Pierluigi Salvo Rossi

Mohammed Ayalew Belay, Adil Rasheed, Pierluigi Salvo Rossi

Anomaly detection is increasingly becoming crucial for maintaining the safety, reliability, and efficiency of industrial systems. Recently, with the advent of digital twins and data-driven decision-making, several statistical and machine-learning methods have been proposed. However, these methods face several challenges, such as dependence on only real sensor datasets, limited labeled data, high false alarm rates, and privacy concerns. To address these problems, we propose a suite of digital twin-integrated federated learning (DTFL) methods that enhance global model performance while preserving data privacy and communication efficiency. Specifically, we present five novel approaches: Digital Twin-Based Meta-Learning (DTML), Federated Parameter Fusion (FPF), Layer-wise Parameter Exchange (LPE), Cyclic Weight Adaptation (CWA), and Digital Twin Knowledge Distillation (DTKD). Each method introduces a unique mechanism to combine synthetic and real-world knowledge, balancing generalization with communication overhead. We conduct an extensive experiment using a publicly available cyber-physical anomaly detection dataset. For a target accuracy of 80%, CWA reaches the target in 33 rounds, FPF in 41 rounds, LPE in 48 rounds, and DTML in 87 rounds, whereas the standard FedAvg baseline and DTKD do not reach the target within 100 rounds. These results highlight substantial communication-efficiency gains (up to 62% fewer rounds than DTML and 31% fewer than LPE) and demonstrate that integrating DT knowledge into FL accelerates convergence to operationally meaningful accuracy thresholds for IIoT anomaly detection.

Amanda Nyholm, Yessica Arellano, Jinyu Liu et al.

Reliable flow measurements are essential in many industries, but current instruments often fail to accurately estimate multiphase flows, which are frequently encountered in real-world operations. Combining machine learning (ML) algorithms with accurate single-phase flowmeters has therefore received extensive research attention in recent years. The Coriolis mass flowmeter is a widely used single-phase meter that provides direct mass flow measurements, which ML models can be trained to correct, thereby reducing measurement errors in multiphase conditions. This paper demonstrates that preserving temporal information significantly improves model performance in such scenarios. We compare a multilayer perceptron, a windowed multilayer perceptron, and a convolutional neural network (CNN) on three-phase air-water-oil flow data from 342 experiments. Whereas prior work typically compresses each experiment into a single averaged sample, we instead compute short-time averages from within each experiment and train models that preserve temporal information at several downsampling intervals. The CNN performed best at 0.25 Hz with approximately 95 % of relative errors below 13 %, a normalized root mean squared error of 0.03, and a mean absolute percentage error of approximately 4.3 %, clearly outperforming the best single-averaged model and demonstrating that short-time averaging within individual experiments is preferable. Results are consistent across multiple data splits and random seeds, demonstrating robustness.

Mohammed Ayalew Belay, Lucas Ferreira Bernardino, Adil Rasheed et al.

Combined-cycle gas turbines (CCGTs) play a key role in modern power generation, offering both high efficiency and reduced environmental impact. However, their complex thermo-fluid and mechanical interactions complicate fault detection, particularly when labeled fault data are scarce. In this paper, we introduce the Kalman Prototypical Network (KPN), a metric-based few-shot learning (FSL) framework specifically tailored for CCGT fault diagnosis. We model the evolution of class prototypes as latent stochastic states in a dynamic system to reduce episodic variance and improve robustness in embedding representation. Synthetic data sets generated with a high-fidelity Modelica-based dynamic simulation of an offshore CCGT system were used, simulating both normal operation and progressive leak faults under transient conditions. Application of the proposed framework on simulated leak fault detection tasks demonstrate that KPN outperforms conventional FSL methods such as Matching Networks, Relation Networks, and MAML in both accuracy and stability under varying support and query configurations. The proposed framework significantly improves training convergence and generalization by stabilizing class representations, making it well-suited for real-world CCGT fault detection where labeled data is limited.

Xiaoyu Zhu, Hefeng Dong, Pierluigi Salvo Rossi et al.

In this paper, we propose an interpretable feature selection method based on principal component analysis (PCA) and principal component regression (PCR), which can extract important features for underwater source localization by only introducing the source location without other prior information. This feature selection method is combined with a two-step framework for underwater source localization based on the semi-supervised learning scheme. In the framework, the first step utilizes a convolutional autoencoder to extract the latent features from the whole available dataset. The second step performs source localization via an encoder multi-layer perceptron (MLP) trained on a limited labeled portion of the dataset. The proposed approach has been validated on the public dataset SwllEx-96 Event S5. The result shows the framework has appealing accuracy and robustness on the unseen data, especially when the number of data used to train gradually decreases. After feature selection, not only the training stage has a 95\% acceleration but the performance of the framework becomes more robust on the depth and more accurate when the number of labeled data used to train is extremely limited.