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.
Machine fault diagnosis from vibration requires learning from scarce labelled fault recordings while meeting the computational constraints of edge devices for local inference. We introduce DualRes, a compact oscillatory state-space model that combines two complementary spectral views of vibration, capturing rapid changes and fine frequency structure. Time-aligned views are processed by selective oscillatory memory, which learns how long to retain temporal patterns. The encoder contains 39,528 parameters. We evaluate supervised learning across six bearing datasets and a gearbox benchmark, with an additional gearbox pilot. Recording-level splits and explicit accounting of labelled duration distinguish data efficiency from repeated exposure to correlated samples. On the main gearbox benchmark, DualRes achieves state-of-the-art performance among the nine evaluated methods at six of seven label budgets. With about six labelled seconds per class, it improves macro-F1 by 16.1 percentage points over the next strongest comparator. On the same benchmark, DualRes achieves a 1.44-fold recording-level speedup and a 24.8-fold reduction in checkpoint storage relative to a selective state-space baseline under matched hardware and runtime conditions. Bearing results reveal task-dependent trade-offs. These findings support oscillatory memory as a compact approach to vibration diagnosis under limited labelled exposure.
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.
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.