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Apr 20

Predictive Maintenance Model Based on Anomaly Detection in Induction Motors: A Machine Learning Approach Using Real-Time IoT Data

With the support of Internet of Things (IoT) devices, it is possible to acquire data from degradation phenomena and design data-driven models to perform anomaly detection in industrial equipment. This approach not only identifies potential anomalies but can also serve as a first step toward building predictive maintenance policies. In this work, we demonstrate a novel anomaly detection system on induction motors used in pumps, compressors, fans, and other industrial machines. This work evaluates a combination of pre-processing techniques and machine learning (ML) models with a low computational cost. We use a combination of pre-processing techniques such as Fast Fourier Transform (FFT), Wavelet Transform (WT), and binning, which are well-known approaches for extracting features from raw data. We also aim to guarantee an optimal balance between multiple conflicting parameters, such as anomaly detection rate, false positive rate, and inference speed of the solution. To this end, multiobjective optimization and analysis are performed on the evaluated models. Pareto-optimal solutions are presented to select which models have the best results regarding classification metrics and computational effort. Differently from most works in this field that use publicly available datasets to validate their models, we propose an end-to-end solution combining low-cost and readily available IoT sensors. The approach is validated by acquiring a custom dataset from induction motors. Also, we fuse vibration, temperature, and noise data from these sensors as the input to the proposed ML model. Therefore, we aim to propose a methodology general enough to be applied in different industrial contexts in the future.

  • 8 authors
·
Oct 14, 2023

IndustryEQA: Pushing the Frontiers of Embodied Question Answering in Industrial Scenarios

Existing Embodied Question Answering (EQA) benchmarks primarily focus on household environments, often overlooking safety-critical aspects and reasoning processes pertinent to industrial settings. This drawback limits the evaluation of agent readiness for real-world industrial applications. To bridge this, we introduce IndustryEQA, the first benchmark dedicated to evaluating embodied agent capabilities within safety-critical warehouse scenarios. Built upon the NVIDIA Isaac Sim platform, IndustryEQA provides high-fidelity episodic memory videos featuring diverse industrial assets, dynamic human agents, and carefully designed hazardous situations inspired by real-world safety guidelines. The benchmark includes rich annotations covering six categories: equipment safety, human safety, object recognition, attribute recognition, temporal understanding, and spatial understanding. Besides, it also provides extra reasoning evaluation based on these categories. Specifically, it comprises 971 question-answer pairs generated from small warehouse and 373 pairs from large ones, incorporating scenarios with and without human. We further propose a comprehensive evaluation framework, including various baseline models, to assess their general perception and reasoning abilities in industrial environments. IndustryEQA aims to steer EQA research towards developing more robust, safety-aware, and practically applicable embodied agents for complex industrial environments. Benchmark and codes are available.

  • 8 authors
·
May 26, 2025

Analysis and Applications of Deep Learning with Finite Samples in Full Life-Cycle Intelligence of Nuclear Power Generation

The advent of Industry 4.0 has precipitated the incorporation of Artificial Intelligence (AI) methods within industrial contexts, aiming to realize intelligent manufacturing, operation as well as maintenance, also known as industrial intelligence. However, intricate industrial milieus, particularly those relating to energy exploration and production, frequently encompass data characterized by long-tailed class distribution, sample imbalance, and domain shift. These attributes pose noteworthy challenges to data-centric Deep Learning (DL) techniques, crucial for the realization of industrial intelligence. The present study centers on the intricate and distinctive industrial scenarios of Nuclear Power Generation (NPG), meticulously scrutinizing the application of DL techniques under the constraints of finite data samples. Initially, the paper expounds on potential employment scenarios for AI across the full life-cycle of NPG. Subsequently, we delve into an evaluative exposition of DL's advancement, grounded in the finite sample perspective. This encompasses aspects such as small-sample learning, few-shot learning, zero-shot learning, and open-set recognition, also referring to the unique data characteristics of NPG. The paper then proceeds to present two specific case studies. The first revolves around the automatic recognition of zirconium alloy metallography, while the second pertains to open-set recognition for signal diagnosis of machinery sensors. These cases, spanning the entirety of NPG's life-cycle, are accompanied by constructive outcomes and insightful deliberations. By exploring and applying DL methodologies within the constraints of finite sample availability, this paper not only furnishes a robust technical foundation but also introduces a fresh perspective toward the secure and efficient advancement and exploitation of this advanced energy source.

  • 11 authors
·
Nov 7, 2023

Snap, Segment, Deploy: A Visual Data and Detection Pipeline for Wearable Industrial Assistants

Industrial assembly tasks increasingly demand rapid adaptation to complex procedures and varied components, yet are often conducted in environments with limited computing, connectivity, and strict privacy requirements. These constraints make conventional cloud-based or fully autonomous solutions impractical for factory deployment. This paper introduces a mobile-device-based assistant system for industrial training and operational support, enabling real-time, semi-hands-free interaction through on-device perception and voice interfaces. The system integrates lightweight object detection, speech recognition, and Retrieval-Augmented Generation (RAG) into a modular on-device pipeline that operates entirely on-device, enabling intuitive support for part handling and procedure understanding without relying on manual supervision or cloud services. To enable scalable training, we adopt an automated data construction pipeline and introduce a two-stage refinement strategy to improve visual robustness under domain shift. Experiments on our generated dataset, i.e., Gear8, demonstrate improved robustness to domain shift and common visual corruptions. A structured user study further confirms its practical viability, with positive user feedback on the clarity of the guidance and the quality of the interaction. These results indicate that our framework offers a deployable solution for real-time, privacy-preserving smart assistance in industrial environments. We will release the Gear8 dataset and source code upon acceptance.

  • 6 authors
·
Jun 9, 2025

Analog and Multi-modal Manufacturing Datasets Acquired on the Future Factories Platform V2

This paper presents two industry-grade datasets captured during an 8-hour continuous operation of the manufacturing assembly line at the Future Factories Lab, University of South Carolina, on 08/13/2024. The datasets adhere to industry standards, covering communication protocols, actuators, control mechanisms, transducers, sensors, and cameras. Data collection utilized both integrated and external sensors throughout the laboratory, including sensors embedded within the actuators and externally installed devices. Additionally, high-performance cameras captured key aspects of the operation. In a prior experiment [1], a 30-hour continuous run was conducted, during which all anomalies were documented. Maintenance procedures were subsequently implemented to reduce potential errors and operational disruptions. The two datasets include: (1) a time-series analog dataset, and (2) a multi-modal time-series dataset containing synchronized system data and images. These datasets aim to support future research in advancing manufacturing processes by providing a platform for testing novel algorithms without the need to recreate physical manufacturing environments. Moreover, the datasets are open-source and designed to facilitate the training of artificial intelligence models, streamlining research by offering comprehensive, ready-to-use resources for various applications and projects.

  • 11 authors
·
Feb 7, 2025

A Benchmark Time Series Dataset for Semiconductor Fabrication Manufacturing Constructed using Component-based Discrete-Event Simulation Models

Advancements in high-computing devices increase the necessity for improved and new understanding and development of smart manufacturing factories. Discrete-event models with simulators have been shown to be critical to architect, designing, building, and operating the manufacturing of semiconductor chips. The diffusion, implantation, and lithography machines have intricate processes due to their feedforward and feedback connectivity. The dataset collected from simulations of the factory models holds the promise of generating valuable machine-learning models. As surrogate data-based models, their executions are highly efficient compared to the physics-based counterpart models. For the development of surrogate models, it is beneficial to have publicly available benchmark simulation models that are grounded in factory models that have concise structures and accurate behaviors. Hence, in this research, a dataset is devised and constructed based on a benchmark model of an Intel semiconductor fabrication factory. The model is formalized using the Parallel Discrete-Event System Specification and executed using the DEVS-Suite simulator. The time series dataset is constructed using discrete-event time trajectories. This dataset is further analyzed and used to develop baseline univariate and multivariate machine learning models. The dataset can also be utilized in the machine learning community for behavioral analysis based on formalized and scalable component-based discrete-event models and simulations.

  • 4 authors
·
Aug 17, 2024

IndustryShapes: An RGB-D Benchmark dataset for 6D object pose estimation of industrial assembly components and tools

We introduce IndustryShapes, a new RGB-D benchmark dataset of industrial tools and components, designed for both instance-level and novel object 6D pose estimation approaches. The dataset provides a realistic and application-relevant testbed for benchmarking these methods in the context of industrial robotics bridging the gap between lab-based research and deployment in real-world manufacturing scenarios. Unlike many previous datasets that focus on household or consumer products or use synthetic, clean tabletop datasets, or objects captured solely in controlled lab environments, IndustryShapes introduces five new object types with challenging properties, also captured in realistic industrial assembly settings. The dataset has diverse complexity, from simple to more challenging scenes, with single and multiple objects, including scenes with multiple instances of the same object and it is organized in two parts: the classic set and the extended set. The classic set includes a total of 4,6k images and 6k annotated poses. The extended set introduces additional data modalities to support the evaluation of model-free and sequence-based approaches. To the best of our knowledge, IndustryShapes is the first dataset to offer RGB-D static onboarding sequences. We further evaluate the dataset on a representative set of state-of-the art methods for instance-based and novel object 6D pose estimation, including also object detection, segmentation, showing that there is room for improvement in this domain. The dataset page can be found in https://pose-lab.github.io/IndustryShapes.

  • 5 authors
·
Feb 5

Real-IAD: A Real-World Multi-View Dataset for Benchmarking Versatile Industrial Anomaly Detection

Industrial anomaly detection (IAD) has garnered significant attention and experienced rapid development. However, the recent development of IAD approach has encountered certain difficulties due to dataset limitations. On the one hand, most of the state-of-the-art methods have achieved saturation (over 99% in AUROC) on mainstream datasets such as MVTec, and the differences of methods cannot be well distinguished, leading to a significant gap between public datasets and actual application scenarios. On the other hand, the research on various new practical anomaly detection settings is limited by the scale of the dataset, posing a risk of overfitting in evaluation results. Therefore, we propose a large-scale, Real-world, and multi-view Industrial Anomaly Detection dataset, named Real-IAD, which contains 150K high-resolution images of 30 different objects, an order of magnitude larger than existing datasets. It has a larger range of defect area and ratio proportions, making it more challenging than previous datasets. To make the dataset closer to real application scenarios, we adopted a multi-view shooting method and proposed sample-level evaluation metrics. In addition, beyond the general unsupervised anomaly detection setting, we propose a new setting for Fully Unsupervised Industrial Anomaly Detection (FUIAD) based on the observation that the yield rate in industrial production is usually greater than 60%, which has more practical application value. Finally, we report the results of popular IAD methods on the Real-IAD dataset, providing a highly challenging benchmark to promote the development of the IAD field.

  • 9 authors
·
Mar 19, 2024

IPAD: Industrial Process Anomaly Detection Dataset

Video anomaly detection (VAD) is a challenging task aiming to recognize anomalies in video frames, and existing large-scale VAD researches primarily focus on road traffic and human activity scenes. In industrial scenes, there are often a variety of unpredictable anomalies, and the VAD method can play a significant role in these scenarios. However, there is a lack of applicable datasets and methods specifically tailored for industrial production scenarios due to concerns regarding privacy and security. To bridge this gap, we propose a new dataset, IPAD, specifically designed for VAD in industrial scenarios. The industrial processes in our dataset are chosen through on-site factory research and discussions with engineers. This dataset covers 16 different industrial devices and contains over 6 hours of both synthetic and real-world video footage. Moreover, we annotate the key feature of the industrial process, ie, periodicity. Based on the proposed dataset, we introduce a period memory module and a sliding window inspection mechanism to effectively investigate the periodic information in a basic reconstruction model. Our framework leverages LoRA adapter to explore the effective migration of pretrained models, which are initially trained using synthetic data, into real-world scenarios. Our proposed dataset and method will fill the gap in the field of industrial video anomaly detection and drive the process of video understanding tasks as well as smart factory deployment.

  • 8 authors
·
Apr 23, 2024

ChangeChip: A Reference-Based Unsupervised Change Detection for PCB Defect Detection

The usage of electronic devices increases, and becomes predominant in most aspects of life. Surface Mount Technology (SMT) is the most common industrial method for manufacturing electric devices in which electrical components are mounted directly onto the surface of a Printed Circuit Board (PCB). Although the expansion of electronic devices affects our lives in a productive way, failures or defects in the manufacturing procedure of those devices might also be counterproductive and even harmful in some cases. It is therefore desired and sometimes crucial to ensure zero-defect quality in electronic devices and their production. While traditional Image Processing (IP) techniques are not sufficient to produce a complete solution, other promising methods like Deep Learning (DL) might also be challenging for PCB inspection, mainly because such methods require big adequate datasets which are missing, not available or not updated in the rapidly growing field of PCBs. Thus, PCB inspection is conventionally performed manually by human experts. Unsupervised Learning (UL) methods may potentially be suitable for PCB inspection, having learning capabilities on the one hand, while not relying on large datasets on the other. In this paper, we introduce ChangeChip, an automated and integrated change detection system for defect detection in PCBs, from soldering defects to missing or misaligned electronic elements, based on Computer Vision (CV) and UL. We achieve good quality defect detection by applying an unsupervised change detection between images of a golden PCB (reference) and the inspected PCB under various setting. In this work, we also present CD-PCB, a synthesized labeled dataset of 20 pairs of PCB images for evaluation of defect detection algorithms.

  • 3 authors
·
Sep 13, 2021