In industrial equipment monitoring, fault diagnosis is critical for ensuring system reliability and enabling predictive maintenance. However, the scarcity of fault data, due to the rarity of fault events and the high cost of data annotation, significantly hinders data-driven approaches. Existing time-series generation models, optimized for abundant normal data, struggle to capture fault distributions in few-shot scenarios, producing samples that lack authenticity and diversity due to the large domain gap and high intra-class variability of faults. To address this, we propose a novel few-shot fault time-series generation framework based on diffusion models. Our approach employs a positive-negative difference adapter, leveraging pre-trained normal data distributions to model the discrepancies between normal and fault domains for accurate fault synthesis. Additionally, a diversity loss is introduced to prevent mode collapse, encouraging the generation of diverse fault samples through inter-sample difference regularization. Experimental results demonstrate that our model significantly outperforms traditional methods in authenticity and diversity, achieving state-of-the-art performance on key benchmarks.

The application of machine learning (ML) algorithms in the intelligent diagnosis of three-phase engines has the potential to significantly enhance diagnostic performance and accuracy. Traditional methods largely rely on signature analysis, which, despite being a standard practice, can benefit from the integration of advanced ML techniques. In our study, we innovate by combining ML algorithms with a novel unsupervised anomaly generation methodology that takes into account the engine physics model. We propose Signature-Guided Data Augmentation (SGDA), an unsupervised framework that synthesizes physically plausible faults directly in the frequency domain of healthy current signals. Guided by Motor Current Signature Analysis, SGDA creates diverse and realistic anomalies without resorting to computationally intensive simulations. This hybrid approach leverages the strengths of both supervised ML and unsupervised signature analysis, achieving superior diagnostic accuracy and reliability along with wide industrial application. The findings highlight the potential of our approach to contribute significantly to the field of engine diagnostics, offering a robust and efficient solution for real-world applications.

Traditional fault diagnosis methods struggle to handle fault data, with complex data characteristics such as high dimensions and large noise. Deep learning is a promising solution, which typically works well only when labeled fault data are available. To address these problems, a robust unsupervised fault diagnosis using machine learning is proposed in this paper. First, a special dimension reduction method for the high-dimensional fault data is designed. Second, the extracted features are enhanced by incorporating nonlinear information through the learning of a graph structure. Third, to alleviate the problem of reduced fault-diagnosis accuracy attributed to noise and outliers, $l_{2,1}$-norm and typicality-aware constraints are introduced from the perspective of model optimization, respectively. Finally, this paper provides comprehensive theoretical and experimental evidence supporting the effectiveness and robustness of the proposed method. The experiments on both the benchmark Tennessee-Eastman process and a real hot-steel milling process show that the proposed method exhibits better robustness compared to other methods, maintaining high diagnostic accuracy even in the presence of outliers or noise.

The safe and reliable operation of complex electromechanical systems in nuclear power plants is crucial for the safe production of nuclear power plants and their nuclear power unit. Therefore, accurate and timely fault diagnosis of nuclear power systems is of great significance for ensuring the safe and reliable operation of nuclear power plants. The existing fault diagnosis methods mainly target a single device or subsystem, making it difficult to analyze the inherent connections and mutual effects between different types of faults at the entire unit level. This article uses the AP1000 full-scale simulator to simulate the important mechanical component failures of some key systems in the primary and secondary circuits of nuclear power units, and constructs a fault dataset. Meanwhile, a hierarchical multi granularity classification fault diagnosis model based on the EfficientNet large model is proposed, aiming to achieve hierarchical classification of nuclear power faults. The results indicate that the proposed fault diagnosis model can effectively classify faults in different circuits and system components of nuclear power units into hierarchical categories. However, the fault dataset in this study was obtained from a simulator, which may introduce additional information due to parameter redundancy, thereby affecting the diagnostic performance of the model.

Predictive maintenance has been used to optimize system repairs in the industrial, medical, and financial domains. This technique relies on the consistent ability to detect and predict anomalies in critical systems. AI models have been trained to detect system faults, improving predictive maintenance efficiency. Typically there is a lack of fault data to train these models, due to organizations working to keep fault occurrences and down time to a minimum. For newly installed systems, no fault data exists since they have yet to fail. By using diffusion models for synthetic data generation, the complex training datasets for these predictive models can be supplemented with high level synthetic fault data to improve their performance in anomaly detection. By learning the relationship between healthy and faulty data in similar systems, a diffusion model can attempt to apply that relationship to healthy data of a newly installed system that has no fault data. The diffusion model would then be able to generate useful fault data for the new system, and enable predictive models to be trained for predictive maintenance. The following paper demonstrates a system for generating useful, multivariate synthetic data for predictive maintenance, and how it can be applied to systems that have yet to fail.

Domain generalization achieves fault diagnosis on unseen modes. In process industrial systems, fault samples are limited, and only single-mode fault data can be obtained. Extracting domain-invariant fault features from single-mode data for unseen mode fault diagnosis poses challenges. Existing methods utilize a generator module to simulate samples of unseen modes. However, multi-mode samples contain complex spatiotemporal information, which brings significant difficulties to accurate sample generation. Therefore, double gradient reversal network (DGRN) is proposed. First, the model is pre-trained to acquire fault knowledge from the single seen mode. Then, pseudo-fault feature generation strategy is designed by Adaptive instance normalization, to simulate fault features of unseen mode. The dual adversarial training strategy is created to enhance the diversity of pseudo-fault features, which models unseen modes with significant distribution differences. Subsequently, domain-invariant feature extraction strategy is constructed by contrastive learning and adversarial learning. This strategy extracts common features of faults and helps multi-mode fault diagnosis. Finally, the experiments were conducted on Tennessee Eastman process and continuous stirred-tank reactor. The experiments demonstrate that DGRN achieves high classification accuracy on unseen modes while maintaining a small model size.

Due to the scarcity of fault samples and the complexity of non-linear and non-smooth characteristics data in hydroelectric units, most of the traditional hydroelectric unit fault localization methods are difficult to carry out accurate localization. To address these problems, a sparse autoencoder (SAE)-generative adversarial network (GAN)-wavelet noise reduction (WNR)- manifold-boosted deep learning (SG-WMBDL) based fault localization method for hydroelectric units is proposed. To overcome the data scarcity, a SAE is embedded into the GAN to generate more high-quality samples in the data generation module. Considering the signals involving non-linear and non-smooth characteristics, the improved WNR which combining both soft and hard thresholding and local linear embedding (LLE) are utilized to the data preprocessing module in order to reduce the noise and effectively capture the local features. In addition, to seek higher performance, the novel Adaptive Boost (AdaBoost) combined with multi deep learning is proposed to achieve accurate fault localization. The experimental results show that the SG-WMBDL can locate faults for hydroelectric units under a small number of fault samples with non-linear and non-smooth characteristics on higher precision and accuracy compared to other frontier methods, which verifies the effectiveness and practicality of the proposed method.

Bearings are one of the vital components of rotating machines that are prone to unexpected faults. Therefore, bearing fault diagnosis and condition monitoring is essential for reducing operational costs and downtime in numerous industries. In various production conditions, bearings can be operated under a range of loads and speeds, which causes different vibration patterns associated with each fault type. Normal data is ample as systems usually work in desired conditions. On the other hand, fault data is rare, and in many conditions, there is no data recorded for the fault classes. Accessing fault data is crucial for developing data-driven fault diagnosis tools that can improve both the performance and safety of operations. To this end, a novel algorithm based on Conditional Generative Adversarial Networks (CGANs) is introduced. Trained on the normal and fault data on any actual fault conditions, this algorithm generates fault data from normal data of target conditions. The proposed method is validated on a real-world bearing dataset, and fault data are generated for different conditions. Several state-of-the-art classifiers and visualization models are implemented to evaluate the quality of the synthesized data. The results demonstrate the efficacy of the proposed algorithm.

Intelligent fault diagnosis has made extraordinary advancements currently. Nonetheless, few works tackle class-incremental learning for fault diagnosis under limited fault data, i.e., imbalanced and long-tailed fault diagnosis, which brings about various notable challenges. Initially, it is difficult to extract discriminative features from limited fault data. Moreover, a well-trained model must be retrained from scratch to classify the samples from new classes, thus causing a high computational burden and time consumption. Furthermore, the model may suffer from catastrophic forgetting when trained incrementally. Finally, the model decision is biased toward the new classes due to the class imbalance. The problems can consequently lead to performance degradation of fault diagnosis models. Accordingly, we introduce a supervised contrastive knowledge distillation for incremental fault diagnosis under limited fault data (SCLIFD) framework to address these issues, which extends the classical incremental classifier and representation learning (iCaRL) framework from three perspectives. Primarily, we adopt supervised contrastive knowledge distillation (KD) to enhance its representation learning capability under limited fault data. Moreover, we propose a novel prioritized exemplar selection method adaptive herding (AdaHerding) to restrict the increase of the computational burden, which is also combined with KD to alleviate catastrophic forgetting. Additionally, we adopt the cosine classifier to mitigate the adverse impact of class imbalance. We conduct extensive experiments on simulated and real-world industrial processes under different imbalance ratios. Experimental results show that our SCLIFD outperforms the existing methods by a large margin.

New operating conditions can result in a significant performance drop of fault diagnostics models due to the domain shift between the training and the testing data distributions. While several domain adaptation approaches have been proposed to overcome such domain shifts, their application is limited if the fault classes represented in the two domains are not the same. To enable a better transferability of the trained models between two different domains, particularly in setups where only the healthy data class is shared between the two domains, we propose a new framework for Partial and Open-Partial domain adaptation based on generating distinct fault signatures with a Wasserstein GAN. The main contribution of the proposed framework is the controlled synthetic fault data generation with two main distinct characteristics. Firstly, the proposed methodology enables to generate unobserved fault types in the target domain by having only access to the healthy samples in the target domain and faulty samples in the source domain. Secondly, the fault generation can be controlled to precisely generate distinct fault types and fault severity levels. The proposed method is especially suited in extreme domain adaption settings that are particularly relevant in the context of complex and safety-critical systems, where only one class is shared between the two domains. We evaluate the proposed framework on Partial as well as Open-Partial domain adaptation tasks on two bearing fault diagnostics case studies. Our experiments conducted in different label space settings showcase the versatility of the proposed framework. The proposed methodology provided superior results compared to other methods given large domain gaps.