Accurate energy consumption prediction in the injection molding process is crucial for optimizing energy efficiency in polymer processing. Traditional parameter optimization methods face challenges in achieving optimal energy prediction due to complex energy transmission. In this study, a data-driven approach based on the Rolling Learning Informer model is proposed to enhance the accuracy and adaptability of energy consumption forecasting. The Informer model addresses the limitations of long-sequence prediction with sparse attention mechanisms, self-attention distillation, and generative decoder techniques. Rolling learning prediction is incorporated to enable continuous updating of the model to reflect new data trends. Experimental results demonstrate that the RL-Informer model achieves a normalized root mean square error of 0.1301, a root mean square error of 0.0758, a mean absolute error of 0.0562, and a coefficient of determination of 0.9831 in energy consumption forecasting, outperforming other counterpart models like Gated Recurrent Unit, Temporal Convolutional Networks, Long Short-Term Memory, and two variants of the pure Informer models without Rolling Learning. It is of great potential for practical engineering applications.

Smart manufacturing systems aim to enhance the efficiency, adaptability, and reliability of industrial operations through advanced data-driven approaches. Achieving these objectives hinges on accurate fault detection and timely maintenance, especially in highly dynamic industrial environments. However, capturing nonlinear and temporal dependencies in dynamic nonlinear industrial processes poses significant challenges for traditional data-driven fault detection methods. To address these limitations, this study presents an Incremental Pyraformer–Deep Canonical Correlation Analysis (DCCA) framework that integrates the Pyramidal Attention Mechanism of the Pyraformer with the Broad Learning System for incremental learning in a DCCA basis. The Pyraformer model effectively captures multi-scale temporal features, while the BLS-based incremental learning mechanism adapts to evolving data without full retraining. The proposed framework enhances both spatial and temporal representation, enabling robust fault detection in high-dimensional and continuously changing industrial environments. Experimental validation on the Tennessee Eastman (TE) process, Continuous Stirred-Tank Reactor (CSTR) system, and injection molding process demonstrated superior detection performance. In the TE scenario, our framework achieved a 100% Fault Detection Rate with a 4.35% False Alarm Rate, surpassing DCCA variants. Similarly, in the CSTR case, the approach reached a perfect 100% Fault Detection Rate (FDR) and 3.48% False Alarm Rate (FAR), while in the injection molding process, it delivered a 97.02% FDR with 0% FAR. The findings underline the framework’s effectiveness in handling complex and dynamic data streams, thereby providing a powerful approach for real-time monitoring and proactive maintenance.