A Hybrid Intelligent Framework for Uncertainty-Aware Condition Monitoring of Industrial Systems

Industrial process monitoring is fundamental to the safety and economic performance of modern process plants. Current practice remains a one-task-one-model paradigm that is label-inefficient and prone to degradation under operating drift. Foundation models have reshaped language, vision, and generic time-series forecasting, but it has not been adapted to industrial process monitoring. This setting poses domain-specific challenges, including safety-critical decisions and asymmetric sampling between process variables and laboratory measurements. We propose the industrial process monitoring foundation model (IPM-FM). It first learns general-purpose representations from unlabeled industrial process data through self-supervised pretraining, then adapts to specific monitoring tasks using a small amount of task-labeled data, and finally produces calibrated predictions through an uncertainty-aware prediction head. IPM-FM integrates a self-supervised Informer backbone with a multi-criteria consensus feature selector, a recursive lag-feature regression head, and a calibrated Monte Carlo dropout uncertainty module. On a seven-year hydrotreater dataset for diesel flash-point soft sensing, IPM-FM attains an RMSE of 2.99, $R^2$ of 0.50, and 97% coverage of its 95% predictive interval, outperforming the strongest classical and from-scratch sequence baselines by 8.3% and 14.6% in RMSE respectively, supporting the viability of a unified pretraining--adaptation framework for industrial process monitoring.

Accurate forecasting of industrial time series requires balancing predictive accuracy with physical plausibility under non-stationary operating conditions. Existing data-driven models often achieve strong statistical performance but struggle to respect regime-dependent interaction structures and transport delays inherent in real-world systems. To address this challenge, we propose DSPR (Dual-Stream Physics-Residual Networks), a forecasting framework that explicitly decouples stable temporal patterns from regime-dependent residual dynamics. The first stream models the statistical temporal evolution of individual variables. The second stream focuses on residual dynamics through two key mechanisms: an Adaptive Window module that estimates flow-dependent transport delays, and a Physics-Guided Dynamic Graph that incorporates physical priors to learn time-varying interaction structures while suppressing spurious correlations. Experiments on four industrial benchmarks spanning heterogeneous regimes demonstrate that DSPR consistently improves forecasting accuracy and robustness under regime shifts while maintaining strong physical plausibility. It achieves state-of-the-art predictive performance, with Mean Conservation Accuracy exceeding 99% and Total Variation Ratio reaching up to 97.2%. Beyond forecasting, the learned interaction structures and adaptive lags provide interpretable insights that are consistent with known domain mechanisms, such as flow-dependent transport delays and wind-to-power scaling behaviors. These results suggest that architectural decoupling with physics-consistent inductive biases offers an effective path toward trustworthy industrial time-series forecasting. Furthermore, DSPR's demonstrated robust performance in long-term industrial deployment bridges the gap between advanced forecasting models and trustworthy autonomous control systems.

Silicon carbide (SiC) power modules are increasingly deployed in automotive traction inverters, where condition monitoring is essential to prevent in-service failures. Despite extensive qualification under AQG 324, no consolidated approach exists for in-field health state estimation: physics-of-failure lifetime models lack real-time applicability, purely data-driven architectures require large labeled datasets and generalize poorly, and physics-informed frameworks remain too demanding for embedded deployment. We address SiC MOSFET modules assembled with sintered packaging, which suppresses solder degradation and produces aging behavior distinct from previously studied devices. Instead of the smooth quasi-exponential drift of solder-based modules, the forward voltage drop $V_{DS}$ exhibits multi-regime profiles, with wirebond liftoff events introducing abrupt, non-monotonic perturbations. We propose a condition monitoring framework combining three elements. First, physics-informed features replace raw sensor signals with cumulative damage indicators derived from junction temperature swing, mean junction temperature and a Miner rule accumulator, encoding degradation history in an interpretable form. Second, a monotonicity constraint enforced by gradient penalty regularization embeds the expected degradation direction as a physics-guided prior. Third, a heavy-tailed output distribution replaces the point estimate, giving calibrated uncertainty robust to the out-of-distribution variance introduced by liftoff. On an industrial power cycling dataset from Infineon Technologies, several neural architectures are compared under a strict cross-validation protocol. The full configuration reduces mean absolute error by approximately 70% over purely data-driven baselines and stays stable across all folds, while remaining lightweight enough for embedded deployment.