EAAI Journal 2026 Journal Article
Digital twin driven fault diagnosis method for early faults of hydraulic system
- Chao Yang
- Baoping Cai
- Zhigang Tian
- Qingping Li
- Yinhang Zhang
- Yi Jiang
- Haidong Shao
Identifying early faults can ensure the safety of hydraulic systems. This is needed for industrial production. Obtaining sensor data and conducting a single diagnosis is the main fault diagnosis method. This method is prone to overlooking early faults. To address that, a digital twin (DT)-driven fault diagnosis method is proposed for detection of early faults in hydraulic systems. A fault diagnosis model capable of identifying faults at varying degrees of severity is established. An iterative updating mechanism is employed to construct a DT model of the hydraulic system. A feedback-based verification process is integrated into the DT framework. It is used to correct incorrect diagnoses. Misclassified faults are fed back into the system for re-diagnosis, and a fault degree matching mechanism is implemented to confirm fault severity. The method is validated using a laboratory hydraulic system. Experimental results demonstrate that the method improves the accuracy of early fault detection.