FedCPG: A class prototype guided personalized lightweight federated learning framework for cross-factory fault detection

Industrial equipment condition monitoring and fault detection are crucial to ensure the reliability of industrial production. Recently, data-driven fault detection methods have achieved significant success, but they all face challenges due to data fragmentation and limited fault detection capabilities. Although centralized data collection can improve detection accuracy, the conflicting interests brought by data privacy issues make data sharing between different devices impractical, thus forming the problem of industrial data silos. To address these challenges, this paper proposes a class prototype guided personalized lightweight federated learning framework(FedCPG). This framework decouples the local network, only uploading the backbone model to the server for model aggregation, while employing the head model for local personalized updates, thereby achieving efficient model aggregation. Furthermore, the framework incorporates prototype constraints to steer the local personalized update process, mitigating the effects of data heterogeneity. Finally, a lightweight feature extraction network is designed to reduce communication overhead. Multiple complex industrial data distribution scenarios were simulated on two benchmark industrial datasets. Extensive experiments have demonstrated that FedCPG can achieve an average detection accuracy of 95% in complex industrial scenarios, while simultaneously reducing memory usage and the number of parameters by 82%, surpassing existing methods in most average metrics. These findings offer novel perspectives on the application of personalized federated learning in industrial fault detection.