predictive maintenance
Enhancing failure prediction in nuclear industry: Hybridization of knowledge- and data-driven techniques
Saley, Amaratou Mahamadou, Moyaux, Thierry, Sekhari, Aïcha, Cheutet, Vincent, Danielou, Jean-Baptiste
The convergence of the Internet of Things (IoT) and Industry 4.0 has significantly enhanced data-driven methodologies within the nuclear industry, notably enhancing safety and economic efficiency. This advancement challenges the precise prediction of future maintenance needs for assets, which is crucial for reducing downtime and operational costs. However, the effectiveness of data-driven methodologies in the nuclear sector requires extensive domain knowledge due to the complexity of the systems involved. Thus, this paper proposes a novel predictive maintenance methodology that combines data-driven techniques with domain knowledge from a nuclear equipment. The methodological originality of this paper is located on two levels: highlighting the limitations of purely data-driven approaches and demonstrating the importance of knowledge in enhancing the performance of the predictive models. The applicative novelty of this work lies in its use within a domain such as a nuclear industry, which is highly restricted and ultrasensitive due to security, economic and environmental concerns. A detailed real-world case study which compares the current state of equipment monitoring with two scenarios, demonstrate that the methodology significantly outperforms purely data-driven methods in failure prediction. While purely data-driven methods achieve only a modest performance with a prediction horizon limited to 3 h and a F1 score of 56.36%, the hybrid approach increases the prediction horizon to 24 h and achieves a higher F1 score of 93.12%.
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AI-Enhanced IoT Systems for Predictive Maintenance and Affordability Optimization in Smart Microgrids: A Digital Twin Approach
Kushal, Koushik Ahmed, Gueniat, Florimond
This study presents an AI enhanced IoT framework for predictive maintenance and affordability optimization in smart microgrids using a Digital Twin modeling approach. The proposed system integrates real time sensor data, machine learning based fault prediction, and cost aware operational analytics to improve reliability and energy efficiency in distributed microgrid environments. By synchronizing physical microgrid components with a virtual Digital Twin, the framework enables early detection of component degradation, dynamic load management, and optimized maintenance scheduling. Experimental evaluations demonstrate improved predictive accuracy, reduced operational downtime, and measurable cost savings compared to baseline microgrid management methods. The findings highlight the potential of Digital Twin driven IoT architectures as a scalable solution for next generation intelligent and affordable energy systems.
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Gen AI in Automotive: Applications, Challenges, and Opportunities with a Case study on In-Vehicle Experience
Shinde, Chaitanya, Garikapati, Divya
Generative Artificial Intelligence is emerging as a transformative force in the automotive industry, enabling novel applications across vehicle design, manufacturing, autonomous driving, predictive maintenance, and in vehicle user experience. This paper provides a comprehensive review of the current state of GenAI in automotive, highlighting enabling technologies such as Generative Adversarial Networks and Variational Autoencoders. Key opportunities include accelerating autonomous driving validation through synthetic data generation, optimizing component design, and enhancing human machine interaction via personalized and adaptive interfaces. At the same time, the paper identifies significant technical, ethical, and safety challenges, including computational demands, bias, intellectual property concerns, and adversarial robustness, that must be addressed for responsible deployment. A case study on Mercedes Benzs MBUX Virtual Assistant illustrates how GenAI powered voice systems deliver more natural, proactive, and personalized in car interactions compared to legacy rule based assistants. Through this review and case study, the paper outlines both the promise and limitations of GenAI integration in the automotive sector and presents directions for future research and development aimed at achieving safer, more efficient, and user centric mobility. Unlike prior reviews that focus solely on perception or manufacturing, this paper emphasizes generative AI in voice based HMI, bridging safety and user experience perspectives.
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OmniFuser: Adaptive Multimodal Fusion for Service-Oriented Predictive Maintenance
Wang, Ziqi, Zhao, Hailiang, Yang, Yuhao, Hu, Daojiang, Bao, Cheng, Liu, Mingyi, Di, Kai, Dustdar, Schahram, Wang, Zhongjie, Deng, Shuiguang
Accurate and timely prediction of tool conditions is critical for intelligent manufacturing systems, where unplanned tool failures can lead to quality degradation and production downtime. In modern industrial environments, predictive maintenance is increasingly implemented as an intelligent service that integrates sensing, analysis, and decision support across production processes. To meet the demand for reliable and service-oriented operation, we present OmniFuser, a multimodal learning framework for predictive maintenance of milling tools that leverages both visual and sensor data. It performs parallel feature extraction from high-resolution tool images and cutting-force signals, capturing complementary spatiotemporal patterns across modalities. To effectively integrate heterogeneous features, OmniFuser employs a contamination-free cross-modal fusion mechanism that disentangles shared and modality-specific components, allowing for efficient cross-modal interaction. Furthermore, a recursive refinement pathway functions as an anchor mechanism, consistently retaining residual information to stabilize fusion dynamics. The learned representations can be encapsulated as reusable maintenance service modules, supporting both tool-state classification (e.g., Sharp, Used, Dulled) and multi-step force signal forecasting. Experiments on real-world milling datasets demonstrate that OmniFuser consistently outperforms state-of-the-art baselines, providing a dependable foundation for building intelligent industrial maintenance services.
Artificial Intelligence Based Predictive Maintenance for Electric Buses
Ercevik, Ayse Irmak, Ozbayoglu, Ahmet Murat
Predictive maintenance (PdM) is crucial for optimizing efficiency and minimizing downtime of electric buses. While these vehicles provide environmental benefits, they pose challenges for PdM due to complex electric transmission and battery systems. Traditional maintenance, often based on scheduled inspections, struggles to capture anomalies in multi-dimensional real-time CAN Bus data. This study employs a graph-based feature selection method to analyze relationships among CAN Bus parameters of electric buses and investigates the prediction performance of targeted alarms using artificial intelligence techniques. The raw data collected over two years underwent extensive preprocessing to ensure data quality and consistency. A hybrid graph-based feature selection tool was developed by combining statistical filtering (Pearson correlation, Cramer's V, ANOVA F-test) with optimization-based community detection algorithms (InfoMap, Leiden, Louvain, Fast Greedy). Machine learning models, including SVM, Random Forest, and XGBoost, were optimized through grid and random search with data balancing via SMOTEEN and binary search-based down-sampling. Model interpretability was achieved using LIME to identify the features influencing predictions. The results demonstrate that the developed system effectively predicts vehicle alarms, enhances feature interpretability, and supports proactive maintenance strategies aligned with Industry 4.0 principles.
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Improving Anomaly Detection in Industrial Time Series: The Role of Segmentation and Heterogeneous Ensemble
Mastriani, Emilio, Costa, Alessandro, Incardona, Federico, Munari, Kevin, Spinello, Sebastiano
Concerning machine learning, segmentation models can identify state changes within time series, facilitating the detection of transitions between normal and anomalous conditions. Specific techniques such as Change Point Detection (CPD), particularly algori thms like ChangeFinder, have been successfully applied to segment time series and improve anomaly detection by reducing temporal uncertainty, especially in multivariate environments. In this work, we explored how the integration of segmentation techniques, combined with a heterogeneous ensemble, can enhance anomaly detection in an industrial production context. The results show that applying segmentation as a pre - processing step before selecting heterogeneous ensemble algorithms provided a significant adva ntage in our case study, improving the AUC - ROC metric from 0.8599 (achieved with a PCA and LSTM ensemble) to 0.9760 (achieved with Random Forest and XGBoost). This improvement is imputable to the ability of segmentation to reduce temporal ambiguity and fac ilitate the learning process of supervised algorithms. In our future work, we intend to assess the benefit of introducing weighted features derived from the study of change points, combined with segmentation and the use of heterogeneous ensembles, to furt her optimize model performance in early anomaly detection. I n recent years, anomaly detection in time series has become a critical issue in the industrial context.
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CVCM Track Circuits Pre-emptive Failure Diagnostics for Predictive Maintenance Using Deep Neural Networks
Mukherjee, Debdeep, Di Santi, Eduardo, Lefebvre, Clément, Mijatovic, Nenad, Martin, Victor, Josse, Thierry, Brown, Jonathan, Saiah, Kenza
Track circuits are critical for railway operations, acting as the main signalling sub-system to locate trains. Continuous Variable Current Modulation (CVCM) is one such technology. Like any field-deployed, safety-critical asset, it can fail, triggering cascading disruptions. Many failures originate as subtle anomalies that evolve over time, often not visually apparent in monitored signals. Conventional approaches, which rely on clear signal changes, struggle to detect them early. Early identification of failure types is essential to improve maintenance planning, minimising downtime and revenue loss. Leveraging deep neural networks, we propose a predictive maintenance framework that classifies anomalies well before they escalate into failures. Validated on 10 CVCM failure cases across different installations, the method is ISO-17359 compliant and outperforms conventional techniques, achieving 99.31% overall accuracy with detection within 1% of anomaly onset. Through conformal prediction, we provide uncertainty estimates, reaching 99% confidence with consistent coverage across classes. Given CVCMs global deployment, the approach is scalable and adaptable to other track circuits and railway systems, enhancing operational reliability.
An Explainable Machine Learning Framework for Railway Predictive Maintenance using Data Streams from the Metro Operator of Portugal
García-Méndez, Silvia, de Arriba-Pérez, Francisco, Leal, Fátima, Veloso, Bruno, Malheiro, Benedita, Burguillo-Rial, Juan Carlos
This work contributes to a real-time data-driven predictive maintenance solution for Intelligent Transportation Systems. The proposed method implements a processing pipeline comprised of sample pre-processing, incremental classification with Machine Learning models, and outcome explanation. This novel online processing pipeline has two main highlights: (i) a dedicated sample pre-processing module, which builds statistical and frequency-related features on the fly, and (ii) an explainability module. This work is the first to perform online fault prediction with natural language and visual explainability. The experiments were performed with the MetroPT data set from the metro operator of Porto, Portugal. The results are above 98 % for F-measure and 99 % for accuracy. In the context of railway predictive maintenance, achieving these high values is crucial due to the practical and operational implications of accurate failure prediction. In the specific case of a high F-measure, this ensures that the system maintains an optimal balance between detecting the highest possible number of real faults and minimizing false alarms, which is crucial for maximizing service availability. Furthermore, the accuracy obtained enables reliability, directly impacting cost reduction and increased safety. The analysis demonstrates that the pipeline maintains high performance even in the presence of class imbalance and noise, and its explanations effectively reflect the decision-making process. These findings validate the methodological soundness of the approach and confirm its practical applicability for supporting proactive maintenance decisions in real-world railway operations. Therefore, by identifying the early signs of failure, this pipeline enables decision-makers to understand the underlying problems and act accordingly swiftly.
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Our Cars Can Talk: How IoT Brings AI to Vehicles
Abstract--Bringing AI to vehicles and enabling them as sensing platforms is key to transforming maintenance from reactive to proactive. Now is the time to integrate AI copilots that speak both languages: machine and driver. This article offers a conceptual and technical perspective intended to spark interdisciplinary dialogue and guide future research and development in intelligent vehicle systems, predictive maintenance, and AI-powered user interaction. Vehicle maintenance remains largely reactive to this day, often triggered by the dreaded check engine light, sometimes at the worst possible time: in the middle of a busy week, or right before a road trip. However, today's vehicles are equipped with a dense network of sensors that can monitor nearly every aspect of performance in real time.
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Multilayer GNN for Predictive Maintenance and Clustering in Power Grids
Kazim, Muhammad, Pirim, Harun, Le, Chau, Le, Trung, Yadav, Om Prakash
Unplanned power outages cost the US economy over $150 billion annually, partly due to predictive maintenance (PdM) models that overlook spatial, temporal, and causal dependencies in grid failures. This study introduces a multilayer Graph Neural Network (GNN) framework to enhance PdM and enable resilience-based substation clustering. Using seven years of incident data from Oklahoma Gas & Electric (292,830 records across 347 substations), the framework integrates Graph Attention Networks (spatial), Graph Convolutional Networks (temporal), and Graph Isomorphism Networks (causal), fused through attention-weighted embeddings. Our model achieves a 30-day F1-score of 0.8935 +/- 0.0258, outperforming XGBoost and Random Forest by 3.2% and 2.7%, and single-layer GNNs by 10 to 15 percent. Removing the causal layer drops performance to 0.7354 +/- 0.0418. For resilience analysis, HDBSCAN clustering on HierarchicalRiskGNN embeddings identifies eight operational risk groups. The highest-risk cluster (Cluster 5, 44 substations) shows 388.4 incidents/year and 602.6-minute recovery time, while low-risk groups report fewer than 62 incidents/year. ANOVA (p < 0.0001) confirms significant inter-cluster separation. Our clustering outperforms K-Means and Spectral Clustering with a Silhouette Score of 0.626 and Davies-Bouldin index of 0.527. This work supports proactive grid management through improved failure prediction and risk-aware substation clustering.
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