FedIFL: A federated cross-domain diagnostic framework for motor-driven systems with inconsistent fault modes

Due to the scarcity of industrial data, individual equipment users, particularly start-ups, struggle to independently train a comprehensive fault diagnosis model; federated learning enables collaborative training while ensuring data privacy, making it an ideal solution. However, the diversity of working conditions leads to variations in fault modes, resulting in inconsistent label spaces across different clients. In federated diagnostic scenarios, label space inconsistency leads to local models focus on client-specific fault modes and causes local models from different clients to map different failure modes to similar feature representations, which weakens the aggregated global model's generalization. To tackle this issue, this article proposed a federated cross-domain diagnostic framework termed Federated Invariant Features Learning (FedIFL). In intra-client training, prototype contrastive learning mitigates intra-client domain shifts, subsequently, feature generating ensures local models can access distributions of other clients in a privacy-friendly manner. Besides, in cross-client training, a feature disentanglement mechanism is introduced to mitigate cross-client domain shifts, specifically, an instance-level federated instance consistency loss is designed to ensure the instance-level consistency of invariant features between different clients, furthermore, a federated instance personalization loss and an orthogonal loss are constructed to distinguish specific features that from the invariant features. Eventually, the aggregated model achieves promising generalization among global label spaces, enabling accurate fault diagnosis for target clients' Motor Driven Systems (MDSs) with inconsistent label spaces. Experiments on real-world MDSs validate the effectiveness and superiority of FedIFL in federated cross-domain diagnosis with inconsistent fault modes.