The wide adoption of smart machine maintenance in manufacturing is blocked by open challenges in the Industrial Internet of Things (IIoT) with regard to robustness, scalability and security. Solving these challenges is of uttermost importance to mission-critical industrial operations. Furthermore, effective application of predictive maintenance requires well-trained machine learning algorithms which on their turn require high volumes of reliable data. This paper addresses both challenges and presents the Smart Maintenance Living Lab, an open test and research platform that consists of a fleet of drivetrain systems for accelerated lifetime tests of rolling-element bearings, a scalable IoT middleware cloud platform for reliable data ingestion and persistence, and a dynamic dashboard application for fleet monitoring and visualization. Each individual component within the presented system is discussed and validated, demonstrating the feasibility of IIoT applications for smart machine maintenance. The resulting platform provides benchmark data for the improvement of machine learning algorithms, gives insights into the design, implementation and validation of a complete architecture for IIoT applications with specific requirements concerning robustness, scalability and security and therefore reduces the reticence in the industry to widely adopt these technologies.

Remaining useful life is of great value in the industry and is a key component of Prognostics and Health Management (PHM) in the context of the Predictive Maintenance (PdM) strategy. Accurate estimation of the remaining useful life (RUL) is helpful for optimizing maintenance schedules, obtaining insights into the component degradation, and avoiding unexpected breakdowns. This paper presents a methodology for creating health index models with monotonicity in a semi-supervised approach. The health indexes are then used for enhancing remaining useful life estimation models. The methodology is evaluated on two bearing datasets. Results demonstrate the advantage of using the monotonic health index for obtaining insights into the bearing degradation and for remaining useful life estimation.

Predictive maintenance attempts to prevent unscheduled downtime by scheduling maintenance before expected failures and/or breakdowns while maximally optimizing uptime. However, this is a non-trivial problem, which requires sufficient data analytics knowledge and labeled data, either to design supervised fault detection models or to evaluate the performance of unsupervised models. While today most companies collect data by adding sensors to their machinery, the majority of this data is unfortunately not labeled. Moreover, labeling requires expert knowledge and is very cumbersome. To solve this mismatch, we present an architecture that guides experts, only requiring them to label a very small subset of the data compared to today’s standard labeling campaigns that are used when designing predictive maintenance solutions. We use auto-encoders to highlight potential anomalies and clustering approaches to group these anomalies into (potential) failure types. The accompanied dashboard then presents the anomalies to domain experts for labeling. In this way, we enable domain experts to enrich routinely collected machine data with business intelligence via a user-friendly hybrid model, combining auto-encoder models with labeling steps and supervised models. Ultimately, the labeled failure data allows for creating better failure prediction models, which in turn enables more effective predictive maintenance. More specifically, our architecture gets rid of cumbersome labeling tasks, allowing companies to make maximum use of their data and expert knowledge to ultimately increase their profit. Using our methodology, we achieve a labeling gain of 90% at best compared to standard labeling tasks.

In roll-to-roll (R2R) web processing systems, traction rollers impose precise velocity profiles on the moving web. Ideally, the web follows this trajectory without deviation, but slip can occur during rapid acceleration or deceleration, leading to tension loss and degraded product quality. Although slip can be detected directly using high-resolution encoders that track the actual web speed, such sensors are expensive and require machine downtime for installation, making them impractical for large-scale industrial deployment. To overcome this limitation, we developed a virtual slip sensor that estimates slip using existing machine signals only. A temporary encoder was used to collect ground-truth data, enabling the training of predictive models that eliminate the need for a permanent physical sensor. The proposed system employs an ensemble modeling approach: a CatBoost model captures low-slip behavior where data is abundant, while a linear model extrapolates to high-slip, out-of-distribution conditions. Targeted feature engineering ensures generalization across varying ramp times and web speeds. Despite being trained primarily on data containing limited slip, the models successfully generalized to scenarios with severe slip, demonstrating robust predictive performance. The ensemble reduces the regular CatBoost model’s MSE at 60 m/min by approximately 54% in the speed-based evaluation and by approximately 68% in the quantile-based evaluation while maintaining comparable performance in the low-speed regimes. The resulting virtual sensor enables continuous real-time slip monitoring, providing operators with timely insights to prevent quality degradation and operate at higher acceleration profiles to increase throughput, even on machines that have not previously experienced extreme slip.