maintenance engineers

Abstract: We present an algorithm that computes the structural signature and the mean time-to-failure (MTTF) of a monotone binary system at every one of its states, rather than only at the state in which all components work. It makes no assumption on the structure function and evaluates it exactly once per state, as many times as needed for the signature of the complete system alone, so computing the MTTF everywhere costs only a factor polynomial in the number of components over computing it once. As a by-product, it identifies all minimal path sets. We assume exchangeable component failure times whose survivor count is a continuous-time Markov chain. This setting admits simultaneous failures, as in the Lévy-frailty Marshall-Olkin, binomial failure rate and lethal-shock models, where the simplifications available for single failures do not apply. We use the per-state MTTF to define threshold repair policies. We show that the per-state signature is a strictly finer decision criterion than the MTTF: signature dominance at a common failure count implies MTTF dominance, but not conversely. Under the Lévy-frailty Marshall-Olkin model the MTTF is monotone in the state, which yields the long-run cost rate of every threshold policy in a single pass. Experiments on 22 benchmark networks with up to 30 components and 31 failure models show that the best MTTF-threshold policy has a median excess cost of 0.36% over the optimal state-based policy, and that it is never worse than the best policy that repairs after a fixed number of failures.

Abstract: Deep remaining-useful-life (RUL) models on NASA C-MAPSS are now routine, and so are heatmaps that colour sensors and timesteps. A heatmap that looks mechanical is not the same as an explanation an engineer can act on. We train three standard architectures - a 1D CNN, an LSTM, and a small Transformer encoder - on the official FD001 and FD003 splits with the piecewise RUL cap of 125 cycles and the official PHM08 asymmetric score. We then attach three attribution maps (Integrated Gradients, occlusion, last-layer attention) and evaluate them with the checks the XAI-for-PdM literature still under-reports: deletion/insertion faithfulness, Spearman stability under sensor-scale noise, agreement across training seeds, and cosine consistency inside RUL bins. Prediction error is a prerequisite, not the claim. The headline is which explanation method moves the RUL output when its top cells are removed, and which map survives a 5% input perturbation. Integrated Gradients and occlusion are similarly faithful on the LSTM; Transformer attention is cheap and temporally smooth but weakly faithful. All three maps are almost unchanged under 5% input noise, yet IG/occlusion agree only moderately across two LSTM seeds - stability to sensor jitter is not the same as stability to retraining. A secondary tabular check on the AI4I 2020 failure dataset shows the same deletion pattern for tree importances. We recommend occlusion or IG for any C-MAPSS-style report that will be read by a maintenance engineer, and we treat raw attention weights as a visualisation only.

Abstract: Can heterogeneous physical degradation systems benefit from joint pretraining and move beyond system-specific prognostics toward reusable cross-system representation learning? CORD combines type-specific observation interfaces with a shared degradation backbone. Its two self-supervised objectives learn at complementary scales: Intra-Observation Structure Modeling (ISM) captures structure within observations, while Inter-Observation Dynamics Modeling (IDM) captures latent degradation evolution across observation histories. We evaluate CORD under two transfer boundaries: Pretraining-Included System Types, where downstream datasets and held-out units are unseen but their system types are represented during source pretraining, and Pretraining-Excluded System Types, where the entire turbofan-engine type is absent from pretraining. Across bearings, batteries, and cutting tools, CORD (Multi-domain) consistently improves over CORD (Single-domain) under Frozen adaptation, provides further gains under Full FT in most settings, and remains competitive with representative external baselines. Source-pretrained initialization also improves low-label adaptation to the pretraining-excluded engine type. Frozen-representation analysis further shows improved cross-unit lifecycle consistency after multi-domain pretraining. Joint pretraining across heterogeneous physical systems thus produces degradation representations reusable across devices, datasets, and system types.

Abstract: Machine fault diagnosis from vibration requires learning from scarce labelled fault recordings while meeting the computational constraints of edge devices for local inference. We introduce DualRes, a compact oscillatory state-space model that combines two complementary spectral views of vibration, capturing rapid changes and fine frequency structure. Time-aligned views are processed by selective oscillatory memory, which learns how long to retain temporal patterns. The encoder contains 39,528 parameters. We evaluate supervised learning across six bearing datasets and a gearbox benchmark, with an additional gearbox pilot. Recording-level splits and explicit accounting of labelled duration distinguish data efficiency from repeated exposure to correlated samples. On the main gearbox benchmark, DualRes achieves state-of-the-art performance among the nine evaluated methods at six of seven label budgets. With about six labelled seconds per class, it improves macro-F1 by 16.1 percentage points over the next strongest comparator. On the same benchmark, DualRes achieves a 1.44-fold recording-level speedup and a 24.8-fold reduction in checkpoint storage relative to a selective state-space baseline under matched hardware and runtime conditions. Bearing results reveal task-dependent trade-offs. These findings support oscillatory memory as a compact approach to vibration diagnosis under limited labelled exposure.

Abstract: Fault detection is essential in industrial systems, enabling early identification of abnormal behaviour and improving safety, reliability, and operational efficiency. Modern systems increasingly rely on heterogeneous sensing modalities that capture complementary aspects of the underlying physical process. However, existing data-driven anomaly detection methods often process each modality independently or use simple feature-level fusion, limiting their ability to exploit cross-modal relationships that characterize normal system behaviour. Their performance also commonly assumes similar training and deployment distributions, whereas real-world operation is affected by changing operating conditions, environmental influences, and system degradation that induce distribution shifts and reduce detection performance, especially in unseen regimes. In this work, we propose a multimodal anomaly detection framework based on cross-modal reconstruction of heterogeneous time-series sensor data. Rather than modeling each modality independently, the framework learns system dynamics by reconstructing each modality from the others, thereby exploiting complementary information across modalities. This integrates information across sensing channels without requiring explicit temporal alignment or identical sampling rates, while improving robustness to sensor noise, missing measurements, and modality-specific disturbances. To address distribution shifts during real-world deployment, anomalies are identified using cross-modal reconstruction error and an adaptive test-time thresholding mechanism that adjusts to changing operating conditions. Experiments on three industrial case studies show strong fault detection performance and substantially improved robustness under out-of-distribution conditions, with the largest gains observed in the most challenging operating regimes.