Physics-Informed Graph Learning with Uncertainty Awareness for Open-Set Domain Generalization in Fault Diagnosis
Authors: Jinfeng Zhu, Shiyu Long, Ye Yuan
Organizations: College of Computer and Information Science, Southwest University, Tiansheng Road, Chongqing, 400715, China
Abstract
Intelligent industrial maintenance critically relies on reliable fault diagnosis of rotating machinery. However, it faces formidable challenges from unknown fault types and domain shifts induced by varying operating conditions, which is formally formulated as the open-set domain generalization (OSDG) problem. Existing methods are mainly data-driven, thereby overlooking the cascaded propagation of uncertainty across feature extraction, topological learning, and decision-making stages.To tackle this challenge, we propose PGU-OD, a novel Physics-Informed Graph Learning framework with Uncertainty Awareness for Open-set Domain generalization. First, it designs a physics-informed spectral attention module to extract condition-robust fault features, thereby suppressing perceptual uncertainty caused by frequency shifts. Further, it constructs an uncertainty aware adaptive graph learning mechanism to dynamically adjust the edge weights of the sample graph guided by class-scale Gaussian distribution parameters, which mitigates the structural propagation of uncertainty. Finally, a Gaussian-distribution-based adaptive boundary loss function and a dual-criteria open-set inference strategy are developed to optimize decision boundaries and reliably reject unknown faults. Extensive experimental evaluations on two public and widely used rotating machinery fault datasets demonstrate that the proposed PGU-OD outperforms state-of-the-art baselines in both known fault classification and unknown fault rejection under domain shifts.
Fault diagnosis under unseen operating conditions remains highly challenging when labeled data are scarce. Semi-supervised domain generalization fault diagnosis (SSDGFD) provides a practical solution by jointly exploiting labeled and unlabeled source domains. However, existing methods still suffer from two coupled limitations. First, pseudo-labels for unlabeled domains are typically generated primarily from knowledge learned on the labeled source domain, which neglects domain-specific geometric discrepancies and thus induces systematic cross-domain pseudo-label bias. Second, unlabeled samples are commonly handled with a hard accept-or-discard strategy, where rigid thresholding causes imbalanced sample utilization across domains, while hard-label assignment for uncertain samples can easily introduce additional noise. To address these issues, we propose a unified framework termed domain-aware hierarchical contrastive learning (DAHCL) for SSDGFD. Specifically, DAHCL introduces a domain-aware learning (DAL) module to explicitly capture source-domain geometric characteristics and calibrate pseudo-label predictions across heterogeneous source domains, thereby mitigating cross-domain bias in pseudo-label generation. In addition, DAHCL develops a hierarchical contrastive learning (HCL) module that combines dynamic confidence stratification with fuzzy contrastive supervision, enabling uncertain samples to contribute to representation learning without relying on unreliable hard labels. In this way, DAHCL jointly improves the quality of supervision and the utilization of unlabeled samples. Furthermore, to better reflect practical industrial scenarios, we incorporate engineering noise into the SSDGFD evaluation protocol. Extensive experiments on three benchmark datasets demonstrate that...
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.
Data streams in real-world industrial scenarios often contain transitional operating conditions that are uncovered during offline training, leading to significant distribution shifts. To bridge the gap between static offline models and dynamic online data, a novel asymmetric adaptation-based fault diagnosis method is proposed in this paper. Specifically, in the offline stage, we employ domain generalization techniques to extract domain-invariant features from multiple stable conditions and construct robust normalized fault prototypes as reference anchors. Subsequently, during online inference, we design an online test-time adaptation method based on a periodic prototype re-projection mechanism to dynamically update prototype positions. Furthermore, we utilize the geometric distribution derived from anchors to guide the updates of classifiers and adopt an asymmetric learning rate strategy for the feature extractor and classifier. The proposed approach ensures rapid adaptation to new transitional conditions while preserving the discriminative power inherited from the offline domain generalization initialization. Experimental results demonstrate that this mechanism effectively leverages offline generalized knowledge to guide online inference, significantly improving robustness in non-stationary environments.