A feature extension and reconstruction method with incremental learning capabilities under limited samples for intelligent diagnosis

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Existing data-driven Intelligent Fault Diagnosis (IFD) methods often struggle with continuous learning and integrating new diagnostic knowledge. These methods necessitate a complete retraining process when new fault data emerges. Furthermore, collecting sufficient data for model training is impractical in real-world applications. This study proposes a Feature Extension and Reconstruction (FER) method for model incremental updating with limited samples. FER employs scalable and modular feature extractors for continuous representation learning of new fault modes. In addition, a domain mapping algorithm based on optimal transport is devised to leverage old classification nodes in aiding new nodes’ training, enhancing models’ generalization performance under limited samples. A feature reconstruction technique is also developed to compress the expanded multi-backbone model, eliminating redundant parameters and dimensions for adaptability in subsequent incremental tasks. Validated on simulated transmission systems and real planetary gearboxes, FER demonstrates a better stability-plasticity trade-off in incremental tasks with limited training samples, offering a novel solution for adaptive IFD model updates in sample-constrained scenarios.