Mengjie Zhao

Mengjie Zhao, Cees Taal, Stephan Baggerohr et al.

Real-time condition monitoring is crucial for the reliable and efficient operation of complex systems. However, relying solely on physical sensors can be limited due to their cost, placement constraints, or inability to directly measure certain critical parameters. Virtual sensing addresses these limitations by leveraging readily available sensor data and system knowledge to estimate inaccessible parameters or infer system states. The increasing complexity of industrial systems necessitates deployments of sensors with diverse modalities to provide a comprehensive understanding of system states. These sensors capture data at varying frequencies to monitor both rapid and slowly varying system dynamics, as well as local and global state evolutions of the systems. This leads to heterogeneous temporal dynamics, which, particularly under varying operational end environmental conditions, pose a significant challenge for accurate virtual sensing. To address this, we propose a Heterogeneous Temporal Graph Neural Network (HTGNN) framework. HTGNN explicitly models signals from diverse sensors and integrates operating conditions into the model architecture. We evaluate HTGNN using two newly released datasets: a bearing dataset with diverse load conditions for bearing load prediction and a year-long simulated dataset for predicting bridge live loads. Our results demonstrate that HTGNN significantly outperforms established baseline methods in both tasks, particularly under highly varying operating conditions. These results highlight HTGNN's potential as a robust and accurate virtual sensing approach for complex systems, paving the way for improved monitoring, predictive maintenance, and enhanced system performance. Our code and data are available under https://github.com/EPFL-IMOS/htgnn.

Mengjie Zhao, Olga Fink

In the Industrial Internet of Things (IIoT), condition monitoring sensor signals from complex systems often exhibit nonlinear and stochastic spatial-temporal dynamics under varying conditions. These complex dynamics make fault detection particularly challenging. While previous methods effectively model these dynamics, they often neglect the evolution of relationships between sensor signals. Undetected shifts in these relationships can lead to significant system failures. Furthermore, these methods frequently misidentify novel operating conditions as faults. Addressing these limitations, we propose DyEdgeGAT (Dynamic Edge via Graph Attention), a novel approach for early-stage fault detection in IIoT systems. DyEdgeGAT's primary innovation lies in a novel graph inference scheme for multivariate time series that tracks the evolution of relationships between time series, enabled by dynamic edge construction. Another key innovation of DyEdgeGAT is its ability to incorporate operating condition contexts into node dynamics modeling, enhancing its accuracy and robustness. We rigorously evaluated DyEdgeGAT using both a synthetic dataset, simulating varying levels of fault severity, and a real-world industrial-scale multiphase flow facility benchmark with diverse fault types under varying operating conditions and detection complexities. The results show that DyEdgeGAT significantly outperforms other baseline methods in fault detection, particularly in the early stages with low severity, and exhibits robust performance under novel operating conditions.

Keivan Faghih Niresi, Mengjie Zhao, Hugo Bissig et al.

The use of Internet of Things (IoT) sensors for air pollution monitoring has significantly increased, resulting in the deployment of low-cost sensors. Despite this advancement, accurately calibrating these sensors in uncontrolled environmental conditions remains a challenge. To address this, we propose a novel approach that leverages graph neural networks, specifically the graph attention network module, to enhance the calibration process by fusing data from sensor arrays. Through our experiments, we demonstrate the effectiveness of our approach in significantly improving the calibration accuracy of sensors in IoT air pollution monitoring platforms.

Mengjie Zhao, Cees Taal, Stephan Baggerohr et al.

Accurate bearing load monitoring is essential for their Prognostics and Health Management (PHM), enabling damage assessment, wear prediction, and proactive maintenance. While bearing sensors are typically placed on the bearing housing, direct load monitoring requires sensors inside the bearing itself. Recently introduced sensor rollers enable direct bearing load monitoring but are constrained by their battery life. Data-driven virtual sensors can learn from sensor roller data collected during a batterys lifetime to map operating conditions to bearing loads. Although spatially distributed bearing sensors offer insights into load distribution (e.g., correlating temperature with load), traditional machine learning algorithms struggle to fully exploit these spatial-temporal dependencies. To address this gap, we introduce a graph-based virtual sensor that leverages Graph Neural Networks (GNNs) to analyze spatial-temporal dependencies among sensor signals, mapping existing measurements (temperature, vibration) to bearing loads. Since temperature and vibration signals exhibit vastly different dynamics, we propose Heterogeneous Temporal Graph Neural Networks (HTGNN), which explicitly models these signal types and their interactions for effective load prediction. Our results demonstrate that HTGNN outperforms Convolutional Neural Networks (CNNs), which struggle to capture both spatial and heterogeneous signal characteristics. These findings highlight the importance of capturing the complex spatial interactions between temperature, vibration, and load.

Olga Fink, Ismail Nejjar, Vinay Sharma et al.

Prognostics and Health Management ensures the reliability, safety, and efficiency of complex engineered systems by enabling fault detection, anticipating equipment failures, and optimizing maintenance activities throughout an asset lifecycle. However, real-world PHM presents persistent challenges: sensor data is often noisy or incomplete, available labels are limited, and degradation behaviors and system interdependencies can be highly complex and nonlinear. Physics-informed machine learning has emerged as a promising approach to address these limitations by embedding physical knowledge into data-driven models. This review examines how incorporating learning and observational biases through physics-informed modeling and data strategies can guide models toward physically consistent and reliable predictions. Learning biases embed physical constraints into model training through physics-informed loss functions and governing equations, or by incorporating properties like monotonicity. Observational biases influence data selection and synthesis to ensure models capture realistic system behavior through virtual sensing for estimating unmeasured states, physics-based simulation for data augmentation, and multi-sensor fusion strategies. The review then examines how these approaches enable the transition from passive prediction to active decision-making through reinforcement learning, which allows agents to learn maintenance policies that respect physical constraints while optimizing operational objectives. This closes the loop between model-based predictions, simulation, and actual system operation, empowering adaptive decision-making. Finally, the review addresses the critical challenge of scaling PHM solutions from individual assets to fleet-wide deployment. Fast adaptation methods including meta-learning and few-shot learning are reviewed alongside domain generalization techniques ...