Physics-Informed Multimodal Bearing Fault Classification under Variable Operating Conditions using Transfer Learning

Accurate and interpretable bearing fault classification is critical for ensuring the reliability of rotating machinery, particularly under variable operating conditions where domain shifts can significantly degrade model performance. This study proposes a physics-informed multimodal convolutional neural network (CNN) with a late fusion architecture, integrating vibration and motor current signals alongside a dedicated physics-based feature extraction branch. The model incorporates a novel physics-informed loss function that penalizes physically implausible predictions based on characteristic bearing fault frequencies - Ball Pass Frequency Outer (BPFO) and Ball Pass Frequency Inner (BPFI) - derived from bearing geometry and shaft speed. Comprehensive experiments on the Paderborn University dataset demonstrate that the proposed physics-informed approach consistently outperforms a non-physics-informed baseline, achieving higher accuracy, reduced false classifications, and improved robustness across multiple data splits. To address performance degradation under unseen operating conditions, three transfer learning (TL) strategies - Target-Specific Fine-Tuning (TSFT), Layer-Wise Adaptation Strategy (LAS), and Hybrid Feature Reuse (HFR) - are evaluated. Results show that LAS yields the best generalization, with additional performance gains when combined with physics-informed modeling. Validation on the KAIST bearing dataset confirms the framework's cross-dataset applicability, achieving up to 98 percent accuracy. Statistical hypothesis testing further verifies significant improvements (p < 0.01) in classification performance. The proposed framework demonstrates the potential of integrating domain knowledge with data-driven learning to achieve robust, interpretable, and generalizable fault diagnosis for real-world industrial applications.