Bridging the Reality Gap in Digital Twins with Context-Aware, Physics-Guided Deep Learning

Digital twins (DTs) enable powerful predictive analytics, but persistent discrepancies between simulations and real systems--known as the reality gap--undermine their reliability. Coined in robotics, the term now applies to DTs, where discrepancies stem from context mismatches, cross-domain interactions, and multi-scale dynamics. Among these, context mismatch is pressing and underexplored, as DT accuracy depends on capturing operational context, often only partially observable. However, DTs have a key advantage: simulators can systematically vary contextual factors and explore scenarios difficult or impossible to observe empirically, informing inference and model alignment. While sim-to-real transfer like domain adaptation shows promise in robotics, their application to DTs poses two key challenges. First, unlike one-time policy transfers, DTs require continuous calibration across an asset's lifecycle--demanding structured information flow, timely detection of out-of-sync states, and integration of historical and new data. Second, DTs often perform inverse modeling, inferring latent states or faults from observations that may reflect multiple evolving contexts. These needs strain purely data-driven models and risk violating physical consistency. Though some approaches preserve validity via reduced-order model, most domain adaptation techniques still lack such constraints. To address this, we propose a Reality Gap Analysis (RGA) module for DTs that continuously integrates new sensor data, detects misalignments, and recalibrates DTs via a query-response framework. Our approach fuses domain-adversarial deep learning with reduced-order simulator guidance to improve context inference and preserve physical consistency. We illustrate the RGA module in a structural health monitoring case study on a steel truss bridge in Pittsburgh, PA, showing faster calibration and better real-world alignment.

Benchmarking Traditional Machine Learning and Deep Learning Models for Fault Detection in Power Transformers

Accurate diagnosis of power transformer faults is essential for ensuring the stability and safety of electrical power systems. This study presents a comparative analysis of conventional machine learning (ML) algorithms and deep learning (DL) algorithms for fault classification of power transformers. Using a condition-monitored dataset spanning 10 months, various gas concentration features were normalized and used to train five ML classifiers: Support Vector Machine (SVM), k-Nearest Neighbors (KNN), Random Forest (RF), XGBoost, and Artificial Neural Network (ANN). In addition, four DL models were evaluated: Long Short-Term Memory (LSTM), Gated Recurrent Unit (GRU), One-Dimensional Convolutional Neural Network (1D-CNN), and TabNet. Experimental results show that both ML and DL approaches performed comparably. The RF model achieved the highest ML accuracy at 86.82%, while the 1D-CNN model attained a close 86.30%.

FT-MoE: Sustainable-learning Mixture of Experts Model for Fault-Tolerant Computing with Multiple Tasks

Intelligent fault-tolerant (FT) computing has recently demonstrated significant advantages of predicting and diagnosing faults in advance, enabling reliable service delivery. However, due to heterogeneity of fault knowledge and complex dependence relationships of time series log data, existing deep learning-based FT algorithms further improve detection performance relying on single neural network model with difficulty. To this end, we propose FT-MoE, a sustainable-learning mixture-of-experts model for fault-tolerant computing with multiple tasks, which enables different parameters learning distinct fault knowledge to achieve high-reliability for service system. Firstly, we use decoder-based transformer models to obtain fault prototype vectors of decoupling long-distance dependencies. Followed by, we present a dual mixture of experts networks for high-accurate prediction for both fault detection and classification tasks. Then, we design a two-stage optimization scheme of offline training and online tuning, which allows that in operation FT-MoE can also keep learning to adapt to dynamic service environments. Finally, to verify the effectiveness of FT-MoE, we conduct extensive experiments on the FT benchmark. Experimental results show that FT-MoE achieves superior performance compared to the state-of-the-art methods. Code will be available upon publication.

Fault Diagnosis in New Wind Turbines using Knowledge from Existing Turbines by Generative Domain Adaptation

Intelligent condition monitoring of wind turbines is essential for reducing downtimes. Machine learning models trained on wind turbine operation data are commonly used to detect anomalies and, eventually, operation faults. However, data-driven normal behavior models (NBMs) require a substantial amount of training data, as NBMs trained with scarce data may result in unreliable fault diagnosis. To overcome this limitation, we present a novel generative deep learning approach to make SCADA samples from one wind turbine lacking training data resemble SCADA data from wind turbines with representative training data. Through CycleGAN-based domain mapping, our method enables the application of an NBM trained on an existing wind turbine to one with severely limited data. We demonstrate our approach on field data mapping SCADA samples across 7 substantially different WTs. Our findings show significantly improved fault diagnosis in wind turbines with scarce data. Our method achieves the most similar anomaly scores to an NBM trained with abundant data, outperforming NBMs trained on scarce training data with improvements of +10.3% in F1-score when 1 month of training data is available and +16.8% when 2 weeks are available. The domain mapping approach outperforms conventional fine-tuning at all considered degrees of data scarcity, ranging from 1 to 8 weeks of training data. The proposed technique enables earlier and more reliable fault diagnosis in newly installed wind farms, demonstrating a novel and promising research direction to improve anomaly detection when faced with training data scarcity.

Continual learning for rotating machinery fault diagnosis with cross-domain environmental and operational variations

Although numerous machine learning models exist to detect issues like rolling bearing strain and deformation, typically caused by improper mounting, overloading, or poor lubrication, these models often struggle to isolate faults from the noise of real-world operational and environmental variability. Conditions such as variable loads, high temperatures, stress, and rotational speeds can mask early signs of failure, making reliable detection challenging. To address these limitations, this work proposes a continual deep learning approach capable of learning across domains that share underlying structure over time. This approach goes beyond traditional accuracy metrics by addressing four second-order challenges: catastrophic forgetting (where new learning overwrites past knowledge), lack of plasticity (where models fail to adapt to new data), forward transfer (using past knowledge to improve future learning), and backward transfer (refining past knowledge with insights from new domains). The method comprises a feature generator and domain-specific classifiers, allowing capacity to grow as new domains emerge with minimal interference, while an experience replay mechanism selectively revisits prior domains to mitigate forgetting. Moreover, nonlinear dependencies across domains are exploited by prioritizing replay from those with the highest prior errors, refining models based on most informative past experiences. Experiments show high average domain accuracy (up to 88.96%), with forgetting measures as low as .0027 across non-stationary class-incremental environments.

Boosting-inspired online learning with transfer for railway maintenance

The integration of advanced sensor technologies with deep learning algorithms has revolutionized fault diagnosis in railway systems, particularly at the wheel-track interface. Although numerous models have been proposed to detect irregularities such as wheel out-of-roundness, they often fall short in real-world applications due to the dynamic and nonstationary nature of railway operations. This paper introduces BOLT-RM (Boosting-inspired Online Learning with Transfer for Railway Maintenance), a model designed to address these challenges using continual learning for predictive maintenance. By allowing the model to continuously learn and adapt as new data become available, BOLT-RM overcomes the issue of catastrophic forgetting that often plagues traditional models. It retains past knowledge while improving predictive accuracy with each new learning episode, using a boosting-like knowledge sharing mechanism to adapt to evolving operational conditions such as changes in speed, load, and track irregularities. The methodology is validated through comprehensive multi-domain simulations of train-track dynamic interactions, which capture realistic railway operating conditions. The proposed BOLT-RM model demonstrates significant improvements in identifying wheel anomalies, establishing a reliable sequence for maintenance interventions.

NAPER: Fault Protection for Real-Time Resource-Constrained Deep Neural Networks

Fault tolerance in Deep Neural Networks (DNNs) deployed on resource-constrained systems presents unique challenges for high-accuracy applications with strict timing requirements. Memory bit-flips can severely degrade DNN accuracy, while traditional protection approaches like Triple Modular Redundancy (TMR) often sacrifice accuracy to maintain reliability, creating a three-way dilemma between reliability, accuracy, and timeliness. We introduce NAPER, a novel protection approach that addresses this challenge through ensemble learning. Unlike conventional redundancy methods, NAPER employs heterogeneous model redundancy, where diverse models collectively achieve higher accuracy than any individual model. This is complemented by an efficient fault detection mechanism and a real-time scheduler that prioritizes meeting deadlines by intelligently scheduling recovery operations without interrupting inference. Our evaluations demonstrate NAPER's superiority: 40% faster inference in both normal and fault conditions, maintained accuracy 4.2% higher than TMR-based strategies, and guaranteed uninterrupted operation even during fault recovery. NAPER effectively balances the competing demands of accuracy, reliability, and timeliness in real-time DNN applications

Fault injection analysis of Real NVP normalising flow model for satellite anomaly detection

Satellites are used for a multitude of applications, including communications, Earth observation, and space science. Neural networks and deep learning-based approaches now represent the state-of-the-art to enhance the performance and efficiency of these tasks. Given that satellites are susceptible to various faults, one critical application of Artificial Intelligence (AI) is fault detection. However, despite the advantages of neural networks, these systems are vulnerable to radiation errors, which can significantly impact their reliability. Ensuring the dependability of these solutions requires extensive testing and validation, particularly using fault injection methods. This study analyses a physics-informed (PI) real-valued non-volume preserving (Real NVP) normalizing flow model for fault detection in space systems, with a focus on resilience to Single-Event Upsets (SEUs). We present a customized fault injection framework in TensorFlow to assess neural network resilience. Fault injections are applied through two primary methods: Layer State injection, targeting internal network components such as weights and biases, and Layer Output injection, which modifies layer outputs across various activations. Fault types include zeros, random values, and bit-flip operations, applied at varying levels and across different network layers. Our findings reveal several critical insights, such as the significance of bit-flip errors in critical bits, that can lead to substantial performance degradation or even system failure. With this work, we aim to exhaustively study the resilience of Real NVP models against errors due to radiation, providing a means to guide the implementation of fault tolerance measures.

Adaptive Fault Tolerance Mechanisms of Large Language Models in Cloud Computing Environments

With the rapid evolution of Large Language Models (LLMs) and their large-scale experimentation in cloud-computing spaces, the challenge of guaranteeing their security and efficiency in a failure scenario has become a main issue. To ensure the reliability and availability of large-scale language models in cloud computing scenarios, such as frequent resource failures, network problems, and computational overheads, this study proposes a novel adaptive fault tolerance mechanism. It builds upon known fault-tolerant mechanisms, such as checkpointing, redundancy, and state transposition, introducing dynamic resource allocation and prediction of failure based on real-time performance metrics. The hybrid model integrates data driven deep learning-based anomaly detection technique underlining the contribution of cloud orchestration middleware for predictive prevention of system failures. Additionally, the model integrates adaptive checkpointing and recovery strategies that dynamically adapt according to load and system state to minimize the influence on the performance of the model and minimize downtime. The experimental results demonstrate that the designed model considerably enhances the fault tolerance in large-scale cloud surroundings, and decreases the system downtime by $\mathbf{30\%}$, and has a better modeling availability than the classical fault tolerance mechanism.

Automated Processing of eXplainable Artificial Intelligence Outputs in Deep Learning Models for Fault Diagnostics of Large Infrastructures

Deep Learning (DL) models processing images to recognize the health state of large infrastructure components can exhibit biases and rely on non-causal shortcuts. eXplainable Artificial Intelligence (XAI) can address these issues but manually analyzing explanations generated by XAI techniques is time-consuming and prone to errors. This work proposes a novel framework that combines post-hoc explanations with semi-supervised learning to automatically identify anomalous explanations that deviate from those of correctly classified images and may therefore indicate model abnormal behaviors. This significantly reduces the workload for maintenance decision-makers, who only need to manually reclassify images flagged as having anomalous explanations. The proposed framework is applied to drone-collected images of insulator shells for power grid infrastructure monitoring, considering two different Convolutional Neural Networks (CNNs), GradCAM explanations and Deep Semi-Supervised Anomaly Detection. The average classification accuracy on two faulty classes is improved by 8% and maintenance operators are required to manually reclassify only 15% of the images. We compare the proposed framework with a state-of-the-art approach based on the faithfulness metric: the experimental results obtained demonstrate that the proposed framework consistently achieves F_1 scores larger than those of the faithfulness-based approach. Additionally, the proposed framework successfully identifies correct classifications that result from non-causal shortcuts, such as the presence of ID tags printed on insulator shells.