Multi-Condition Digital Twin Calibration for Axial Piston Pumps : Compound Fault Simulation

Intelligent fault diagnosis (IFD) has emerged as a powerful paradigm for ensuring the safety and reliability of industrial machinery. However, traditional IFD methods rely heavily on abundant labeled data for training, which is often difficult to obtain in practical industrial environments. Constructing a digital twin (DT) of the physical asset to obtain simulation data has therefore become a promising alternative. Nevertheless, existing DT-assisted diagnosis methods mainly transfer diagnostic knowledge through domain adaptation techniques, which still require a considerable amount of unlabeled data from the target asset. To address the challenges in few-shot scenarios where only extremely limited samples are available, a bi-directional DT prototype anchoring method with multi-periodicity learning is proposed. Specifically, a framework involving meta-training in the DT virtual space and test-time adaptation in the physical space is constructed for reliable few-shot model adaptation for the target asset. A bi-directional twin-domain prototype anchoring strategy with covariance-guided augmentation for adaptation is further developed to improve the robustness of prototype estimation. In addition, a multi-periodicity feature learning module is designed to capture the intrinsic periodic characteristics within current signals. A DT of an asynchronous motor is built based on finite element method, and experiments are conducted under multiple few-shot settings and three working conditions. Comparative and ablation studies demonstrate the superiority and effectiveness of the proposed method for few-shot fault diagnosis.

In many cyber-physical systems, especially in critical applications such as aeroplanes, data to train anomaly detection and diagnosis algorithms is lacking due to data protection issues and partial observability. To combat this inherent lack of data, we introduce a high-fidelity, physics-informed co-simulation of a common aircraft main-fuel-pump system modelled in MATLAB/Simulink Simscape Fluids. We also describe its generated time-series data with health and fault mode annotations. To show feasibility of our benchmark, we apply an unsupervised Recurrent Variational Autoencoder (RNN-VAE) for anomaly detection and a SOM-VAE for operating mode discretization, trained to separate healthy and faulty conditions.

Fault diagnosis of general aviation aircraft faces challenges including scarce real fault data, diverse fault types, and weak fault signatures. This paper proposes an intelligent fault diagnosis framework based on multi-fidelity digital twin, integrating four modules: high-fidelity flight dynamics simulation, FMEA-driven fault injection, multi-fidelity residual feature extraction, and large language model (LLM)-enhanced interpretable report generation. A digital twin is constructed using the JSBSim six-degree-of-freedom (6-DoF) flight dynamics engine, generating 23-channel engine health monitoring data via semi-empirical sensor synthesis equations. A three-layer fault injection engine based on failure mode and effects analysis (FMEA) models the physical causal propagation of 19 engine fault types. A multi-fidelity residual computation framework comprising paired-mirror residuals and GRU surrogate prediction residuals is proposed: the high-fidelity path obtains clean fault deviation signals using nominal mirror trajectories with identical initial conditions, while the low-fidelity path achieves online real-time residual computation through a multi-step prediction GRU surrogate model. A 1D-CNN classifier performs end-to-end diagnosis of 20 fault classes. An LLM diagnostic report engine enhanced with FMEA knowledge fuses classification results, residual evidence, and domain causal knowledge to generate interpretable natural language reports. Experiments show the paired-mirror residual scheme achieves a Macro-F1 of 96.2% on the 20-class task, while the GRU surrogate scheme achieves 4.3x inference acceleration at only 0.6% performance cost. Comparison across 24 schemes reveals that residual feature quality contributes approximately 5x more to diagnostic performance than classifier architecture, establishing the "residual quality first" design principle.