Predictive Maintenance: Deep Learning-Based Remaining Useful Life Prediction for Combat Aircraft Engines

To improve the operational readiness of combat aircraft engines and reduce unplanned maintenance costs, accurately estimating the remaining useful life (RUL) is critical. Traditional maintenance often proves insufficient under dynamic mission profiles. In this study, a deep learning-based predictive maintenance model capable of autonomously extracting features from multivariate sensor data was developed. Using the NASA C-MAPSS FD001 and FD004 datasets, data were converted into sequential blocks via 50- and 30-step sliding windows, respectively. The model's architectural superiority in autonomously extracting temporal degradation features was validated against RF, CNN-LSTM, and BiLSTM baselines. On FD001, it achieved an R-squared (R2) of 0.8901, a 13.28 RMSE, and a 320.34 NASA risk score, demonstrating generalizability on the multi-regime FD004 dataset with a 15.71 RMSE. The proposed maintenance protocol achieved a 0.9973 AUC at the critical 30-cycle threshold, ensuring high reliability. Additionally, a decision-support simulator has been developed to validate this protocol under aggressive combat flight profiles.

Generalization bounds and sample complexity for remaining useful life prediction from complete degradation trajectories

Data-driven remaining useful life (RUL) prediction requires complete degradation trajectories for training, yet such run-to-failure data are scarce and expensive. Practitioners currently lack principled guidance on how many failure examples suffice for a given model and accuracy target. This paper develops a sample complexity framework for RUL prediction comprising seven main results organised around three themes. First, we establish fundamental learning rates: a distribution-free generalization bound shows that the uniform deviation of the mean squared error decreases as $O(B^{2}\sqrt{p/n})$, where $p$ is the model complexity and $n$ the number of trajectories, and a minimax lower bound proves that the $Θ(p/n)$ rate is unimprovable.} \rev{Second, we quantify how domain knowledge accelerates learning: incorporating degradation physics reduces data requirements by up to two orders of magnitude for deep networks, a Bernstein-type analysis achieves the minimax-optimal $O(p/n)$ rate under high signal-to-noise conditions, and closed-form penalties reveal when an incorrectly assumed physics model hurts rather than helps. Third, we characterise the impact of data quality: fleet variability induces an irreducible bias$-$variance tradeoff, while right-censored observations suffer an efficiency loss that depends critically on the degradation class.} Closed-form expressions are provided for exponential, power-law, and stretched-exponential degradation. \rev{Cross-domain validation against published turbofan, battery, and bearing benchmarks confirms the theoretical predictions within a factor of 2$-$3 on average. The results yield practical guidelines for planning data collection, selecting model complexity, and evaluating physics model assumptions in prognostics applications.

General Value Functions for Remaining Useful Life and Failure-Mode Prediction

Remaining useful life (RUL) prediction and failure-mode classification are central tasks in predictive maintenance. Many data-driven pipelines use fixed-window supervised learning with complete terminal labels; such routes do not naturally encode the temporal recursion linking successive degradation-state predictions when observations are partial or unit identities are unavailable. We formulate prognostics as vector General Value Function (GVF) prediction on an absorbing degradation process, treating RUL and failure-mode probabilities as temporally consistent targets rather than independent window-level labels, and estimate them with a multi-step temporal-difference estimator, TD($n,λ$). Supporting theory identifies the Bellman fixed point of the vector GVFs, characterizes the linear projected-TD limit and its relation to complete-return Monte Carlo regression under realizability, and explains when bootstrapped TD targets are less variable than Monte Carlo returns. On an event-triggered multimode simulation and NASA C-MAPSS label-scarce stitch data, TD improves RUL and failure-mode prediction relative to a supervised same-backbone Monte Carlo control, especially under scarce complete labels. Practically, fragmented, identity-free degradation records can contribute local Bellman transitions instead of being discarded until complete run-to-failure labels are available.

Physics-Guided Masked Multi-Task Network for Edge-Friendly Battery Health Diagnostics from Sto-chastically Fragmented Charging Profiles

The deployment of reliable lithium-ion battery management systems is crucial for accelerating electrification, yet the joint prognosis of State of Health (SOH) and Remaining Useful Life (RUL) remains severely hindered by task heteroscedasticity. Conventional multi-task learning frameworks fail to balance the bounded, low-variance noise of SOH estimation with the unbounded, nonlinearly expanding uncertainty of long-term RUL predictions. Here, we present the Rotary SOH-Injected Prior Battery Transformer (RoSIP-Batt), a unified co-estimation framework that resolves these optimization conflicts. By formulating joint prediction as a Bayesian multi-task objective, RoSIP-Batt introduces a homoscedastic uncertainty weighting mechanism to dynamically scale task-specific gradients based on learned residual noise levels. The architecture leverages decoupled dual classification tokens and a per-dimension gated fusion mechanism, secured by a gradient-detachment operator to prevent high-variance RUL updates from corrupting the stable SOH representation space. To capture electrochemical degradation patterns without relying on absolute cycle steps, Rotary Position Embedding (RoPE) is incorporated into a shared Transformer backbone to model translation-invariant relative temporal profiles. Crucially, the intermediate SOH estimate is directly injected into the RUL regression head as a physical degradation prior. Evaluations across the NASA, MIT-Stanford, and HUST datasets show that RoSIP-Batt significantly outperforms state-of-the-art baselines, reducing SOH estimation error to 1.994% MAE on NASA and restricting RUL prediction error to 62.85 cycles on Stanford. These findings establish RoSIP-Batt as a highly generalizable, computationally efficient solution suitable for real-time embedded BMS deployment.

Leakage-Robust Evaluation and Data-Scale Sensitivity of Attention-Enhanced Multi-Task Learning for Joint Fault Diagnosis and Remaining Useful Life Estimation

Multi-task deep learning models that jointly perform fault classification and remaining useful life (RUL) regression are increasingly used in predictive maintenance, yet reported performance can be strongly affected by how sliding-window sequences are split into training and test sets. We investigate this issue using AMTLNet, an attention-enhanced multi-task architecture, on three public benchmarks: NASA C-MAPSS, NASA IMS, and the UCI Hydraulic System dataset. We show that naive splitting can inflate classification accuracy from a genuine 20-60 percent to 99.9 percent, or reduce it to 0 percent through degenerate class representation. To address this, we introduce a chunk-based, leakage-audited splitting protocol and evaluate all models using five seeds, one-way ANOVA, and Tukey HSD tests. On C-MAPSS, with 19,976 leakage-free training windows, AMTLNet matches a single-task CNN-LSTM baseline in classification, achieving 84.12 +/- 0.96 percent accuracy with Tukey p = 1.0, and reaches an R2 of 0.86 +/- 0.01 while significantly outperforming a naive multi-task baseline. On the smaller Bearing and Hydraulic datasets, multi-task training is unstable, but the failure mode differs: classification degrades for Bearing, whereas regression degrades for Hydraulic. We relate this asymmetry to label provenance and propose a practical framework for deciding when joint training is appropriate under data scarcity. Ablation results show that the multi-head attention branch is the main contributor to regression stability. Removing it reduces R2 from 0.861 to 0.766 and more than doubles classification variance, whereas the convolutional branch contributes little to regression despite using about one-third of the parameters. This study contributes a reusable leakage-audit protocol, seed-transparent evaluation, and evidence that task-specific stability depends more on label provenance than on task type.

Time-Series Retrieval for Grounding Multimodal Language Models in Remaining Useful Life Prediction

Large language models (LLMs) and agentic AI systems are increasingly being explored for domain-specific maintenance and prognostics tasks, raising the question of whether they can effectively support prognostics and health management (PHM). In this paper, we investigate remaining useful life (RUL) estimation with multimodal large language models (MLLMs) grounded through time-series retrieval. We propose a framework in which historically similar degradation segments are retrieved from the training set and, together with the test trajectory, transformed into a visual comparison artifact that is processed by the MLLM through a structured multimodal prompt. The approach is evaluated on the FD001 partition of the C-MAPSS benchmark under repeated experiments comparing retrieval-based inference against a non-retrieval baseline based on random reference selection. The results show that time-series retrieval consistently improves MLLM-based RUL prediction across the evaluated models, yielding lower error and more stable performance. At the same time, the magnitude of the benefit depends on model capacity, indicating that retrieval is most effective when the underlying MLLM is able to exploit the retrieved evidence. Overall, the study shows that time-series RAG is a promising mechanism for improving multimodal prognostic reasoning, while also highlighting the current limitations of MLLM-based RUL estimation in practical PHM settings.

Quantum Annealing Enhanced Reinforcement Learning for Accurate Remaining Useful Lifetime Prediction

Remaining useful life (RUL) estimation is central to predictive maintenance, where an unplanned failure can cost far more than the asset itself. Statistical degradation models miss the strong nonlinearity of real systems, and data-driven models often converge to suboptimal solutions in high-dimensional, non-convex search spaces. We propose a Quantum Annealing enhanced Q-Learning (QAQL) framework that couples the sampling behaviour of quantum annealing with the sequential decision making of Q-learning. Each Q-value update is encoded as a small quadratic unconstrained binary optimization (QUBO) whose ground state is the greedy action; rather than acting as a deterministic optimizer, the annealer returns a distribution over near-optimal actions across many reads, and this stochastic action selection supplies the exploration that curbs premature convergence on nonlinear degradation trajectories. The QUBO is solved on the D-Wave Advantage system using minor embedding, with the annealer woven into the reinforcement-learning loop rather than bolted on after training. We validate QAQL on two public benchmarks: the NASA C-MAPSS turbofan engine datasets and a device-fleet predictive maintenance dataset. Averaged over many independent runs and across six error metrics, QAQL outperforms the classical and quantum baselines considered in this study, with statistically significant improvements. The results indicate that quantum annealing is a usable, not merely theoretical, optimizer inside a reinforcement-learning loop for industrial predictive-maintenance applications.