Condition Monitoring and Predictive Maintenance in Industrial Equipment: An NLP-Assisted Review of Signal Processing, Hybrid Models, and Implementation Challenges

Abstract

Failures in critical industrial components (bearings, compressors, and conveyor belts) often lead to unplanned downtime, high costs, and safety concerns. Traditional diagnostic approaches underperform in noisy or changing environments due to heavy reliance on manual feature engineering and rule-based systems. In response, advanced machine learning, deep learning, and sophisticated signal processing techniques have emerged as transformative solutions for fault detection and predictive maintenance. To address the complexity of these advancements and their practical implications, this review combines analyses from large language models with expert validation to categorize key methodologies—spanning classical machine learning models, deep neural networks, and hybrid physics–data approaches. It also explores essential signal processing tools (e.g., Fast Fourier Transform (FFT), wavelets, and Complete Ensemble Empirical Mode Decomposition with Adaptive Noise (CEEMDAN)) and methods for estimating Remaining Useful Life (RUL) while highlighting major challenges such as the scarcity of labeled data, the need for model explainability, and adaptation to evolving operational conditions. By synthesizing these insights, this article offers a path forward for the adoption of new technologies (deep learning, IoT/Industry 4.0, etc.) in complex industrial contexts, anticipating the collaborative and sustainable paradigms of Industry 5.0, where human–machine collaboration and sustainability play central roles.

Keywords

• predictive maintenance
• fault diagnosis
• machine learning
• deep learning
• signal processing
• Industry 5.0