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Appropriate maintenance of industrial equipment keeps production systems in good health and ensures the stability of production processes. In specific production sectors, such as the electrical power industry, equipment failures are rare but may lead to high costs and substantial economic losses not only for the power plant but for consumers and the larger society. Therefore, the power production industry relies on a variety of approaches to maintenance tasks, ranging from traditional solutions and engineering know-how to smart, AI-based analytics to avoid potential downtimes. This review shows the evolution of maintenance approaches to support maintenance planning, equipment monitoring and supervision. We present older techniques traditionally used in maintenance tasks and those that rely on IT analytics to automate tasks and perform the inference process for failure detection. We analyze prognostics and health-management techniques in detail, including their requirements, advantages and limitations. The review focuses on the power-generation sector. However, some of the issues addressed are common to other industries. The article also presents concepts and solutions that utilize emerging technologies related to Industry 4.0, touching on prescriptive analysis, Big Data and the Internet of Things. The primary motivation and purpose of the article are to present the existing practices and classic methods used by engineers, as well as modern approaches drawing from Artificial Intelligence and the concept of Industry 4.0. The summary of existing practices and the state of the art in the area of predictive maintenance provides two benefits. On the one hand, it leads to improving processes by matching existing tools and methods. On the other hand, it shows researchers potential directions for further analysis and new developments.

In the era of the fourth industrial revolution, several concepts have arisen in parallel with this new revolution, such as predictive maintenance, which today plays a key role in sustainable manufacturing and production systems by introducing a digital version of machine maintenance. The data extracted from production processes have increased exponentially due to the proliferation of sensing technologies. Even if Maintenance 4.0 faces organizational, financial, or even data source and machine repair challenges, it remains a strong point for the companies that use it. Indeed, it allows for minimizing machine downtime and associated costs, maximizing the life cycle of the machine, and improving the quality and cadence of production. This approach is generally characterized by a very precise workflow, starting with project understanding and data collection and ending with the decision-making phase. This paper presents an exhaustive literature review of methods and applied tools for intelligent predictive maintenance models in Industry 4.0 by identifying and categorizing the life cycle of maintenance projects and the challenges encountered, and presents the models associated with this type of maintenance: condition-based maintenance (CBM), prognostics and health management (PHM), and remaining useful life (RUL). Finally, a novel applied industrial workflow of predictive maintenance is presented including the decision support phase wherein a recommendation for a predictive maintenance platform is presented. This platform ensures the management and fluid data communication between equipment throughout their life cycle in the context of smart maintenance.

Prognostics and health management (PHM) is critical for enhancing equipment reliability and reducing maintenance costs, and research on intelligent PHM has made significant progress driven by big data and deep learning techniques in recent years. However, complex working conditions and high-cost data collection inherent in real-world scenarios pose small-data challenges for the application of these methods. Given the urgent need for data-efficient PHM techniques in academia and industry, this paper aims to explore the fundamental concepts, ongoing research, and future trajectories of small data challenges in the PHM domain. This survey first elucidates the definition, causes, and impacts of small data on PHM tasks, and then analyzes the current mainstream approaches to solving small data problems, including data augmentation, transfer learning, and few-shot learning techniques, each of which has its advantages and disadvantages. In addition, this survey summarizes benchmark datasets and experimental paradigms to facilitate fair evaluations of diverse methodologies under small data conditions. Finally, some promising directions are pointed out to inspire future research.

Prognostics and Health Management (PHM) is an important technical means to realize condition-based maintenance of complex systems. As a complex space application engineering, the space application fluid loop system has the requirements of high safety, high reliability and long life. Therefore, this paper adopts PHM technology to comprehensively study the space application fluid loop system from two aspects of architecture and key technology respectively. Firstly, this paper introduces the current status of health management of fluid loop system for space application and the problems to be solved urgently. Secondly, the PHM system architecture and key technologies such as condition monitoring, health assessment, fault diagnosis, fault prediction and health management are described, and the PHM system research scheme of fluid loop for space application is established. Finally, a case study is carried out by taking the fluid loop main engine of the core power equipment as an example. The analysis results show that the PHM technology can effectively reduce the system failure rate, improve the system safety and reliability, and provide a strong guarantee for the long-term on-orbit operation of the system.

Prognostics and Health Management (PHM), including monitoring, diagnosis, prognosis, and health management, occupies an increasingly important position in reducing costly breakdowns and avoiding catastrophic accidents in modern industry. With the development of artificial intelligence (AI), especially deep learning (DL) approaches, the application of AI-enabled methods to monitor, diagnose and predict potential equipment malfunctions has gone through tremendous progress with verified success in both academia and industry. However, there is still a gap to cover monitoring, diagnosis, and prognosis based on AI-enabled methods, simultaneously, and the importance of an open source community, including open source datasets and codes, has not been fully emphasized. To fill this gap, this paper provides a systematic overview of the current development, common technologies, open source datasets, codes, and challenges of AI-enabled PHM methods from three aspects of monitoring, diagnosis, and prognosis.

Research on scheduling problems is an evergreen challenge for industrial engineers. The growth of digital technologies opens the possibility to collect and analyze great amount of field data in real-time, representing a precious opportunity for an improved scheduling activity. Thus, scheduling under uncertain scenarios may benefit from the possibility to grasp the current operating conditions of the industrial equipment in real-time and take them into account when elaborating the best production schedules. To this end, the article proposes a proof-of-concept of a simheuristics framework for robust scheduling applied to a Flow Shop Scheduling Problem. The framework is composed of genetic algorithms for schedule optimization and discrete event simulation and is synchronized with the field through a Digital Twin (DT) that employs an Equipment Prognostics and Health Management (EPHM) module. The contribution of the EPHM module inside the DT-based framework is the real time computation of the failure probability of the equipment, with data-driven statistical models that take sensor data from the field as input. The viability of the framework is demonstrated in a flow shop application in a laboratory environment.

Surveys on explainable artificial intelligence (XAI) are related to biology, clinical trials, fintech management, medicine, neurorobotics, and psychology, among others. Prognostics and health management (PHM) is the discipline that links the studies of failure mechanisms to system lifecycle management. There is a need, which is still absent, to produce an analytical compilation of PHM-XAI works. In this paper, we use preferred reporting items for systematic reviews and meta-analyses (PRISMA) to present a state of the art on XAI applied to PHM of industrial assets. This work provides an overview of the trend of XAI in PHM and answers the question of accuracy versus explainability, considering the extent of human involvement, explanation assessment, and uncertainty quantification in this topic. Research articles associated with the subject, since 2015 to 2021, were selected from five databases following the PRISMA methodology, several of them related to sensors. The data were extracted from selected articles and examined obtaining diverse findings that were synthesized as follows. First, while the discipline is still young, the analysis indicates a growing acceptance of XAI in PHM. Second, XAI offers dual advantages, where it is assimilated as a tool to execute PHM tasks and explain diagnostic and anomaly detection activities, implying a real need for XAI in PHM. Third, the review shows that PHM-XAI papers provide interesting results, suggesting that the PHM performance is unaffected by the XAI. Fourth, human role, evaluation metrics, and uncertainty management are areas requiring further attention by the PHM community. Adequate assessment metrics to cater to PHM needs are requested. Finally, most case studies featured in the considered articles are based on real industrial data, and some of them are related to sensors, showing that the available PHM-XAI blends solve real-world challenges, increasing the confidence in the artificial intelligence models’ adoption in the industry.

This paper presents a survey of the applications of prognostics and health management maintenance strategy to machine tools. A complete perspective on this Industry 4.0 cutting-edge maintenance policy, through the analysis of all its preliminary phases, is given as an introduction. Then, attention is given to prognostics, whose different approaches are briefly classified and explained, pointing out their advantages and shortcomings. After that, all the works on prognostics of machine tools and their main subsystem are reviewed, highlighting current open research areas for improvement.

With the rapid development of fault prognostics and health management (PHM) technology, more and more deep learning algorithms have been applied to the intelligent fault diagnosis of rolling bearings, and although all of them can achieve over 90% diagnostic accuracy, the generality and robustness of the models cannot be truly verified under complex extreme variable loading conditions. In this study, an end-to-end rolling bearing fault diagnosis model of a hybrid deep neural network with principal component analysis is proposed. Firstly, in order to reduce the complexity of deep learning computation, data pre-processing is performed by principal component analysis (PCA) with feature dimensionality reduction. The preprocessed data is imported into the hybrid deep learning model. The first layer of the model uses a CNN algorithm for denoising and simple feature extraction, the second layer makes use of bi-directional long and short memory (BiLSTM) for greater in-depth extraction of the data with time series features, and the last layer uses an attention mechanism for optimal weight assignment, which can further improve the diagnostic precision. The test accuracy of this model is fully comparable to existing deep learning fault diagnosis models, especially under low load; the test accuracy is 100% at constant load and nearly 90% for variable load, and the test accuracy is 72.8% at extreme variable load (2.205 N·m/s–0.735 N·m/s and 0.735 N·m/s–2.205 N·m/s), which are the worst possible load conditions. The experimental results fully prove that the model has reliable robustness and generality.

Reliability of prognostics and health management systems relies upon accurate understanding of critical components’ degradation process to predict the remaining useful life (RUL). Traditionally, degradation process is represented in the form of physical or expert models. Such models require extensive experimentation and verification that are not always feasible. Another approach that builds up knowledge about the system degradation over the time from component sensor data is known as data driven. Data driven models, however, require that sufficient historical data have been collected. In this paper, a two phases data driven method for RUL prediction is presented. In the offline phase, the proposed method builds on finding variables that contain information about the degradation behavior using unsupervised variable selection method. Different health indicators (HIs) are constructed from the selected variables, which represent the degradation as a function of time, and saved in the offline database as reference models. In the online phase, the method finds the most similar offline HI, to the online HI, using k-nearest neighbors classifier to use it as a RUL predictor. The method finally estimates the degradation state using discrete Bayesian filter. The method is verified using battery and turbofan engine degradation simulation data acquired from NASA data repository. The results show the effectiveness of the method in predicting the RUL for both applications.