Iot MM 1
Iot MM 1
Iot MM 1
https://www.emerald.com/insight/1741-038X.htm
Abstract
Purpose – The recent innovations of Industry 4.0 have made it possible to easily collect data related to a
production environment. In this context, information about industrial equipment – gathered by proper
sensors – can be profitably used for supporting predictive maintenance (PdM) through the application of data-
driven analytics based on artificial intelligence (AI) techniques. Although deep learning (DL) approaches have
proven to be a quite effective solutions to the problem, one of the open research challenges remains – the design
of PdM methods that are computationally efficient, and most importantly, applicable in real-world internet of
things (IoT) scenarios, where they are required to be executable directly on the limited devices’ hardware.
Design/methodology/approach – In this paper, the authors propose a DL approach for PdM task, which is
based on a particular and very efficient architecture. The major novelty behind the proposed framework is to
leverage a multi-head attention (MHA) mechanism to obtain both high results in terms of remaining useful life
(RUL) estimation and low memory model storage requirements, providing the basis for a possible
implementation directly on the equipment hardware.
Findings – The achieved experimental results on the NASA dataset show how the authors’ approach
outperforms in terms of effectiveness and efficiency the majority of the most diffused state-of-the-art techniques.
Research limitations/implications – A comparison of the spatial and temporal complexity with a typical
long-short term memory (LSTM) model and the state-of-the-art approaches was also done on the NASA dataset.
Despite the authors’ approach achieving similar effectiveness results with respect to other approaches, it has a
significantly smaller number of parameters, a smaller storage volume and lower training time.
Practical implications – The proposed approach aims to find a compromise between effectiveness and
efficiency, which is crucial in the industrial domain in which it is important to maximize the link between
performance attained and resources allocated. The overall accuracy performances are also on par with the
finest methods described in the literature.
Originality/value – The proposed approach allows satisfying the requirements of modern embedded AI
applications (reliability, low power consumption, etc.), finding a compromise between efficiency and
effectiveness.
Keywords Decision support systems, Decision making, Industry 4.0, Predictive maintenance,
Deep neural networks
Paper type Research paper
© Roberto De Luca, Antonino Ferraro, Antonio Galli, Mose Gallo, Vincenzo Moscato and Giancarlo
Sperlı. Published by Emerald Publishing Limited. This article is published under the Creative Commons Journal of Manufacturing
Attribution (CC BY 4.0) licence. Anyone may reproduce, distribute, translate and create derivative works Technology Management
Vol. 34 No. 4, 2023
of this article (for both commercial and non-commercial purposes), subject to full attribution to the pp. 535-556
original publication and authors. The full terms of this licence may be seen at http://creativecommons. Emerald Publishing Limited
1741-038X
org/licences/by/4.0/legalcode DOI 10.1108/JMTM-02-2022-0093
JMTM 1. Introduction
34,4 Currently, we are living in the Industry 4.0 era that refers to the ongoing automation of
traditional manufacturing and industrial practices by using modern smart technologies, such
as internet of things (IoT) and artificial intelligence (AI) (Hansen and Bøgh, 2021). In this
context, an increasing integration between physical and digital systems of production
environments is more and more required, allowing the collection of large amounts of data that
are gathered by different and distributed smart equipment and sensors.
536 Generally speaking, smart sensors are particular devices which generate data regarding
physical parameters (e.g. temperature, humidity or vibration speed, etc.) and can provide
further functionalities from self-monitoring and self-configuration to efficiently manage
complex processes (Zhang et al., 2019).
The analysis of such data provides at the same time useful information about the health
status of the machinery and the level of production. By applying data driven analytic
approaches, it is then possible to find important results for strategic decision-making,
providing advantages such as: maintenance cost reduction, machine fault reduction, spare
parts inventory reduction and increased production.
Most of these benefits certainly concern maintenance procedures. This aspect is
particularly critical in the industrial field because it has a strong impact on the production and
availability of the offered services. Nowadays, the industry is making significant investments
for equipping itself with the elements necessary for applying maintenance strategies based
on gathered data.
In the literature, there are two main kinds of approaches for supporting maintenance
tasks, namely model-driven and data-driven methods, but also hybrid-driven approaches have
also become popular in recent years. Specifically, model-driven techniques require expert’s
strong theoretical understanding to model the behavior of equipment and its detailed
degradation process (Petrillo et al., 2020; Liu et al., 2022). From the other hand, as mentioned
above, thanks to the huge amount of information that is possible to collect, data-driven
techniques are emerging as the more promising ones to detect anomalies in the operation of
the machinery. Regarding hybrid-driven solutions, they are based on the construction of
multi-domain models and the development of hybrid algorithms in order to achieve model
and data fusion (Luo et al., 2020; Zhang et al., 2022a, b).
According to Susto et al. (2015), approaches for maintenance management can be further
grouped into three categories: run-to-failure (R2F), preventive maintenance (PvM) and
predictive maintenance (PdM). Here, we focused on PdM, where maintenance is performed
based on the health status of the specific equipment as reported by attached sensors.
Through data driven analysis techniques, it is possible to know when the machinery is going
to fail and then planning maintenance procedures accordingly. Basically, maintenance
operations are conducted only when necessary, without waiting for machinery to report a
fault. With this strategy, companies can save costs due to unnecessary maintenance, but also
increase the longevity of the machine. Nevertheless, critical PdM requires several strictly
requirements such as reliability, low latency, privacy and power (Mohammadi et al., 2018;
Sharma et al., 2019).
As in many other areas concerned with huge amount of complex data to be analyzed,
approaches exploiting machine learning (ML) and deep learning (DL) techniques appear to be
the best among the diverse array of modern PdM techniques (Carvalho et al., 2019; Ran et al.,
2019; Rieger et al., 2019). Such approaches usually leverage historical datasets, structured as
labeled time series about equipment operations, to train a variety of regression/classification
models which can then be used to predict possible failures, in terms of remaining useful life
(RUL) estimation.
Although DL approaches have proven to be a quite effective solution to the PdM problem,
one of the open research challenges remains the design of PdM methods that are
computationally efficient, and most importantly, applicable in real-world IoT scenarios, PdM
where they are required to be executable directly on the limited devices’ hardware. applications in
Indeed, one of the most important issues for deploying DL architectures in real production
scenario is related to the required high computational resources, not available for current
IoT scenarios
equipment micro-controllers, thus favoring cloud or edge/fog computing solutions, which
efficiency is often influenced by network connectivity (Teoh et al., 2023).
To overcome such problems, embedded AI techniques are more and more diffusing to
propose efficient and not computational expensive data driven analysis approach, directly 537
executable on devices’ hardware of industrial equipment (Brandalero et al., 2020).
In this paper, we propose a DL approach for PdM task, which is based on a particular and
very efficient architecture. The major novelty behind the proposed framework is to leverage a
multi-head attention (MHA) mechanism to obtain both high results in terms of RUL
estimation and low memory model storage requirements, providing the basis for a possible
implementation directly on the equipment hardware. The attention mechanism has gained a
lot of popularity in last years for its better capacities in several analytics tasks (e.g. NLP) in
terms of achieved results and model complexity than recurrent models. For this reason, our
basic intuition has been to rearrange such a mechanism to analyze time-series data.
The achieved experimental results on the NASA dataset show how our approach
outperforms in terms of effectiveness and efficiency the majority of the most diffused state
of the art techniques, thus providing a suitable solution for PdM in real scenarios.
The paper is organized as in the following. Section 2 reports the related work about PdM
approaches and the related challenges, while Section 3 describes the proposed methodology
together with the introduced deep architecture for PdM task. Sections 4 and 5 present the
experimental protocol and the achieved results, respectively. Finally, Section 6 reports a final
discussion together with some conclusions and future work.
2. Related work
PdM is one of the hottest research topics of recent years and several techniques have been
developed in this area. More in detail, the spread of IoT and AI technologies has led several
studies to design data-driven methodologies based on ML and DL, exploiting techniques
for time series analysis and mining (see Tortorella et al., 2022 and Lundgren et al., 2021).
In addition, a recent study proposed by Sala et al. (2021) underlines the features of a
framework for PdM capable of jointly analyzing historical and real-time data, to make a
continuous improvement of its performances.
Some of the most popular proposals are summarized in Table 1, where it is easy to note as
the majority of the approaches is based on long-short term memory (LSTM) networks and
convolutional neural networks (CNNs). Among the plethora of DL approaches, the most
interesting ones for benchmark aims are surely those leveraging the Nasa Turbofan Engine
dataset. In particular, the most recent methods that have inspired our work can be classified
into two broad categories: Recurrent models and Hybrid models (see Table 2). In the following,
we are describing the adopted criteria for literature section, the discussed models and how our
proposal overcomes the related limitations.
Aydemir and Acar (2020) 2020 Anomaly triggered long short-term memory (LSTM)
Listou Ellefsen 2019 Restricted Boltzmann machine (RBM) þ long short-term memory (LSTM)
Table 2. et al. (2019)
A summary of the most Ragab et al. (2021) 2020 Long short-term memory (LSTM) with attention
recent papers Al-Dulaimi et al. (2019) 2019 Long short-term memory (LSTM) þ convolutional neural network (CNN)
regarding NASA Falcon et al. (2020) 2020 Multi-head attention (MHA) þ LSTM þ CNN þ neural turing machine
turbofan engine (NTM)
dataset Al-Dulaimi et al. (2020) 2020 Noisy bidirectional long short-term memory (BLSTM) þ CNN
reporting the results. Operationally, we focused on retrieving the most relevant published PdM
works in the field of PdM with DL-based approaches in different industrial contexts, with applications in
special emphasis on those that used our own dataset for experimentation (see Table 1). Works
based on recurrent and hybrid network models were the considered. Eventually, the literature
IoT scenarios
study led to the answer to what are the open research challenges in the PdM field.
In detail, articles on Scopus and Google Scholar in the time interval 2017–2022 were
consulted and the following keywords, also combined, were used:
539
“predictive maintenance”, “deep learning”, “recurrent model”, “hybrid”, “machine learning”,
“attention mechanism” and “multi-head attention”.
To be specific, based on the selection criteria defined by the keywords above, 21 articles were
collected, 17 of which were retrieved from Scopus and four from Google Scholar. A screening
of the abstract and methodology was performed, while for only those articles that used the
Nasa Turbofan Engine Dataset, a full-paper screening was conducted.
3. Methodology
As we have seen from previous sections, tasks related to PdM can be modeled as:
(1) regression problem, in which the main purpose is the RUL estimation of a machinery;
(2) a classification problem, namely the health state prediction. Using data driven techniques,
maintenance procedures can be then optimally scheduled, avoiding a downtime period due to
the replacement or repair of the faulty asset.
Our aim is to design an AI model capable of estimating RUL from different types of
measured equipment data. The general workflow for a RUL estimation process is:
(1) Choose the best type of RUL estimation model for the data and available system
knowledge.
(2) Train the estimation model using the historical data.
(3) Using test data of the same type as historical data, estimate the RUL of the test
component.
In this section, we details the adopted methodology: we first provide the PdM task definition,
then we present the model architecture, with a focus on the related core part, the introduced
attention module.
τ being a set of unknown parameters, which we have to determine for our model, and e
consists in some error terms that are not directly observed in input data.
The PdM task goal is to estimate the function Y 5 f(X, τ) that most closely fits the real data.
Thus, we have to chosen an AI model providing a reliable mapping function f.
JMTM 3.2 Model architecture
34,4 Figure 1 shows a high-level view of the proposed model architecture for the described PdM
task. The figure also describes the data analysis pipeline required for the generation of
estimated RUL values.
In particular, the input consists in the historical data coming from sensors giving useful
information about the conditions of the monitored machinery. Such data have a temporal
component, which is crucial in detecting the degradation trend.
542 After processing the input data, they are fed into the model able to capture temporal
dependencies between features. After setting a proper time window, the data that is gathered
as input to the model, is a matrix of size (Tw, Nx), where Tw is the length of the input time
window and Nx is the number of considered features. The output of the model is a real number
representing the RUL of the machinery.
Specifically, the main components of the proposed architecture are.
(1) the positional encoding block to take into account the relative or absolute position of
the time-steps in the input sequence;
(2) the attention module, which is composed by two sub-layers (with residual
connections between them):
the MHA block;
a fully connected network module.
In the following, we are reporting more details about each component.
Figure 1.
Proposed AI
architecture
As it can be derived from the formulas, the frequencies are decreasing along the vector PdM
dimension. Thus the wavelengths form a geometric progression from 2π to 10,000 3 2π . applications in
Finally, the obtained encoding for position t is summed to the t-th timestep in the input
sequence.
IoT scenarios
MHA mechanism (Figure 2) simply repeats the above computation a number of times equal to
the chosen number of heads, h. More precisely, instead of calculating a single attention
function with one set of queries, keys and values, this mechanism first creates h different sets
of queries, keys and values and for each of them performs the attention function in parallel.
Figure 2.
Multi-head attention
JMTM The outputs of each head are concatenated and the final result is linearly projected in order to
34,4 obtain the matrix of shape (Tw, Nx).
Mathematically, MHA is defined as,
MultiHeadðQ; K; V Þ ¼ Concatðhead1 ; . . . ; headh ÞW O (5)
where
544
headi ¼ Attention QW Qi ; KW Ki ; VW Vi (6)
At a higher level of abstraction, the MHA sub-module computes a new representation of the
input time window. In this representation, each timestep is enriched by the knowledge of the
timesteps that precede or follow it in the sequence.
After the attention module, there is a feed forward network. This network is applied to
each position separately and identically. Specifically, it consists of two linear transformations
with a ReLU activation function.
Mathematically:
FFN ðxÞ ¼ maxð0; W1 x þ b1 ÞW2 þ b2 (7)
As regards to the input and output dimensions, they are equal to Nx. The inner-layer has a
variable dimension, given by Nx 3 FFN_FACTOR.
Finally, after stacking a variable number of attention modules, there are a flatten layer and
a final layer containing only one neuron with a ReLU activation function.
4. Experimental evaluation
As already described, the major novelty of this work is to introduce an attention-based deep
architecture for PdM. In particular, we designed it for applications requiring predictive
models to be stored in memory constraint device. In order to show its validity with respect
to common recurrent deep models, a comparison has been made with the most diffused
architecture in terms of model’s storage size and accuracy performance according to
specific metrics. Specifically, we chose an LSTM network with two layers, each containing
128 units and a final Dense layer with a ReLU as activation function to perform the
regression task.
Furthermore, the comparison has been realized by using Turbofan engine degradation
simulation dataset [1] provided by NASA Ames Prognostics Data Repository. It is a well-
known benchmark used in prognostic and health management (PHM) field. It is generated by
C-MAPSS tool that simulates various degradation scenarios of the fleet of engines of the same
type. It contains four sub-datasets (called FD001, . . ., FD004) with different operating
conditions and fault modes. Each sub-dataset includes training dataset and testing dataset.
The training dataset is composed of run-to-failure sequential data collected from 21
sensors (see Saxena et al. (2008) for detailed information about the sensors). The engine
operates normally at the beginning with certain degrees of initial wear. The sensors record
the data of the engine until the fault develops to a system failure.
More in details, each row of the dataset has 26 fields.
(1) Engine ID,
(2) Cycle index,
(3) Three fields representing the operating condition of the engine,
(4) 21 sensor readings.
Test set data is different: the engine starts in an unknown deteriorated state and the readings PdM
terminates at some point prior to system failure. Therefore, the aim is to predict the RUL of each applications in
engine. For evaluation purposes, the true RUL values for the test trajectories are provided.
In the test dataset, the sensory data of the system prior to the system failure are recorded. The
IoT scenarios
task is to estimate the RUL of the engine in the testing dataset. Therefore, in the testing dataset,
the actual RUL of each data sample is provided to check the result of the proposed method.
545
4.1 Hyperparameters
In order to provide more details about the model’s hyperparameters, here is reported a
summary.
(1) NUM_ENC: the number of stacked attention modules.
(2) NUM_HEADS: the number of attention heads in the MHA mechanism.
(3) KEY_DIM: the dimension of the query and key vectors. Although it is not mandatory,
in this work the value vector has this dimension.
(4) FFN_FACTOR: this regulates the number of neurons in the first layer of the fully
connected sublayer in each of the attention modules.
However, there are other hyperparameters such as learning rate, batch size and number of
epochs which are not dependent on the proposed model but affect the training stage of the
model. The proposed model has been implemented in Tensorflow 2.0 using the corresponding
Keras layers.
Below are summarized the steps followed in the analysis and then give more details
about them.
(1) Feature selection and normalization;
(2) RUL target function definition;
(3) Time-windows creation.
546
Figure 3.
Features plot of the
first engine
We used the so called piece-wise linear degradation model. The main idea behind this
strategy is quite simple. Because the engine failure occurred gradually, it is not appropriate to
utilize the real RUL when adding the RUL label. In general, the strategy used is to establish
the degradation threshold and ignore the period before the engine degrades. When the
operating time reaches the degradation threshold, the engine’s remaining useable life reduces
monotonically. To address this issue and map this process, a piece-wise linear deterioration
model was developed on the basis of Ramasso (2014) approach.
According to most of the related works, we set the clip value equal to 125.
Figure 4 shows the difference between the two main used RUL target functions.
Let us formalize this idea. Let ni be the number of cycles for the i-th engine. Let xi be the
actual cycle of the engine. If ni xi > 125 then the RUL value for this cycle is fixed to 125.
Otherwise, it is equal to ni xi.
547
Figure 4.
Linear and
Piece-wise linear
degradation model
Figure 5.
Time windows creation
The scoring function was initially proposed in Saxena et al. (2008), but now is widely used in
PHM applications. Defining hi ¼ RUL0i − RULi, this function can be expressed by:
X
N
S¼ si (9)
i¼1
JMTM where
8 −h
34,4 < e 13i 1 if hi < 0
si ¼ (10)
: 10hi
e 1 if hi ≥ 0
Ideally, this function should be as lower as possible.
548 In Figure 6 there is a plot representing the scoring function and the RMSE. As we can see,
RMSE does not make difference between an early prediction (when the estimated RUL is lower
than the real) and a late one. However, in PHM it is crucial to have useful RUL predictions, i.e.
predictions that makes possible to repair a machine before its failure. This characteristic is
evident in the plot: as the predicted RUL is greater than the real one, the scoring function
increases exponentially; if the predicted RUL is lower than the real, clearly it is an error, but not
as bad as the previous case. Therefore, the scoring function increases with a lower rate.
5. Results
In this section the achieved results are reported and discussed. In particular, Table 3 shows
the performance metrics of the proposed model varying the time window length. To obtain a
more robust estimation, all the tests were repeated 10 times and means and standard
deviations were taken. Similarly, Table 4 reports the performance metrics of the LSTM
network varying the time window length.
More in details, the hyperparameters chosen for the proposed model are: NUM_ENC 1,
NUM_HEADS 8, KEY_DIM 28 and FFN_FACTOR 517. Regarding the LSTM model we
used two layer each with 128 units. Adam optimizer has been used to train both models, the
maximum number of epochs was set to 300, batch size to 128 and learning rate to 10e 3.
Figure 6.
Scoring function
551
Figuer 7.
Best proposed model’s
prediction errors
avoid failures and optimize the use of the industrial equipment. Data-driven approaches to
PdM have been studied in last years, especially ones adopting ML algorithms. Thanks to
these techniques, it is now possible estimate the RUL of the machinery just analyzing
related past operational data.
JMTM
34,4
552
Figure 8.
Best LSTM model’s
prediction errors
One of most recent trend is using DL models for PdM purposes because of their state-of-the-
art results in fields such as computer vision and NLP are easily extensible for PdM task. The
first attempts have shown promising results.
However, proposed models often are too complex and not well suited for critical applications.
Indeed, in those cases, trained models are hosted in resource constrained hardware, especially in
terms of memory size and power consumption. While in general it could be possible to process
data in a cloud environment, this is not desirable for such applications requiring high reliability, PdM
low latency, data privacy and low energy consumption. applications in
In this work, a light attention-based model has been proposed to deal with the exposed problem.
The attention mechanism has gained a lot of popularity in last years for its better capacities in NLP
IoT scenarios
tasks in terms of achieved results and model complexity than recurrent models. For this reason, it
has been rearranged in a novel manner in this work to analyze time-series data.
In order to validate the proposal, the well-known Turbofan engine degradation dataset
provided by NASA has been used. In addition to making a comparison with the best latest 553
methods on this dataset in the literature, a spatial and temporal complexity comparison with
a standard LSTM model was also made. The results show there is no significant difference in
terms of RMSE and a PHM scoring function with such a recurrent model. However, the
proposed model has far fewer parameters, its storage size is much lower than the LSTM’s one
and it is also faster in the training stage. A trade-off between efficiency and effectiveness was
thus achieved, which is of paramount importance in industrial contexts where the
relationship between performance obtained and resources allocated is to be optimized
(Chen et al., 2021; Markiewicz et al., 2019). In addition, the overall accuracy performances are
comparable with the best techniques of the literature.
Summarizing, the achieved experimental results showed how the proposed approach
enables it to meet the requirements of modern embedded AI applications, with obvious
benefits for smart manufacturing systems where the requirements of reliability, low latency,
privacy and low power are imperative and important implications from a management point
of view in order to optimize the operation of a production line.
Possible future works could concern the further investigation of the attention mechanism
applied to different PdM applications.
Moreover, it would be interesting to inspect what actually the model learns (i.e. gives more
attention) in order to provide a sort of explanations using explainable artificial intelligence
(XAI) tools.
Note
1. https://data.nasa.gov/Aerospace/Turbofan-engine-degradation-simulation-data-set/vrks-gjie
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Corresponding author
Giancarlo Sperlı can be contacted at: giancarlo.sperli@unina.it
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