A Novel Integrated Fault Diagnosis Method Based on Digital Twins

Fault diagnosis is essential in industrial production. With the advancement of IoT technology, real-time data acquisition and storage have become feasible, enabling deep learning-based fault diagnosis methods to achieve remarkable results. However, existing approaches often overlook the temporal characteristics of fault occurrences and struggle with data imbalance between normal and faulty conditions, impacting diagnostic performance. To address these challenges, this paper proposes an integrated fault diagnosis method that incorporates data balancing, feature extraction, and temporal information analysis. The approach consists of two key components: (1) dataset construction using digital twin technology and (2) an integrated fault diagnosis model (CNN-BLSTM-attention). Digital twin technology generates virtual data under various operating conditions, mitigating the small-sample issue. The proposed model leverages a sliding window mechanism to capture both feature and temporal information, enhancing fault pattern recognition. Experimental results demonstrate that, compared to traditional methods, this approach effectively reduces noise interference and achieves a high diagnostic accuracy of 96.46%, validating its robustness in complex industrial settings. This research provides valuable theoretical and practical insights for improving fault diagnosis in industrial equipment such as screw presses.