Acoustic Anomaly Detection for Early Identification of Drill Jamming

Reliable fault detection is crucial for industrial machinery in large-scale facilities, where unexpected failures can cause costly downtime and production interruptions. Although acoustic monitoring provides a scalable solution for machine condition monitoring, its deployment is often constrained by high false-positive rates. We propose a two-step approach to automatic anomalous sound detection: first, when only normal operating audio samples are available, a regularized unsupervised model is deployed; then, after the first machine fault, a few-shot adaptation strategy exploits the anomalous samples acquired during the fault to improve the system. This adaptation increases the area under the precision-recall curve (AUPR) from 23.0 to 64.0 and improves detection in the low false-positive-rate region, with the partial area under the receiver operating characteristic curve (pAUROC) increasing from 39.6 to 72.8. We also show that covariance regularization improves both prediction accuracy and training stability in the unsupervised model. These results provide a practical strategy for acoustic anomaly detection systems, enabling improved accuracy and reduced false alarms.

Predictive maintenance in Industry 4.0 refers to using data from sensors, machines, and production systems to estimate when equipment is likely to fail, so maintenance can be planned before a breakdown occurs [1]. However, a model that predicts maintenance may work perfectly in the lab but fail unexpectedly when applied to real factory data [2]. To solve this "reliability" gap, we evaluated six deep learning architectures across more than 700 experimental runs. We focused on the two dominant approaches in the field: Recurrent Neural Networks (RNNs), which process data step-by-step, like reading a sentence [3], and Transformers, a recent dominant approach, which look at the entire sequence at once to spot important connections [4]. We examined whether Transformers still outperform recurrent neural networks (RNNs) when the data includes noise [5]. We found that while Transformers excelled at tracking stable, slow-moving processes, they tend to overreact to chaotic data, mistakenly taking sensor noise for meaningful signals [6]. We also found that the hybrid method that combines a Long Short-Term Memory (LSTM) layer with a Transformer layer is more resilient to noisy data from factory shops [7]. Functioning as a noise filter, the LSTM smooths out data volatility, allowing the Transformer to focus on the bigger picture without being distracted [8]. The hybrid model did not just improve accuracy; it proved to be significantly more consistent than complex models, delivering reliable predictions regardless of how chaotic the underlying system became.

The reliability and quality of 3D printing processes are critically dependent on the timely detection of mechanical faults. Traditional monitoring methods often rely on visual inspection and hardware sensors, which can be both costly and limited in scope. This paper explores a scalable and contactless method for the use of real-time audio signal analysis for detecting mechanical faults in 3D printers. By capturing and classifying acoustic emissions during the printing process, we aim to identify common faults such as nozzle clogging, filament breakage, pully skipping and various other mechanical faults. Utilizing Convolutional neural networks, we implement algorithms capable of real-time audio classification to detect these faults promptly. Our methodology involves conducting a series of controlled experiments to gather audio data, followed by the application of advanced machine learning models for fault detection. Additionally, we review existing literature on audio-based fault detection in manufacturing and 3D printing to contextualize our research within the broader field. Preliminary results demonstrate that audio signals, when analyzed with machine learning techniques, provide a reliable and cost-effective means of enhancing real-time fault detection.