DESIGN OF AN AI-POWERED PREDICTIVE MAINTENANCE SYSTEM FOR INDUSTRIAL IOT NETWORKS
Keywords:
Predictive Maintenance, Artificial Intelligence, Internet of Things, Industrial IoT, Deep LearningAbstract
The Industrial Revolution 4.0 presents new challenges in industrial asset management, particularly regarding equipment maintenance. Traditional maintenance approaches, both reactive and preventive, have proven to be less efficient because they cause downtime and waste costs. Therefore, predictive maintenance emerges as a promising solution through the utilization of the Internet of Things (IoT) for real-time data collection and Artificial Intelligence (AI) for failure pattern analysis. This article presents a literature review on the design of an AI-based predictive maintenance system integrated with an industrial IoT network. The study was conducted by searching literature from reputable databases such as IEEE Xplore, ScienceDirect, ACM, and Springer, using the keywords "Predictive Maintenance", "AI", "IoT", "Industrial IoT", and "Machine Learning". The review results show that classic machine learning algorithms (e.g., Random Forest, SVM, and Decision Tree) are capable of making predictions with structured data, while deep learning approaches (LSTM, CNN, Autoencoder) are superior in processing complex and time-series data. Nevertheless, challenges still exist in the aspects of IoT device interoperability, data security, limitations of failure datasets, and the need for energy efficiency for real-time processing. This literature review contributes to summarizing the trends, advantages, and limitations of AI methods used in industrial IoT predictive maintenance. Future development potential includes the application of Edge AI for efficient computing, Federated Learning for data privacy, and Digital Twin integration to improve the accuracy of predictive simulations. By addressing these challenges, AI-powered predictive maintenance systems are expected to become a key pillar in supporting reliable, efficient, and highly competitive industrial performance in the digital age.
Downloads
References
abbas, asad. (2024). AI for Predictive Maintenance in Industrial Systems. Query date: 2025-10-01 20:30:36. https://doi.org/10.31219/osf.io/vq8zg
Aldeoes, Y. N., Gokhale, P., & Sondkar, S. Y. (2023). A Review of Predictive Maintenance of Bearing Failures in Rotary Machines by Predictive Analytics Using Machine-Learning Techniques. Signals and Communication Technology, Query date: 2025-10-01 20:30:36, 115–138. https://doi.org/10.1007/978-3-031-29713-7_6
Bhambri, P., & Kumar, S. (2024). Cloud and IoT Integration for Smart Healthcare. Smart Healthcare Systems, Query date: 2025-10-01 20:30:36, 69–84. https://doi.org/10.1201/9781032698519-6
Chawla, H. S., Veerasamy, K., Patil, S. R., Sivakumar, V., Shunmugapriya, B., & Krishna, C. B. (2023). AI-Enabled Predictive Analytics for Proactive Maintenance in IoT Systems. 2023 6th International Conference on Contemporary Computing and Informatics (IC3I), 9(Query date: 2025-10-01 20:30:36), 1791–1795. https://doi.org/10.1109/ic3i59117.2023.10398098
Deepan, S., Buradkar, M., Akhila, P., Kumar, K. S., Sharma, M. K., & Chakravarthi, M. K. (2024). AI-Powered Predictive Maintenance for Industrial IoT Systems. 2024 International Conference on Advances in Computing, Communication and Applied Informatics (ACCAI), Query date: 2025-10-01 20:30:36, 1–6. https://doi.org/10.1109/accai61061.2024.10601983
Devi, E. M. R., Shanthakumari, R., Dhanushya, S., & Kiruthika, G. (2024). AI Models for Predictive Maintenance. Data Analytics and Artificial Intelligence for Predictive Maintenance in Smart Manufacturing, Query date: 2025-10-01 20:30:36, 69–94. https://doi.org/10.1201/9781003480860-5
Dey, S., & Nagavalli, S. P. (2022). AI-Based Predictive Maintenance in Edge IoT Devices: A Proactive Approach to Latency Reduction. International Journal of Emerging Trends in Computer Science and Information Technology, 3(1), 55–64. https://doi.org/10.63282/3050-9246.ijetcsit-v3i1p107
Gaddam, N. (2023). AI-DRIVEN PREDICTIVE MAINTENANCE FOR AEROSPACE IOT SENSORS. ISCSITR - INTERNATIONAL JOURNAL OF SCIENTIFIC RESEARCH IN INFORMATION TECHNOLOGY, 4(1), 1–15. https://doi.org/10.63397/iscsitr-ijsrit_04_01_001
Ghosh, D. (2024). Enhancing Security, Privacy, and Predictive Maintenance through IoT and Big Data Integration. Internet of Things and Big Data Analytics-Based Manufacturing, Query date: 2025-10-01 20:30:36, 209–217. https://doi.org/10.1201/9781032673479-17
Gupta, K., & Kaur, P. (2024). Application of Predictive Maintenance in Manufacturing with the utilization of AI and IoT Tools. Query date: 2025-10-01 20:30:36. https://doi.org/10.36227/techrxiv.173532375.50630906/v1
Juliet, A. H., Legapriyadharshini, N., & Malathi, P. (2024). IoT Enhanced Resilience: Advanced AI Technique for Leak Detection and Predictive Maintenance in Oil and Gas Pipeline. 2024 10th International Conference on Communication and Signal Processing (ICCSP), Query date: 2025-10-01 20:30:36, 1338–1343. https://doi.org/10.1109/iccsp60870.2024.10544329
Kamgba, R. B. (2024). Development of Predictive Maintenance Technologies for Critical Industrial Systems Using AI and IoT. Query date: 2025-10-01 20:30:36. https://doi.org/10.22541/au.172172848.85394455/v1
Keshwani, P., Gehani, H., & Agrawal, P. K. (2024). Introduction to the Integration of AI, IoT, and Cloud Computation for Social Welfare. Developing AI, IoT and Cloud Computing-Based Tools and Applications for Women’s Safety, Query date: 2025-10-01 20:30:36, 1–18. https://doi.org/10.1201/9781003538172-1
Kumar, P., & Tiwari, R. (2024). AI-Based Predictive Maintenance for Industrial IOT Applications. International Academic Journal of Science and Engineering, 11(4), 10–15. https://doi.org/10.71086/iajse/v11i4/iajse1164
Mahadev, N., Premkumar, A., Sowmya, V. L., & Natarajan, R. (2024). Exploring AI and IoT Integration for Medicine Recommendation with Chimp Optimized Dynamic XGBoost (CO-DXB). Information Systems Engineering and Management, Query date: 2025-10-01 20:30:36, 23–31. https://doi.org/10.1007/978-3-031-65022-2_2
Matos, I. de. (2023). Análise Preditiva com IA na Manutenção de Frotas: Redução de Custos e Ganhos de Eficiência. RCMOS - Revista Científica Multidisciplinar O Saber, 1(1). https://doi.org/10.51473/rcmos.v1i1.2023.1397
Mehta, V. H. (2024). Enhancing Equipment Reliability and Reducing Maintenance Costs with MSET2: A Predictive Maintenance Approach Using IoT Sensor Data. SSRN Electronic Journal, Query date: 2025-10-01 20:30:36. https://doi.org/10.2139/ssrn.4951531
Mohapatra, A. (2024). Generative AI for Predictive Maintenance: Predicting Equipment Failures and Optimizing Maintenance Schedules Using AI. International Journal of Scientific Research and Management (IJSRM), 12(11), 1648–1672. https://doi.org/10.18535/ijsrm/v12i11.ec03
Nagaraj, A. (2023). Integration of AI and IoT-cloud. The Role of AI in Enhancing IoT-Cloud Applications, Query date: 2025-10-01 20:30:36, 116–165. https://doi.org/10.2174/9789815165708123010008
Paroha, A. D. (2024). Advancing Predictive Maintenance in the Oil and Gas Industry: A Generative AI Approach with GANs and LLMs for Sustainable Development. Communications in Computer and Information Science, Query date: 2025-10-01 20:30:36, 3–15. https://doi.org/10.1007/978-3-031-71729-1_1
Pohakar, P. Y., Gandhi, R., & Champaty, B. (2024). Enhancing Grid Reliability and Renewable Integration Through AI-Based Predictive Maintenance. Advances in Computational Intelligence and Robotics, Query date: 2025-10-01 20:30:36, 47–62. https://doi.org/10.4018/979-8-3693-1586-6.ch003
Rebahi, Y., Hilliger, B., Lowin, P., & Cardoso, A. (2023). AI Based Predictive Maintenance as a Key Enabler for Circular Economy: The KYKLOS 4.0 Approach. 2023 19th International Conference on Distributed Computing in Smart Systems and the Internet of Things (DCOSS-IoT), Query date: 2025-10-01 20:30:36, 367–372. https://doi.org/10.1109/dcoss-iot58021.2023.00066
Saboo, S., & Shekhawat, D. (2024). Enhancing Predictive Maintenance in an Oil & Gas Refinery Using IoT, AI & ML: An Generative AI Solution. International Petroleum Technology Conference, Query date: 2025-10-01 20:30:36. https://doi.org/10.2523/iptc-23466-ms
Sangwan, A. (2024). Building Predictive Models for Cardiovascular Health. Information Systems Engineering and Management, Query date: 2025-10-01 20:30:36, 329–356. https://doi.org/10.1007/978-3-031-65022-2_19
Sharanya, S., Venkataraman, R., & Murali, G. (2022). Edge AI: From the Perspective of Predictive Maintenance. Applied Edge AI, Query date: 2025-10-01 20:30:36, 171–192. https://doi.org/10.1201/9781003145158-7
Sharma, A., & Aslekar, A. (2022). IOT Based Predictive Maintenance in Industry 4.0. 2022 International Interdisciplinary Humanitarian Conference for Sustainability (IIHC), 12(Query date: 2025-10-01 20:30:36), 143–145. https://doi.org/10.1109/iihc55949.2022.10059639
Snyder, H. (2019). Literature review as a research methodology: An overview and guidelines. Journal of Business Research, 104, 333–339. https://doi.org/10.1016/j.jbusres.2019.07.039
Srivastav, Dr. A. K., & Das, Dr. P. (2024). Integration of AI and IoT in Healthcare 4.0. Emerging Technologies in Healthcare 4.0, Query date: 2025-10-01 20:30:36, 115–130. https://doi.org/10.1007/979-8-8688-1014-5_4
Subbiah, M. R., Devi, K., M, D., Shareef, A. M., AI-Shaikhli, T. R., & Nidamanuri, S. (2024). AI-Enabled Predictive Maintenance for Industrial Equipment in the Era of IoT. 2024 Ninth International Conference on Science Technology Engineering and Mathematics (ICONSTEM), Query date: 2025-10-01 20:30:36, 1–5. https://doi.org/10.1109/iconstem60960.2024.10568814
Tranfield, D., Denyer, D., & Smart, P. (2003). Towards a Methodology for Developing Evidence-Informed Management Knowledge by Means of Systematic Review. British Journal of Management, 14(3), 207–222. https://doi.org/10.1111/1467-8551.00375
Tripathi, R. K. P. (2024). Data Analytics and AI for Predictive Maintenance in Pharmaceutical Manufacturing. Data Analytics and Artificial Intelligence for Predictive Maintenance in Smart Manufacturing, Query date: 2025-10-01 20:30:36, 117–149. https://doi.org/10.1201/9781003480860-7