Bearing Fault Diagnosis

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.

Deep learning predictive maintenance models suffer from poor transferability across machines and operating conditions, especially when labelled data are scarce and signals span five orders of magnitude in sampling frequency (1 Hz to ~100 kHz). We propose FreqCondNorm, a Transformer-based architecture that introduces a FiLM-style frequency-conditioned normalization layer to unify heterogeneous time-series within a single model. The architecture is pretrained on five public predictive maintenance datasets (CWRU, MFPT, UOC18, PRONOSTIA, CMAPSS) using masked auto-encoding and contrastive learning with balanced domain sampling. On fault diagnosis, the model achieves 99.2% accuracy on CWRU (+6.4 pp over CNN) and 82.1% zero-shot accuracy on MFPT, demonstrating strong transfer across sampling frequencies. However, the approach does not improve remaining useful life prediction, suggesting a mismatch between pretraining and RUL objectives that warrants future investigation.

To address the degradation of bearing fault diagnosis accuracy under strong noise, this paper proposes a time-frequency dual-domain multi-scale convolutional neural network. The time-domain branch employs three parallel convolutional kernels to capture multi-scale impulse features, while the frequency-domain branch applies the Fast Fourier Transform to extract noise-robust spectral structure information. Features from both branches are fused for fault classification, yielding a compact model of 110,122 parameters. Experiments on the CWRU bearing dataset across seven signal-to-noise ratio levels demonstrate that the proposed method achieves 99.75% accuracy under clean conditions and maintains 92.50% at -4 dB SNR, representing a 7.25 percentage-point improvement over the single-domain baseline with monotonically increasing gains under stronger noise. Ablation experiments validate the independent performance contributions of the time-domain multi-scale branch and the frequency-domain branch. Comparative experiments against WDCNN, DRSN-CW, MCNN, and 1D-LeNet confirm the superiority of the proposed method under strong noise conditions.

Integrating multi-level information, from physical models through data-driven diagnostics to natural language reasoning, into verifiable decision chains is a growing need in intelligent manufacturing. In bearing fault diagnosis, taken here as a representative testbed, the standard output is a class label and a confidence score derived from the classifier's own distribution, offering limited means of comparison against independent physical knowledge. Meanwhile, language models increasingly used for maintenance communication may introduce unsupported content. This work addresses both limitations from the output side. The proposed Diagnostic Evidence Network (DENet) is an encoder-agnostic multi-task framework that extends the output to a structured evidence record: the classification, a predicted characteristic frequency comparable against the theoretical value determined by bearing geometry and shaft speed, and a temporal localization of transient impulses inspectable on the raw waveform. Across four encoders and three public datasets, this evidence incurs no statistically significant accuracy cost, with a frequency error of about 6 Hz on 1,024-point segments. The deviation between predicted and theoretical frequency constitutes a label-free, inference-time validation signal. It detects misclassifications with AUROC of 0.970 and 0.871, and retains separation within the high-confidence subset. Finally, a QLoRA-adapted language model renders DENet's evidence into traceable maintenance reports without contributing diagnostic decisions, reducing unsupported-claim rates from 10-12% to 2% with no fabricated quantities observed.

In bearing vibration datasets, most samples receive predicted fault probabilities close to 0 or 1, while samples with intermediate (gray-zone) probabilities are rare. Such borderline samples are important because they reflect conditions in which maintenance decisions may require additional inspection or a conservative response and are useful for studying decision boundaries. To address this scarcity, this paper proposes and compares two approaches that generate vibration signals whose predicted fault probability matches a target probability of 0.25, 0.50, or 0.75. We use the average output of a heterogeneous ensemble classifier with different architectures and random initializations as a fixed, gradient-accessible probability oracle. The first, training-based approach, Probability-Regularized Generative Adversarial Network (PR-GAN), extends Wasserstein Generative Adversarial Network with Gradient Penalty (WGAN-GP) and edits a real signal through a residual generator while pushing the classifier output toward the target probability. The second is a training-free, per-sample Wachter-style counterfactual (CF) procedure that directly optimizes each input signal to reach the target probability while remaining close to the source signal. We evaluate both methods on the Case Western Reserve University (CWRU) and Paderborn bearing datasets using mean absolute target-probability error, time-domain total variation, and frequency-domain log power spectral density (log-PSD) differences. Across all settings, CF reaches the target with a mean absolute probability error of 0.005-0.008 and a within-tolerance success rate of 1.000 on retained samples, whereas PR-GAN's mean error is 0.046-0.059 with success rates between 0.501 and 0.680. CF therefore steers the probability more reliably and requires smaller average L1 changes, whereas PR-GAN has a lower reported runtime in most settings.

Accurate fault diagnosis of rolling element bearings in rotating machinery is considered essential for ensuring industrial safety and enabling predictive maintenance. Conventional statistical feature-based methods rely on predefined descriptors, whose diagnostic sensitivity is constrained by fixed configurations and limited adaptability across varying fault conditions. Although deep learning approaches offer strong representational capacity, their effectiveness is often restricted by high data requirements and reduced interpretability. In this work, a parametric adaptive feature extraction framework is proposed, in which feature characteristics are learned directly from data rather than being manually specified. Multiple complementary representations are extracted from vibration signals, including absolute features capturing signal energy distribution, signed moment features reflecting waveform asymmetry, and AC-coupled moment features emphasizing dynamic fluctuations, while interactions between multiple sensor channels are modeled through a structured fusion mechanism to enhance fault representation. The proposed approach is evaluated on a benchmark gearbox bearing dataset comprising five health conditions, including normal operation and multiple fault types. Improved classification performance is observed compared to conventional methods, with consistent results under cross-validation, indicating strong generalization capability. Additionally, enhanced feature separability is demonstrated through clearer clustering patterns in low-dimensional projections. The learned representations effectively capture a wide range of signal characteristics, supporting both improved diagnostic performance and practical applicability in industrial monitoring systems.

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.

Vibration-based bearing fault diagnosis requires resolving three interrelated measurement challenges, including the trade-off between global statistical feature efficiency and local transient signal fidelity, insufficient traceability of measurement features to underlying fault physics, and ineffective multi-source measurement information fusion across diagnostic scales. This paper presents a progressive physics-guided multi-scale vibration signal processing framework that addresses all three challenges within a unified diagnostic pipeline. An 81-dimensional measurement descriptor, derived from bearing kinematic theory and characteristic defect frequencies, establishes a physically traceable feature space enabling real-time fault screening at approximately 20 ms per sample. A fault-adaptive signal segmentation mechanism then directs analytical attention toward fault-relevant waveform regions guided by physics-based priors, without manual feature engineering. Structured fault mechanism knowledge is further encoded implicitly in model parameters during training, enabling autonomous multi-scale measurement fusion without external knowledge dependencies at inference. Validated on four public benchmark datasets under diverse operating conditions, the framework achieves 98.49% diagnostic accuracy with a 12.6-fold reduction in computational cost relative to signal-level baselines. Interpretability analysis confirms that diagnostic feature activations align with established bearing fault mechanics, supporting measurement traceability in safety-critical industrial systems.

This paper proposes a two-stage pseudo anomaly-guided anomaly detection method (\textbf{T}wo-stage \textbf{P}seudo \textbf{A}nomaly-guided \textbf{A}nomaly \textbf{D}etection, \textbf{TPA-AD}) for axle-box bearing time-series anomaly detection (time series anomaly detection, TSAD) under the setting where only normal samples are available for training. The method first generates pseudo-anomalous windows near the normal boundary using a reconstruction model and per-feature target-error control. It then learns anomaly-sensitive representations through contrastive learning between normal and pseudo-anomalous windows, and finally produces window-level and point-level anomaly scores using k-nearest neighbors (KNN). Compared with existing methods that rely on known fault categories, real anomaly priors, or random anomaly injection, TPA-AD improves the separability of the normal boundary by constructing pseudo-anomalies in boundary neighborhoods and can jointly handle continuous and discrete features in mixed-variable scenarios. The main experiments are conducted on bearing fault detection datasets and degradation-process datasets, with an additional exploratory extension on $13$ public TSAD datasets. The results show that the proposed method yields relatively stable anomaly responses, is sensitive to degradation evolution, and demonstrates a certain degree of broader applicability on public TSAD benchmarks and real high-speed-train-related bearing data.

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.

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...

Reliable detection of bearing faults is essential for maintaining the safety and operational efficiency of rotating machinery. While recent advances in machine learning (ML), particularly deep learning, have shown strong performance in controlled settings, many studies fail to generalize to real-world applications due to methodological flaws, most notably data leakage. This paper investigates the issue of data leakage in vibration-based bearing fault diagnosis and its impact on model evaluation. We demonstrate that common dataset partitioning strategies, such as segment-wise and condition-wise splits, introduce spurious correlations that inflate performance metrics. To address this, we propose a rigorous, leakage-free evaluation methodology centered on bearing-wise data partitioning, ensuring no overlap between the physical components used for training and testing. Additionally, we reformulate the classification task as a multi-label problem, enabling the detection of co-occurring fault types and the use of prevalence-independent metrics based on the ROC curve. Beyond preventing leakage, we also examine the effect of dataset diversity on generalization, showing that the number of unique training bearings is a decisive factor for achieving robust performance. We evaluate our methodology on four widely adopted datasets: Case Western Reserve University (CWRU), Paderborn University (PU), University of Ottawa (UORED-VAFCLS) and Hanoi University of Science and Technology (HUST bearing). This study highlights the importance of leakage-aware evaluation protocols and provides practical guidelines for dataset partitioning, model selection, and validation, fostering the development of more trustworthy ML systems for industrial fault diagnosis applications.

This letter presents a CWT-enhanced vibration sensing framework for bearing fault monitoring through localized time-frequency region detection on continuous wavelet transform (CWT) spectrograms. Vibration signals are transformed into CWT spectrograms to improve the observability of weak and non-stationary fault signatures, and YOLOv9, YOLOv10, and YOLOv11 are employed to detect and identify localized fault-related energy regions in the time-frequency domain. Experiments on the CWRU, PU, and IMS datasets show that the proposed framework improves the detectability and robustness of fault-related sensing patterns compared with conventional time-series models, modern vision backbones, and short-time Fourier transform (STFT)-based representations, achieving mean average precision (mAP) values up to 99.4%, 97.8%, and 99.5%, respectively. In addition, the localized region detection framework provides a more interpretable relationship between time-frequency energy distributions and characteristic bearing fault frequencies. These results demonstrate an effective and generalizable approach for interpretable vibration sensing in noisy industrial environments.