Prognostics of Multisensor Systems with Unknown and Unlabeled Failure Modes via Bayesian Nonparametric Process Mixtures

Deep-space habitats (DSHs) are safety-critical systems that must operate autonomously for long periods, often beyond the reach of ground-based maintenance or expert intervention. Monitoring system health and anticipating failures are therefore essential. Prognostics based on remaining useful life (RUL) prediction support this goal by estimating how long a subsystem can operate before failure. Critical DSH subsystems, including environmental control and life support, power generation, and thermal control, are monitored by many sensors and can degrade through multiple failure modes. These failure modes are often unknown, and informative sensors may vary across modes, making accurate RUL prediction challenging when historical failure data are unlabeled. We propose an unsupervised prognostics framework for RUL prediction that jointly identifies latent failure modes and selects informative sensors using unlabeled run-to-failure data. The framework consists of two phases: an offline phase, where system failure times are modeled using a mixture of Gaussian regressions and an Expectation-Maximization algorithm to cluster degradation trajectories and select mode-specific sensors, and an online phase for real-time diagnosis and RUL prediction using low-dimensional features and a weighted functional regression model. The approach is validated on simulated DSH telemetry data and the NASA C-MAPSS benchmark, demonstrating its ability to identify unknown failure modes, select mode-specific informative sensors, and accurately predict RUL.

Digital Twins rely on surrogate models to mirror physical systems in real time, yet these models can degrade as operating conditions evolve, a phenomenon known as concept drift. Maintaining surrogate fidelity under drift, particularly when models must also capture aleatoric uncertainty, remains an open challenge. Existing adaptive frameworks lack principled mechanisms for detecting when updates are needed, for efficiently adapting models from limited streaming data, and for certifying that updates genuinely improve predictive performance. Here we present an adaptive Digital Twin framework that integrates a Fisher score--based multivariate drift detector, Low-Rank Adaptation (LoRA) for parameter-efficient continual learning, and a Mann--Whitney $U$ test for online statistical validation. The framework monitors surrogate-model confidence via Fisher score vectors, triggers targeted fine-tuning of fewer than 1% of model parameters upon drift detection, and statistically certifies predictive improvement before deploying the updated surrogate. Applied to a stochastic linear system and a directed energy deposition additive manufacturing process as case studies, the framework successfully detects distributional shifts with short delays and restores both predictive accuracy and uncertainty quantification under abrupt and incremental drift. These results establish a statistically rigorous and computationally tractable pathway for sustaining the trustworthiness of neural-network--based Digital Twins throughout their operational life cycle.

Accurate condition monitoring of industrial equipment requires inferring latent degradation parameters from indirect sensor measurements under uncertainty. While traditional Bayesian methods like Markov Chain Monte Carlo (MCMC) provide rigorous uncertainty quantification, their heavy computational bottlenecks render them impractical for real-time process control. To overcome this limitation, we propose an AI-driven framework utilizing Simulation-Based Inference (SBI) powered by amortized neural posterior estimation to diagnose complex failure modes in heat exchangers. By training neural density estimators on a simulated dataset, our approach learns a direct, likelihood-free mapping from thermal-fluid observations to the full posterior distribution of degradation parameters. We benchmark this framework against an MCMC baseline across various synthetic fouling and leakage scenarios, including challenging low-probability, sparse-event failures. The results show that SBI achieves comparable diagnostic accuracy and reliable uncertainty quantification, while accelerating inference time by a factor of82$\times$ compared to traditional sampling. The amortized nature of the neural network enables near-instantaneous inference, establishing SBI as a highly scalable, real-time alternative for probabilistic fault diagnosis and digital twin realization in complex engineering systems.