Hydraulic Seal Wear Classification by Fine-Tuning a Transformer-Based Audio Model Using Acoustic Emission

Accurate classification of seal wear is essential for condition-based and predictive maintenance of hydraulic cylinders, where seal degradation can cause fluid leakage and impair normal system operation. This study investigates the adaptation of a Transformer-based audio model for classifying seal wear conditions using acoustic emission (AE) signals. Specifically, we adapt the Audio Spectrogram Transformer (AST), a convolution-free, purely attention-based model that operates directly on audio spectrograms. The Transformer architecture enables the modeling of long-range dependencies, while the model learns discriminative representations directly from AE data without relying on manually engineered features. A selective fine-tuning strategy was implemented by adding layer-freezing functionality to the AST training pipeline, enabling different freezing configurations during fine-tuning. This allowed earlier pretrained representations to be preserved while adapting the later layers to the target AE signals, thereby reducing the risk of overfitting in the small-data setting. In addition, validation-driven early stopping was implemented to further improve generalization during fine-tuning. The model was initialized with ImageNet and AudioSet pretrained weights to exploit general-purpose representations learned from large-scale datasets. The AE data were acquired under varying pressure conditions on a hydraulic test rig designed to simulate hydraulic cylinder leakage. The datasets were partitioned into fine-tuning, validation, and evaluation subsets and labeled into three wear states: unworn, semi-worn, and worn. In addition, data augmentation techniques were applied to the fine-tuning data to increase diversity and mitigate class imbalance. The adapted model achieved 97.92% classification accuracy across all wear conditions and pressure settings, demonstrating its ability to learn discriminative wear-related patterns directly from AE data. Furthermore, the framework’s versatility was further assessed on a bearing strip dataset acquired from the same hydraulic test rig. Using the same fine-tuning configuration, the model achieved 95.65% accuracy and 100% recall for the worn state. These findings highlight the potential of transformer-based architectures for data-efficient, end-to-end AE-based diagnostics across hydraulic system components.