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Search Results (683)

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Keywords = predictive maintenance decisions

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19 pages, 736 KB  
Article
Modeling and Optimization for Reverse Osmosis Water Treatment Using Artificial Neural Network and Genetic Algorithm Approach: Economic and Operational Perspectives
by Hamdani Hamdani, Iwan Vanany and Heri Kuswanto
Water 2026, 18(7), 810; https://doi.org/10.3390/w18070810 (registering DOI) - 28 Mar 2026
Abstract
This study contributes to the modeling and optimization model for reverse osmosis water treatment (ROWT) due to a lack of economic and operational aspects. This study proposes a hybrid modeling and optimization framework using a hybrid artificial neural network (ANN) and genetic algorithm [...] Read more.
This study contributes to the modeling and optimization model for reverse osmosis water treatment (ROWT) due to a lack of economic and operational aspects. This study proposes a hybrid modeling and optimization framework using a hybrid artificial neural network (ANN) and genetic algorithm (GA) to enhance the accuracy of economic and operational predictions for ROWT. The ANN model is developed using seventeen key process parameters extracted from various ROWT plants, including flow rate, pH, conductivity, and turbidity. The GA is employed to optimize the network architecture and learning parameters based on the mean absolute percentage error (MAPE) as the fitness function. The findings of this study indicate that the GA-optimized model significantly outperforms the baseline model, reducing MAPE for the economic aspect (84.9% improvement) and the operational aspect (32.2% improvement). The findings from this study indicate that the hybrid ANN–GA approach is a management decision-making tool for reducing expenses without compromising water quality in ROWT management. The practical implications of this study are that predictions not only meet operational parameters but also predict expenses incurred, allowing managers to plan future budgets by optimizing ROWT resources and maintenance activities. Full article
(This article belongs to the Section Wastewater Treatment and Reuse)
36 pages, 1068 KB  
Article
Service-Oriented Architecture for Decision Support in Industrial Life-Cycle Management: Design, Implementation, and Evaluation
by Rui Neves-Silva
Processes 2026, 14(7), 1088; https://doi.org/10.3390/pr14071088 - 27 Mar 2026
Abstract
Manufacturing enterprises face increasing complexity in managing the complete life cycle of production systems, requiring integration of information from diverse sources to support timely maintenance, diagnostics, and operational decisions. This paper presents a comprehensive service-oriented architecture (SOA) for decision support in industrial life-cycle [...] Read more.
Manufacturing enterprises face increasing complexity in managing the complete life cycle of production systems, requiring integration of information from diverse sources to support timely maintenance, diagnostics, and operational decisions. This paper presents a comprehensive service-oriented architecture (SOA) for decision support in industrial life-cycle management, integrating real-time monitoring, predictive maintenance, and collaborative problem-solving across extended manufacturing enterprises. The architecture implements a three-layer service model comprising eight core collaborative services, three application services, and six life-cycle management services, orchestrated through a risk assessment module that monitors life-cycle parameters and triggers appropriate maintenance, diagnostics, or hazard prevention actions. The system was developed in the context of a European research project and validated in two industrial settings: automotive assembly lines at a German SME and air conditioning manufacturing at a Portuguese company. Results demonstrated substantial operational improvements, including reduced problem resolution time, lower diagnostic travel requirements, reduced spare-parts consumption, and increased structured problem registration. The original SOAP-based web-services implementation is further contextualized within the contemporary Industry 4.0 landscape through comparison with microservices architectures and discussion of integration paths involving OPC UA, Asset Administration Shells, and digital twins. The paper contributes a validated reference architecture for service-based industrial life-cycle management and clarifies its relevance as an early precursor of contemporary smart manufacturing approaches. Full article
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23 pages, 3375 KB  
Article
SHAP-Driven Fractional Long-Range Model for Degradation Trend Prediction of Proton Exchange Membrane Fuel Cells
by Tongbo Zhu, Fan Cai and Dongdong Chen
Energies 2026, 19(7), 1655; https://doi.org/10.3390/en19071655 - 27 Mar 2026
Abstract
Under dynamic loading conditions, the output voltage of proton exchange membrane fuel cells (PEMFCs) exhibits nonlinear degradation characterized by non-Gaussian fluctuations, abrupt changes, and long-range temporal dependence, which are difficult to model using conventional short-correlation or remaining useful life (RUL) prediction approaches. To [...] Read more.
Under dynamic loading conditions, the output voltage of proton exchange membrane fuel cells (PEMFCs) exhibits nonlinear degradation characterized by non-Gaussian fluctuations, abrupt changes, and long-range temporal dependence, which are difficult to model using conventional short-correlation or remaining useful life (RUL) prediction approaches. To capture both historical dependency and stochastic jump behavior, this study proposes a SHAP-driven mechanism–data fusion fractional stochastic degradation model based on fractional Brownian motion (fBm) and fractional Poisson process (fPp) for degradation trend forecasting. A terminal voltage mechanism model considering activation, ohmic, and concentration polarization losses is first established, and SHapley Additive exPlanations (SHAP) analysis is employed to quantify the contributions of multi-source operational variables and enhance interpretability. The Hurst exponent is then used to verify long-range dependence and jump characteristics in the voltage sequence. Subsequently, fBm is integrated with a fPp to construct a unified stochastic degradation framework capable of jointly describing continuous decay and discrete abrupt variations, enabling multi-step probabilistic prediction with confidence intervals. Validation on the publicly available FCLAB FC1 and FC2 datasets shows that the proposed model achieves superior overall performance under both steady and dynamic conditions, with MAPE/RMSE/R2 of 0.027%/0.00178/0.9895 and 0.056%/0.00259/0.9896, respectively, outperforming fBm, Wiener, WTD-RS-LSTM, and CNN-LSTM methods. The proposed approach provides accurate and interpretable degradation forecasting for PEMFC health management and maintenance decision support. Full article
(This article belongs to the Section D2: Electrochem: Batteries, Fuel Cells, Capacitors)
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20 pages, 2881 KB  
Article
Structural Deformation Prediction and Uncertainty Quantification via Physics-Informed Data-Driven Learning
by Tong Zhang and Shiwei Qin
Appl. Sci. 2026, 16(7), 3194; https://doi.org/10.3390/app16073194 - 26 Mar 2026
Viewed by 100
Abstract
In structural health monitoring, purely data-driven methods for deformation prediction are often susceptible to time-varying boundary conditions under complex operating scenarios, leading to insufficient physical interpretability and limited generalization across different conditions. To address these challenges, this study proposes a Physics-Informed Dual-branch Long [...] Read more.
In structural health monitoring, purely data-driven methods for deformation prediction are often susceptible to time-varying boundary conditions under complex operating scenarios, leading to insufficient physical interpretability and limited generalization across different conditions. To address these challenges, this study proposes a Physics-Informed Dual-branch Long Short-Term Memory framework (PINN-DualSHM). The framework employs dual-branch LSTMs to separately extract temporal features of structural mechanical responses and environmental thermal effects. Dynamic decoupling and fusion of these heterogeneous features are achieved through an adaptive cross-attention mechanism. Furthermore, physical priors, including the thermodynamic superposition principle and structural settlement monotonicity, are embedded into the loss function as regularization terms, complemented by a dual uncertainty quantification system based on heteroscedastic regression and MC Dropout. Experimental results based on long-term measured data from an industrial base project in Shenzhen demonstrate that PINN-DualSHM significantly outperforms baseline models such as LSTM, CNN-LSTM, and GAT-LSTM. Specifically, the Root Mean Square Error (RMSE) is reduced by 65.25%, and the coefficient of determination (R2) reaches 0.925. Physical consistency analysis confirms that the introduction of physical constraints effectively suppresses anomalous predictive fluctuations that violate mechanical laws. Uncertainty decomposition reveals that aleatoric uncertainty is dominant (93.7%), objectively indicating that the current system’s accuracy bottleneck lies in sensor noise rather than model capability. By enhancing prediction accuracy while providing credible quantitative assessments and physical interpretability, the proposed method provides a scientific basis for the operation, maintenance optimization, and upgrading decisions of SHM systems. Full article
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18 pages, 375 KB  
Review
AI-Driven and Algorithm-Supported Decision Support Using Continuous, Remote, and Self-Monitoring Patient Data for Early Deterioration Detection and Escalation: A Scoping Review
by Kazumi Kubota and Anna Kubota
Appl. Sci. 2026, 16(7), 3131; https://doi.org/10.3390/app16073131 - 24 Mar 2026
Viewed by 127
Abstract
Continuous ward monitoring, remote patient monitoring, and self-monitoring can generate high-frequency physiological data streams, yet clinical benefit depends on whether signals lead to timely escalation without excessive non-actionable alerts and workflow burden. This scoping review, reported in accordance with the Preferred Reporting Items [...] Read more.
Continuous ward monitoring, remote patient monitoring, and self-monitoring can generate high-frequency physiological data streams, yet clinical benefit depends on whether signals lead to timely escalation without excessive non-actionable alerts and workflow burden. This scoping review, reported in accordance with the Preferred Reporting Items for Systematic Reviews and Meta-Analyses extension for Scoping Reviews (PRISMA-ScR), mapped AI-driven and algorithm-supported decision support approaches using continuous, remote, or self-monitoring patient data for early deterioration detection or prediction and escalation support, with emphasis on nursing relevance, workflow integration, alert burden, and implementation outcomes. PubMed (MEDLINE), Ovid MEDLINE, Web of Science Core Collection, and Scopus were searched on 14 February 2026. The search identified 47 records; 12 duplicates were removed; 35 records were screened; 28 were excluded; and 7 full-text reports were included. The included evidence comprised two original studies, two protocol/design papers, and three reviews. Within these included sources, decision support was commonly described as linking monitoring inputs to interpretive outputs, such as tiered alerts or risk predictions, and then to escalation-related actions or response pathways. Because the evidence base was small and heterogeneous, the review should be interpreted as exploratory evidence mapping rather than as a basis for broad generalization. Within the included studies, key reporting gaps included inconsistent description of escalation endpoints, limited standardized reporting of alert burden and acknowledgment patterns, incomplete workflow descriptions in some remote monitoring evidence, and limited attention to maintenance risks such as dataset shift. Full article
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19 pages, 1015 KB  
Article
Smart Energy Management in Agricultural Wireless Sensor Nodes Using TinyML-Based Adaptive Sampling
by Adrian Hinostroza, Jimmy Tarrillo and Moises Nuñez
Sensors 2026, 26(7), 2014; https://doi.org/10.3390/s26072014 - 24 Mar 2026
Viewed by 250
Abstract
Smart sensors are increasingly used in agriculture to monitor environmental conditions and support data-driven decision-making. However, traditional sensor implementations face critical challenges related to power consumption, especially in remote farms—such as pitaya plantations—where access to electricity and ongoing maintenance is limited. This paper [...] Read more.
Smart sensors are increasingly used in agriculture to monitor environmental conditions and support data-driven decision-making. However, traditional sensor implementations face critical challenges related to power consumption, especially in remote farms—such as pitaya plantations—where access to electricity and ongoing maintenance is limited. This paper presents a smart energy management system for agricultural sensor nodes integrating a machine learning model for adaptive sampling and a batching strategy to optimize energy usage. A lightweight Stochastic Gradient Descent (SGD) regressor trained on temperature dynamics runs on-device to predict the sampling interval (Ts). In parallel, the node adjusts the number of buffered samples as the battery state of charge (SOC) decreases, reducing Long Range (LoRa) transmissions. Field experiments show that the proposed approach reduces energy consumption by 77.8% compared with fixed-interval sampling, while maintaining good temperature fidelity with Mean Absolute Error (MAE) of 0.537 °C for temperature reconstruction. Full article
(This article belongs to the Special Issue Sensing and Machine Learning in Autonomous Agriculture)
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37 pages, 3341 KB  
Systematic Review
Quality–Diversity and Illumination Algorithms in Discrete Combinatorial Domains: Diversity Metrics and Implications for Resilient Mining Operations
by Luis Rojas, Emanuel Vega, Lorena Jorquera and José Garcia
Mathematics 2026, 14(7), 1091; https://doi.org/10.3390/math14071091 - 24 Mar 2026
Viewed by 276
Abstract
Quality–Diversity (QD) optimization has emerged as a distinctive paradigm in evolutionary computation, shifting the focus from identifying a single global optimum to illuminating a high-dimensional repertoire of elite solutions that jointly maximize performance and behavioral diversity. While algorithms like MAP-Elites have enabled transformative [...] Read more.
Quality–Diversity (QD) optimization has emerged as a distinctive paradigm in evolutionary computation, shifting the focus from identifying a single global optimum to illuminating a high-dimensional repertoire of elite solutions that jointly maximize performance and behavioral diversity. While algorithms like MAP-Elites have enabled transformative results in robotics and procedural content generation, their generalization to discrete combinatorial domains remains insufficiently consolidated in the literature. To address this gap, a systematic literature review was conducted strictly following PRISMA 2020 guidelines. The synthesis reveals rapid exponential growth in QD research, accompanied by significant algorithmic diversification toward gradient-informed variations and hardware-accelerated implementations. Despite this maturation, discrete combinatorial applications remain comparatively underrepresented, with only a small fraction (12.5%) of the analyzed corpus explicitly addressing discrete problems using domain-specific representations and heuristics. Based on these empirical findings, a conceptual framework is proposed. This framework positions QD as a vital mechanism for operational resilience in stochastic industrial contexts—specifically mining operations, including predictive maintenance, mineral processing optimization, and blast design—demonstrating its strategic value for complex decision-making. Full article
(This article belongs to the Special Issue Diversity Metrics in Combinatorial Problems)
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28 pages, 838 KB  
Review
Smart Technologies for Water Resources Management (WRM) in Semi-Arid Latin America: A Narrative Review and Adoption Agenda
by Eduardo Alonso Sánchez Ruiz, Lázaro V. Cremades and Stephanie Villanueva Benites
Sustainability 2026, 18(6), 3153; https://doi.org/10.3390/su18063153 - 23 Mar 2026
Viewed by 210
Abstract
Semi-arid territories in Latin America face chronic water stress; limited observability and fragmented institutions constrain effective water resources management (WRM). This narrative review synthesizes peer-reviewed evidence (2020–2026) on smart technologies that strengthen basin- and utility-level WRM, using Peru (Piura-like coastal semi-arid contexts) as [...] Read more.
Semi-arid territories in Latin America face chronic water stress; limited observability and fragmented institutions constrain effective water resources management (WRM). This narrative review synthesizes peer-reviewed evidence (2020–2026) on smart technologies that strengthen basin- and utility-level WRM, using Peru (Piura-like coastal semi-arid contexts) as an anchor and Latin America as a comparative lens. We used a structured, traceable database-based workflow and synthesized studies reporting measurable outcomes across five application categories: drought/flood early warning, hydrometeorological forecasting, water quality surveillance, non-revenue water (NRW)/leakage, and allocation and compliance. Findings were organized into an application-oriented taxonomy spanning remote sensing (RS) and GIS, Internet of Things (IoT)/telemetry, analytics/AI-enabled decision support, and hybrid approaches. Evidence most consistently reports operational gains (coverage, timeliness, predictive performance), while governance outcomes are less frequently measured and appear contingent on interoperability, digital capacity, and sustainable operations and maintenance (O&M) conditions. We conclude with a territorial adoption agenda specifying minimum enabling conditions and a phased pathway from pilots to scalable, eco-efficient smart WRM in Peru and comparable semi-arid settings across Latin America. Full article
(This article belongs to the Special Issue Smart Technologies Toward Sustainable Eco-Friendly Industry)
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17 pages, 4872 KB  
Article
Aerial Thermography Using UAV Platforms: Modernization of Critical Energy Infrastructure Diagnostics
by Matej Ščerba, Marek Kišš, Robert Wieszala, Jacek Mendala and Adam Tomaszewski
Appl. Sci. 2026, 16(6), 3014; https://doi.org/10.3390/app16063014 - 20 Mar 2026
Viewed by 129
Abstract
Unmanned aerial vehicles (UAVs) are increasingly being used as diagnostic platforms in electricity transmission and distribution, enabling safer and faster inspections compared to manual climbing operations or manned aerial support. This article presents an implementation-oriented inspection process that integrates RGB imaging, infrared (IR) [...] Read more.
Unmanned aerial vehicles (UAVs) are increasingly being used as diagnostic platforms in electricity transmission and distribution, enabling safer and faster inspections compared to manual climbing operations or manned aerial support. This article presents an implementation-oriented inspection process that integrates RGB imaging, infrared (IR) thermography and (optionally) LiDAR documentation for critical energy infrastructure and photovoltaic (PV) installations. The survey consists of two stages: a preliminary stage under controlled conditions and an operational stage in a real-world environment, limited only by UAV flight restrictions. Thermal measurements are recorded in radiometric formats and analyzed using polygon- and profile-based tools to identify temperature anomalies (hot spots) and support maintenance escalation decisions. This manuscript presents standardized sample templates for mission logs, QA/QC activities, and anomaly lists, intended to support reproducible data collection in future studies. The proposed process supports predictive maintenance by enabling repeatable inspections, archive-based trend analysis, and integration with asset management processes, while minimizing operational risk and avoiding power outages when technically feasible. Full article
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34 pages, 1788 KB  
Article
A Two-Stage Comparative Framework for Predicting Photovoltaic Cleaning Schedules: Modeling and Comparisons Based on Real and Simulated Data
by Ali Al-Humairi, Enmar Khalis, Zuhair A. Al Hemyari and Peter Jung
Appl. Sci. 2026, 16(6), 2976; https://doi.org/10.3390/app16062976 - 19 Mar 2026
Viewed by 220
Abstract
This study develops and validates a two-stage comparative framework for predicting Photovoltaic (PV) cleaning schedules by integrating high-resolution operational data with regression-based simulated datasets generated from statistical models trained on real measurements. The work directly addresses the growing need to assess whether model-based [...] Read more.
This study develops and validates a two-stage comparative framework for predicting Photovoltaic (PV) cleaning schedules by integrating high-resolution operational data with regression-based simulated datasets generated from statistical models trained on real measurements. The work directly addresses the growing need to assess whether model-based regression-based simulated data can reliably substitute real measurements in predictive PV maintenance. These models are employed to generate clean-condition power baselines and to estimate daily energy losses attributable to soiling under two distinct paradigms: (i) using real historical PV performance and environmental measurements, and (ii) using regression-derived, regression-based simulated data representing idealized clean operating conditions. Model performance is rigorously quantified using correlation coefficients (R), coefficients of determination (R2), mean absolute deviations, and binary classification metrics including accuracy, precision, recall, and F1-score. The comprehensive results demonstrate that regression-based simulated datasets exhibit high fidelity with real measurements across key electrical variables. This is evident for datasets generated using PLSR, Ridge Regression, and Robust Regression. Strong correlations are observed for DC power (R2 = 0.9545) and DC current (R2 = 0.9520), with mean deviations consistently below 2.2%. When a threshold-based binary decision rule (“clean” versus “do not clean”) is applied, cleaning decisions derived from simulated and real datasets show near-perfect concordance, achieving a mean F1-score of 0.9792. These results indicate that for a fixed performance-loss threshold, models using regression-based simulated data reproduce real-data-based cleaning triggers with an accuracy exceeding 97%. Furthermore, the findings confirm that regression-based simulation frameworks constitute a reliable and scalable foundation for data-driven PV maintenance optimization. By enabling efficient cleaning scheduling, these frameworks can significantly reduce operational expenditure and maximize energy yield, particularly in regions where continuous, high-quality PV monitoring data are limited or difficult to obtain. Full article
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21 pages, 3159 KB  
Article
Optimizing Predictive and Prescriptive Maintenance Using Unified Namespace (UNS) for Industrial Equipments
by Renjithkumar Surendran Pillai, Patrick Denny, Eoin O'Connell, Adam Dooley and Mihai Penica
J. Exp. Theor. Anal. 2026, 4(1), 13; https://doi.org/10.3390/jeta4010013 - 19 Mar 2026
Viewed by 185
Abstract
This paper proposes a new Unified Namespace (UNS)-based architecture to improve predictive and prescriptive maintenance of industrial equipment and overcome challenges such as incomplete data, poor interoperability, and disconnected IT/OT environments. The framework combines interoperable data formats in real-time sensor data, predictive modeling, [...] Read more.
This paper proposes a new Unified Namespace (UNS)-based architecture to improve predictive and prescriptive maintenance of industrial equipment and overcome challenges such as incomplete data, poor interoperability, and disconnected IT/OT environments. The framework combines interoperable data formats in real-time sensor data, predictive modeling, prescriptive analytics, and simulations of digital twins, using UNS as a centralized, protocol-agnostic data layer that is scalable and complies with Industry 4.0 and Pharma 4.0 standards. The suggested methodology increases data accessibility, reduces integration complexity, and allows low-latency analytics and automated decision-making. Machine learning predictive models achieved more than 94% accuracy in predicting equipment failures. Prescriptive analytics provides maintenance recommendations to reduce downtime and risks. The feedback loops of digital twins can enhance the accuracy of predictions and allow decision optimization through what-if analysis. A test-bench deployment showed a higher performance compared to traditional point-to-point integration, with lower latency (approximately 18 ms vs. approximately 31 ms), decreasing packet loss (0.40% vs. 3.11%), and higher model accuracy (94.20% vs. 87.51%). The structure avoided more than 4000 simulated breakdowns in the test-bench environment, indicating dependability. The study connects the theoretical applications of the UNS with the actual maintenance processes and provides a sound approach to the industrial analytics and optimization of the equipment. Full article
(This article belongs to the Special Issue Digital Twin Technologies: Concepts, Methods, and Applications)
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19 pages, 1298 KB  
Article
Evidential Deep Learning for Quantification of Uncertainty in Lithium-Ion Batteries Remaining Useful Life Estimation
by Luca Martiri and Loredana Cristaldi
Energies 2026, 19(6), 1513; https://doi.org/10.3390/en19061513 - 18 Mar 2026
Viewed by 196
Abstract
Lithium-ion batteries are widely used across diverse applications due to their high energy density, long cycle life, and fast charging capabilities. As battery-powered systems become increasingly critical, accurate estimation of the Remaining Useful Life (RUL) is essential for ensuring reliability, safety, and effective [...] Read more.
Lithium-ion batteries are widely used across diverse applications due to their high energy density, long cycle life, and fast charging capabilities. As battery-powered systems become increasingly critical, accurate estimation of the Remaining Useful Life (RUL) is essential for ensuring reliability, safety, and effective maintenance planning. This work investigates Evidential Deep Learning (EDL) for data-driven RUL estimation and introduces a novel risk-aware loss function designed to enhance both predictive accuracy and uncertainty quantification in the End-of-Life (EoL) region, where precise and trustworthy predictions are most needed. Using a publicly available dataset of lithium iron phosphate (LFP) cells, we benchmark the proposed approach against a baseline Conv–LSTM model, Monte Carlo (MC) Dropout, and Deep Ensembles. The results show that integrating the risk-aware loss into the EDL framework substantially improves the calibration of predictive uncertainty while achieving state-of-the-art accuracy near EoL. Unlike MC Dropout and Deep Ensembles, which exhibit increasing or unstable uncertainty as degradation accelerates, the proposed EDL model demonstrates a consistent reduction in uncertainty and significantly higher reliability in late-stage predictions. The findings indicate that the risk-aware evidential framework offers a reliable and computationally efficient solution for battery RUL estimation, enabling more informed decision-making in both safety-critical and consumer-oriented applications. Full article
(This article belongs to the Special Issue Advances in Battery Modelling, Applications, and Technology)
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40 pages, 927 KB  
Review
Survival Models for Predictive Maintenance and Remaining Useful Life in Sensor-Enabled Smart Energy Networks: A Review
by Mohammad Reza Shadi, Hamid Mirshekali, Maryamsadat Tahavori and Hamid Reza Shaker
Sensors 2026, 26(6), 1915; https://doi.org/10.3390/s26061915 - 18 Mar 2026
Viewed by 204
Abstract
Smart energy networks, including electricity distribution and district heating, are increasingly operated as sensor-enabled infrastructures where maintenance decisions must be made under heterogeneous and time-varying operating conditions. In these settings, time-to-event data are rarely complete; preventive actions and limited observation horizons routinely introduce [...] Read more.
Smart energy networks, including electricity distribution and district heating, are increasingly operated as sensor-enabled infrastructures where maintenance decisions must be made under heterogeneous and time-varying operating conditions. In these settings, time-to-event data are rarely complete; preventive actions and limited observation horizons routinely introduce censoring and truncation, so models and validation procedures must account for partially observed lifetimes to avoid biased inference and misleading performance estimates. This review surveys survival models for predictive maintenance (PdM) and remaining useful life (RUL) estimation, spanning non-parametric, semi-parametric, parametric, and learning-based approaches, with emphasis on censoring-aware formulations and the use of static and time-varying covariates derived from sensor, inspection, and contextual information. A structured taxonomy and a systematic mapping of model families to data types, core assumptions (proportional hazards versus parametric distributional structure), and decision-oriented outputs such as risk ranking, horizon failure probabilities, and RUL distributions are presented. Evaluation practice is also synthesized by covering discrimination metrics, censoring-aware RUL accuracy measures, and probabilistic assessment via proper scoring rules, including the time-dependent Brier score and Integrated Brier Score (IBS). The review provides researchers and practitioners with a practical guide to selecting, fitting, and evaluating survival models for risk-informed maintenance planning in smart energy networks. Full article
(This article belongs to the Section Sensor Networks)
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48 pages, 6279 KB  
Article
Data-Driven Fleet Optimization Using ML Algorithms and a Decision-Making Grid Framework
by Ashraf Labib, Coralia Tǎnǎsuicǎ (Zotic), Turuna S. Seecharan and Mihai-Daniel Roman
Appl. Syst. Innov. 2026, 9(3), 63; https://doi.org/10.3390/asi9030063 - 17 Mar 2026
Viewed by 287
Abstract
The most impactful factors for the cost of fleet management are maintenance expenses and fuel consumption. Traditional ways of monitoring fleet performance fail to connect raw operational data with driving habits. The current study addresses this challenge by developing an architecture of frameworks, [...] Read more.
The most impactful factors for the cost of fleet management are maintenance expenses and fuel consumption. Traditional ways of monitoring fleet performance fail to connect raw operational data with driving habits. The current study addresses this challenge by developing an architecture of frameworks, consisting of unsupervised and supervised machine learning algorithms, statistical testing, simulation and survival analysis to discover insights that lead to key behavioral predictors. The nucleus of this complex architecture is the decision-making grid (DMG), a two-dimensional matrix that groups vehicles based on their frequency of entering the service and the cost of their repairs. It is the first integration of DMG with ML for prescriptive fleet management. The objective of the study is twofold: firstly, to build a system that classifies vehicles according to their risk profile, and secondly, to offer clear directions for changing driver patterns that most affect vehicle costs or for keeping good practices. The framework proposed by this study not only drives the optimization of operational efficiency but also contributes to a methodology that links driver profiles to costs, offering a scalable methodology for similar business contexts. Full article
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25 pages, 1694 KB  
Article
Tool-Health Digital Twin for CNC Predictive Maintenance via Innovation-Adaptive Sensor Fusion and Uncertainty-Aware Prognostics
by Zhuming Cao, Lihua Chen, Chunhui Li, Laifa Zhu and Zhengjian Deng
Machines 2026, 14(3), 335; https://doi.org/10.3390/machines14030335 - 16 Mar 2026
Viewed by 311
Abstract
A tool-health digital twin for CNC predictive maintenance is developed and operationalised as a fusion-and-state-estimation core that produces a latent tool-health trajectory (wear level and wear-rate dynamics) from multi-rate sensor streams for diagnosis and remaining useful life (RUL) forecasting under strict edge latency [...] Read more.
A tool-health digital twin for CNC predictive maintenance is developed and operationalised as a fusion-and-state-estimation core that produces a latent tool-health trajectory (wear level and wear-rate dynamics) from multi-rate sensor streams for diagnosis and remaining useful life (RUL) forecasting under strict edge latency constraints. The scope is tool-health–informed maintenance decisions (condition-based tool replacement/scheduling), rather than a comprehensive maintenance twin for all CNC subsystems. Multi-rate vibration, spindle-current, and temperature signals are synchronized and windowed, and a linear state-space model with Kalman filtering and innovation-guided adaptive noise estimation stabilizes the latent health state across operating-regime changes. The fused state is then used by compact sequence learners, an LSTM for edge feasibility, and a compact Transformer as a higher-accuracy comparison, to output fault categories and RUL estimates. Predictive uncertainty is quantified via a Monte Carlo dropout and linked to reliability-aware actions through a simple alarm/defer/schedule policy, while SHAP provides feature-level interpretability. On a CNC testbed, fusion improves fault F1 from 0.811 to 0.892 and PR-AUC from 0.867 to 0.918 while reducing RUL RMSE from 10.4 to 8.1 cycles; the compact Transformer reaches 0.903 F1 and 7.9-cycle RMSE at higher inference time. The end-to-end pipeline remains within a ≤100 ms breakdown, maintains in-band innovation statistics, supports rehearsal-based updates under drift, and is additionally evaluated on external tool-wear and turbofan datasets. Full article
(This article belongs to the Section Advanced Manufacturing)
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