neuralized inertia are treated as learnable modeling choices, with added complexity retained only when validation evidence justifies its cost. Evaluated across four diverse HEC-RAS 2D benchmarks, LRFIO retains different response structures for different domains, demonstrating adaptive learned complexity. The selector audit shows controlled complexity with a maximum validation regret of 4.30%. During deployment, retained rollout times range from 0.003 s to 0.242 s, and the Beaver Bayou measured-solve comparison gives an estimated 2.75 x 10^4 horizon-normalized speedup over HEC-RAS. These results indicate that the current native-cell increment is a strong solver-conditioned predictive scaffold and that added response-field, neural, or spatial complexity should be retained only when empirically justified.

Reservoir simulation workflows face a fundamental data asymmetry: input parameter fields (geostatistical permeability realizations, porosity distributions) are free to generate in arbitrary quantities, yet existing neural operator surrogates require large corpora of expensive labeled simulation trajectories and cannot exploit this unlabeled structure. We introduce PI-JEPA (Physics-Informed Joint Embedding Predictive Architecture), a surrogate pretraining framework that trains without any completed PDE solves, using masked latent prediction on unlabeled parameter fields under per-sub-operator PDE residual regularization. The predictor bank is structurally aligned with the Lie--Trotter operator-splitting decomposition of the governing equations, dedicating a separate physics-constrained latent module to each sub-process (pressure, saturation transport, reaction), enabling fine-tuning with as few as 100 labeled simulation runs. On single-phase Darcy flow, PI-JEPA achieves $1.9\times$ lower error than FNO and $2.4\times$ lower error than DeepONet at $N_\ell{=}100$, with 24% improvement over supervised-only training at $N_\ell{=}500$, demonstrating that label-free surrogate pretraining substantially reduces the simulation budget required for multiphysics surrogate deployment.