Closing the Simulation-to-Reality Gap for Fault Diagnosis in Unknown Environment: A Sim2Real Knowledge Transfer Approach With Contrastive Learning
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Bibliographic record
Abstract
Training a supervised model for fault diagnosis often requires labeled data samples, typically gathered from controlled environments because collecting such data in real-world scenarios is expensive and labor-intensive. As a result, these datasets often lack scalability and fail to capture the wide range of fault types encountered in practice. To address this limitation, synthetic data are frequently used to generate virtually unlimited labeled samples, providing a diverse array of fault patterns. However, despite its benefits, synthetic data introduces a challenge due to the distribution divergence between synthetic and real-world data, which can affect model generalization. Domain adaptation approaches has been used to mitigate the distribution divergence but it usually failed in such simulation-to-real-world cases as the large volume of labeled synthetic data dominates the feature extractor and make the knowledge hard to transfer to the unlabeled real-world data domain. To address this challenge, we propose the contrastive Sim2Real adaptation (CSRA) approach, which pretrains model on the labeled synthetic data and knowledge transfer to real-world unlabeled data in a self-supervised manner. By only using the pretrained model from the synthetic data, CSRA does not depend on the labeled synthetic data during the knowledge transfer; hence the feature extractor can focus on the real-world data. Then, CSRA employs contrastive learning techniques to align the feature distributions of synthetic and real-world data in a self-supervised way, thereby enhancing the robustness and accuracy of the fault diagnosis model. Our extensive experiments demonstrate that CSRA outperforms standard cross-domain models in handling large domain gaps. Specifically, CSRA improves model generalization in new environments, significantly narrowing the synthetic-to-real-world gap. The results indicate that our approach not only enhances the reliability of fault diagnosis systems but also provides a scalable solution for real-world applications, reducing the dependency on costly and labor-intensive data collection processes.
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Full frame distilled prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. Learned from the 10,348 direct Codex labels and 10,348 direct Gemma labels. Candidate is the union of thresholded teacher heads; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels or direct frontier model labels.
Codex and Gemma teacher scores by category
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.000 | 0.000 |
| Meta-epidemiology (narrow) | 0.000 | 0.000 |
| Meta-epidemiology (broad) | 0.000 | 0.000 |
| Bibliometrics | 0.000 | 0.001 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.000 | 0.000 |
| Open science | 0.000 | 0.000 |
| Research integrity | 0.000 | 0.001 |
| Insufficient payload (model declined to judge) | 0.000 | 0.000 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from it