Label-free Industrial Fault Detection via Adversarial Inverse Reinforcement Learning: A System for Run-to-Failure Prognostics

Reinforcement fine-tuning (RFT) has become a core paradigm for post-training large language models, yet its training process remains highly fragile. Existing efforts mainly improve reliability at the system level or address specific issues in individual subproblems by modifying RFT algorithms. Despite their effectiveness, they largely overlook the problem of failure management at the training-process level. When training goes wrong, practitioners still rely heavily on expert-driven manual inspection and correction, and automatic failure management for RFT remains largely unexplored. In this paper, we take a first step toward systematic failure management for reinforcement fine-tuning. To understand the empirical structure of RFT failures, we first construct RFT-FaultBench, the first benchmark for fine-grained failures in reinforcement fine-tuning, covering 5 fault families, 16 fault types, 779 training runs, 22,549 train-step records, and 1,457,288 trajectory-level records. Based on this benchmark, we conduct a comprehensive empirical study showing that RFT failures are both observable from training dynamics and distinguishable through their empirical fault fingerprints. Building on these findings, we propose RFT-FM, an automatic failure management framework for reinforcement fine-tuning that unifies anomaly detection, failure diagnosis, and auto remediation in a closed loop. Experimental results show that RFT-FaultBench is neither trivial nor saturated: it exhibits clear anomaly structure while still posing substantial challenges, especially under subtle fault settings. Moreover, RFT-FM shows strong capability in detecting, diagnosing, and mitigating RFT failures.

Deep learning is a new way for machinery fault diagnosis but requires extensive labeled data, a scarce resource in industrial settings. We propose Spectral Aliasing Pretext (SAP), a self-supervised learning method that pretrains models on unlabeled vibration data by exploiting spectral aliasing. We deliberately undersample signals to create folded spectrum, then train a Transformer to reconstruct the original unfolded spectrum. This pretext task forces the model to learn frequency-domain invariants characteristic of mechanical faults, without potentially destructive augmentations. Experiments on the CWRU dataset show that SAP learns stable and highly discriminative representations. In a linear probing setting, SAP quickly achieves very high classification performance with only a small fraction of labeled data and low variance. In contrast, full fine-tuning, including fully supervised training, does not lead to more stable or better results. Overall, these findings suggest that SAP combined with linear probing can be more effective and reliable than fully supervised training for fault diagnosis with limited labeled data.

On-device fault detection enables real-time diagnostics without cloud dependency, but deploying machine learning models on resource-constrained hardware demands careful tradeoffs between accuracy, latency, and model size. We present a benchmark comparing traditional ML methods (Random Forest, XGBoost, SVM, Logistic Regression) against lightweight transformer architectures (DistilBERT, TinyBERT-6L, TinyBERT-4L, MobileBERT) for binary fault detection across three public datasets: NASA C-MAPSS turbofan degradation, SECOM semiconductor manufacturing, and UCI AI4I 2020 predictive maintenance. We evaluate classification performance (F1-score, AUC), model size, and CPU inference latency, and further assess INT8 dynamic quantization and a two-stage adaptive inference pipeline. Our results reveal that on well-separated sensor data (C-MAPSS), lightweight transformers match traditional ML at 87.8% F1 but at 100x the model size and 9000x the latency. TinyBERT-4L emerges as the most deployment-friendly transformer at 55 MB and 18 ms CPU latency. INT8 quantization reduces size by 25% while preserving 86.9% F1. Our adaptive pipeline, routing 97.9% of predictions through a quantized triage model and only 2.1% to a larger expert, achieves 87.6% F1 at 19.5 ms average latency. On severely imbalanced datasets (SECOM, UCI-PM), both traditional and transformer methods struggle significantly, highlighting fundamental limitations of current approaches for extreme class imbalance in fault detection. All code is publicly available.