Exposing Vulnerabilities: Physical Adversarial Attacks on AI-Based Fault Diagnosis Models in Industrial Air-Cooling Systems
Stavros Bezyrgiannidis, Ioannis Polymeropoulos, Εleni Vrochidou, George A. Papakostas · Processes · 2025
Although neural network-based methods have significantly advanced the field of machine fault diagnosis, they remain vulnerable to physical adversarial attacks. This work investigates such attacks in the physical context of a real production line. Attacks simulate failures or irregularities arising from the maintenance or production department during the production process, a scenario commonly encountered in industrial environments. The experiments are conducted using data from vibration signals and operational parameters of a motor installed in an industrial air-cooling system used for staple fiber production. In this context, we propose the Mean Confusion Impact Index (MCII), a novel and simple robustness metric that measures the average misclassification confidence of models under adversarial physical attacks. By performing a series of hardware-level interventions, this work aims to demonstrate that even minor physical disturbances can lead to a significant reduction in the model’s diagnostic accuracy. Additionally, a hybrid defense approach is proposed, which leverages deep feature representations extracted from the original classification model and integrates them with lightweight classifiers retrained on adversarial labeled data. Research findings underscore an important limitation in existing industrial artificial intelligence (AI)-based monitoring systems and introduce a practical, scalable framework for improving the physical resilience of machine fault diagnosis in real-world environments.