PHASE 2

AI Integration for Improving Sensor Data Quality in Predictive Maintenance

PHASE 2 – Solution Architecture

College Name: Maratha Mandal Engineering College

Group Members:

 Name: G S RAHUL GORPADE

CAN ID Number: 33991012

 Name: AMIT TEGGI

CAN ID: 33992410

 Name: ANIKET JABADE

CAN ID: 33831554

 Name: VIKAS TEGGI

CAN ID: 34002637

1.ABSTRACT
The project titled "AI Integration for Improving Sensor Data Quality in Predictive
Maintenance" addresses the challenges in leveraging sensor data for predictive maintenance by
deploying a robust AI-based solution architecture. The architecture is designed to preprocess raw
sensor data, engineer meaningful features, train machine learning models, and provide actionable
predictions.

Key components of the solution architecture include:

1. Data Ingestion and Preprocessing: Handling missing values, detecting and
removing outliers, and reducing noise using techniques like Savitsky-Golay
filters.
2. Feature Engineering Module: Dynamically calculating rolling statistics such as
mean and standard deviation to capture trends and enhance model input relevance.
3. Model Training and Deployment: Implementing a Random Forest algorithm to predict
potential failures, followed by rigorous performance evaluation through classification
metrics.
4. Prediction and Decision Support: Developing a prediction mechanism that
preprocesses new sensor data in real-time and integrates historical data for accurate
trend analysis and predictions.
5. Visualization and Insights: Generating intuitive visualizations to depict sensor
behavior, smoothed data trends, and prediction outcomes for stakeholders'
understanding and quick decision-making.
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2. Data Visualizations for Analyzing Patterns and Detecting Anomalies
Data visualization serves as a powerful tool for gaining insights into the underlying patterns in
sensor data. It is especially useful for detecting trends, anomalies, and assessing model outputs.
Below are key visualizations for analyzing sensor data:

2.1 Raw Sensor Data Visualization

Purpose:
A simple line plot of raw sensor data over time allows for a quick visual inspection of data
trends and potential anomalies.

Justification:
Raw sensor data often contains noise, outliers, or missing values. Visualizing the raw data
helps detect these issues and provides an initial understanding of the data's behavior.

plt.plot(timestamps, sensor_data)
plt.title("Raw Sensor Data")
plt.xlabel("Timestamp")
plt.ylabel("Sensor Value")
plt.show()

2.2 Smoothed Sensor Data Visualization

Purpose:
After noise reduction, it is crucial to compare the raw data to the smoothed version to
understand the impact of noise filtering.

Justification:
Noise in sensor data can obscure meaningful patterns. Smoothing techniques, such as
Savitzky-Golay filters, help highlight trends and remove random fluctuations.

plt.plot(timestamps, raw_data, label="Raw Data")

plt.plot(timestamps, smoothed_data, label="Smoothed Data", linestyle="--")
plt.legend()
plt.show()

2.3 Anomaly Detection Visualization

Purpose:
Highlighting predicted anomalies or failures within sensor data helps in assessing how
well the model performs in detecting critical events.

Justification:
It is essential to validate the model’s ability to detect anomalies, such as sensor failures
or other abnormal behaviors, by comparing predicted points to actual sensor data.

plt.plot(timestamps, sensor_data)
plt.scatter(anomaly_times, anomaly_values, color='red', label="Detected Anomalies")
plt.legend()
plt.show()

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2.4 Correlation Matrix Visualization

Purpose:
A correlation heatmap visualizes relationships between different features (e.g., readings
from different sensors), helping to identify dependencies that may influence the
prediction model.

Justification:
Understanding correlations between features is crucial for feature selection. Strongly
correlated features might be redundant, while weakly correlated features could provide
unique insights.

sns.heatmap(data.corr(), annot=True, cmap="coolwarm")

plt.show()

2.5 Time Series Analysis for Sensor Health

Purpose:
A line plot can be used to visualize the overall health of sensors over time, showing trends
in sensor data that indicate failure or performance degradation.

Justification:
Monitoring the cumulative trends of metrics such as failure rates or sensor reliability is
essential for detecting long-term trends that might not be apparent in short-term data.

plt.plot(timestamps, sensor_health_metric, color='green')

plt.title("Sensor Health Over Time") plt.xlabel("Timestamp")
plt.ylabel("Sensor Health Metric")
plt.show()

2.6 Interactive Visualizations

Purpose:
Interactive plots, such as those made with Plotly, allow users to explore the data by zooming,
filtering, and examining individual data points.

Justification:
Interactivity enhances the user's ability to investigate specific anomalies or trends in the
dataset, providing a more hands-on approach to data exploration.

import plotly.express as px
fig = px.line(x=timestamps, y=sensor_data, labels={'x': 'Time', 'y': 'Sensor Value'},
title="Interactive Sensor Data Plot")
fig.show()

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3. Data Preparation Techniques
Data preparation is critical to building robust AI models. It ensures that the data used for training
and testing is clean, relevant, and structured. The following preparation techniques are
recommended:

3.1 Handling Missing Data

Description:
Missing values in sensor data can arise due to device malfunctions or data collection issues.
These gaps must be filled before proceeding with analysis.

Approach:
Use imputation techniques (e.g., mean or median imputation) to replace missing
values. In cases of large gaps, interpolation or time-series-based methods can be
employed.

sensor_data.fillna(sensor_data.median(), inplace=True)

3.2 Outlier Detection and Removal

Description:
Outliers can distort data analysis and model performance. Identifying and removing them is
vital for ensuring accurate predictions.

Approach:
Statistical techniques, such as the Z-score method or Interquartile Range (IQR), can be
used to detect and remove extreme values that lie outside the expected rang

from scipy import stats

z_scores = stats.zscore(sensor_data)
clean_data = sensor_data[(z_scores > -3) & (z_scores < 3)]

3.3 Noise Reduction

Description:
Noise in sensor data can be caused by environmental factors or sensor limitations. Applying
noise reduction techniques improves the clarity of the data.

Approach:
Smoothing techniques like Savitzky-Golay filters, moving averages, or Gaussian smoothing
can be applied to reduce high-frequency noise.

from scipy.signal import savgol_filter

smoothed_data = savgol_filter(raw_data, window_length=11, polyorder=2)

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3.4 Feature Engineering

Description:
Feature engineering involves creating new features or transforming existing ones to
improve model performance.

Approach:
Compute rolling statistics (e.g., mean, standard deviation) or lag features that capture temporal
trends. These features provide additional context for the model, helping it recognize long-term
patterns.

rolling_mean = sensor_data.rolling(window=5).mean()
rolling_std = sensor_data.rolling(window=5).std()

4. AI Models for Anomaly Detection

Selecting the right model is crucial for detecting anomalies and predicting sensor failures. Below
are some suitable AI models for this task:

a. Isolation Forest

Description:
Isolation Forest is an unsupervised learning algorithm designed for anomaly detection. It
works by isolating observations through recursive partitioning, making it well- suited for
detecting rare events or outliers.

Justification:
Isolation Forest is highly efficient for high-dimensional datasets and does not require
labeled data, making it ideal for sensor data anomaly detection.

from sklearn.ensemble import IsolationForest

model = IsolationForest(contamination=0.05)
anomalies = model.fit_predict(sensor_data)

b. Random Forest

Description:
Random Forest is an ensemble method that combines multiple decision trees to improve
prediction accuracy. It works well for classification tasks, such as predicting sensor failures
based on historical data.

Justification:
Random Forest can handle both numerical and categorical data and is effective in
capturing complex relationships within the data. It also provides feature importance
scores, which can help in understanding the most influential features.

from sklearn.ensemble import RandomForestClassifier model

= RandomForestClassifier(n_estimators=100)
model.fit(train_data, train_labels)
predictions = model.predict(test_data)

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c. Natural Language Processing (NLP) Techniques

Description:
If sensor data includes unstructured logs or maintenance records, NLP techniques like keyword
extraction or sentiment analysis can be used to detect recurring issues.

Justification:
NLP can process sensor logs or reports that might provide early warnings about sensor
behavior, especially in scenarios where sensor data is complemented by text- based
maintenance logs.

from sklearn.feature_extraction.text import CountVectorizer vectorizer =

CountVectorizer()
X = vectorizer.fit_transform(sensor_logs)

5. Conclusion
The combination of effective visualizations, data preparation techniques, and AI models allows for a
comprehensive approach to sensor data analysis. Visualization helps uncover patterns, identify
anomalies, and assess model performance, while data preparation ensures that the data is clean and
suitable for training. AI models like Isolation Forest and Random Forest offer strong tools for
detecting anomalies and predicting failures. By utilizing these techniques, predictive maintenance
systems can be enhanced, reducing downtime and improving operational efficiency

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