A Trustworthy Framework for Condition Monitoring and Remaining Useful Life Prediction of Rotating Machinery

Abstract

The increasing adoption of smart manufacturing technologies has intensified the need for reliable predictive maintenance solutions to reduce unexpected equipment failures and production downtime. Rotating machinery, including bearings, electric motors, gearboxes, pumps, and turbines, represents a critical class of industrial assets whose degradation directly affects manufacturing productivity, operational safety, and maintenance costs. This study presents a trustworthy AI-driven framework for condition monitoring and Remaining Useful Life (RUL) prediction of rotating machinery in smart manufacturing environments. The proposed framework integrates multi-sensor condition monitoring using vibration, temperature, acoustic emission, pressure, and motor current measurements with machine learning and deep learning models for intelligent fault diagnosis and prognostics. To improve transparency and industrial trust, the framework incorporates Explainable Artificial Intelligence (XAI) techniques, including SHAP and LIME, to identify the operational factors influencing prediction outcomes. In addition, Digital Twin technology and Physics-Informed Artificial Intelligence are integrated to enhance prediction reliability and maintain consistency with engineering knowledge. The framework is evaluated using benchmark datasets and standard classification and regression metrics, including Accuracy, Precision, Recall, F1-Score, MAE, RMSE, and RUL prediction error. The results demonstrate that the integration of multi-sensor monitoring, explainable AI, and Digital Twin-assisted analysis improves diagnostic reliability, prediction consistency, and maintenance decision support. The proposed approach offers practical benefits for Industry 4.0 applications by reducing unplanned downtime, optimizing maintenance scheduling, improving equipment availability, and enhancing the trustworthiness of AI-based predictive maintenance systems for critical rotating machinery.