Data-driven industrial health prognostics require rich training data to develop accurate and reliable predictive models. However, stringent data privacy laws and the abundance of edge industrial data necessitate decentralized data utilization. Thus, the industrial health prognostics field is well suited to significantly benefit from federated learning (FL), a decentralized and privacy-preserving learning technique. However, FL-based health prognostics tasks have hardly been investigated due to the complexities of meaningfully aggregating model parameters trained from heterogeneous data to form a high performing federated model. Specifically, data heterogeneity among edge devices, stemming from dissimilar degradation mechanisms and unequal dataset sizes, poses a critical statistical challenge for developing accurate federated models. We propose a pioneering FL-based health prognostic model with a feature similarity-matched parameter aggregation algorithm to discriminatingly learn from heterogeneous edge data. The algorithm searches across the heterogeneous locally trained models and matches neurons with probabilistically similar feature extraction functions first, before selectively averaging them to form the federated model parameters. As the algorithm only averages similar neurons, as opposed to conventional naive averaging of coordinate-wise neurons, the distinct feature extractors of local models are carried over with less dilution to the resultant federated model. Using both cyclic degradation data of Li-ion batteries and non-cyclic data of turbofan engines, we demonstrate that the proposed method yields accuracy improvements as high as 44.5\% and 39.3\% for state-of-health estimation and remaining useful life estimation, respectively.

Federated learning allows edge devices to collaboratively learn a shared model while keeping the training data on device, decoupling the ability to do model training from the need to store the data in the cloud. We propose Federated matched averaging (FedMA) algorithm designed for federated learning of modern neural network architectures e.g. convolutional neural networks (CNNs) and LSTMs. FedMA constructs the shared global model in a layer-wise manner by matching and averaging hidden elements (i.e. channels for convolution layers; hidden states for LSTM; neurons for fully connected layers) with similar feature extraction signatures. Our experiments indicate that FedMA not only outperforms popular state-of-the-art federated learning algorithms on deep CNN and LSTM architectures trained on real world datasets, but also reduces the overall communication burden.