将预测与决策联合优化,提升维修决策的可靠性。
Toward Decision-Oriented Prognostics: An Integrated Estimate-Optimize Framework for Predictive Maintenance
- 提出集成估计-优化框架,同步优化预测与维修决策。
- 在涡扇发动机案例中,维修失误减少最多22%。
- 特别适合目标不匹配时的工业维修规划。
近期研究越来越多地将机器学习融入预测性维护(PdM),以降低数据丰富场景下的运营与维护成本。然而,模型误设带来的不确定性仍限制其工业广泛应用。本文提出一种新框架,让传感器驱动的寿命预测在有限决策空间内,基于经济权衡指导维护决策。研究两个核心问题:(1) 更高预测准确率是否必然带来更好决策?(2) 若否,如何减轻预测误差对下游决策的影响?首先证明,在传统估计-再优化(ETO)框架中,概率预测误差会导致不一致且次优的维护决策。为此,提出集成估计-优化(IEO)框架,联合调优预测模型并直接优化维护结果。在标准假设下建立了决策一致性的有限样本理论保证,设计了适用于小规模运行至失效数据集的随机扰动梯度下降算法。在涡扇发动机维护案例中,实证表明该框架相比ETO可将平均维修遗憾降低最高22%。本研究为数据驱动型预测性维护中的预测误差管理提供原则性方法,通过将预测训练与维护目标对齐,提升了模型误设下的鲁棒性与决策质量。当决策策略与决策者目标不一致时,改进尤为显著。这些发现支持在不确定操作环境中实现更可靠的维护规划。
原文摘要 · Abstract (English)
Recent research increasingly integrates machine learning (ML) into predictive maintenance (PdM) to reduce operational and maintenance costs in data-rich operational settings. However, uncertainty due to model misspecification continues to limit widespread industrial adoption. This paper proposes a PdM framework in which sensor-driven prognostics inform decision-making under economic trade-offs within a finite decision space. We investigate two key questions: (1) Does higher predictive accuracy necessarily lead to better maintenance decisions? (2) If not, how can the impact of prediction errors on downstream maintenance decisions be mitigated? We first demonstrate that in the traditional estimate-then-optimize (ETO) framework, errors in probabilistic prediction can result in inconsistent and suboptimal maintenance decisions. To address this, we propose an integrated estimate-optimize (IEO) framework that jointly tunes predictive models while directly optimizing for maintenance outcomes. We establish theoretical finite-sample guarantees on decision consistency under standard assumptions. Specifically, we develop a stochastic perturbation gradient descent algorithm suitable for small run-to-failure datasets. Empirical evaluations on a turbofan maintenance case study show that the IEO framework reduces average maintenance regret up to 22% compared to ETO. This study provides a principled approach to managing prediction errors in data-driven PdM. By aligning prognostic model training with maintenance objectives, the IEO framework improves robustness under model misspecification and improves decision quality. The improvement is particularly pronounced when the decision-making policy is misaligned with the decision-maker's target. These findings support more reliable maintenance planning in uncertain operational environments.
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