A Deep Learning-Based Stacking Ensemble Framework for Turbofan Engine Remaining Useful Life Prediction

Remaining Useful Life (RUL) estimation is a critical component of Prognostics and Health Management (PHM), enabling proactive maintenance scheduling and reducing unplanned failures in industrial equipment. This paper presents a comparative study of machine learning approaches for RUL estimation on the NASA C-MAPSS turbofan engine dataset: classical baselines (Ridge Regression, Polynomial Ridge, and XGBoost), a 1D Convolutional Neural Network (CNN), and a Long Short-Term Memory (LSTM) network. All models are evaluated on the FD001 and FD003 subsets under an identical preprocessing pipeline to ensure a fair comparison. Among raw-sequence models, the LSTM achieves RMSE of 14.93 and 14.20 on FD001 and FD003 respectively, outperforming the deep LSTM reported by Zheng et al.~\cite{paper} (RMSE 16.14 and 16.18) despite using a simpler single-layer architecture. The 1D CNN achieves RMSE of 16.97 on FD001 and 15.68 on FD003, demonstrating competitive performance on FD003 while producing more conservative RUL predictions on FD001. Ridge Regression is evaluated on raw and engineered features, while other classical models use only engineered inputs. XGBoost achieves an RMSE of 13.36 on FD003, highlighting the competitiveness of nonlinear modeling.

This study presents a novel hybrid prognostic framework for uncertainty-aware Remaining Useful Life (RUL) estimation in turbofan engines using the NASA C-MAPSS dataset. The framework employs a state-aware strategy that bifurcates the engines operational lifespan into "healthy" and "degraded" regimes. An LSTM-based autoencoder, trained strictly on nominal data (RUL > 150 cycles), monitors reconstruction error to act as a robust state classifier. For the healthy regime, a Conditional Weibull Survival Analysis is used for Mean Residual Life estimation. For the degraded regime, a Probabilistic Neural Network with Monte Carlo Dropout captures both aleatoric and epistemic uncertainties. Rather than using rigid binary labels, a calibrated sigmoid function converts the autoencoders output into continuous state probabilities, dynamically weighting the final ensemble prediction. The primary strength of this framework is its generation of physically consistent uncertainty bands, yielding high-confidence predictions near end-of-life while accurately reflecting the inherent variance of early operation, providing a robust tool for risk-informed maintenance.

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.