PNN: A Novel Progressive Neural Network for Fault Classification in Rotating Machinery under Small Dataset Constraint

Fault detection in rotating machinery is a complex task, particularly in small and heterogeneous dataset scenarios. Variability in sensor placement, machinery configurations, and structural differences further increase the complexity of the problem. Conventional deep learning approaches often demand large, homogeneous datasets, limiting their applicability in data-scarce industrial environments. While transfer learning and few-shot learning have shown potential, however, they are often constrained by the need for extensive fault datasets. This research introduces a unified framework leveraging a novel progressive neural network (PNN) architecture designed to address these challenges. The PNN sequentially estimates the fixed-size refined features of the higher order with the help of all previously estimated features and appends them to the feature set. This fixed-size feature output at each layer controls the complexity of the PNN and makes it suitable for effective learning from small datasets. The framework's effectiveness is validated on eight datasets, including six open-source datasets, one in-house fault simulator, and one real-world industrial dataset. The PNN achieves state-of-the-art performance in fault detection across varying dataset sizes and machinery types, highlighting superior generalization and classification capabilities.