Accurate and reliable prediction of bearing remaining useful life (RUL) is crucial to the prognostics and health management (PHM) of rotation machinery. Despite the rapid progress of data-driven methods, the generalizability of data-driven models remains an open issue to be addressed. In this paper, we tackle this challenge by resolving the feature misalignment problem that arises in extracting features from the raw vibration signals. Towards this goal, we introduce a logarithmic cumulative transformation (LCT) operator consisting of cumulative, logarithmic, and another cumulative transformation for feature extraction. In addition, we propose a novel method to estimate the reliability associated with each RUL prediction by integrating a linear regression model and an auxiliary exponential model. The linear regression model rectifies bias from neural network’s point predictions while the auxiliary exponential model fits the differential slopes of the linear models and generates the upper and lower bounds for building the reliability indicator. The proposed approach comprised of LCT, an attention GRU-based encoder-decoder network, and reliability evaluation is validated on the FEMETO-ST dataset. Computational results demonstrate the superior performance of the proposed approach several other state-of-the-art methods.

Principled quantification of predictive uncertainty in neural networks (NNs) is essential to safeguard their applications in high-stakes decision settings. In this paper, we develop a differentiable mathematical formulation to quantify the uncertainty in NN prediction using prediction intervals (PIs). The formulated optimization problem is differentiable and compatible with the built-in gradient descent optimizers in prevailing deep learning platforms, and two performance metrics composed of prediction interval coverage probability (PICP) and mean prediction interval width (MPIW) are considered in the construction of PIs. Different from existing methods, the developed methodology features four salient characteristics. Firstly, we design two distance-based functions that are differentiable to impose constraints associated with the target coverage in PI construction, where PICP is prioritized explicitly over MPIW in the devised composite loss function. Next, we adopt a shared-bottom NN architecture with intermediate layers to separate the learning of shared and task-specific feature representations along the construction of lower and upper bounds. Thirdly, we leverage the projection of conflicting gradients (PCGrad) to mitigate interference of gradients associated with the two individual learning tasks so as to increase the convergence stability and solution quality. Finally, we design a customized early stopping mechanism to monitor PICP and MPIW simultaneously for the purpose of selecting the set of parameters that not only meets the target coverage but also has a minimal MPIW as the ultimate NN parameters. A broad range of datasets are used to rigorously examine the performance of the developed methodology. Computational results suggest that the developed method significantly outperforms the classic LUBE method across the nine datasets by reducing the PI width by 31.26% on average. More importantly, it achieves competitive results compared to the other three state-of-the-art methods by outperforming them on four out of ten datasets. An ablation study is used to explicitly demonstrate the benefit of shared-bottom NN architecture in the construction of PIs.

Deep learning has achieved remarkable success in the field of bearing fault diagnosis. However, this success comes with larger models and more complex computations, which cannot be transferred into industrial fields requiring models to be of high speed, strong portability, and low power consumption. In this paper, we propose a lightweight and deployable model for bearing fault diagnosis, referred to as BearingPGA-Net, to address these challenges. Firstly, aided by a well-trained large model, we train BearingPGA-Net via decoupled knowledge distillation. Despite its small size, our model demonstrates excellent fault diagnosis performance compared to other lightweight state-of-the-art methods. Secondly, we design an FPGA acceleration scheme for BearingPGA-Net using Verilog. This scheme involves the customized quantization and designing programmable logic gates for each layer of BearingPGA-Net on the FPGA, with an emphasis on parallel computing and module reuse to enhance the computational speed. To the best of our knowledge, this is the first instance of deploying a CNN-based bearing fault diagnosis model on an FPGA. Experimental results reveal that our deployment scheme achieves over 200 times faster diagnosis speed compared to CPU, while achieving a lower-than-0.4% performance drop in terms of F1, Recall, and Precision score on our independently-collected bearing dataset. Our code is available at https://github.com/asdvfghg/BearingPGA-Net.

On top of machine learning (ML) models, uncertainty quantification (UQ) functions as an essential layer of safety assurance that could lead to more principled decision making by enabling sound risk assessment and management. The safety and reliability improvement of ML models empowered by UQ has the potential to significantly facilitate the broad adoption of ML solutions in high-stakes decision settings, such as healthcare, manufacturing, and aviation, to name a few. In this tutorial, we aim to provide a holistic lens on emerging UQ methods for ML models with a particular focus on neural networks and the applications of these UQ methods in tackling engineering design as well as prognostics and health management problems. Toward this goal, we start with a comprehensive classification of uncertainty types, sources, and causes pertaining to UQ of ML models. Next, we provide a tutorial-style description of several state-of-the-art UQ methods: Gaussian process regression, Bayesian neural network, neural network ensemble, and deterministic UQ methods focusing on spectral-normalized neural Gaussian process. Established upon the mathematical formulations, we subsequently examine the soundness of these UQ methods quantitatively and qualitatively (by a toy regression example) to examine their strengths and shortcomings from different dimensions. Then, we review quantitative metrics commonly used to assess the quality of predictive uncertainty in classification and regression problems. Afterward, we discuss the increasingly important role of UQ of ML models in solving challenging problems in engineering design and health prognostics. Two case studies with source codes available on GitHub are used to demonstrate these UQ methods and compare their performance in the life prediction of lithium-ion batteries at the early stage (case study 1) and the remaining useful life prediction of turbofan engines (case study 2).

In recent years, multi-agent deep reinforcement learning has progressed rapidly as reflected by its increasing adoptions in industrial applications. This paper proposes a Guided Probabilistic Reinforcement Learning (Guided-PRL) model to tackle maintenance scheduling of multi-component systems in the presence of uncertainty with the goal of minimizing the overall life-cycle cost. The proposed Guided-PRL is deeply rooted in the Actor-Critic (AC) scheme. Since traditional AC falls short in sampling efficiency and suffers from getting stuck in local minima in the context of multi-agent reinforcement learning, it is thus challenging for the actor network to converge to a solution of desirable quality even when the critic network is properly configured. To address these issues, we develop a generic framework to facilitate effective training of the actor network, and the framework consists of environmental reward modeling, degradation formulation, state representation, and policy optimization. The convergence speed of the actor network is significantly improved with a guided sampling scheme for environment exploration by exploiting rules-based domain expert policies. To handle data scarcity, the environmental modeling and policy optimization are approximated with Bayesian models for effective uncertainty quantification. The Guided-PRL model is evaluated using the simulations of a 12-component system as well as GE90 and CFM56 engines. Compared with four alternative deep reinforcement learning schemes, the Guided-PRL lowers life-cycle cost by 34.92% to 88.07%. In comparison with rules-based expert policies, the Guided-PRL decreases the life-cycle cost by 23.26% to 51.36%.