Asymmetric Adaptation-based Real-time Fault Diagnosis Under Transitional Operating Conditions

Bearing fault diagnosis faces critical challenges when dataset heterogeneity, operating condition variations, and limited labeled data occur simultaneously in industrial environments. Existing approaches address these issues in isolation and rely on implicit feature alignment, limiting effectiveness under concurrent challenges. This paper proposes a knowledge-guided two-stage transfer learning framework that employs a lightweight GPT-2-style Transformer with causal self-attention for hierarchical feature extraction from vibration signals, establishing explicit pathways where pre-trained encoder weights and fault prototype embeddings serve as knowledge carriers from multi-source pre-training to target adaptation. The framework addresses the dual-shift challenge through multi-source learning for generalizable representations, prototype-based knowledge modulation for target adaptation, and taxonomy-adaptive classification for seamless transfer across heterogeneous fault categories. Experimental validation on four real-world datasets demonstrates 92.61% average accuracy with only 10% labeled target data, outperforming state-of-the-art methods by 17.24 percentage points, establishing a practical pathway toward cost-effective predictive maintenance in Industry 4.0 applications.

Mechanical equipment forms the critical backbone of modern industrial production, yet domain shift severely limits the generalization of deep learning based fault diagnosis models across different equipment and operating conditions.Inspired by the success of foundation models in achieving zero-shotgeneralization, we propose YOTOnet (You Only Train Once), a novel architecture specifically designed for cross-domain fault diagnosis in mechanical equipment.YOTOnet comprises three core components: (1) a physics-aware Invariant Feature Distiller that extracts domain-agnostic representations using multi-scale dilated convolutions and FFT-based time-frequency fusion,(2) Domain-Conditioned Sparse Experts (DC-MoE) that adaptively route inputs to specialized processors via learned gating without external meta-data, and (3) a dual-head classification system with auxiliary supervision.Extensive validation on five public bearing datasets (CWRU, MFPT, XJTU,OTTAWA, HUST) through 30 cross-dataset protocols demonstrates the superiority of YOTOnet compared with other state-of-the-art methods. Critically, we observe a clear scaling effect-average test F1 improves from 0.5339(1 training dataset) to 0.705 (4 datasets), with a clear gain when moving from 3 to 4 datasets. These findings provide empirical evidence that foundation model principles can enable robust, train-once deployment for industrial fault diagnosis.

Vibration-based health monitoring of rotating machinery requires reliable fault diagnosis under operational data constraints, yet condition assessment remains challenged by structural scarcity of fault events and heterogeneous sim-to-real gaps in digital twin-generated signals. Each fault type generates impulses with distinct periodicity, amplitude modulation, and spectral character, making feature-space discrepancies fundamentally heterogeneous across fault classes. Existing domain adaptation methods apply a class-agnostic global transformation that cannot close all fault-specific gaps without distorting inter-class separability, while uniform source-target mixing introduces distributional noise into the data-abundant Normal class. These limitations stem from treating a sequential, state-dependent alignment problem as a one-shot optimization. Each corrective transformation simultaneously reshapes all class distributions, creating state dependencies that static gradient descent cannot resolve. We formulate feature alignment as a continuous-action Markov decision process solved via Proximal Policy Optimization, where the learned policy issues fault-type-specific affine corrections responsive to the current feature-space configuration, with a dual-objective reward balancing gap minimization against separability preservation. An asymmetry-aware strategy reserves real data for the Normal class while augmenting fault classes with policy-aligned simulated samples. Validation across XJTU-SY, CWRU, and a self-built slewing bearing testbed confirms the dominant gain from reinforcement learning-driven alignment, and cross-equipment linear probing achieves 92.8% without encoder retraining, demonstrating transferable monitoring capability.