Deep Learning Approaches for Predictive Maintenance and Intelligent Fault Diagnosis

Authors

  • Dr. Sunita Dixit Professor Department of Computer Science & Engineering St. Andrews Institute of Technology & Management, Gurgaon. Author

DOI:

https://doi.org/10.63282/3050-922X.IJERET-V7I1P116

Keywords:

Predictive Maintenance, Intelligent Fault Diagnosis, Deep Learning, Vibration Analysis, Rotating Machinery, Industrial Systems Reliability

Abstract

Deep-learning-based intelligent fault diagnosis methods are the new research hotspots in the fault diagnosis field. Auto detection and correct detection of the emerging micro-fault of rotating machinery, particularly with respect to fault orientation and level of severity, remains a significant issue in the area of intelligent fault diagnosis. To detect an early fault successfully in rotating machinery, this paper presents a Hybrid Recurrent Neural Network and Gated Recurrent Unit (RNN +GRU) that can be used to diagnose intelligent faults on the Case Western Reserve University (CWRU) bearing dataset. The suggested hybrid model covers both the short- and long-term temporal characteristics of bearing vibration signals. Experimental outcomes show high-quality performance with an accuracy of 99.7, a precision of 99.4, a recall of 99 and an F1-score of 99.8, which is considerably better than the traditional machine learning models as well as standalone deep learning models. Such findings confirm how effective and appropriate the proposed solution is in terms of high-precision predictive maintenance and intelligent diagnosis of faults in industries.

References

[1] R. Patel and P. Patel, “A Survey on AI-Driven Autonomous Robots for Smart Manufacturing and Industrial Automation,” Tech. Int. J. Eng. Res., vol. 9, no. 2, pp. 46–55, 2022, doi: 10.56975/tijer.v9i2.158819.

[2] R. Patel, “Optimizing Communication Protocols in Industrial IoT Edge Networks: A Review of State-of-the-Art Techniques,” Int. J. Adv. Res. Sci. Commun. Technol., vol. 4, no. 19, pp. 503–514, May 2023, doi: 10.48175/IJARSCT-11979B.

[3] M. Drakaki, Y. L. Karnavas, I. A. Tziafettas, V. Linardos, and P. Tzionas, “Machine learning and deep learning-based methods toward industry 4.0 predictive maintenance in induction motors: State of the art survey,” J. Ind. Eng. Manag., vol. 15, no. 1, Feb. 2022, doi: 10.3926/jiem.3597.

[4] R. Patel and P. Patel, “A Review on Mechanical System Reliability & Maintenance strategies for Maximizing Equipment Lifespan,” ESP J. Eng. Technol. Adv., vol. 2, no. 1, pp. 173–179, 2025, doi: 10.56472/25832646/JETA-V2I1P120.

[5] H. Wang, W. Zhang, D. Yang, and Y. Xiang, “Deep-Learning-Enabled Predictive Maintenance in Industrial Internet of Things: Methods, Applications, and Challenges,” IEEE Syst. J., vol. 17, no. 2, pp. 2602–2615, Jun. 2023, doi: 10.1109/JSYST.2022.3193200.

[6] R. Patel, “Remote Troubleshooting Techniques for Hardware and Control Software Systems: Challenges and Solutions,” Int. J. Res. Anal. Rev., vol. 11, no. 2, pp. 1–7, 2024, doi: 10.56975/ijrar.v11i2.311510.

[7] R. Patel and P. Patel, “Machine Learning-Driven Predictive Maintenance for Early Fault Prediction and Detection in Smart Manufacturing Systems,” ESP J. Eng. Technol. Adv., vol. 4, no. 1, pp. 141–149, 2024, doi: 10.56472/25832646/JETA-V4I1P120.

[8] V. Prajapati, “Improving Fault Detection Accuracy in Semiconductor Manufacturing with Machine Learning Approaches,” J. Glob. Res. Electron. Commun., vol. 1, no. 1, pp. 20–25, 2025.

[9] N. Prajapati, “The Role of Machine Learning in Big Data Analytics: Tools, Techniques, and Applications,” ESP J. Eng. Technol. Adv., vol. 5, no. 2, pp. 16–22, 2025, doi: 10.56472/25832646/JETA-V5I2P103.

[10] R. Patel and P. Patel, “Mission-critical Facilities: Engineering Approaches for High Availability and Disaster Resilience,” Asian J. Comput. Sci. Eng., vol. 8, no. 3, pp. 1–9, 2023, doi: 10.22377/ajcse.v10i2.212.

[11] V. Varma, “Data Analytics for Predictive Maintenance for Business Intelligence for Operational Efficiency,” Asian J. Comput. Sci. Eng., vol. 7, no. 4, pp. 1–9, 2022, doi: 10.22377/ajcse.v7i04.247.

[12] M. Raparthi, S. B. Dodda, and S. Maruthi, “Predictive Maintenance in Manufacturing: Deep Learning for Fault Detection in Mechanical Systems.,” Dandao Xuebao/Journal Ballist., vol. 35, no. 2, pp. 59–66, Dec. 2023, doi: 10.52783/dxjb.v35.116.

[13] S. Thangavel, “Deep Learning for Predictive Analytics in Environmental and Social Sciences,” in Edible Electronics for Smart Technology Solutions, IGI Global, 2024, pp. 415–444. doi: 10.4018/979-8-3693-5573-2.ch017.

[14] L. Zou, H. Ling, M. Lei, X. Fang, M. Cai, and H. Yu, “Domain-Independent Gear Pitting Fault Diagnosis Using Transformer Encoder and LinSoftmax,” Big Data Min. Anal., vol. 8, no. 5, pp. 1127–1147, Oct. 2025, doi: 10.26599/BDMA.2025.9020018.

[15] S. Zhao, Y. Sang, X. Han, and Z. Han, “Fault Diagnosis and Predictive Maintenance Technology of Hydraulic and Pneumatic Transmission System,” in 2025 International Conference on Digital Analysis and Processing, Intelligent Computation (DAPIC), IEEE, Feb. 2025, pp. 741–746. doi: 10.1109/DAPIC66097.2025.00142.

[16] K. Ma, J. Ding, A. Ji, F. Lin, W. Zhang, and X. Li, “An On-site Fault Remote Intelligent Diagnosis and Warning Method for Electricity Information Collection Terminal Based on Deep Learning,” in 2024 3rd Asian Conference on Frontiers of Power and Energy (ACFPE), IEEE, Oct. 2024, pp. 443–447. doi: 10.1109/ACFPE63443.2024.10801055.

[17] X. Bai, Z. Ma, W. Chen, S. Wang, and Y. Fu, “Fault diagnosis research of laser gyroscope based on optimized-kernel extreme learning machine,” Comput. Electr. Eng., vol. 111, Nov. 2023, doi: 10.1016/j.compeleceng.2023.108956.

[18] Z. Du, K. Chen, S. Chen, J. He, X. Zhu, and X. Jin, “Deep learning GAN-based data generation and fault diagnosis in the data center HVAC system,” Energy Build., vol. 289, Jun. 2023, doi: 10.1016/j.enbuild.2023.113072.

[19] Z. Soltani, K. K. Sørensen, J. Leth, and J. D. Bendtsen, “Fault detection and diagnosis in refrigeration systems using machine learning algorithms,” Int. J. Refrig., vol. 144, pp. 34–45, Dec. 2022, doi: 10.1016/j.ijrefrig.2022.08.008.

[20] N. B. Ghazali et al., “Twisted Pair Cable Fault Diagnosis via Random Forest Machine Learning,” Comput. Mater. Contin., vol. 71, no. 3, pp. 5427–5440, 2022, doi: 10.32604/cmc.2022.023211.

[21] G. Bhatti and R. R. Singh, “Intelligent Fault Diagnosis Mechanism for Industrial Robot Actuators using Digital Twin Technology,” in 2021 IEEE International Power and Renewable Energy Conference (IPRECON), IEEE, Sep. 2021, pp. 1–6. doi: 10.1109/IPRECON52453.2021.9641000.

[22] D. K. Yadav, A. Kaushik, and N. Yadav, “Predicting machine failures using machine learning and deep learning algorithms,” Sustain. Manuf. Serv. Econ., vol. 3, 2024, doi: 10.1016/j.smse.2024.100029.

[23] M. Diwakar, S. Sharma, R. Dhabliya, R. Sonar, S. T. Shirkande, and S. Bhattacharya, “AIdriven Strategy for Predicting Equipment Failure in Manufacturing,” in Proceedings of the 5th International Conference on Information Management & Machine Intelligence, New York, NY, USA: ACM, Nov. 2023, pp. 1–5. doi: 10.1145/3647444.3647932.

[24] S. Joshi and S. Gupta, “Optimizing Machine Performance and Reliability: A Predictive Maintenance Approach,” vol. 8, no. 5, pp. 611–614, 2023.

[25] A. Jain, “AI-Powered Predictive Maintenance Using Deep Learning for Industrial IoT Environments,” vol. 4, no. 6, pp. 5824–5837, 2021, doi: 10.15662/IJARCST.2021.0406009.

[26] E. Akcan, “Detection of Bearing Faults from Vibration Signals,” Balk. J. Electr. Comput. Eng., vol. 13, no. 3, pp. 295–306, Sep. 2025, doi: 10.17694/bajece.1757057.

[27] S. Bensaoucha, G. M. Gharib, M. Al Soudi, A. Teta, and S. Benzita, “Robust Bearing Fault Detection and Classification Using Deep Neural Networks: A Comprehensive Study on the CWRU Dataset,” Int. Inf. Eng. Technol. Assoc., vol. 58, no. 11, pp. 2435–2443, 2025.

Downloads

Published

2026-02-06

Issue

Section

Articles

How to Cite

1.
Dixit S. Deep Learning Approaches for Predictive Maintenance and Intelligent Fault Diagnosis. IJERET [Internet]. 2026 Feb. 6 [cited 2026 Feb. 10];7(1):109-17. Available from: https://ijeret.org/index.php/ijeret/article/view/430