Process Monitoring and Fault Diagnosis of Multi-Mode Complex Industry

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Process Control and Monitoring".

Deadline for manuscript submissions: 10 September 2026 | Viewed by 383

Special Issue Editor


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Guest Editor
School of Science and Technology, Federal University of Rio Grande do Norte, Natal 59078-970, Brazil
Interests: multi-mode industrial systems; fault detection and diagnosis; process safety and monitoring techniques; industry safety KPIs; data-driven fault analysis

Special Issue Information

Dear Colleagues,

In the ever-evolving industrial landscape, emphasis has been placed on efficiency, safety and sustainability, rendering process monitoring and fault diagnosis essential components of operational excellence, particularly in complex multi-mode manufacturing environments. This Special Issue invites researchers, practitioners and experts to submit original research articles that explore innovative methodologies, technologies and applications in the area of process monitoring and fault diagnosis, adapted to the complexities of multi-mode industrial systems.

Process monitoring serves not only to ensure the smooth operation of various manufacturing processes but also to increase productivity and minimize downtime. Fault diagnosis is equally vital as it enables the early detection of anomalies and failures, thus reducing the impact of unplanned interruptions on production. As industries increasingly adopt automation and smart technologies, the need for robust monitoring and diagnostic frameworks becomes paramount, especially in environments characterized by variable operating modes.

We seek submissions that address, but are not limited to, the following topics:

  • Advanced Analytics and AI Techniques: Applications of machine learning, deep learning, and data analytics for real-time process monitoring and fault diagnosis.
  • Sensor Technologies: Innovations in sensor technologies and their integration for comprehensive monitoring in multi-mode settings.
  • Modeling and Simulation: The development of models and simulations for predicting process behaviors and identifying potential faults in complex industrial systems.
  • Industry 4.0 Practices: Explorations of the IoT and cyber–physical systems in enhancing process monitoring and fault diagnosis capabilities.
  • Case Studies and Practical Applications: Real-world case studies that highlight the challenges and successes in implementing monitoring and diagnostic systems in multi-mode industries.
  • Human–Machine Interaction: Research on improving human decision making through user-friendly interfaces and decision support systems in monitoring and diagnosis tasks.

This Special Issue aims to contribute to the collective knowledge on process monitoring and fault diagnosis, fostering discussions that can provide innovative solutions for the complexities faced by multi-mode industries. We look forward to receiving your contributions, aiming to advance research and practical applications in this essential area of industrial engineering.

Dr. Diego Rodrigo Cabral Silva
Guest Editor

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. Processes 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

  • process monitoring
  • fault diagnosis
  • multi-mode systems
  • Industry 4.0
  • machine learning
  • data analytics
  • sensor technologies
  • real-time monitoring
  • cyber–physical systems
  • predictive maintenance

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Published Papers (1 paper)

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Research

25 pages, 2062 KB  
Article
Multi-Sensor Process Monitoring and Fault Diagnosis for Multi-Mode Industrial Servomotor Systems with Fault Classification and RUL Prediction: A Representative Case Study for Smart Manufacturing Applications
by Ugur Simsir
Processes 2026, 14(5), 772; https://doi.org/10.3390/pr14050772 - 27 Feb 2026
Viewed by 72
Abstract
Unexpected degradation in servomotor-driven multi-mode industrial systems such as CNC feed drives and robotic machining cells compromises positioning accuracy, availability and operational safety, rendering early fault diagnosis and predictive maintenance essential in smart manufacturing environments. In this study, a predictive maintenance framework based [...] Read more.
Unexpected degradation in servomotor-driven multi-mode industrial systems such as CNC feed drives and robotic machining cells compromises positioning accuracy, availability and operational safety, rendering early fault diagnosis and predictive maintenance essential in smart manufacturing environments. In this study, a predictive maintenance framework based on multi-sensor data fusion was developed to support condition monitoring, fault classification, and remaining useful life estimation of robot servomotors. Time- and frequency-domain features were extracted from synchronized electrical current, vibration, acoustic, and temperature signals using fixed-length sliding windows. Feature-level fusion was applied to combine complementary information from different sensor modalities. A data-driven health assessment approach was employed in which an autoencoder model trained on healthy operating data was used to generate a scalar Servomotor Health Score representing degradation progression. Fault types were identified using a Random Forest classifier, while remaining useful life was estimated in terms of operational cycles using a Gradient Boosting regression model. Experimental evaluations were carried out under repeated reference motion profiles, and representative mechanical and electrical fault conditions were introduced in a controlled manner. The results demonstrated that the proposed health score provided a smooth and monotonic degradation trend, enabling early fault detection without false alarms under healthy conditions. High classification performance was achieved for fault identification, and remaining useful life predictions showed low estimation error on previously unseen faulty servomotors. Feature contribution analysis indicated that electrical current and temperature signals provided the most robust indicators of degradation, while vibration and acoustic measurements offered complementary diagnostic information. The proposed framework was shown to be an effective and practical solution for predictive maintenance of servomotor-driven manufacturing systems such as CNC axes and robotic machining platforms operating under low-speed and variable-load conditions. Full article
(This article belongs to the Special Issue Process Monitoring and Fault Diagnosis of Multi-Mode Complex Industry)
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