Detecting anomalies in datasets is a longstanding problem in machine learning. In this context, anomalies are defined as a sample that significantly deviates from the remaining data. Meanwhile, optimal transport (OT) is a field of mathematics concerned with the transportation, between two probability measures, at least effort. In classical OT, the optimal transportation strategy of a measure to itself is the identity. In this paper, we tackle anomaly detection by forcing samples to displace its mass, while keeping the least effort objective. We call this new transportation problem Mass Repulsing Optimal Transport (MROT). Naturally, samples lying in low density regions of space will be forced to displace mass very far, incurring a higher transportation cost. We use these concepts to design a new anomaly score. Through a series of experiments in existing benchmarks, and fault detection problems, we show that our algorithm improves over existing methods.
The anomaly detection literature is abundant with offline methods, which require repeated access to data in memory, and impose impractical assumptions when applied to a streaming context. Existing online anomaly detection methods also generally fail to address these constraints, resorting to periodic retraining to adapt to the online context. We propose Online-iForest, a novel method explicitly designed for streaming conditions that seamlessly tracks the data generating process as it evolves over time. Experimental validation on real-world datasets demonstrated that Online-iForest is on par with online alternatives and closely rivals state-of-the-art offline anomaly detection techniques that undergo periodic retraining. Notably, Online-iForest consistently outperforms all competitors in terms of efficiency, making it a promising solution in applications where fast identification of anomalies is of primary importance such as cybersecurity, fraud and fault detection.
Accurate diagnosis of power transformer faults is essential for ensuring the stability and safety of electrical power systems. This study presents a comparative analysis of conventional machine learning (ML) algorithms and deep learning (DL) algorithms for fault classification of power transformers. Using a condition-monitored dataset spanning 10 months, various gas concentration features were normalized and used to train five ML classifiers: Support Vector Machine (SVM), k-Nearest Neighbors (KNN), Random Forest (RF), XGBoost, and Artificial Neural Network (ANN). In addition, four DL models were evaluated: Long Short-Term Memory (LSTM), Gated Recurrent Unit (GRU), One-Dimensional Convolutional Neural Network (1D-CNN), and TabNet. Experimental results show that both ML and DL approaches performed comparably. The RF model achieved the highest ML accuracy at 86.82%, while the 1D-CNN model attained a close 86.30%.
The medical device industry has significantly advanced by integrating sophisticated electronics like microchips and field-programmable gate arrays (FPGAs) to enhance the safety and usability of life-saving devices. These complex electro-mechanical systems, however, introduce challenging failure modes that are not easily detectable with conventional methods. Effective fault detection and mitigation become vital as reliance on such electronics grows. This paper explores three generative machine learning-based approaches for fault detection in medical devices, leveraging sensor data from surgical staplers,a class 2 medical device. Historically considered low-risk, these devices have recently been linked to an increasing number of injuries and fatalities. The study evaluates the performance and data requirements of these machine-learning approaches, highlighting their potential to enhance device safety.
Robust Recurrent Neural Networks (R-RENs) are a class of neural networks that have built-in system-theoretic robustness and incremental stability properties. In this manuscript, we leverage these properties to construct a data-driven Fault Detection and Isolation (FDI) method for sensor faults with proven performance guarantees. The underlying idea behind the scheme is to construct a bank of multiple R-RENs (acting as fault isolation filters), each with different levels of sensitivity (increased or decreased) to faults at different sensors. That is, each R-REN is designed to be specifically sensitive to faults occurring in a particular sensor and robust against faults in all the others. The latter is guaranteed using the built-in incremental stability properties of R-RENs. The proposed method is unsupervised (as it does not require labeled data from faulty sensors) and data-driven (because it exploits available fault-free input-output system trajectories and does not rely on dynamic models of the system under study). Numerical simulations on a roll-plane model of a vehicle demonstrate the effectiveness and practical applicability of the proposed methodology.
The rapid growth of the wind energy sector underscores the urgent need to optimize turbine operations and ensure effective maintenance through early fault detection systems. While traditional empirical and physics-based models offer approximate predictions of power generation based on wind speed, they often fail to capture the complex, non-linear relationships between other input variables and the resulting power output. Data-driven machine learning methods present a promising avenue for improving wind turbine modeling by leveraging large datasets, enhancing prediction accuracy but often at the cost of interpretability. In this study, we propose a hybrid semi-parametric model that combines the strengths of both approaches, applied to a dataset from a wind farm with four turbines. The model integrates a physics-inspired submodel, providing a reasonable approximation of power generation, with a non-parametric submodel that predicts the residuals. This non-parametric submodel is trained on a broader range of variables to account for phenomena not captured by the physics-based component. The hybrid model achieves a 37% improvement in prediction accuracy over the physics-based model. To enhance interpretability, SHAP values are used to analyze the influence of input features on the residual submodel's output. Additionally, prediction uncertainties are quantified using a conformalized quantile regression method. The combination of these techniques, alongside the physics grounding of the parametric submodel, provides a flexible, accurate, and reliable framework. Ultimately, this study opens the door for evaluating the impact of unmodeled variables on wind turbine power generation, offering a basis for potential optimization.
Principal component analysis is commonly used for dimensionality reduction, feature extraction, denoising, and visualization. The most commonly used principal component analysis method is based upon optimization of the L2-norm, however, the L2-norm is known to exaggerate the contribution of errors and outliers. When optimizing over the L1-norm, the components generated are known to exhibit robustness or resistance to outliers in the data. The L1-norm components can be solved for with a binary optimization problem. Previously, L1-BF has been used to solve the binary optimization for multiple components simultaneously. In this paper we propose QAPCA, a new method for finding principal components using quantum annealing hardware which will optimize over the robust L1-norm. The conditions required for convergence of the annealing problem are discussed. The potential speedup when using quantum annealing is demonstrated through complexity analysis and experimental results. To showcase performance against classical principal component analysis techniques experiments upon synthetic Gaussian data, a fault detection scenario and breast cancer diagnostic data are studied. We find that the reconstruction error when using QAPCA is comparable to that when using L1-BF.
Machine learning algorithms are increasingly being applied to fault detection and diagnosis (FDD) in chemical processes. However, existing data-driven FDD platforms often lack interpretability for process operators and struggle to identify root causes of previously unseen faults. This paper presents FaultExplainer, an interactive tool designed to improve fault detection, diagnosis, and explanation in the Tennessee Eastman Process (TEP). FaultExplainer integrates real-time sensor data visualization, Principal Component Analysis (PCA)-based fault detection, and identification of top contributing variables within an interactive user interface powered by large language models (LLMs). We evaluate the LLMs' reasoning capabilities in two scenarios: one where historical root causes are provided, and one where they are not to mimic the challenge of previously unseen faults. Experimental results using GPT-4o and o1-preview models demonstrate the system's strengths in generating plausible and actionable explanations, while also highlighting its limitations, including reliance on PCA-selected features and occasional hallucinations.
Rolling element bearings are critical components of rotating machinery, with their performance directly influencing the efficiency and reliability of industrial systems. At the same time, bearing faults are a leading cause of machinery failures, often resulting in costly downtime, reduced productivity, and, in extreme cases, catastrophic damage. This study presents a methodology that utilizes Kolmogorov-Arnold Networks to address these challenges through automatic feature selection, hyperparameter tuning and interpretable fault analysis within a unified framework. By training shallow network architectures and minimizing the number of selected features, the framework produces lightweight models that deliver explainable results through feature attribution and symbolic representations of their activation functions. Validated on two widely recognized datasets for bearing fault diagnosis, the framework achieved perfect F1-Scores for fault detection and high performance in fault and severity classification tasks, including 100% F1-Scores in most cases. Notably, it demonstrated adaptability by handling diverse fault types, such as imbalance and misalignment, within the same dataset. The symbolic representations enhanced model interpretability, while feature attribution offered insights into the optimal feature types or signals for each studied task. These results highlight the framework's potential for practical applications, such as real-time machinery monitoring, and for scientific research requiring efficient and explainable models.
As wind energy adoption is growing, ensuring the efficient operation and maintenance of wind turbines becomes essential for maximizing energy production and minimizing costs and downtime. Many AI applications in wind energy, such as in condition monitoring and power forecasting, may benefit from using operational data not only from individual wind turbines but from multiple turbines and multiple wind farms. Collaborative distributed AI which preserves data privacy holds a strong potential for these applications. Federated learning has emerged as a privacy-preserving distributed machine learning approach in this context. We explore federated learning in wind turbine condition monitoring, specifically for fault detection using normal behaviour models. We investigate various federated learning strategies, including collaboration across different wind farms and turbine models, as well as collaboration restricted to the same wind farm and turbine model. Our case study results indicate that federated learning across multiple wind turbines consistently outperforms models trained on a single turbine, especially when training data is scarce. Moreover, the amount of historical data necessary to train an effective model can be significantly reduced by employing a collaborative federated learning strategy. Finally, our findings show that extending the collaboration to multiple wind farms may result in inferior performance compared to restricting learning within a farm, specifically when faced with statistical heterogeneity and imbalanced datasets.
This article focuses on estimating relative transfer functions (RTFs) for beamforming applications. Traditional methods often assume that spectra are uncorrelated, an assumption that is often violated in practical scenarios due to factors such as time-domain windowing or the non-stationary nature of signals, as observed in speech. To overcome these limitations, we propose an RTF estimation technique that leverages spectral and spatial correlations through subspace analysis. Additionally, we derive Cram\'er--Rao bounds (CRBs) for the RTF estimation task, providing theoretical insights into the achievable estimation accuracy. These bounds reveal that channel estimation can be performed more accurately if the noise or the target signal exhibits spectral correlations. Experiments with both real and synthetic data show that our technique outperforms the narrowband maximum-likelihood estimator, known as covariance whitening (CW), when the target exhibits spectral correlations. Although the proposed algorithm generally achieves accuracy close to the theoretical bound, there is potential for further improvement, especially in scenarios with highly spectrally correlated noise. While channel estimation has various applications, we demonstrate the method using a minimum variance distortionless (MVDR) beamformer for multichannel speech enhancement. A free Python implementation is also provided.
Health monitoring, fault analysis, and detection are critical for the safe and sustainable operation of battery systems. We apply Gaussian process resistance models on lithium iron phosphate battery field data to effectively separate the time-dependent and operating point-dependent resistance. The data set contains 29 battery systems returned to the manufacturer for warranty, each with eight cells in series, totaling 232 cells and 131 million data rows. We develop probabilistic fault detection rules using recursive spatiotemporal Gaussian processes. These processes allow the quick processing of over a million data points, enabling advanced online monitoring and furthering the understanding of battery pack failure in the field. The analysis underlines that often, only a single cell shows abnormal behavior or a knee point, consistent with weakest-link failure for cells connected in series, amplified by local resistive heating. The results further the understanding of how batteries degrade and fail in the field and demonstrate the potential of efficient online monitoring based on data. We open-source the code and publish the large data set upon completion of the review of this article.
Rolling bearing fault detection has developed rapidly in the field of fault diagnosis technology, and it occupies a very important position in this field. Deep learning-based bearing fault diagnosis models have achieved significant success. At the same time, with the continuous improvement of new signal processing technologies such as Fourier transform, wavelet transform and empirical mode decomposition, the fault diagnosis technology of rolling bearings has also been greatly developed, and it can be said that it has entered a new research stage. However, most of the existing methods are limited to varying degrees in the industrial field. The main ones are fast feature extraction and computational complexity. The key to this paper is to propose a lightweight bearing fault diagnosis model DKDL-Net to solve these challenges. The model is trained on the CWRU data set by decoupling knowledge distillation and low rank adaptive fine tuning. Specifically, we built and trained a teacher model based on a 6-layer neural network with 69,626 trainable parameters, and on this basis, using decoupling knowledge distillation (DKD) and Low-Rank adaptive (LoRA) fine-tuning, we trained the student sag model DKDL-Net, which has only 6838 parameters. Experiments show that DKDL-Net achieves 99.48% accuracy in computational complexity on the test set while maintaining model performance, which is 0.58% higher than the state-of-the-art (SOTA) model, and our model has lower parameters. Our code is available at Github link: https://github.com/SPBU-LiPengyi/DKDL-Net.git.
Unsupervised fault detection in multivariate time series is critical for maintaining the integrity and efficiency of complex systems, with current methodologies largely focusing on statistical and machine learning techniques. However, these approaches often rest on the assumption that data distributions conform to Gaussian models, overlooking the diversity of patterns that can manifest in both normal and abnormal states, thereby diminishing discriminative performance. Our innovation addresses this limitation by introducing a combination of data augmentation and soft contrastive learning, specifically designed to capture the multifaceted nature of state behaviors more accurately. The data augmentation process enriches the dataset with varied representations of normal states, while soft contrastive learning fine-tunes the model's sensitivity to the subtle differences between normal and abnormal patterns, enabling it to recognize a broader spectrum of anomalies. This dual strategy significantly boosts the model's ability to distinguish between normal and abnormal states, leading to a marked improvement in fault detection performance across multiple datasets and settings, thereby setting a new benchmark for unsupervised fault detection in complex systems. The code of our method is available at \url{https://github.com/zangzelin/code_USD.git}.
In recent years, deep learning has led to significant advances in bearing fault diagnosis (FD). Most techniques aim to achieve greater accuracy. However, they are sensitive to noise and lack robustness, resulting in insufficient domain adaptation and anti-noise ability. The comparison of studies reveals that giving equal attention to all features does not differentiate their significance. In this work, we propose a novel FD model by integrating multi-scale quaternion convolutional neural network (MQCNN), bidirectional gated recurrent unit (BiGRU), and cross self-attention feature fusion (CSAFF). We have developed innovative designs in two modules, namely MQCNN and CSAFF. Firstly, MQCNN applies quaternion convolution to multi-scale architecture for the first time, aiming to extract the rich hidden features of the original signal from multiple scales. Then, the extracted multi-scale information is input into CSAFF for feature fusion, where CSAFF innovatively incorporates cross self-attention mechanism to enhance discriminative interaction representation within features. Finally, BiGRU captures temporal dependencies while a softmax layer is employed for fault classification, achieving accurate FD. To assess the efficacy of our approach, we experiment on three public datasets (CWRU, MFPT, and Ottawa) and compare it with other excellent methods. The results confirm its state-of-the-art, which the average accuracies can achieve up to 99.99%, 100%, and 99.21% on CWRU, MFPT, and Ottawa datasets. Moreover, we perform practical tests and ablation experiments to validate the efficacy and robustness of the proposed approach. Code is available at https://github.com/mubai011/MQCCAF.
Anomaly detection in distributed systems such as High-Performance Computing (HPC) clusters is vital for early fault detection, performance optimisation, security monitoring, reliability in general but also operational insights. Deep Neural Networks have seen successful use in detecting long-term anomalies in multidimensional data, originating for instance from industrial or medical systems, or weather prediction. A downside of such methods is that they require a static input size, or lose data through cropping, sampling, or other dimensionality reduction methods, making deployment on systems with variability on monitored data channels, such as computing clusters difficult. To address these problems, we present DeepHYDRA (Deep Hybrid DBSCAN/Reduction-Based Anomaly Detection) which combines DBSCAN and learning-based anomaly detection. DBSCAN clustering is used to find point anomalies in time-series data, mitigating the risk of missing outliers through loss of information when reducing input data to a fixed number of channels. A deep learning-based time-series anomaly detection method is then applied to the reduced data in order to identify long-term outliers. This hybrid approach reduces the chances of missing anomalies that might be made indistinguishable from normal data by the reduction process, and likewise enables the algorithm to be scalable and tolerate partial system failures while retaining its detection capabilities. Using a subset of the well-known SMD dataset family, a modified variant of the Eclipse dataset, as well as an in-house dataset with a large variability in active data channels, made publicly available with this work, we furthermore analyse computational intensity, memory footprint, and activation counts. DeepHYDRA is shown to reliably detect different types of anomalies in both large and complex datasets.
This letter presents a novel approach in the field of Active Fault Detection (AFD), by explicitly separating the task into two parts: Passive Fault Detection (PFD) and control input design. This formulation is very general, and most existing AFD literature can be viewed through this lens. By recognizing this separation, PFD methods can be leveraged to provide components that make efficient use of the available information, while the control input is designed in order to optimize the gathering of information. The core contribution of this work is FIERL, a general simulation-based approach for the design of such control strategies, using Constrained Reinforcement Learning (CRL) to optimize the performance of arbitrary passive detectors. The control policy is learned without the need of knowing the passive detector inner workings, making FIERL broadly applicable. However, it is especially useful when paired with the design of an efficient passive component. Unlike most AFD approaches, FIERL can handle fairly complex scenarios such as continuous sets of fault modes. The effectiveness of FIERL is tested on a benchmark problem for actuator fault diagnosis, where FIERL is shown to be fairly robust, being able to generalize to fault dynamics not seen in training.
Predicting the remaining useful life (RUL) of ball bearings plays an important role in predictive maintenance. A common definition of the RUL is the time until a bearing is no longer functional, which we denote as an event, and many data-driven methods have been proposed to predict the RUL. However, few studies have addressed the problem of censored data, where this event of interest is not observed, and simply ignoring these observations can lead to an overestimation of the failure risk. In this paper, we propose a probabilistic estimation of RUL using survival analysis that supports censored data. First, we analyze sensor readings from ball bearings in the frequency domain and annotate when a bearing starts to deteriorate by calculating the Kullback-Leibler (KL) divergence between the probability density function (PDF) of the current process and a reference PDF. Second, we train several survival models on the annotated bearing dataset, capable of predicting the RUL over a finite time horizon using the survival function. This function is guaranteed to be strictly monotonically decreasing and is an intuitive estimation of the remaining lifetime. We demonstrate our approach in the XJTU-SY dataset using cross-validation and find that Random Survival Forests consistently outperforms both non-neural networks and neural networks in terms of the mean absolute error (MAE). Our work encourages the inclusion of censored data in predictive maintenance models and highlights the unique advantages that survival analysis offers when it comes to probabilistic RUL estimation and early fault detection.
In vibration-based condition monitoring, optimal filter design improves fault detection by enhancing weak fault signatures within vibration signals. This process involves optimising a derived objective function from a defined objective. The objectives are often based on proxy health indicators to determine the filter's parameters. However, these indicators can be compromised by irrelevant extraneous signal components and fluctuating operational conditions, affecting the filter's efficacy. Fault detection primarily uses the fault component's prominence in the squared envelope spectrum, quantified by a squared envelope spectrum-based signal-to-noise ratio. New optimal filter objective functions are derived from the proposed generalised envelope spectrum-based signal-to-noise objective for machines operating under variable speed conditions. Instead of optimising proxy health indicators, the optimal filter coefficients of the formulation directly maximise the squared envelope spectrum-based signal-to-noise ratio over targeted frequency bands using standard gradient-based optimisers. Four derived objective functions from the proposed objective effectively outperform five prominent methods in tests on three experimental datasets.
Integrating machine learning into Automated Control Systems (ACS) enhances decision-making in industrial process management. One of the limitations to the widespread adoption of these technologies in industry is the vulnerability of neural networks to adversarial attacks. This study explores the threats in deploying deep learning models for fault diagnosis in ACS using the Tennessee Eastman Process dataset. By evaluating three neural networks with different architectures, we subject them to six types of adversarial attacks and explore five different defense methods. Our results highlight the strong vulnerability of models to adversarial samples and the varying effectiveness of defense strategies. We also propose a novel protection approach by combining multiple defense methods and demonstrate it's efficacy. This research contributes several insights into securing machine learning within ACS, ensuring robust fault diagnosis in industrial processes.