A comparative study of ensemble methods and multi-output classifiers for predictive maintenance of hydraulic systems

The maintenance and upkeep of hydraulic systems play a pivotal role in various industrial applications, from manufacturing processes to heavy machinery operations. Traditional strategies often face significant limitations, particularly concerning intervention time and the costs associated with delays between fault occurrence and maintenance. Over the past decades, proactive strategies have emerged with promising potential, primarily due to their predictive capabilities. These proactive approaches aim to anticipate faults and maintenance needs, thereby mitigating costs and operational disruptions associated with reactive approaches. This study explores the applicability of single output, ensemble methods, and the integration of multi-output classifiers in hydraulic predictive maintenance problems with relatively limited data. First, data is analyzed using Pearson correlation coefficients, and then feature extraction is conducted using recursive feature extraction, aiming to optimize the performance of predictive models, particularly Random Forest and CatBoost. Results show that the stacking ensemble method, incorporating LightGBM, XGBoost, CatBoost, and Random Forest, yields the most notable improvement, achieving a final accuracy of 98.63%. The results obtained in this study show satisfying performances for single-output models, ensemble methods, and multi-output models in predicting the health of hydraulic systems. Moreover, combining single output, ensemble methods, and the integration of multi-output classifiers has created a relatively reliable and robust predictive maintenance system. • Applying single output, ensemble methods, and multi-output classifiers to hydraulic predictive maintenance. • Optimizing the performance of predictive models using Pearson correlation coefficients and Recursive Feature Extraction. • Achieving around 98% across the adopted performance metrics using the proposed stacking ensemble method.