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From Concepts to Conditions: Bridging the Gap in AI-Based Maintenance Systems
Mid Sweden University, Faculty of Science, Technology and Media, Department of Computer and Electrical Engineering (2023-).ORCID iD: 0000-0003-0058-2306
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The importance of preventing machine failures and reducing costly unplanned downtime has led to extensive research aiming to develop methods that predict maintenance needs. In this context, data-driven and particularly Deep Learning (DL) based methods for anomaly detection, fault diagnosis, and health prognosis have been studied extensively because of their ability to handle the complexity of the sensor data describing the health state of machines. However, many challenging factors exist before it is possible to utilize these methods in practice. These primarily include the lack of labelled failure events, the heterogeneous nature of the data, and the occurrence of multi-component fault scenarios. Currently, most studies ignore these aspects and focus on scenarios limited to a laboratory environment, which means there is a need to develop methods that can be deployed in practice. Therefore, this thesis suggests methods for these challenges and gives insight, aiming to reduce the gap between research-defined scenarios and scenarios found in industrial environments. To achieve this, different areas in the context of DL for Predictive Maintenance (PdM) are examined, including multivariate anomaly detection, fault diagnosis, and Remaining Useful Life (RUL) prediction methods.

One of the contributions is a threshold-setting procedure that optimizes anomaly detection models with the user's support and a novel separate scoring method, and outperforms state-of-the-art alternatives for deployments in industrial applications. A published dataset of bearing faults from an industrial environment is also described, which is beneficial when developing and evaluating methods. In addition, a novel DL method for fault diagnosis of bearings using vibration data constructed with knowledge enrichment, time-based contextual enrichment, and a transfer learning technique is suggested. This method can be deployed on any machine without historical faults and outperforms state-of-the-art methods. Lastly, the most significant contribution is a prognostic hybrid framework for multi-component fault scenarios in rotating machines using vibration data that utilizes advancements in methods for anomaly detection, fault diagnosis, and RUL prediction of machines.

In summary, this thesis suggests novel methods for PdM adapted for industrial applications that can be used on a general basis and provides insights that lower the gap between research-defined scenarios and scenarios found in industrial environments.

 

Place, publisher, year, edition, pages
Sundsvall: Mid Sweden University , 2025. , p. 56
Series
Mid Sweden University doctoral thesis, ISSN 1652-893X ; 431
Keywords [en]
predictive maintenance, fault diagnosis, prognostics, remaining useful life, deep learning, machine learning
National Category
Artificial Intelligence Computer Sciences
Identifiers
URN: urn:nbn:se:miun:diva-54539ISBN: 978-91-90017-26-5 (print)OAI: oai:DiVA.org:miun-54539DiVA, id: diva2:1962319
Public defence
2025-06-16, C312, Holmgatan 10, Sundsvall, 13:00 (English)
Opponent
Supervisors
Funder
Knowledge Foundation
Note

Vid tidpunkten för disputationen var följande delarbete opublicerat: delarbete 6 accepterat.

At the time of the doctoral defence the following paper was unpublished: paper 6 accepted.

Available from: 2025-06-02 Created: 2025-05-29 Last updated: 2025-09-25Bibliographically approved
List of papers
1. Improving deep learning based anomaly detection on multivariate time series through separated anomaly scoring
Open this publication in new window or tab >>Improving deep learning based anomaly detection on multivariate time series through separated anomaly scoring
2022 (English)In: IEEE Access, E-ISSN 2169-3536, Vol. 10, p. 108194-108204Article in journal (Refereed) Published
Abstract [en]

The importance of anomaly detection in multivariate time series has led to the development of several prominent deep learning solutions. As a part of the anomaly detection method, the scoring method has shown to be of significant importance when separating non-anomalous points from anomalous ones. At this time, most of the solutions utilize an aggregated score which means that relevant information created by the anomaly detection model might be lost. Therefore, this study has set out to examine to what extent anomaly detection in multivariate time series based on deep learning can be improved if all the residuals from each individual channel is considered in the anomaly score. To achieve this, an aggregated and separated scoring method has been applied with a simple denoising convulutional autoencoder (DCAE). In addition, the performance has been compared with other state-of-the-art methods. The result showed that the separated approach has the potential to generate a significantly higher performance than the aggregated one. At the same time, there were some indications suggesting that an aggregated scoring is better at generalizing when no labels to base the anomaly thresholds on, are available. Therefore, the result should serve as an encouragement to use a separated scoring approach together with a small sample of labeled anomalies to optimise the thresholds. Lastly, due to the impact of the anomaly score, the result suggests that future research within this field should consider applying the same anomaly scoring method when comparing the performance of deep learning algorithms. 

Keywords
Anomaly detection, Anomaly scoring, Deep learning, Generative adversarial networks, Multivariate time series (MVTS), Optimization, Predictive models, Time series analysis, Training data
National Category
Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
urn:nbn:se:miun:diva-46336 (URN)10.1109/ACCESS.2022.3213038 (DOI)000870215300001 ()2-s2.0-85139827298 (Scopus ID)
Available from: 2022-10-26 Created: 2022-10-26 Last updated: 2025-09-25Bibliographically approved
2. An interactive threshold-setting procedure for improved multivariate anomaly detection in time series
Open this publication in new window or tab >>An interactive threshold-setting procedure for improved multivariate anomaly detection in time series
2023 (English)In: IEEE Access, E-ISSN 2169-3536, Vol. 11, p. 93898-93907Article in journal (Refereed) Published
Abstract [en]

Anomaly detection in multivariate time series is valuable for many applications. In this context, unsupervised and semi-supervised deep learning methods that estimate how normal a new observation is have shown promising results on benchmark datasets. These methods are dependent on a threshold that determines which points should be regarded as anomalous and not be anomalous. However, finding the optimal threshold is not easy since no information about the ground truth is known in advance, which implies that there are limitations to automatic threshold-setting methods available today. An alternative is to utilize the expertise of users that can interact in a threshold-setting procedure, but for this to be practically feasible, the method needs to be both accurate and efficient in relation to the state-of-the-art automatic methods. Therefore, this study develops an interactive threshold-setting schema and examines to what extent it can outperform the current state-of-the-art automatic threshold-setting methods. The result of the study strongly indicates that the suggested method with little effort can provide higher accuracy than the automatic threshold-setting methods on a general basis. 

Place, publisher, year, edition, pages
IEEE, 2023
Keywords
Anomaly detection, Anomaly scoring, Data models, Deep learning, Electronic mail, Multivariate time series (MVTS), Time series analysis, Time-domain analysis, Training, Training data
National Category
Computer and Information Sciences
Identifiers
urn:nbn:se:miun:diva-49293 (URN)10.1109/ACCESS.2023.3310653 (DOI)001063183300001 ()2-s2.0-85169696562 (Scopus ID)
Available from: 2023-09-13 Created: 2023-09-13 Last updated: 2025-09-25Bibliographically approved
3. Factory-Based Vibration Data for Bearing-Fault Detection
Open this publication in new window or tab >>Factory-Based Vibration Data for Bearing-Fault Detection
2023 (English)In: DATA, ISSN 2306-5729, Vol. 8, no 7, article id 115Article in journal (Refereed) Published
Abstract [en]

The importance of preventing failures in bearings has led to a large amount of research being conducted to find methods for fault diagnostics and prognostics. Many of these solutions, such as deep learning methods, require a significant amount of data to perform well. This is a reason why publicly available data are important, and there currently exist several open datasets that contain different conditions and faults. However, one challenge is that almost all of these data come from a laboratory setting, where conditions might differ from those found in an industrial environment where the methods are intended to be used. This also means that there may be characteristics of the industrial data that are important to take into account. Therefore, this study describes a completely new dataset for bearing faults from a pulp mill. The analysis of the data shows that the faults vary significantly in terms of fault development, rotation speed, and the amplitude of the vibration signal. It also suggests that methods built for this environment need to consider that no historical examples of faults in the target domain exist and that external events can occur that are not related to any condition of the bearing.

Place, publisher, year, edition, pages
MDPI, 2023
Keywords
bearing, diagnostics, fault detection, dataset, fault diagnosis
National Category
Control Engineering
Identifiers
urn:nbn:se:miun:diva-49074 (URN)10.3390/data8070115 (DOI)001035081000001 ()2-s2.0-85166415713 (Scopus ID)
Available from: 2023-08-16 Created: 2023-08-16 Last updated: 2025-09-25Bibliographically approved
4. Contextual knowledge-informed deep domain generalization for bearing fault diagnosis
Open this publication in new window or tab >>Contextual knowledge-informed deep domain generalization for bearing fault diagnosis
2024 (English)In: IEEE Access, E-ISSN 2169-3536, Vol. 12, p. 196842-196854Article in journal (Refereed) Published
Abstract [en]

Reliable methods for bearing fault diagnosis are of great importance because they provide the possibility of preventing failures in machines. A significant challenge is developing solutions that can handle the variances in the data across different domains i.e., the operational context of the bearing and settings including noise, bearing type, rotational speed, and sampling frequency. To solve this issue, a common approach is to use transfer learning. However, most existing methods either assume that faults are available in the target domain or that only operational conditions on a single machine are changed between the source and target domain. Unfortunately, neither of these assumptions can be made in an industrial environment where there is a need to deploy the method on new machines with no historical faults. Therefore, there is a need to develop methods for bearing fault diagnosis that can provide accurate predictions on a general basis without needing access to historical faults from the target domain. To address this problem, this study develops a novel method including a knowledge-enriched standardization procedure used to lower the domain shift, a feature-targeted metric learning procedure enriched with contextual data that can be deployed to any new domain without having access to historical faults. The method is compared against state-of-the-art solutions in three cases with various tasks where it achieves the highest accuracy and displays high robustness and generalizability. The results also show a low level of false positives, a high level of fault segment recall and the possibility of giving feedback to the user about the model's decision. The conclusion is that the method can be used on a general basis for fault diagnosis of bearings without having access to historical faults from the target domain. 

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE), 2024
Keywords
deep domain generalization, fault transfer diagnosis, rolling bearing, rotating machinery, XAI
National Category
Computer and Information Sciences
Identifiers
urn:nbn:se:miun:diva-53539 (URN)10.1109/ACCESS.2024.3520624 (DOI)001387130900024 ()2-s2.0-85212980885 (Scopus ID)
Available from: 2025-01-07 Created: 2025-01-07 Last updated: 2025-09-25
5. Towards practically applicable transfer learning methods for remaining useful life prediction of bearings
Open this publication in new window or tab >>Towards practically applicable transfer learning methods for remaining useful life prediction of bearings
2024 (English)In: 2024 IEEE 22nd International Conference on Industrial Informatics (INDIN), IEEE conference proceedings, 2024Conference paper, Published paper (Refereed)
Abstract [en]

Methods for estimating the remaining useful life of bearings are of great value in preventing them from failing. Because of this, different types of methods have been suggested. One of the most prominent is transfer learning since it achieves high performance despite the discrepancies in data expected in industrial applications. However, most current research ignores aspects such as the influence of non-bearing related faults, the non-existence of historical run-to-failure data from the target domain and knowledge transfer between machines. Considering this, how existing methods will cope with these scenarios is not established. Therefore, this study examines the performance of transfer learning methods based on current studies methodologies. The result suggests that there are limitations to the assumptions made in the current research and that more considerations for scenarios found in industrial applications are needed both in the development and evaluation phases to increase the possibility of applying transfer learning methods in practice. 

Place, publisher, year, edition, pages
IEEE conference proceedings, 2024
Keywords
bearings, remaining useful life (RUL), transfer learning (TL)
National Category
Other Engineering and Technologies
Identifiers
urn:nbn:se:miun:diva-53683 (URN)10.1109/INDIN58382.2024.10774504 (DOI)2-s2.0-85215530990 (Scopus ID)9798331527471 (ISBN)
Conference
IEEE International Conference on Industrial Informatics (INDIN)
Available from: 2025-01-28 Created: 2025-01-28 Last updated: 2025-09-25Bibliographically approved

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Lycksam, Adam

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