Search Results (140)

In the context of intelligent manufacturing, deep learning-based remaining useful life (RUL) prediction has become a research hotspot in the field of Prognostics and Health Management (PHM). The traditional approaches often require strong programming skills and repeated model building, posing a high entry barrier. To address this, in this study, we propose and implement a visualization tool that supports multiple model selections and result visualization and eliminates the need for complex coding and mathematical derivations, helping users to efficiently conduct RUL prediction with lower technical requirements. This study introduces and summarizes various novel neural network models for DL-based RUL prediction. The models are validated using the NASA and HNEI datasets, and among the validated models, the LSTM model best met the requirements for remaining useful life (RUL) prediction. In order to achieve the low-code usage of deep learning for RUL prediction, the following tasks were performed: (1) multiple models were developed using the Python (3.9.18) language and were implemented on the PyTorch (1.12.1) framework, providing users with the freedom to choose their desired model; (2) a user-friendly and low-code RUL prediction interface was built using Streamlit, enabling users to easily make predictions; (3) the visualization of prediction results was implemented using Matplotlib (3.8.2), allowing users to better understand and analyze the results. In addition, the tool offers functionalities such as automatic hyperparameter tuning to optimize the performance of the prediction model and reduce the complexity of operations. Full article

In the contemporary big data era, data-driven prognostic and health management (PHM) methodologies have emerged as indispensable tools for ensuring the secure and reliable operation of complex equipment systems. Central to these methodologies is the accurate prediction of remaining useful life (RUL), which serves as a pivotal cornerstone for effective maintenance and operational decision-making. While significant advancements in computer hardware and artificial intelligence (AI) algorithms have catalyzed substantial progress in AI-based RUL prediction, extant research frequently exhibits a narrow focus on specific algorithms, neglecting a comprehensive and comparative analysis of AI techniques across diverse equipment types and operational scenarios. This study endeavors to bridge this gap through the following contributions: (1) A rigorous analysis and systematic categorization of application scenarios for equipment RUL prediction, elucidating their distinct characteristics and requirements. (2) A comprehensive summary and comparative evaluation of several AI algorithms deemed suitable for RUL prediction, delineating their respective strengths and limitations. (3) An in-depth comparative analysis of the applicability of AI algorithms across varying application contexts, informed by a nuanced understanding of different application scenarios and AI algorithm research. (4) An insightful discussion on the current challenges confronting AI-based RUL prediction technology, coupled with a forward-looking examination of its future prospects. By furnishing a meticulous and holistic understanding of the traits of various AI algorithms and their contextual applicability, this study aspires to facilitate the attainment of optimal application outcomes in the realm of equipment RUL prediction. Full article

The remaining useful life (RUL) of complex mechanical systems is the primary aspect of prognostics and health management, which is critical for ensuring reliability and safety. Recent developments have shifted towards a data-driven approach, emphasizing empirical insights over expert opinions. The similarity-based data-driven approach operates on the premise that systems with similar historical behaviors will likely exhibit similar future behaviors, making it suitable for RUL estimation. Conventionally, most similarity-based approaches utilize all historical data to identify reference systems for RUL estimations. However, not all historical events within a system hold equal significance for RUL. Certain events have a substantial impact on the remaining lifespan of a system. These significant and impactful events are called degradation events (DEs) in this study. Based on the hypothesis that systems undergoing similar DEs may share the same RUL, this study presents an innovative framework for RUL estimation that leverages only the DEs of a test system to identify reference systems that have experienced similar DEs. Furthermore, the model incorporates novel strategies for adjusting the RUL of the reference system based on the initial wear and degradation rates, thereby improving estimation accuracy. The effectiveness of the proposed model, in comparison with similar state-of-the-art models, is demonstrated through experiments on widely recognized jet engine datasets provided by NASA and bearing degradation data from the XJTU-SY. Full article

With the advancement of industrial manufacturing and the shift toward high automation, machines have increasingly taken over many production tasks, greatly improving efficiency and reducing human labor. However, this also introduces new challenges, particularly the inability of machines to autonomously detect and diagnose faults. Such undetected issues may cause unexpected breakdowns, interrupting critical operations, leading to economic losses and potential safety hazards. To address this, the present study proposes a novel hybrid deep learning framework that integrates Convolutional Neural Networks (CNN) for feature extraction with Transformer architecture for temporal modeling. The model is validated using NASA’s CMAPSS dataset, a widely used benchmark that includes multi-sensor data and Remaining Useful Life (RUL) labels from aeroengines. By learning from time-series sensor data, the framework achieves accurate RUL predictions and early fault detection. Experimental results show that the model attains over 97% accuracy under both single and multiple operating conditions, highlighting its robustness and adaptability. These findings suggest the framework’s potential in developing intelligent maintenance systems and contribute to the field of Prognostics and Health Management (PHM), enabling more reliable, efficient, and self-monitoring industrial systems. Full article

The accurate real-time estimation of the remaining useful life (RUL) of lithium-polymer (LiPo) batteries is a critical enabler for ensuring the safety, reliability, and operational efficiency of unmanned aerial vehicles (UAVs). Nevertheless, achieving such prognostics on resource-constrained embedded platforms remains a considerable technical challenge. This study proposes an end-to-end TinyML-based framework that integrates embedded sensor data fusion with an optimized feedforward neural network (FFNN) model for efficient RUL estimation under strict hardware limitations. The system collects voltage, discharge time, and capacity measurements through a lightweight data fusion pipeline and leverages the Edge Impulse platform with the EON™Compiler for model optimization. The trained model is deployed on a dual-core ARM Cortex-M0+ Raspberry Pi RP2040 microcontroller, communicating wirelessly with a LabVIEW-based visualization system for real-time monitoring. Experimental validation on an 80-gram UAV equipped with a 1100 mAh LiPo battery demonstrates a mean absolute error (MAE) of 3.46 cycles and a root mean squared error (RMSE) of 3.75 cycles. Model testing results show an overall accuracy of $98.82\%$, with a mean squared error (MSE) of 55.68, a mean absolute error (MAE) of 5.38, and a variance score of 0.99, indicating strong regression precision and robustness. Furthermore, the quantized (int8) version of the model achieves an inference latency of 2 ms, with memory utilization of only 1.2 KB RAM and 11 KB flash, confirming its suitability for real-time deployment on resource-constrained embedded devices. Overall, the proposed framework effectively demonstrates the feasibility of combining embedded sensor data fusion and TinyML to enable accurate, low-latency, and resource-efficient real-time RUL estimation for UAV battery health management. Full article

The accurate estimation of the remaining useful life (RUL) of lithium-ion batteries (LIBs) is essential for ensuring safety and enabling effective battery health management systems. To address this challenge, data-driven solutions leveraging advanced machine learning and deep learning techniques have been developed. This study introduces a novel framework, Deep Neural Networks with Memory Features (DNNwMF), for predicting the RUL of LIBs. The integration of memory features significantly enhances the model’s accuracy, and an autoencoder is incorporated to optimize the feature representation. The focus of this work is on feature engineering and uncovering hidden patterns in the data. The proposed model was trained and tested using lithium-ion battery cycle life datasets from NASA’s Prognostic Centre of Excellence and CALCE Lab. The optimized framework achieved an impressive RMSE of 6.61%, and with suitable modifications, the DNN model demonstrated a prediction accuracy of 92.11% for test data, which was used to estimate the RUL of Nissan Leaf Gen 01 battery modules. Full article

Estimating Remaining Useful Life (RUL) is crucial in modern Prognostic and Health Management (PHM) systems providing valuable information for planning the maintenance strategy of critical components in complex systems such as aircraft engines. Deep Learning (DL) models have shown great performance in the accurate prediction of RUL, building hierarchical representations by the stacking of multiple explicit neural layers. In the current research paper, we follow a different approach presenting a Deep Equilibrium Model (DEM) that effectively captures the spatial and temporal information of the sequential sensor. The DEM, which incorporates convolutional layers and a novel dual-input interconnection mechanism to capture sensor information effectively, estimates the degradation representation implicitly as the equilibrium solution of an equation, rather than explicitly computing it through multiple layer passes. The convergence representation of the DEM is estimated by a fixed-point equation solver while the computation of the gradients in the backward pass is made using the Implicit Function Theorem (IFT). The Monte Carlo Dropout (MCD) technique under calibration is the final key component of the framework that enhances regularization and performance providing a confidence interval for each prediction, contributing to a more robust and reliable outcome. Simulation experiments on the widely used NASA Turbofan Jet Engine Data Set show consistent improvements, with the proposed framework offering a competitive alternative for RUL prediction under diverse conditions. Full article

Lithium-ion batteries experience nonlinear degradation characteristics during long-term operation. Accurate estimation of their remaining useful life (RUL) is of significant importance for early fault diagnosis and residual value evaluation. However, existing RUL prediction approaches often suffer from limited accuracy and insufficient specificity. To address these limitations, this study proposes an RUL prediction methodology based on Gaussian process regression, which incorporates degradation pattern recognition and auxiliary features derived from knee points. First, 9 health-related features are extracted from the first 100 charge/discharge cycles of the battery. Based on these extracted features, clustering and classification techniques are employed to categorize the batteries into three distinct degradation patterns. Moreover, feature importance is assessed to identify and eliminate redundant indicators, thereby enhancing the relevance of the feature set for prediction. Subsequently, for each degradation pattern, GPR-based models with composite kernel functions are constructed by integrating knee point positions and their corresponding slopes. The model hyperparameters are further optimized through the particle swarm optimization (PSO) algorithm to improve the adaptability and generalization capability of the predictive models. Experimental results demonstrate that the proposed method achieves a high level of predictive accuracy, with an overall mean absolute percentage error (MAPE) of approximately 8.70%. Furthermore, compared with conventional prediction methods, the proposed approach exhibits superior performance and can serve as an effective evaluation tool for diverse application scenarios, including lithium-ion battery health monitoring, early prognostics, and echelon utilization. Full article

Remaining useful life (RUL) prediction plays a core role in industrial prognostics and health management (PHM), requiring data-driven models with higher predictive capability for accurate long time series prediction. Developing reliable deep learning-based models based on multi-sensor monitoring data is fundamental for accurately predicting vibration trends during bearing operation and is crucial for bearing fault diagnosis and RUL prediction. In this work, a method for constructing a health index based on vibration signal is developed to describe the performance features of rolling bearings, which mainly includes feature extraction, sensitive feature index selection, dimensionality reduction, and normalization methods. In addition, a new RUL prediction method, TCN–Transformer, is developed which can efficiently learn and integrate local and global features of vibration signals, addressing the long time series prediction problem in RUL prediction. The TCN extracts local features, while the Transformer learns global features, both of which are seamlessly integrated through a specially designed feature fusion attention module. Both the health indicator (HI) constructed from extracted time domain and frequency domain feature parameters and the RUL prediction method were rigorously validated using the IEEE PHM 2012 Data Challenge dataset for rolling bearing prognostics. By employing the proposed HI construction method, the average comprehensive bearing performance index, used to evaluate RUL prediction accuracy, is improved by 8.69% across the entire dataset compared to the original feature-based composite index. The proposed RUL prediction model can more accurately predict the RUL of rolling bearings under different conditions, reducing the RMSE and MAE by 14.62% and 9.26%, respectively, and improving the SCORE by 13.04%. These results underscore the efficacy and superiority of our approach in RUL prediction of rotating machinery across varying conditions. Full article

Proton-Exchange-Membrane Fuel Cell (PEMFC) systems are proving to be a promising solution for decarbonizing various means of transport, especially heavy ones. However, their reliability, availability, performance, durability, safety and operating costs are not yet fully competitive with industrial and commercial systems (actual systems). Predictive maintenance (PrM) is proving to be one of the most promising solutions for improving these critical points. In this paper, several PrM approaches will be developed considering the constraints of actual systems. The first approach involves estimating the overall State of Health (SOH) of a PEMFC operating under a dynamic load according to an FC-DLC (Fuel Cell Dynamic Load Cycle) profile, using a Health Indicator (HI). This section will also discuss the relevance of current End-of-Life (EoL) indicators by putting the performance, safety and economic profitability of PEMFC systems into perspective. The second approach involves predicting the voltage of the PEMFC while operating under this same profile in order to estimate its overall Remaining Useful Life (RUL). Finally, the last approach proposed will make it possible to estimate the time when it will be worthwhile, or even economically necessary, to replace a degraded PEMFC with a new one. Full article

This study, set within the vast and varied research field of industrial Internet of Things (IoT) systems, proposes a methodology to address uncertainty quantification (UQ) issues in predictive maintenance (PdM) practices. At its core, this paper leverages the commercial modular aero-propulsion system simulation (CMAPSS) dataset to evaluate different artificial intelligence (AI) prognostic algorithms for remaining useful life (RUL) forecasting while supporting the estimation of a robust confidence interval (CI). The methodology primarily involves the comparison of statistical learning (SL), machine learning (ML), and deep learning (DL) techniques for each different scenario of the CMAPSS, evaluating the performances through a tailored metric, the S-score metric, and then benchmarking diverse conformal-based uncertainty estimation techniques, remarkably naive, weighted, and bootstrapping, offering a more suitable and reliable alternative to classical RUL prediction. The results obtained highlight the peculiarities and benefits of the conformal approach, despite probabilistic models favoring the adoption of complex models in cases where the operating conditions of the machine are multiple, and suggest the use of weighted conformal practices in non-exchangeability conditions while recommending bootstrapping alternatives for contexts with a more substantial presence of noise in the data. Full article

Remaining Useful Life (RUL) plays a critical role in prognostics and health management systems. It helps increase reliability and safety for the equipment used in the modern industry. The new idea proposed is the Mamba deep learning model, which aims to find a good balance between predictive performance and computation cost. This paper presents a multimodal RUL prediction model, Cau–BiMamba–LSTM, using causal discovery, a bidirectional Mamba (BiMamba), attention mechanism, and Long Short-Term Memory (LSTM). The framework utilizes maximum information transfer entropy and simple exponential smoothing in building a causal graph model that extracts groups of feature variable groupsLSTM performs long-range dependencies; the attention mechanism dynamically focuses attention according to the temporal context; finally, the bidirectional state space model captures all contextual information over time for a richer insight into underlying data patterns. Tests conducted on the C-MAPSS dataset confirm that this model achieves superior predictive accuracy and robustness. Moreover, the model achieves high predictive performance in very complex, long time–series and provides fast responses. Full article

Accurate forecasting of the remaining useful life (RUL) of aviation equipment is crucial for enhancing safety and reducing maintenance costs. This study presents a novel hybrid prognostic methodology that integrates physics-based and data-driven models to improve RUL estimations for critical aircraft components. The physics-based approach simulates long-term degradation patterns using fundamental principles such as mass conservation and Bernoulli’s equation, while the data-driven model employs a hyper tangent boosted neural network (HTBNN) to detect short-term anomalies and deviations in real-time sensor data. The integration of various models enhances accuracy, adaptability, and reliability in prognostics. The proposed methodology is assessed using NASA’s N-CMAPSS dataset for gas turbines and a fuel system test rig, demonstrating a 15% improvement in prediction accuracy and a 20% reduction in uncertainty compared to traditional methods. These findings highlight the potential for widespread application of this hybrid methodology in predictive maintenance and prognostic and health management (PHM) of aircraft systems. Full article

This paper introduces a novel framework for generating synthetic time-series data from turbine engine sensor readings using a text-conditioned diffusion model. The approach begins with dataset preprocessing, including correlation analysis, feature selection, and normalization. Principal Component Analysis (PCA) transforms the normalized signals into three components, mapped to the RGB channels of an image. These components, combined with engine identifiers and cycle information, form compact 19 × 19 × 3 pixel images, later scaled to 512 × 512 × 3 pixels. A variational autoencoder (VAE)-based diffusion model, fine-tuned on these images, leverages text prompts describing engine characteristics to generate high-quality synthetic samples. A reverse transformation pipeline reconstructs synthetic images back into time-series signals, preserving the original engine-specific attributes while removing padding artifacts. The quality of the synthetic data is assessed by training Remaining Useful Life (RUL) estimation models and comparing performance across original, synthetic, and combined datasets. Results demonstrate that synthetic data can be beneficial for model training, particularly in the early epochs when working with limited datasets. Compared to existing approaches, which rely on generative adversarial networks (GANs) or deterministic transformations, the proposed framework offers enhanced data fidelity and adaptability. This study highlights the potential of text-conditioned diffusion models for augmenting time-series datasets in industrial Prognostics and Health Management (PHM) applications. Full article

Lithium-ion batteries (LIBs) are widely utilized in consumer electronics, electric vehicles, and large-scale energy storage systems due to their high energy density and long lifespan. Accurately estimating the state of health (SOH) and predicting the remaining useful life (RUL) of cells is crucial to ensuring their safety and preventing potential risks. Existing state estimation methodologies primarily rely on electrical signal measurements, which predominantly capture electrochemical reaction dynamics but lack sufficient integration of thermomechanical process data critical to holistic system characterization. In this study, relevant thermal and mechanical features collected during the formation process are extracted and incorporated as additional data sources for battery state estimation. By integrating diverse datasets with advanced algorithms and models, we perform correlation analyses of parameters such as capacity, voltage, temperature, pressure, and strain, enabling precise SOH estimation and RUL prediction. Reliable predictions are achieved by considering the interaction mechanisms involved in the formation process from a mechanistic perspective. Full lifecycle data of batteries, gathered under varying pressures during formation, are used to predict RUL using convolutional neural networks (CNN) and Gaussian process regression (GPR). Models that integrate all formation-related data yielded the lowest root mean square error (RMSE) of 2.928% for capacity estimation and 16 cycles for RUL prediction, highlighting the significant role of surface-level physical features in improving accuracy. This research underscores the importance of formation features in battery state estimation and demonstrates the effectiveness of deep learning in performing thorough analyses, thereby guiding the optimization of battery management systems. Full article