2026· IEEE Transactions on Instrumentation and Measurement· Vol 75, pp. 3520217-3520217· 0 citations· 62 references
Abstract
Flange bolted joints are widely used in the rotor systems of aeroengines. Intelligent fault diagnosis of these bolted joints is crucial for ensuring operational safety. However, due to the extreme scarcity of real-world fault cases, deep learning-based fault diagnosis methods are difficult to apply in engineering practice. Although simulation-to-reality (Sim2Real) transfer learning provides a promising solution, its application in rotor systems faces three challenges: 1) bolt looseness at different locations can excite the similar combination resonance frequencies, making feature differences weak and difficult to distinguish; 2) various inevitable uncertainties introduced during rotor system assembly are difficult to fully account for in mechanical modeling; and 3) the types of faults occurring in actual operation rarely cover all categories present in computational simulations, and this asymmetric label space ( $\mathcal {Y}_{t} \subset \mathcal {Y}_{s}$ ) leads to negative transfer. To overcome these difficulties, this article proposes a novel hybrid physical-data-driven framework, called physics-guided domain randomization and adversarial domain adaptation (Phys-DRADA). This method integrates physical model-based domain randomization (Phys-DR) and frequency-based normalization (F-Norm), eliminating absolute amplitude interference and establishing a robust physical baseline. Subsequently, a physics-guided operational-spatial representation network is proposed. It employs a harmonic-aware dilated spectrum extractor (HADS) to match the equidistant comb-like topologies in the vibration spectrum that shift with operating conditions, and utilizes an operational-spatial coupled transformer to extract the implicit rotor mode shape information from the vibration spectrum and characterize its dynamic variations with rotational speed, thereby distinguishing bolt looseness at different locations. Furthermore, a partial adversarial domain adaptation (PADA) mechanism is introduced to dynamically cutoff the feature alignment of source-private classes. Extensive experimental validations demonstrate that, entirely without prelabeled real-world fault data, Phys-DRADA achieves diagnostic accuracies of 99.33 % and 93.71 % under standard and partial domain adaptation (PDA) scenarios, respectively, providing a highly reliable algorithmic paradigm with practical engineering value for complex rotating machinery.
To maintain high efficiency and reduce operational downtime in industrial manufacturing, effective Predictive Maintenance (PdM) for robotic manipulators is essential. Although combining Model-Agnostic Meta-Learning (MAML) with digital twin technology offers a solid basis for quickly identifying faults, conventional methods often face challenges regarding parameter sensitivity and generalizing to new domains. To mitigate these issues, we introduce an ensemble-based metalearning framework that combines MAML with majority voting and operational grouping. This methodology improves generalization, stabilizes performance across diverse conditions, and strengthens few-shot learning capabilities. We validated the framework using a synthetic vibration dataset generated via a digital twin to simulate various robotic arm faults. Our findings demonstrate that this method achieves 93.8% accuracy and 93.1% precision in the ten-shot regime, outperforming the MAML baseline by 11.1%, across a broad range of mechanical faults, showing strength in cross-domain few-shot (CDFS) scenarios. Comparisons with established frameworks - including Reptile, Protonet, and ANIL, confirm the effectiveness of our model. By employing ensemble learning, we attain greater robustness and classification accuracy, establishing the method as a viable solution for industrial PdM. Furthermore, the integration of digital twins bridges the gap between simulation and real-world deployment, reducing data dependency and enabling effective fault classification even in dynamic environments with limited labeled data.
Mainak Mallick, Seung-Kyum Choi· 2026 6th International Confe...· 0 citations
A novel and robust Source-Free Domain Adaptation (SFDA) framework equipped with post-hoc explainability for bearing fault diagnosis is proposed, and a post-hoc visualization mechanism is incorporated to explain the model's decision-making process, enhancing the transparency and credibility of the diagnosis for practical industrial deployment.
chenghao yan, Dongsheng Liu, Tong Wu et al.· Measurement science and tech...· 0 citations
Fault diagnosis of rolling bearings is crucial for operational safety. However, the scarcity of labeled data and significant domain shifts are two key challenges. Existing studies neglect robustness to physical disturbances and the interpretability of diagnostic decisions. To address these issues, this paper proposes a physics-informed cross-domain fault diagnosis framework. First, based on bearing fault modulation mechanisms, multi-domain features are extracted. A physics-regularized feature selection strategy combining Sparse Group Lasso with stability selection and Random Forest is used to retain fault-relevant features. Recognizing that velocity variations are a major source of domain shifts, order analysis is introduced as a physics-prior alignment method. Deep CORAL and pseudo-label self-training are combined for unsupervised knowledge transfer. Finally, multi-level interpretability analysis is embedded to quantify domain shift, track adaptation geometry and explain final decisions. Two case studies demonstrate its robustness, trustworthiness and engineering applicability.
Yi Xie, Ruyang Zheng, Xuepeng Guo et al.· Eksploatacja I Niezawodnosc-...· 0 citations
Although intelligent diagnosis methods based on deep learning have achieved significant theoretical advancements, the application in real-world industrial scenarios remains challenging. The scarcity of fault samples in real-world environments hinders the effective training of deep learning models, thereby compromising their diagnostic accuracy and generalization ability. To address this issue, a small sample transfer diagnosis method driven by a high-precision dynamic model for rolling bearings is proposed this paper. Firstly, a high-precision dynamic model of rolling bearing with defects is constructed to simulate vibration signals under various fault types and severities, generating a large-scale and diverse library of simulated fault samples. Then, an improved Transformer-based deep transfer learning network is developed to extract features from both simulated samples and measured small samples at local and global scales, and perform multi-layer deep domain adaptation to minimize the distribution discrepancy between the simulated and measured data, facilitating accurate fault diagnosis under small sample conditions. Finally, experimental verification on two datasets with different tasks demonstrated that the proposed method not only effectively diagnoses rolling bearing faults but also exhibits excellent generalization ability on small sample datasets.
Jinyu Tong, Guotao Chen, Xun Huang et al.· Structural Health Monitoring· 0 citations
In cross-condition bearing fault diagnosis, the target domain often contains only a subset of the fault classes available in the source domain. This asymmetric label-space setting makes conventional domain alignment prone to negative transfer, because source-private and unreliable samples may still participate in adaptation. To address this problem, this paper proposes a contrastive error-perception-based partial adversarial domain adaptation method, named CEPADA. Instead of relying only on class-level target predictions, CEPADA introduces an error-perception mechanism to jointly evaluate class-level transfer reliability and sample-level uncertainty. Samples with high error risk are assigned lower influence during adversarial alignment, while more reliable shared-class samples are emphasized. Meanwhile, contrastive learning is embedded into the adaptation process to make features of the same fault class more compact and features of different classes more separable. A pseudo-label refinement strategy is also used to provide additional target-domain guidance under the unlabeled setting. Experiments on the case western reserve university and JNU bearing datasets show that CEPADA achieves average accuracies of 93.17% and 86.02%, respectively, with improvements of 1.47 and 1.52 percentage points over the best-performing compared unsupervised baseline in our experiments.
Na Lei, Zhuo Wang, Xue Wang et al.· Engineering Research Express· 0 citations