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

Hybrid approaches that combine data-driven learning with physics-based insight have shown promise for improving the reliability of industrial condition monitoring. This work develops a hybrid condition monitoring framework that integrates primary sensor measurements, lagged temporal features, and physics-informed residuals derived from nominal surrogate models. Two hybrid integration strategies are examined. The first is a feature-level fusion approach that augments the input space with residual and temporal information. The second is a model-level ensemble approach in which machine learning classifiers trained on different feature types are combined at the decision level. Both hybrid approaches of the condition monitoring framework are evaluated on a continuous stirred-tank reactor (CSTR) benchmark using several machine learning models and ensemble configurations. Both feature-level and model-level hybridization improve diagnostic accuracy relative to single-source baselines, with the best model-level ensemble achieving a 2.9% improvement over the best baseline ensemble. To assess predictive reliability, conformal prediction is applied to quantify coverage, prediction-set size, and abstention behavior. The results show that hybrid integration enhances uncertainty management, producing smaller and well-calibrated prediction sets at matched coverage levels. These findings demonstrate that lightweight physics-informed residuals, temporal augmentation, and ensemble learning can be combined effectively to improve both accuracy and decision reliability in nonlinear industrial systems.