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AI-Based Machine Condition Monitoring and Maintenance

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Computing and Artificial Intelligence".

Deadline for manuscript submissions: 31 July 2026 | Viewed by 2361

Special Issue Editors


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Guest Editor
RCM2+ Faculty of Engineering, Lusófona University, 1749-024 Lisbon, Portugal
Interests: condition-based maintenance; hidden Markov models; deep neural networks; industrial sensors; data-driven models; digital twins

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Guest Editor
1. Instituto Superior de Engenharia de Coimbra, Polytechnic of Coimbra, 3045-093 Coimbra, Portugal
2. Research Centre for Asset Management and Systems Engineering (RCM2+), Polytechnic University of Coimbra, Rua Pedro Nunes, 3030-199 Coimbra, Portugal
Interests: artificial intelligence; robotics; automation; maintenance; computer vision
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Engineering and Physical Sciences, University of Southampton, Southampton SO17 1BJ, UK
Interests: data and analytics; lubrication; condition monitoring; machinery management
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue focuses on the transformative role of Artificial Intelligence in machine condition monitoring, diagnostics, prognostics and maintenance decision-making. As industrial systems become increasingly complex and data-rich, AI-driven approaches offer unprecedented capabilities to detect anomalies, predict failures, and optimize maintenance strategies. We invite high-quality contributions that explore advanced algorithms, intelligent sensor networks, virtual sensing technologies, digital twins, and data-driven prognostics approaches for improving asset reliability and operational efficiency.

Topics of interest include (but are not limited to) the following: supervised and unsupervised learning models; machine learning methods; deep neural networks (DNNs); reinforcement learning for autonomous maintenance decision-making; adaptable data-driven models; edge and cloud AI architectures; calibration monitoring and self-calibrating sensors; agent-based AI systems and multi-agent maintenance management; generative AI; virtual sensing; anomaly detection and predictive modelling; multimodal data fusion; and explainable AI for industrial systems. We also welcome studies combining AI with metrology, data quality, and sensor reliability to enhance maintenance precision.

This Special Issue aims to bring together innovative research, practical applications, and industrial case studies that showcase how AI is reshaping the future of maintenance. By integrating intelligent systems with robust data infrastructure, this Issue seeks to highlight new pathways for building resilient, efficient, and autonomous industrial operations.

Dr. Alexandre Martins
Dr. Inácio Fonseca
Prof. Dr. Honor Powrie
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • AI-based condition monitoring
  • predictive maintenance
  • intelligent sensor systems
  • AI-driven metrology
  • digital twins

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Published Papers (2 papers)

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Research

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25 pages, 2621 KB  
Article
Ensuring Data Accuracy, Completeness, and Interpretation in Advanced Manufacturing
by Nathan Eskue and Amalia Macali
Appl. Sci. 2026, 16(5), 2409; https://doi.org/10.3390/app16052409 - 2 Mar 2026
Viewed by 805
Abstract
Advanced manufacturing is undergoing a profound transformation, with data quickly becoming its most strategic asset. The industry is pushing toward Industry 4.0 with its sights already on the human-centric Industry 5.0. Manufacturing firms are rapidly integrating AI, IoT, and advanced analytics to enable [...] Read more.
Advanced manufacturing is undergoing a profound transformation, with data quickly becoming its most strategic asset. The industry is pushing toward Industry 4.0 with its sights already on the human-centric Industry 5.0. Manufacturing firms are rapidly integrating AI, IoT, and advanced analytics to enable real-time decision making, predictive maintenance, and full manufacturing lifecycle optimization. However, this data-driven revolution exposes a critical vulnerability: the hidden direct costs and cascading downstream consequences of inaccurate, missing, or corrupt data. This paper provides an in-depth examination of the data quality crisis facing modern manufacturing, exploring its quantifiable impact on cost, safety, and strategic decision making; and identifies the tangible barriers preventing scalable AI in manufacturing today. We investigate how bad data undermines the digital thread, erodes both operational and strategic trust, and stalls the transition to autonomous systems. Supported by recent industry surveys, academic findings, and leading trends, we reveal that most manufacturers suffer from systemic data quality issues, with billions lost annually to inefficiencies, rework, and flawed decisions. Addressing this, the paper evaluates state-of-the-art solutions for real-time data validation, anomaly detection, and predictive imputation. Building upon this, we identify key gaps—including the lack of unified data quality frameworks, integration across legacy/modern systems, and actionable imputation under uncertainty—and propose a roadmap to bridge them. The paper concludes by outlining four research directions that support a seamless, scalable transition toward a trustworthy data foundation in manufacturing. Industry 4.0/5.0 is defined by data, insight, and actionable intelligence: only manufacturers that tame their data chaos will thrive. Full article
(This article belongs to the Special Issue AI-Based Machine Condition Monitoring and Maintenance)
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Review

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21 pages, 2001 KB  
Review
A Systematic Literature Review on AI-Driven Predictive Maintenance and Fault Detection in Aircraft Systems
by João Costa, José Torres Farinha, Hugo Raposo, Antonio J. Marques Cardoso, Alice Carmo, Paula Gonçalves and João Farto
Appl. Sci. 2026, 16(7), 3381; https://doi.org/10.3390/app16073381 - 31 Mar 2026
Viewed by 1173
Abstract
The increasing availability of onboard sensors and digital monitoring platforms has enabled the continuous acquisition of operational and health-related data in aircraft systems. In parallel, advances in Big Data analytics and Artificial Intelligence (AI) have driven significant progress in Predictive Maintenance (PdM), enabling [...] Read more.
The increasing availability of onboard sensors and digital monitoring platforms has enabled the continuous acquisition of operational and health-related data in aircraft systems. In parallel, advances in Big Data analytics and Artificial Intelligence (AI) have driven significant progress in Predictive Maintenance (PdM), enabling earlier fault detection and more reliable estimations of Remaining Useful Life (RUL). This systematic literature review examines recent developments in AI-driven PdM and fault detection applied to aircraft over the last years. A total of 20 studies were selected based on predefined inclusion criteria and analyzed with respect to research trends, application domains, algorithmic approaches, and expected outputs. The findings indicate a strong research emphasis on civil aviation supported by accessible operational datasets, whereas military aviation research prioritizes fleet readiness and mission continuity, often with limited data transparency. Deep learning approaches, particularly hybrid models combining convolutional and recurrent architectures, dominate recent prognostic methodologies, while optimization and Model-Based Systems Engineering (MBSE) frameworks support decision-making integration. Despite these advancements, the transition from experimental models to operational deployment remains constrained by data heterogeneity, model explainability requirements, and regulatory certification processes. This review highlights current progress and identifies gaps and research opportunities to accelerate the adoption of robust and scalable PdM solutions in aviation. Full article
(This article belongs to the Special Issue AI-Based Machine Condition Monitoring and Maintenance)
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