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This paper provides a framework based on machine learning approach in I4.0 environment to predict the remaining useful life of an aviation engine. For illustration purpose, an industrial case study is presented which applies machine learning algorithms to analyze the data collected using the Commercial Modular Aero-Propulsion System Simulation (C-MAPSS) simulation which includes run-to-degradation data for a turbofan engine. The results obtained from the study validate the proposed framework to identify prominent features and perform sequential analysis on unstructured data for predicting the remaining useful life of an aviation engine. Six machine learning models are applied to the dataset containing four subsets: FD001, FD002, FD003 and FD004 in C-MAPSS dataset each working on different degradation conditions for turbofan engine. For FD001, random forest had the lowest RMSE (11.59), and for FD002, FD003 and FD004, the lowest RMSE was given by LGBM classifier (12.78, 7.95 and 11.04), respectively. From the findings, it is observed that LGBM performs better with higher AUC 89% and lowest RMSE. The proposed framework can be applied to a wide range of failure prediction applications. Regardless of the underlying physics, ML-based data-driven methodologies can be used to analyze a wide range of systems. [ABSTRACT FROM AUTHOR]

Industry 4.0 brings about a convergence between traditional industrial practices and modern computational techniques. The manufacturing sector is expected to make a greater number of decisions and actions based on the advanced computational analysis of the measurable machinery data. Predictive maintenance of the CNC lathe spindle unit helps the machine avoid unexpected downtimes and meet closer machining tolerances. In this paper, the vibration signals acquired from an experimental run-to-failure test rig are first processed to extract health degradation features, which are then subjected to a neighborhood component analysis-based regression feature selection criteria. Finally, the selected spindle health degradation features are used to train a support-vector machine (SVM) algorithm to evolve a remaining useful life (RUL) estimation model. The SVM hyperparameters that strongly affect the prediction performance are tuned using the Bayesian optimization approach. The evolved predictive model is tested using an independent lathe spindle health degradation data set to obtain the root-mean-square error for predicted and actual RUL. The overall predicted RUL is having an acceptable agreement with the actual RUL. An RMSE equal to 206.23 is obtained as a quantitative measure of prediction accuracy for the Bayesian optimized SVM model for the given dataset. In industrial practice, the evolved SVM predictive model can be employed for the real-time RUL estimation of a similar mechanical system. The proposed predictive model with the integrated feature extraction, selection, and prognosis algorithm can be employed on a real-time spindle health monitoring and predictive maintenance platform for maintenance decision-making. [ABSTRACT FROM AUTHOR]