Due to its probabilistic nature, fault prognostics is a prime example of a use case for deep learning utilizing big data. However, the low availability of such data sets combined with the high effort of fitting, parameterizing and evaluating complex learning algorithms to the heterogenous and dynamic settings typical for industrial applications oftentimes prevents the practical application of this approach. Automatic adaptation to new or dynamically changing fault prognostics scenarios can be achieved using transfer learning or continual learning methods. In this paper, a first survey of such approaches is carried out, aiming at establishing best practices for future research in this field. It is shown that the field is lacking common benchmarks to robustly compare results and facilitate scientific progress. Therefore, the data sets utilized in these publications are surveyed as well in order to identify suitable candidates for such benchmark scenarios.
Advancements in sensing and computing technologies, the development of human and computer interaction frameworks, big data storage capabilities, and the emergence of cloud storage and could computing have resulted in an abundance of data in the modern industry. This data availability has encouraged researchers and industry practitioners to rely on data-based machine learning, especially deep learning, models for fault diagnostics and prognostics more than ever. These models provide unique advantages, however, their performance is heavily dependent on the training data and how well that data re…
UBMF: Uncertainty-Aware Bayesian Meta-Learning Framework for Fault Diagnosis with Imbalanced Industrial Data
Hangzhou International Innovation Institute, Beihang University（北京航空航天大学杭州国际创新研究院）；Institute of Reliability Engineering, Beihang University（北京航空航天大学可靠性工程研究所）；Science & Technology on Reliability & Environmental Engineering Laboratory（可靠性与环境工程技术重点实验室）；School of Reliability and Systems Engineering, Beihang University（北京航空航天大学可靠性与系统工程学院）
Center for Industrial Artificial Intelligence（工业人工智能中心）；University of Maryland（马里兰大学）
In the field of Prognostics and Health Management (PHM), recent years have witnessed a significant surge in the application of machine learning (ML). Despite this growth, the field grapples with a lack of unified guidelines and systematic approaches for effectively implementing these ML techniques and comprehensive analysis regarding industrial open-source data across varied scenarios. To address these gaps, this paper provides a comprehensive review of ML approaches for diagnostics and prognostics of industrial systems using open-source datasets from PHM Data Challenge Competitions held betwe…
A Federated Learning-based Industrial Health Prognostics for Heterogeneous Edge Devices using Matched Feature Extraction
Singapore University of Technology and Design（新加坡科技设计大学）；Centre for Frontier AI Research, Agency for Science, Technology and Research (A*STAR)（新加坡科技研究局（A*STAR）前沿人工智能研究中心）；Chongqing University（重庆大学）；Nanyang Technological University（南洋理工大学）
Data-driven fault diagnostics and prognostics suffers from class-imbalance problem in industrial systems and it raises challenges to common machine learning algorithms as it becomes difficult to learn the features of the minority class samples. Synthetic oversampling methods are commonly used to tackle these problems by generating the minority class samples to balance the distributions between majority and minority classes. However, many of oversampling methods are inappropriate that they cannot generate effective and useful minority class samples according to different distributions of data, …
In Prognostics and Health Management (PHM) sufficient prior observed degradation data is usually critical for Remaining Useful Lifetime (RUL) prediction. Most previous data-driven prediction methods assume that training (source) and testing (target) condition monitoring data have similar distributions. However, due to different operating conditions, fault modes, noise and equipment updates distribution shift exists across different data domains. This shift reduces the performance of predictive models previously built to specific conditions when no observed run-to-failure data is available for …
In recent years, an increasing popularity of deep learning model for intelligent condition monitoring and diagnosis as well as prognostics used for mechanical systems and structures has been observed. In the previous studies, however, a major assumption accepted by default, is that the training and testing data are taking from same feature distribution. Unfortunately, this assumption is mostly invalid in real application, resulting in a certain lack of applicability for the traditional diagnosis approaches. Inspired by the idea of transfer learning that leverages the knowledge learnt from rich…
Indian Institute of Technology, Kanpur（印度理工学院坎普尔分校）
The fault diagnostic model trained for a laboratory case machine fails to perform well on the industrial machines running under variable operating conditions. For every new operating condition of such machines, a new diagnostic model has to be trained which is a time-consuming and uneconomical process. Therefore, we propose a quick learning mechanism that can transform the existing diagnostic model into a new model suitable for industrial machines operating in different conditions. The proposed method uses the Net2Net transformation followed by a fine-tuning to cancel/minimize the maximum mean…
In this article, the concepts of transfer and continual learning are introduced. The ensuing review reveals promising approaches for industrial deep transfer learning, utilizing methods of both classes of algorithms. In the field of computer vision, it is already state-of-the-art. In others, e.g. fault prediction, it is barely starting. However, over all fields, the abstract differentiation between continual and transfer learning is not benefitting their practical use. In contrast, both should be brought together to create robust learning algorithms fulfilling the industrial automation sector'…
University of Engineering and Technology, Peshawar（白沙瓦工程技术大学）；Hamad Bin Khalifa University（哈马德·本·哈利法大学）
Since the depletion of fossil fuels, the world has started to rely heavily on renewable sources of energy. With every passing year, our dependency on the renewable sources of energy is increasing exponentially. As a result, complex and hybrid generation systems are being designed and developed to meet the energy demands and ensure energy security in a country. The continual improvement in the technology and an effort towards the provision of uninterrupted power to the end-users is strongly dependent on an effective and fault resilient Operation and Maintenance (O&M) system. Ingenious algorithm…
Prognostics or early detection of incipient faults is an important industrial challenge for condition-based and preventive maintenance. Physics-based approaches to modeling fault progression are infeasible due to multiple interacting components, uncontrolled environmental factors and observability constraints. Moreover, such approaches to prognostics do not generalize to new domains. Consequently, domain-agnostic data-driven machine learning approaches to prognostics are desirable. Damage progression is a path-dependent process and explicitly modeling the temporal patterns is critical for accu…
Many approaches for estimation of Remaining Useful Life (RUL) of a machine, using its operational sensor data, make assumptions about how a system degrades or a fault evolves, e.g., exponential degradation. However, in many domains degradation may not follow a pattern. We propose a Long Short Term Memory based Encoder-Decoder (LSTM-ED) scheme to obtain an unsupervised health index (HI) for a system using multi-sensor time-series data. LSTM-ED is trained to reconstruct the time-series corresponding to healthy state of a system. The reconstruction error is used to compute HI which is then used f…
Nanyang Technological University（南洋理工大学）；University of California, Santa Barbara（加利福尼亚大学圣巴巴拉分校）；ENN Group（新奥集团）
Artificial intelligence (AI)-empowered industrial fault diagnostics is important in ensuring the safe operation of industrial applications. Since complex industrial systems often involve multiple industrial plants (possibly belonging to different companies or subsidiaries) with sensitive data collected and stored in a distributed manner, collaborative fault diagnostic model training often needs to leverage federated learning (FL). As the scale of the industrial fault diagnostic models are often large and communication channels in such systems are often not exclusively used for FL model trainin…
Vienna University of Technology（维也纳工业大学）；Austrian Institute of Technology（奥地利技术研究所）；Hauser（豪瑟）；Siemens Technology（西门子科技）
Anomaly detection in large industrial cooling systems is very challenging due to the high data dimensionality, inconsistent sensor recordings, and lack of labels. The state of the art for automated anomaly detection in these systems typically relies on expert knowledge and thresholds. However, data is viewed isolated and complex, multivariate relationships are neglected. In this work, we present an autoencoder based end-to-end workflow for anomaly detection suitable for multivariate time series data in large industrial cooling systems, including explained fault localization and root cause anal…
As the Industrial Internet of Things (IIoT) grows, systems are increasingly being monitored by arrays of sensors returning time-series data at ever-increasing 'volume, velocity and variety' (i.e. Industrial Big Data). An obvious use for these data is real-time systems condition monitoring and prognostic time to failure analysis (remaining useful life, RUL). (e.g. See white papers by Senseye.io, and output of the NASA Prognostics Center of Excellence (PCoE).) However, as noted by Agrawal and Choudhary 'Our ability to collect "big data" has greatly surpassed our capability to analyze it, undersc…
Institut Clément Ader（克莱蒙·阿代尔研究所）；Université de Toulouse（图卢兹大学）；ISAE-SUPAERO（法国高等航空航天学院）
With the increasing availability of data for Prognostics and Health Management (PHM), Deep Learning (DL) techniques are now the subject of considerable attention for this application, often achieving more accurate Remaining Useful Life (RUL) predictions. However, one of the major challenges for DL techniques resides in the difficulty of obtaining large amounts of labelled data on industrial systems. To overcome this lack of labelled data, an emerging learning technique is considered in our work: Self-Supervised Learning, a sub-category of unsupervised learning approaches. This paper aims to in…
Deep learning-based time series models are being extensively utilized in engineering and manufacturing industries for process control and optimization, asset monitoring, diagnostic and predictive maintenance. These models have shown great improvement in the prediction of the remaining useful life (RUL) of industrial equipment but suffer from inherent vulnerability to adversarial attacks. These attacks can be easily exploited and can lead to catastrophic failure of critical industrial equipment. In general, different adversarial perturbations are computed for each instance of the input data. Th…
We adopted an approach based on an LSTM neural network to monitor and detect faults in industrial multivariate time series data. To validate the approach we created a Modelica model of part of a real gasoil plant. By introducing hacks into the logic of the Modelica model, we were able to generate both the roots and causes of fault behavior in the plant. Having a self-consistent data set with labeled faults, we used an LSTM architecture with a forecasting error threshold to obtain precision and recall quality metrics. The dependency of the quality metric on the threshold level is considered. An…
East China University of Science and Technology（华东理工大学）；Tongji University（同济大学）
Quality-relevant fault detection plays an important role in industrial processes, while the current quality-related fault detection methods based on neural networks main concentrate on process-relevant variables and ignore quality-relevant variables, which restrict the application of process monitoring. Therefore, in this paper, a fault detection scheme based on the improved teacher-student network is proposed for quality-relevant fault detection. In the traditional teacher-student network, as the features differences between the teacher network and the student network will cause performance d…
Combining SHAP and Causal Analysis for Interpretable Fault Detection in Industrial Processes
Labcin - Nature Inspired Computing Laboratory（自然启发计算实验室）；Graduate Program in Computer Science, Federal University of Espírito Santo（计算机科学研究生项目，巴西圣埃里希托萨大学）
China-EU Institute for Clean and Renewable Energy, Huazhong University of Science and Technology（华中科技大学中欧清洁与可再生能源学院）；School of Artificial Intelligence and Automation, Huazhong University of Science and Technology（华中科技大学人工智能与自动化学院）；State Key Lab of Digital Manufacturing Equipment and Technology（数字制造装备与技术国家重点实验室）
This paper proposes a novel fault diagnosis approach based on generative adversarial networks (GAN) for imbalanced industrial time series where normal samples are much larger than failure cases. We combine a well-designed feature extractor with GAN to help train the whole network. Aimed at obtaining data distribution and hidden pattern in both original distinguishing features and latent space, the encoder-decoder-encoder three-sub-network is employed in GAN, based on Deep Convolution Generative Adversarial Networks (DCGAN) but without Tanh activation layer and only trained on normal samples. I…
AI-Powered Machine Learning Approaches for Fault Diagnosis in Industrial Pumps
Humboldt-Universität zu Berlin, Institut für Physik, AG Moderne Optik（柏林洪堡大学物理学院现代光学小组）；University of Doha for Science and Technology, College of Engineering and Technology, Department of Mechanical Engineering Technology（多哈科学技术大学工程学院机械工程技术系）
Deep learning and big data algorithms have become widely used in industrial applications to optimize several tasks in many complex systems. Particularly, deep learning model for diagnosing and prognosing machinery health has leveraged predictive maintenance (PdM) to be more accurate and reliable in decision making, in this way avoiding unnecessary interventions, machinery accidents, and environment catastrophes. Recently, Transformer Neural Networks have gained notoriety and have been increasingly the favorite choice for Natural Language Processing (NLP) tasks. Thus, given their recent major a…
Quantum computing (QC) and deep learning techniques have attracted widespread attention in the recent years. This paper proposes QC-based deep learning methods for fault diagnosis that exploit their unique capabilities to overcome the computational challenges faced by conventional data-driven approaches performed on classical computers. Deep belief networks are integrated into the proposed fault diagnosis model and are used to extract features at different levels for normal and faulty process operations. The QC-based fault diagnosis model uses a quantum computing assisted generative training p…
