From Manned to Unmanned Helicopters: A Transformer-Driven Cross-Scale Transfer Learning Framework for Vibration-Based Anomaly Detection

Unmanned helicopters play a critical role in various fields including defense, disaster response, and infrastructure inspection. Military platforms such as the MQ-8C Fire Scout represent high-value assets exceeding $40 million per unit including development costs, particularly when compared to expendable multicopter drones costing approximately $500–2000 per unit. Unexpected failures of these high-value assets can lead to substantial economic losses and mission failures, making the implementation of Health and Usage Monitoring Systems (HUMS) essential. However, the scarcity of failure data in unmanned helicopters presents significant challenges for HUMS development, while the economic feasibility of investing resources comparable to manned helicopter programs remains questionable. This study presents a novel cross-scale transfer learning framework for vibration-based anomaly detection in unmanned helicopters. The framework successfully transfers knowledge from a source domain (Airbus large manned helicopter) using publicly available data to a target domain (Stanford small RC helicopter), achieving excellent anomaly detection performance without labeled target domain data. The approach consists of three key processes. First, we developed a multi-task learning transformer model achieving an F-β score of 0.963 (β = 0.3) using only Airbus vibration data. Second, we applied CORAL (Correlation Alignment) domain adaptation techniques to reduce the distribution discrepancy between source and target domains by 79.7%. Third, we developed a Control Effort Score (CES) based on control input data as a proxy labeling metric for 20 flight maneuvers in the target domain, achieving a Spearman correlation coefficient ρ of 0.903 between the CES and the Anomaly Index measured by the transfer-learned model. This represents a 95.5% improvement compared to the non-transfer learning baseline of 0.462.