A Multi-head Attention Fusion Network for Industrial Prognostics under Discrete Operational Conditions

Multivariate time-series models for prognostics are often evaluated by point prediction accuracy, yet their internal states rarely expose a coherent degradation process. We study liquid neural networks as latent dynamics models for aircraft engine health monitoring on the C-MAPSS benchmark. The proposed model encodes a history window into a latent state, evolves that state with a liquid transition model, and decodes future sensor observations. To separate health evolution from operating-condition variation, the latent state is factorized into degradation and condition components. Remaining useful life, monotonic risk, and latent-consistency losses supervise the degradation component, while condition prediction and decorrelation losses discourage operating-condition leakage. Across FD001--FD004, the full disentangled model improves overall sensor forecasting RMSE from 0.2438 for a GRU baseline to 0.2266, with the largest gains on the multi-condition subsets FD002 and FD004. The learned degradation state also forms a clearer temporal degradation axis, reaching an average state-speed Spearman correlation of 0.5960. Direct remaining-useful-life regression remains stronger for the GRU baseline, indicating that the proposed representation is currently more effective as an interpretable world model for degradation dynamics than as a calibrated lifetime regressor. These results suggest that liquid latent dynamics can bridge predictive maintenance forecasting and inspectable health-state modeling.

Turbofan engine degradation under sustained operational stress necessitates robust prognostic systems capable of accurately estimating the Remaining Useful Life (RUL) of critical components. Existing deep learning approaches frequently fail to simultaneously capture multi-sensor spatial correlations and long-range temporal dependencies, while standard symmetric loss functions inadequately penalize the safety-critical error of over-estimating residual life. This study proposes a hybrid architecture integrating Twin-Stage One-Dimensional Convolutional Neural Networks (1D-CNN), a Bidirectional Long Short-Term Memory (BiLSTM) network, and a custom Bahdanau Additive Attention mechanism. The model was trained and evaluated on the NASA Commercial Modular Aero-Propulsion System Simulation (C-MAPSS) FD001 sub-dataset employing a zero-leakage preprocessing pipeline, piecewise-linear RUL labeling capped at 130 cycles, and the NASA-specified asymmetric exponential loss function that disproportionately penalizes over-estimation to enforce industrial safety constraints. Experiments on 100 test engines achieved a Root Mean Squared Error (RMSE) of 17.52 cycles and a NASA S-Score of 922.06. Furthermore, extracted attention weight heatmaps provide interpretable, per-engine insights into the temporal progression of degradation, supporting informed maintenance decision-making. The proposed framework demonstrates competitive performance against established baselines and offers a principled approach to safe, interpretable prognostics in industrial settings.

Predictive maintenance requires reliable remaining useful life (RUL) estimation. Existing methods mainly follow two paradigms: wear-based aging models that capture cumulative degradation and sensor-driven data models that reflect instantaneous health conditions, each providing only partial information. In this work, we propose a probabilistic fusion framework that integrates wear-based and sensor-based prognostic components through failure probability distributions. Based on explicit structural assumptions linking wear, latent health, sensor observations, and failure, we derive a principled combination rule that enables uncertainty-aware integration with adaptive weighting of the components. Experimentally, we assess this combination rule by learning the wear-based component using a parametric survival model and the sensor-based component using a 1D convolutional neural network (1D-CNN) with a post-hoc uncertainty model. Evaluation on multiple N-CMAPSS datasets demonstrates that the fused model improves point accuracy, preserves the C-index, and produces narrower yet well-calibrated prediction intervals compared to either component alone. The results highlight the complementary roles of wear-based survival model and sensor-based deep learning model, and show that their probabilistic integration provides a structured pathway toward more robust and consistent prognostics over the life-time.