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Sensor-Based Condition Monitoring and Intelligent Fault Diagnosis

A special issue of Sensors (ISSN 1424-8220). This special issue belongs to the section "Fault Diagnosis & Sensors".

Deadline for manuscript submissions: 25 August 2026 | Viewed by 1071

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Guest Editor
Department of Electrical and Computer Engineering, University of Patras, 265 04 Patras, Greece
Interests: condition monitoring; electrical machines and drives; fault diagnosis
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In recent years, Sensor-Based Condition Monitoring and Intelligent Fault Diagnosis have evolved into key technologies for ensuring reliability and safety in industrial processes, power equipment, vehicles of all types and rotating machines.

Condition monitoring uses sensors to acquire physical signals from a process, such as current, vibration, and sound, to estimate the health status of the system without interrupting its operation. In this way, potential faults can be diagnosed early, avoiding unplanned downtime and catastrophic failure incidents, reducing safety risks and keeping maintenance costs to a minimum.

To enable Fault Diagnosis to reach its full potential, advanced processing techniques and feature extraction methodologies are often applied to acquired data. In addition, to reliably identify faults and predict fault progress for both stationary and non-stationary operating conditions, advanced techniques may also be used, such as Machine Learning and Artificial Intelligence algorithms. Combining Sensor Data from multiple sources and Intelligent Methods for Fault Diagnosis, Predictive Maintenance can be accomplished, supporting modern industrial systems.

Dr. Epaminondas D. Mitronikas
Guest Editor

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Keywords

  • fault diagnosis
  • condition monitoring
  • sensors
  • signal processing
  • intelligent methods
  • machine learning
  • artificial intelligence

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Published Papers (3 papers)

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Research

16 pages, 3687 KB  
Article
A Safe-Domain Generative Adversarial Network with Swin Transformer for Noisy Imbalanced Fault Diagnosis
by Xiao Lai, Xiaohan Zhang, Zhiqi Xie and Min Liu
Sensors 2026, 26(12), 3754; https://doi.org/10.3390/s26123754 - 12 Jun 2026
Viewed by 197
Abstract
Currently, data-driven fault diagnosis methods have achieved remarkable progress. However, in industrial scenarios, acquiring a sufficient amount of fault data poses a challenge, thereby leading to the issue of imbalanced data in intelligent fault diagnosis. Furthermore, manual recording and instrument measurement errors will [...] Read more.
Currently, data-driven fault diagnosis methods have achieved remarkable progress. However, in industrial scenarios, acquiring a sufficient amount of fault data poses a challenge, thereby leading to the issue of imbalanced data in intelligent fault diagnosis. Furthermore, manual recording and instrument measurement errors will introduce label noise, which significantly impacts diagnosis performance. To address these problems, this paper proposes a safe-domain generative adversarial network with Swin Transformer (SDGAN-ST). A safe domain selection method is utilized to eliminate noisy samples and construct a pure dataset that poses no risk to the GAN training process. Consequently, GAN can generate high-quality minority samples to rebalance the original dataset. Additionally, the Swin Transformer is employed as a classifier to capture global information for each fault sample, thereby achieving high diagnostic accuracy. Experiments on the CWRU dataset and a real-world oxygen compressor bearing dataset demonstrate the effectiveness of the proposed method. On the CWRU dataset, SDGAN-ST achieves accuracies of 98.88%, 97.63%, and 97.50% under imbalance ratios of 1:10, 1:20, and 1:30, respectively. On the real-world dataset, SDGAN-ST achieves 100% accuracy under all three imbalance ratios. Additional experiments under noise ratios of 20%, 30%, and 40% show that SDGAN-ST maintains stable diagnostic performance and is more robust to label noise than ordinary WGAN-GP-based methods. Full article
(This article belongs to the Special Issue Sensor-Based Condition Monitoring and Intelligent Fault Diagnosis)
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24 pages, 1197 KB  
Article
Physics-Informed Neural Network-Based Elevator Degradation Diagnosis and Early Warning
by Ren Li, Gang Xiao, Yuanming Zhang, Yaxing Ren, Fangfang Yao, Xiaoying Ru and Zhenhao Li
Sensors 2026, 26(12), 3718; https://doi.org/10.3390/s26123718 - 11 Jun 2026
Viewed by 185
Abstract
With the continuous growth of urban building density and elevator deployment, the reliability, maintenance, and degradation risk warning of elevator systems have attracted increasing attention. Conventional monitoring methods based on fixed thresholds or rule logic are easy to implement, but they often fail [...] Read more.
With the continuous growth of urban building density and elevator deployment, the reliability, maintenance, and degradation risk warning of elevator systems have attracted increasing attention. Conventional monitoring methods based on fixed thresholds or rule logic are easy to implement, but they often fail to identify progressive degradation and are sensitive to complex operating conditions and measurement noise. This paper proposes a physics-informed neural network (PINN)-based method for elevator health monitoring and early warning. First, multi-sensor data are processed through time alignment and feature reconstruction, and a dual-path acceleration estimation method is introduced to improve the stability of dynamic state calculation. Second, a simplified traction elevator dynamic model considering load variation, motor drive, and mechanical resistance is embedded into PINN training to identify hidden parameters. Electrical and dynamic residual indicators are then constructed to characterise system condition from different physical perspectives. Finally, a time-accumulated risk model combining anomaly magnitude and persistence duration is developed to detect progressive degradation trends. Results show stable parameter convergence and effective condition assessment. The proposed approach detects degradation trends earlier than conventional threshold-based monitoring methods and reduces false alarms caused by transient disturbances. It provides an interpretable and practical solution for predictive maintenance and intelligent operation of elevator systems. Full article
(This article belongs to the Special Issue Sensor-Based Condition Monitoring and Intelligent Fault Diagnosis)
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17 pages, 5075 KB  
Article
Integrating Frequency Guidance into Multi-Source Domain Generalization for Acoustic-Based Fault Diagnosis in Industrial Systems
by Yu Wang, Hongyang Zhang, Yinhao Liu, Chenyu Ma, Xiaolu Li, Xiaotong Tu and Xinghao Ding
Sensors 2026, 26(9), 2647; https://doi.org/10.3390/s26092647 - 24 Apr 2026
Viewed by 328
Abstract
With the increasing demand for intelligent fault monitoring, acoustic-based diagnosis has emerged as a promising solution for industrial applications such as pipeline leakage and electrical equipment fault detection. However, complex working conditions and domain shifts significantly degrade model performance, especially when unseen target [...] Read more.
With the increasing demand for intelligent fault monitoring, acoustic-based diagnosis has emerged as a promising solution for industrial applications such as pipeline leakage and electrical equipment fault detection. However, complex working conditions and domain shifts significantly degrade model performance, especially when unseen target domain data is unavailable. To address this, we propose an amplitude-phase collaborative augmentation network named AP-CANet tailored for acoustic fault diagnosis. Specifically, the network adaptively aligns amplitude and phase features across multiple source domains and performs label-consistent sample augmentation to enrich data diversity while preserving semantic consistency. A frequency–spatial interaction module further integrates global spectral information with local temporal details to improve feature discriminability. Moreover, we introduce a manifold triplet loss that scales shortest path distances in the feature manifold, encouraging the model to better capture subtle distinctions among hard samples and improving intra-class compactness and inter-class separability. We evaluate the proposed method on two publicly available datasets: the Pipeline Leak Acoustic Dataset (GPLA-12) and the Electrical Sound Dataset (MIMII-DG). Experimental results demonstrate superior performance under domain-shift scenarios, highlighting the method’s potential for scalable and low-cost acoustic fault diagnosis in real-world industrial environments. Full article
(This article belongs to the Special Issue Sensor-Based Condition Monitoring and Intelligent Fault Diagnosis)
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