LSTM VS. Feed-Forward Autoencoders for Unsupervised Fault Detection in Hydraulic Pumps

Unplanned failures in industrial hydraulic pumps can halt production and incur substantial costs. We explore two unsupervised autoencoder (AE) schemes for early fault detection: a feed-forward model that analyses individual sensor snapshots and a Long Short-Term Memory (LSTM) model that captures short temporal windows. Both networks are trained only on healthy data drawn from a minute-level log of 52 sensor channels; evaluation uses a separate set that contains seven annotated fault intervals. Despite the absence of fault samples during training, the models achieve high reliability.

Early Fault Detection on CMAPSS with Unsupervised LSTM Autoencoders

This paper introduces an unsupervised health-monitoring framework for turbofan engines that does not require run-to-failure labels. First, operating-condition effects in NASA CMAPSS sensor streams are removed via regression-based normalisation; then a Long Short-Term Memory (LSTM) autoencoder is trained only on the healthy portion of each trajectory. Persistent reconstruction error, estimated using an adaptive data-driven threshold, triggers real-time alerts without hand-tuned rules. Benchmark results show high recall and low false-alarm rates across multiple operating regimes, demonstrating that the method can be deployed quickly, scale to diverse fleets, and serve as a complementary early-warning layer to Remaining Useful Life models.

Machine Learning-Based Framework for Real Time Detection and Early Prediction of Control Valve Stiction in Industrial Control Systems

Control valve stiction, a friction that prevents smooth valve movement, is a common fault in industrial process systems that causes instability, equipment wear, and higher maintenance costs. Many plants still operate with conventional valves that lack real time monitoring, making early predictions challenging. This study presents a machine learning (ML) framework for detecting and predicting stiction using only routinely collected process signals: the controller output (OP) from control systems and the process variable (PV), such as flow rate. Three deep learning models were developed and compared: a Convolutional Neural Network (CNN), a hybrid CNN with a Support Vector Machine (CNN-SVM), and a Long Short-Term Memory (LSTM) network. To train these models, a data-driven labeling method based on slope ratio analysis was applied to a real oil and gas refinery dataset. The LSTM model achieved the highest accuracy and was able to predict stiction up to four hours in advance. To the best of the authors' knowledge, this is the first study to demonstrate ML based early prediction of control valve stiction from real industry data. The proposed framework can be integrated into existing control systems to support predictive maintenance, reduce downtime, and avoid unnecessary hardware replacement.

Vision-Based Early Fault Diagnosis and Self-Recovery for Strawberry Harvesting Robots

Strawberry harvesting robots faced persistent challenges such as low integration of visual perception, fruit-gripper misalignment, empty grasping, and strawberry slippage from the gripper due to insufficient gripping force, all of which compromised harvesting stability and efficiency in orchard environments. To overcome these issues, this paper proposed a visual fault diagnosis and self-recovery framework that integrated multi-task perception with corrective control strategies. At the core of this framework was SRR-Net, an end-to-end multi-task perception model that simultaneously performed strawberry detection, segmentation, and ripeness estimation, thereby unifying visual perception with fault diagnosis. Based on this integrated perception, a relative error compensation method based on the simultaneous target-gripper detection was designed to address positional misalignment, correcting deviations when error exceeded the tolerance threshold. To mitigate empty grasping and fruit-slippage faults, an early abort strategy was implemented. A micro-optical camera embedded in the end-effector provided real-time visual feedback, enabling grasp detection during the deflating stage and strawberry slip prediction during snap-off through MobileNet V3-Small classifier and a time-series LSTM classifier. Experiments demonstrated that SRR-Net maintained high perception accuracy. For detection, it achieved a precision of 0.895 and recall of 0.813 on strawberries, and 0.972/0.958 on hands. In segmentation, it yielded a precision of 0.887 and recall of 0.747 for strawberries, and 0.974/0.947 for hands. For ripeness estimation, SRR-Net attained a mean absolute error of 0.035, while simultaneously supporting multi-task perception and sustaining a competitive inference speed of 163.35 FPS.

Detection and Classification of Internal Leakage in Hydraulic Cylinders

Hydraulic systems have been one of the most used technologies in many industries due to their reliance on incompressible fluids that facilitate energy and power transfer. Within such systems, hydraulic cylinders are prime devices that convert hydraulic energy into mechanical energy. Some of the genuine and very common problems related to hydraulic cylinders are leakages. Leakage in hydraulic systems can cause a drop in pressure, general inefficiency, and even complete failure of such systems. The various ways leakage can occur define the major categorization of leakage: internal and external leakage. External leakage is easily noticeable, while internal leakage, which involves fluid movement between pressure chambers, can be harder to detect and may gradually impact system performance without obvious signs. When leakage surpasses acceptable limits, it is classified as a fault or failure. In such cases, leakage is divided into three categories: no leakage, low leakage, and high leakage. It suggests a fault detection algorithm with the basic responsibility of detecting minimum leakage within the Hydraulic system, and minimizing detection time is the core idea of this paper. In order to fully develop this idea, experimental data collection of Hydraulic systems is required. The collected data uses pressure sensors and other signals that are single-related. Due to the utilization of Long Short-Term Memory (LSTM) recurrent neural networks, more complex data analysis was enabled, which the LSTM-based leakage detection algorithm successfully achieved, providing almost 96% accuracy in classifying leakage types. Results demonstrate that the proposed method can perform real-time and online fault diagnosis for each cycle, reducing maintenance costs and prolonging the hydraulic system's lifespan.

Agent-Based Decentralized Energy Management of EV Charging Station with Solar Photovoltaics via Multi-Agent Reinforcement Learning

In the pursuit of energy net zero within smart cities, transportation electrification plays a pivotal role. The adoption of Electric Vehicles (EVs) keeps increasing, making energy management of EV charging stations critically important. While previous studies have managed to reduce energy cost of EV charging while maintaining grid stability, they often overlook the robustness of EV charging management against uncertainties of various forms, such as varying charging behaviors and possible faults in faults in some chargers. To address the gap, a novel Multi-Agent Reinforcement Learning (MARL) approach is proposed treating each charger to be an agent and coordinate all the agents in the EV charging station with solar photovoltaics in a more realistic scenario, where system faults may occur. A Long Short-Term Memory (LSTM) network is incorporated in the MARL algorithm to extract temporal features from time-series. Additionally, a dense reward mechanism is designed for training the agents in the MARL algorithm to improve EV charging experience. Through validation on a real-world dataset, we show that our approach is robust against system uncertainties and faults and also effective in minimizing EV charging costs and maximizing charging service satisfaction.

Runtime Anomaly Detection for Drones: An Integrated Rule-Mining and Unsupervised-Learning Approach

UAVs, commonly referred to as drones, have witnessed a remarkable surge in popularity due to their versatile applications. These cyber-physical systems depend on multiple sensor inputs, such as cameras, GPS receivers, accelerometers, and gyroscopes, with faults potentially leading to physical instability and serious safety concerns. To mitigate such risks, anomaly detection has emerged as a crucial safeguarding mechanism, capable of identifying the physical manifestations of emerging issues and allowing operators to take preemptive action at runtime. Recent anomaly detection methods based on LSTM neural networks have shown promising results, but three challenges persist: the need for models that can generalise across the diverse mission profiles of drones; the need for interpretability, enabling operators to understand the nature of detected problems; and the need for capturing domain knowledge that is difficult to infer solely from log data. Motivated by these challenges, this paper introduces RADD, an integrated approach to anomaly detection in drones that combines rule mining and unsupervised learning. In particular, we leverage rules (or invariants) to capture expected relationships between sensors and actuators during missions, and utilise unsupervised learning techniques to cover more subtle relationships that the rules may have missed. We implement this approach using the ArduPilot drone software in the Gazebo simulator, utilising 44 rules derived across the main phases of drone missions, in conjunction with an ensemble of five unsupervised learning models. We find that our integrated approach successfully detects 93.84% of anomalies over six types of faults with a low false positive rate (2.33%), and can be deployed effectively at runtime. Furthermore, RADD outperforms a state-of-the-art LSTM-based method in detecting the different types of faults evaluated in our study.

A domain adaptation neural network for digital twin-supported fault diagnosis

Digital twins offer a promising solution to the lack of sufficient labeled data in deep learning-based fault diagnosis by generating simulated data for model training. However, discrepancies between simulation and real-world systems can lead to a significant drop in performance when models are applied in real scenarios. To address this issue, we propose a fault diagnosis framework based on Domain-Adversarial Neural Networks (DANN), which enables knowledge transfer from simulated (source domain) to real-world (target domain) data. We evaluate the proposed framework using a publicly available robotics fault diagnosis dataset, which includes 3,600 sequences generated by a digital twin model and 90 real sequences collected from physical systems. The DANN method is compared with commonly used lightweight deep learning models such as CNN, TCN, Transformer, and LSTM. Experimental results show that incorporating domain adaptation significantly improves the diagnostic performance. For example, applying DANN to a baseline CNN model improves its accuracy from 70.00% to 80.22% on real-world test data, demonstrating the effectiveness of domain adaptation in bridging the sim-to-real gap.

Predicting Human Behavior in Autonomous Systems: A Collaborative Machine Teaching Approach for Reducing Transfer of Control Events

As autonomous systems become integral to various industries, effective strategies for fault handling are essential to ensure reliability and efficiency. Transfer of Control (ToC), a traditional approach for interrupting automated processes during faults, is often triggered unnecessarily in non-critical situations. To address this, we propose a data-driven method that uses human interaction data to train AI models capable of preemptively identifying and addressing issues or assisting users in resolution. Using an interactive tool simulating an industrial vacuum cleaner, we collected data and developed an LSTM-based model to predict user behavior. Our findings reveal that even data from non-experts can effectively train models to reduce unnecessary ToC events, enhancing the system's robustness. This approach highlights the potential of AI to learn directly from human problem-solving behaviors, complementing sensor data to improve industrial automation and human-AI collaboration.

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%.