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Data-Driven Remaining Useful Life Prediction of Energy-Intensive Industrial Assets
Mälardalen University, School of Business, Society and Engineering, Future Energy Center. RISE Research Institutes of Sweden AB.
2025 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

In response to increasing demands for reliability and uptime, organizations are progressively monitoring more of their mission-critical assets through various sensing and data collection devices. The accumulated data enables several emerging technologies, particularly data-driven approaches such as machine learning, which are becoming more viable in industrial contexts. These technologies have the potential to enhance the effectiveness and efficiency of asset management and maintenance. A key framework for realizing this potential is prognostics and health management, an engineering approach that deals with the identification and prognostication of system degradation. A major aspect of prognostics and health management is remaining useful life prediction, which develops models to forecast the remaining operational time of systems. Accurate prediction of future system state provides useful insight that aids maintenance planning. This thesis addresses challenges and aspects of data-driven remaining useful life prediction with a focus on deep learning-based approaches. The research proposes solutions to key challenges in remaining useful life prediction, including limited access to complete run-to-failure trajectories, data sharing constraints, and decentralized training requirements. Additionally, this thesis investigates remaining useful life predictions for discrete power electronics, components used in safety-critical high-power applications such as automotive systems -- an area that remains understudied within prognostics and health management. The findings demonstrate that remaining useful life prediction is a viable technology in these domains, with models benefiting from self-supervised pretraining and decentralized training through federated learning. Furthermore, the research establishes that discrete power electronics can be effectively monitored using data-driven remaining useful life prediction methods.

Place, publisher, year, edition, pages
Västerås: Mälardalens universitet, 2025.
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 375
National Category
Reliability and Maintenance
Research subject
Energy- and Environmental Engineering
Identifiers
URN: urn:nbn:se:mdh:diva-70764ISBN: 978-91-7485-707-8 (print)OAI: oai:DiVA.org:mdh-70764DiVA, id: diva2:1950250
Presentation
2025-05-15, Pi, Mälardalens universitet, Västerås, 09:00 (English)
Opponent
Supervisors
Available from: 2025-04-10 Created: 2025-04-07 Last updated: 2025-04-24Bibliographically approved
List of papers
1. Self-supervised learning for efficient remaining useful life prediction
Open this publication in new window or tab >>Self-supervised learning for efficient remaining useful life prediction
2022 (English)In: Proceedings of the Annual Conference of the Prognostics and Health Management Society, PHM, vol 14, nr 1, Prognostics and Health Management Society , 2022, no 1Conference paper, Published paper (Refereed)
Abstract [en]

Canonical deep learning-based remaining useful life prediction relies on supervised learning methods, which in turn requires large data sets of run-to-failure data to ensure model performance. In a considerable class of cases, run-to-failure data is difficult to collect in practice as it may be expensive and unsafe to operate assets until failure. As such, there is a need to leverage data that are not run-to-failure but may still contain some measurable, and thus learnable, degradation signal. In this paper, we propose utilizing self-supervised learning as a pretraining step to learn representations of data which will enable efficient training on the downstream task of remaining useful life prediction. The self-supervised learning task chosen is time series sequence ordering, a task that involves constructing tuples each consisting of n sequences sampled from the time series and reordered with some probability p. Subsequently, a classifier is trained on the resulting binary classification task; distinguishing between correctly ordered and shuffled tuples. The classifier’s weights are then transferred to the remaining useful life prediction model and fine-tuned using run-to-failure data. To conduct our experiments, we use a data set of simulated run-to-failure turbofan jet engines. We show that the proposed self-supervised learning scheme can retain performance when training on a fraction of the full data set. In addition, we show indications that self-supervised learning as a pretraining step can enhance the performance of the model even when training on the full run-to-failure data set. 

Place, publisher, year, edition, pages
Prognostics and Health Management Society, 2022
National Category
Computer Sciences
Identifiers
urn:nbn:se:mdh:diva-62157 (URN)10.36001/phmconf.2022.v14i1.3222 (DOI)2-s2.0-85150477154 (Scopus ID)9781936263059 (ISBN)
Conference
2022 Annual Conference of the Prognostics and Health Management Society, PHM 2022, Nashville31 October 2022 through 4 November 2022
Available from: 2023-03-30 Created: 2023-03-30 Last updated: 2025-04-07Bibliographically approved
2. Data-Driven Remaining Useful Life Estimation of Discrete Power Electronic Devices
Open this publication in new window or tab >>Data-Driven Remaining Useful Life Estimation of Discrete Power Electronic Devices
Show others...
2023 (English)In: Proceedings of the 33rd European Safety and Reliability Conference (ESREL 2023): The Future of Safety in a Reconnected World / [ed] Mário P. Brito, Terje Aven, Piero Baraldi, Marko Čepin and Enrico Zio, 2023Conference paper, Published paper (Refereed)
Abstract [en]

Robust and accurate prognostics models for estimation of remaining useful life (RUL) are becoming an increasingly important aspect of research in reliability and safety in modern electronic components and systems. In this work, a data driven approach to the prognostics problem is presented. In particular, machine learning models are trained to predict the RUL of wire-bonded silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETs) subjected to power cycling until failure. During such power cycling, ON-state voltage and various temperature measurements are continuously collected. As the data set contains full run-to-failure trajectories, the issue of estimating RUL is naturally formulated in terms of supervised learning. Three neural network architectures were trained, evaluated, and compared on the RUL problem: a temporal convolutional neural network (TCN), a long short-term memory neural network (LSTM) and a convolutional gated recurrent neural network (Conv-GRU). While the results show that all networks perform well on held out testing data if the testing samples are of similar aging acceleration as the samples in the training data set, performance on out-of-distribution data is significantly lower. To this end, we discuss potential research directions to improve model performance in such scenarios.

Keywords
Electronics, Prognostics and health management, Remaining useful life, Data-driven, Machine learning, Deep learning, Power cycling
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:mdh:diva-70763 (URN)10.3850/978-981-18-8071-1_P561-cd (DOI)978-981-18-8071-1 (ISBN)
Conference
33rd European Safety and Reliability Conference (ESREL 2023)
Note

Research is conducted within the iRel4.0 Intelligent Reliability project, which is funded by Horizon2020 Electronics Components for European LeadershipJoint Undertaking Innovation Action (H2020-ECSELJU-IA). This work is also funded by the Swedish innovation agency Vinnova, through co-funding of H2020-ECSEL-JU-IA.

Available from: 2025-04-03 Created: 2025-04-03 Last updated: 2025-04-07Bibliographically approved
3. Collaborative Training of Data-Driven Remaining Useful Life Prediction Models Using Federated Learning
Open this publication in new window or tab >>Collaborative Training of Data-Driven Remaining Useful Life Prediction Models Using Federated Learning
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2024 (English)In: International Journal of Prognostics and Health Management, E-ISSN 2153-2648, Vol. 15, no 2Article in journal (Refereed) Published
Abstract [en]

Remaining useful life prediction models are a central aspect of developing modern and capable prognostics and health management systems. Recently, such models are increasingly data-driven and based on various machine learning techniques, in particular deep neural networks. Such models are notoriously “data hungry”, i.e., to get adequate performance of such models, a substantial amount of diverse training data is needed. However, in several domains in which one would like to deploy data-driven remaining useful life models, there is a lack of data or data are distributed among several actors. Often these actors, for various reasons, cannot share data among themselves. In this paper a method for collaborative training of remaining useful life models based on federated learning is presented. In this setting, actors do not need to share locally held secret data, only model updates. Model updates are aggregated by a central server, and subsequently sent back to each of the clients, until convergence. There are numerous strategies for aggregating clients’ model updates and in this paper two strategies will be explored: 1) federated averaging and 2) federated learning with personalization layers. Federated averaging is the common baseline federated learning strategy where the clients’ models are averaged by the central server to update the global model. Federated averaging has been shown to have a limited ability to deal with non-identically and independently distributed data. To mitigate this problem, federated learning with personalization layers, a strategy similar to federated averaging but where each client is allowed to append custom layers to their local model, is explored. The two federated learning strategies will be evaluated on two datasets: 1) run-to-failure trajectories from power cycling of silicon-carbide metal-oxide semiconductor field-effect transistors, and 2) C-MAPSS, a well-known simulated dataset of turbofan jet engines. Two neural network model architectures commonly used in remaining useful life prediction, long shortterm memory with multi-layer perceptron feature extractors, and convolutional gated recurrent unit, will be used for the evaluation. It is shown that similar or better performance is achieved when using federated learning compared to when the model is only trained on local data.

Place, publisher, year, edition, pages
Prognostics and Health Management Society, 2024
Keywords
deep learning, electronics, federated learning, machine learning, prognostics and health management, remaining useful life, turbofan jet engines
National Category
Computer and Information Sciences
Identifiers
urn:nbn:se:mdh:diva-69546 (URN)10.36001/ijphm.2024.v15i2.3821 (DOI)001415118000002 ()2-s2.0-85191173890 (Scopus ID)
Available from: 2024-12-12 Created: 2024-12-12 Last updated: 2025-04-07Bibliographically approved

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