A Data-Driven Aero-Engine Degradation Prognostic Strategy

A Multi-Task Joint Learning Model Based on Transformer and Customized Gate Control for Predicting Remaining Useful Life and Health Status of Tools

Previous studies have primarily focused on predicting the remaining useful life (RUL) of tools as an independent process. However, the RUL of a tool is closely related to its wear stage. In light of this, a multi-task joint learning model based on a transformer encoder and customized gate control (TECGC) is proposed for simultaneous prediction of tool RUL and tool wear stages. Specifically, the transformer encoder is employed as the backbone of the TECGC model for extracting shared features from the original data. The customized gate control (CGC) is utilized to extract task-specific features relevant to tool RUL prediction and tool wear stage and shared features. Finally, by integrating these components, the tool RUL and the tool wear stage can be predicted simultaneously by the TECGC model. In addition, a dynamic adaptive multi-task learning loss function is proposed for the model's training to enhance its calculation efficiency. This approach avoids unsatisfactory prediction performance of the model caused by unreasonable selection of trade-off parameters of the loss function. The effectiveness of the TECGC model is evaluated using the PHM2010 dataset. The results demonstrate its capability to accurately predict tool RUL and tool wear stages.

A novel gear RUL prediction method by diffusion model generation health index and attention guided multi-hierarchy LSTM

Gears, as indispensable components of machinery, demand accurate prediction of their Remaining Useful Life (RUL). To enhance the utilization of ordered information within time series data and elevate RUL prediction precision, this study introduces the attention-guided multi-hierarchy LSTM (AGMLSTM). This innovative approach leverages attention mechanisms to capture the intricate interplay between high and low hierarchical features of the input data, marking the first application of such a technique in gear RUL prediction. Additionally, a refined health indicator (HI) is introduced, constructed through a diffusion model, to precisely reflect the gears' health condition. The proposed RUL prediction method unfolds as follows: firstly, HIs are computed from gear vibration data. Subsequently, leveraging the known HIs, AGMLSTM predicts future HIs, and the RUL of the gear is determined upon surpassing the failure threshold. Quantitative analysis of experimental results conclusively demonstrates the superiority of the proposed RUL prediction method over existing approaches for gear RUL estimation.

Conformal Fabrication of Thick Film Platinum Strain Gauge Via Error Regulation Strategies for In Situ High-Temperature Strain Detection

Monitoring high-temperature strain on curved components in harsh environments is a challenge for a wide range of applications, including in aircraft engines, gas turbines, and hypersonic vehicles. Although there are significant improvements in the preparation of high-temperature piezoresistive film on planar surfaces using 3D printing methods, there are still difficulties with poor surface compatibility and high-temperature strain testing on curved surfaces. Herein, a conformal direct ink writing (CDIW) system coupled with an error feedback regulation strategy was used to fabricate high-precision, thick films on curved surfaces. This strategy enabled the maximum amount of error in the distance between the needle and the substrate on a curved surface to be regulated from 155 to 4 μm. A conformal Pt thick-film strain gauge (CPTFSG) with a room-temperature strain coefficient of 1.7 was created on a curved metallic substrate for the first time. The resistance drift rate at 800 °C for 1 h was 1.1%, which demonstrated the excellent stability and oxidation resistance of the CPTFSG. High-temperature dynamic strain tests up to 769 °C revealed that the sensor had excellent high-temperature strain test performance. Furthermore, the CPTFSG was conformally deposited on an aero-engine turbine blade to perform in situ tensile and compressive strain testing at room temperature. High-temperature strain tests were conducted at 100 and 200 °C for 600 and 580 με, respectively, demonstrating a high steady-state response consistent with the commercial high-temperature strain transducer. In addition, steady-state strain tests at high temperatures up to 496 °C were tested. The CDIW error modulation strategy provides a highly promising approach for the high-precision fabrication of Pt thick films on complex surfaces and driving in situ sensing of high-temperature parameters on curved components toward practical applications.

An Adaptive Parallel Feature Learning and Hybrid Feature Fusion-Based Deep Learning Approach for Machining Condition Monitoring

The rapid development of information and communication technologies has facilitated machining condition monitoring toward a data-driven paradigm, of which the Industrial Internet of Things (IIoT) serves as the fundamental basis to acquire data from physical equipment with sensing technologies as well as to learn the relationship between the system condition and the collected condition monitoring data. However, most data-driven methods suffer from using a single-domain space, ignoring the importance of the learned features, and failing to incorporate the handcrafted features assisted by domain knowledge. To solve these limitations, a novel deep learning approach is proposed for machining condition monitoring in the IIoT environment, which consists of three phases, including: 1) the unsupervised parallel feature extraction; 2) adaptive feature importance weighting; and 3) hybrid feature fusion. First, separate sparse autoencoders are utilized to conduct the unsupervised parallel feature extraction, which enables to learn abstract feature representation from multiple domain spaces simultaneously. Then, an attention module is designed for the adaptive feature importance weighting, which can assign higher weights to those critical features accordingly. Moreover, a hybrid feature fusion is deployed to complement the automatic feature learning and further yield better model performance by fusing the handcrafted features assisted by domain knowledge. Finally, a real-life case study and extensive experiments have been conducted to show the effectiveness and superiority of the proposed approach.

Self-Supervised Graph Learning With Hyperbolic Embedding for Temporal Health Event Prediction

Electronic health records (EHRs) have been heavily used in modern healthcare systems for recording patients' admission information to health facilities. Many data-driven approaches employ temporal features in EHR for predicting specific diseases, readmission times, and diagnoses of patients. However, most existing predictive models cannot fully utilize EHR data, due to an inherent lack of labels in supervised training for some temporal events. Moreover, it is hard for the existing methods to simultaneously provide generic and personalized interpretability. To address these challenges, we propose Sherbet, a self-supervised graph learning framework with hyperbolic embeddings for temporal health event prediction. We first propose a hyperbolic embedding method with information flow to pretrain medical code representations in a hierarchical structure. We incorporate these pretrained representations into a graph neural network (GNN) to detect disease complications and design a multilevel attention method to compute the contributions of particular diseases and admissions, thus enhancing personalized interpretability. We present a new hierarchy-enhanced historical prediction proxy task in our self-supervised learning framework to fully utilize EHR data and exploit medical domain knowledge. We conduct a comprehensive set of experiments on widely used publicly available EHR datasets to verify the effectiveness of our model. Our results demonstrate the proposed model's strengths in both predictive tasks and interpretable abilities.

Deep Bidirectional Recurrent Neural Networks Ensemble for Remaining Useful Life Prediction of Aircraft Engine

Remaining useful life (RUL) prediction of aircraft engine (AE) is of great importance to improve its reliability and availability, and reduce its maintenance costs. This article proposes a novel deep bidirectional recurrent neural networks (DBRNNs) ensemble method for the RUL prediction of the AEs. In this method, several kinds of DBRNNs with different neuron structures are built to extract hidden features from sensory data. A new customized loss function is designed to evaluate the performance of the DBRNNs, and a series of the RUL values is obtained. Then, these RUL values are reencapsulated into a predicted RUL domain. By updating the weights of elements in the domain, multiple regression decision tree (RDT) models are trained iteratively. These models integrate the predicted results of different DBRNNs to realize the final RUL prognostics with high accuracy. The proposed method is validated by using C-MAPSS datasets from NASA. The experimental results show that the proposed method has achieved more superior performance compared with other existing methods.

A Multi-Source Weighted Deep Transfer Network for Open-Set Fault Diagnosis of Rotary Machinery

In real industries, there often exist application scenarios where the target domain holds fault categories never observed in the source domain, which is an open-set domain adaptation (DA) diagnosis issue. Existing DA diagnosis methods under the assumption of sharing identical label space across domains fail to work. What is more, labeled samples can be collected from different sources, where multisource information fusion is rarely considered. To handle this issue, a multisource open-set DA diagnosis approach is developed. Specifically, multisource domain data of different operation conditions sharing partial classes are adopted to take advantage of fault information. Then, an open-set DA network is constructed to mitigate the domain gap across domains. Finally, a weighting learning strategy is introduced to adaptively weigh the importance on feature distribution alignment between known class and unknown class samples. Extensive experiments suggest that the proposed approach can substantially boost the performance of open-set diagnosis issues and outperform existing diagnosis approaches.

Slow-Varying Dynamics-Assisted Temporal Capsule Network for Machinery Remaining Useful Life Estimation

Capsule network (CapsNet) acts as a promising alternative to the typical convolutional neural network, which is the dominant network to develop the remaining useful life (RUL) estimation models for mechanical equipment. Although CapsNet comes with an impressive ability to represent entities' hierarchical relationships through a high-dimensional vector embedding, it fails to capture the long-term temporal correlation of run-to-failure time series measured from degraded mechanical equipment. On the other hand, the slow-varying dynamics, which reveals the low-frequency information hidden in mechanical dynamical behavior, is overlooked in the existing RUL estimation models (including CapsNet), limiting the utmost ability of advanced networks. To address the aforementioned concerns, we propose a slow-varying dynamics-assisted temporal CapsNet (SD-TemCapsNet) to simultaneously learn the slow-varying dynamics and temporal dynamics from measurements for accurate RUL estimation. First, in light of the sensitivity of fault evolution, slow-varying features are decomposed from normal raw data to convey the low-frequency components corresponding to the system dynamics. Next, the long short-term memory (LSTM) mechanism is introduced into CapsNet to capture the temporal correlation of time series. To this end, experiments conducted on an aircraft engine and a milling machine verify that the proposed SD-TemCapsNet outperforms the mainstream methods. In comparison with CapsNet, the estimation accuracy of the aircraft engine with four different scenarios has been improved by 10.17%, 24.97%, 3.25%, and 13.03% about the index root mean squared error, respectively. Similarly, the estimation accuracy of the milling machine has been improved by 23.57% compared to LSTM and 19.54% compared to CapsNet.

Transfer Relation Network for Fault Diagnosis of Rotating Machinery With Small Data

Many deep-learning methods have been developed for fault diagnosis. However, due to the difficulty of collecting and labeling machine fault data, the datasets in some practical applications are relatively much smaller than the other big data benchmarks. In addition, the fault data come from different machines. Therefore, on some occasions, fault diagnosis is a multidomain problem with small data, where satisfactory transfer performance is difficult to obtain and has been rarely explored from the few-shot learning viewpoint. Different from the existing deep transfer learning solutions, a novel transfer relation network (TRN), combining a few-shot learning mechanism and transfer learning, is developed in this study. Specifically, the fault diagnosis problem has been treated as a similarity metric-learning problem instead of solely feature weighted classification. A feature net and a relation net have been, respectively, constructed for feature extraction and relation computation. The Siamese structure has been borrowed to extract the features of the source and the target domain samples with shared weights. Multikernel maximum mean discrepancy (MK-MMD) is employed on several higher layers with different tradeoff parameters to enable an efficient domain feature transfer considering different feature properties. To implement efficient diagnosis based on small data, an episode-based few-shot training strategy is adopted to train TRN. Average pooling has been adopted to suppress the noise influence from the vibration sequence which turns out to be important for the success of time sequence-based fault diagnosis. Transfer experiments on four datasets have verified the superior performance of TRN. A significant improvement of classification accuracy has been made compared with the state-of-the-art methods on the adopted datasets.

Multisource-Refined Transfer Network for Industrial Fault Diagnosis Under Domain and Category Inconsistencies

Unsupervised cross-domain fault diagnosis has been actively researched in recent years. It learns transferable features that reduce distribution inconsistency between source and target domains without target supervision. Most of the existing cross-domain fault diagnosis approaches are developed based on the consistency assumption of the source and target fault category sets. This assumption, however, is generally challenged in practice, as different working conditions can have different fault category sets. To solve the fault diagnosis problem under both domain and category inconsistencies, a multisource-refined transfer network is proposed in this article. First, a multisource-domain-refined adversarial adaptation strategy is designed to reduce the refined categorywise distribution inconsistency within each source-target domain pair. It avoids the negative transfer trap caused by conventional global-domainwise-forced alignments. Then, a multiple classifier complementation module is developed by complementing and transferring the source classifiers to the target domain to leverage different diagnostic knowledge existing in various sources. Different classifiers are complemented by the similarity scores produced by the adaptation module, and the complemented smooth predictions are used to guide the refined adaptation. Thus, the refined adversarial adaptation and the classifier complementation can benefit from each other in the training stage, yielding target-faults-discriminative and domain-refined-indistinguishable feature representations. Extensive experiments on two cases demonstrate the superiority of the proposed method when domain and category inconsistencies coexist.

Remaining Useful Life Prediction of Aeroengines Based on Multi-Head Attention Mechanism

Aeroengines are the core components of an aircraft; therefore, their health determines flight safety. Currently, owing to their complex structure and problems associated with their various detection parameters, predicting the remaining useful life (RUL) of aeroengines is very important to ensure their safety and reliability. In this paper, we propose a new hybrid method based on convolutional neural networks (CNN), timing convolutional neural networks (TCN), and the multi-head attention mechanism. Firstly, an CNN-TCN model is established for multi-dimensional features, in which two layers of the CNN extract features of multi-dimensional input data, and the TCN process the timing features. Subsequently, the outputs of multiple CNN-TCNs are weighted using the multi-head attention mechanism, and the results are stitched together. Next, we compare the root mean square error (RMSE) and scores of various RUL prediction methods to show the superiority of the proposed method. The results showed that compared with previous research results, the RMSE and Score of FD001 decreased by 10.87% and 42.57%, respectively, whereas those of FD003 decreased by 14.13% and 58.15%, respectively.

Deep Auto-Encoder and Deep Forest-Assisted Failure Prognosis for Dynamic Predictive Maintenance Scheduling

Prognostics and health management (PHM) with failure prognosis and maintenance decision-making as the core is an advanced technology to improve the safety, reliability, and operational economy of engineering systems. However, studies of failure prognosis and maintenance decision-making have been conducted separately over the past years. Key challenges remain open when the joint problem is considered. The aim of this paper is to develop an integrated strategy for dynamic predictive maintenance scheduling (DPMS) based on a deep auto-encoder and deep forest-assisted failure prognosis method. The proposed DPMS method involves a complete process from performing failure prognosis to making maintenance decisions. The first step is to extract representative features reflecting system degradation from raw sensor data by using a deep auto-encoder. Then, the features are fed into the deep forest to compute the failure probabilities in moving time horizons. Finally, an optimal maintenance-related decision is made through quickly evaluating the costs of different decisions with the failure probabilities. Verification was accomplished using NASA's open datasets of aircraft engines, and the experimental results show that the proposed DPMS method outperforms several state-of-the-art methods, which can benefit precise maintenance decisions and reduce maintenance costs.

A Novel Ensemble Model on Defects Identification in Aero-Engine Blade

Machine learning-based defect identification has emerged as a promising solution to improving the defect accuracy of the aero-engine blade. This solution adopts machine learning classifiers to classify the types of defects. These classifiers are trained to use features collected in ultrasonic echo signals. However, the current studies show the potential number of features, such as statistic values, for identifying defect reaches a number more than that offered by an ultrasonic echo signal. This necessitates multiple acquisitions of echo signal and increases manual effort, and the feature obtained from feature selection is sensitive to the characteristic of the classifier, which further increases the uncertainty of the classifier result. This paper proposes an ensemble learning technique that is only based on few features obtained from an echo signal and still achieves a high accuracy of defect identification as that in traditional machine learning, eliminating the need for multiple acquisitions of the echo signal. To this end, we apply two well-known ensemble learning classifiers and simultaneously compare three widely used machine learning models on defect identification of blades. The result shows that the proposed ensemble learning models outperform machine learning-based models with an equal number of features. In addition, the two-feature-based ensemble learning model reaches an accuracy close to that of multiple statistic features-based machine learning models, where features are obtained from multiple collections of the signal.

Aircraft Engine Prognostics Based on Informative Sensor Selection and Adaptive Degradation Modeling with Functional Principal Component Analysis

Engine prognostics are critical to improve safety, reliability, and operational efficiency of an aircraft. With the development in sensor technology, multiple sensors are embedded or deployed to monitor the health condition of the aircraft engine. Thus, the challenge of engine prognostics lies in how to model and predict future health by appropriate utilization of these sensor information. In this paper, a prognostic approach is developed based on informative sensor selection and adaptive degradation modeling with functional data analysis. The presented approach selects sensors based on metrics and constructs health index to characterize engine degradation by fusing the selected informative sensors. Next, the engine degradation is adaptively modeled with the functional principal component analysis (FPCA) method and future health is prognosticated using the Bayesian inference. The prognostic approach is applied to run-to-failure data sets of C-MAPSS test-bed developed by NASA. Results show that the proposed method can effectively select the informative sensors and accurately predict the complex degradation of the aircraft engine.