Industrial machines are used continuously in many manufacturing environments, so a small fault can quickly affect production, increase maintenance cost, or cause unexpected downtime. Bearing failure is a common example. Before a bearing becomes seriously damaged, the machine may start producing an unusual sound. Finding these changes by manual listening requires experience and regular monitoring. Machine AI was developed to support this task by analyzing machine sounds with artificial intelligence. The system accepts recorded machine audio or a WAV file and uses a Convolutional Neural Network (CNN) to decide whether the sound represents normal operation or a bearing fault. Industrial audio data, including the MIMII dataset, is used during model development. Librosa and SoundFile are used to prepare the audio, while PyTorch supports the machine-learning model. After the CNN gives a prediction, the result is sent through the Gemini API to a generative-AI module. Gemini prepares a maintenance report with the detected condition, possible causes, severity, and suggested actions. This gives the user more useful information than a fault label alone. The complete application is delivered through HTML, CSS, JavaScript, and Flask, with a database for user details, audio-analysis results, predictions, and reports. Overall, Machine AI combines audio analysis, deep learning, and generative AI to support predictive maintenance in a practical web-based system.
Machine AI presents a practical approach to detecting industrial machine faults from audio. The main idea is that changes in the sound of equipment can provide useful information about its operating condition. The system uses a CNN-based deep-learning model to classify machine audio as normal or associated with a bearing fault. Librosa and SoundFile are used to prepare the audio, while PyTorch supports the machine-learning component. An important part of the project is the use of generative AI after classification. Once the CNN produces a prediction, Gemini generates a maintenance report describing the detected condition, possible causes, severity, and recommended actions. The application is implemented as a web system using HTML, CSS, JavaScript, and Flask. A database stores user information, audio-related records, predictions, and generated reports. The overall workflow shows how audio processing, deep learning, web technology, database storage, and generative AI can work together for predictive maintenance. The current project also provides a base for future development. Better models, more machine types, additional fault categories, real-time monitoring, mobile access, stronger security, and IoT integration could make the system more complete. Overall, Machine AI demonstrates a useful application of artificial intelligence in machine maintenance. By combining audio-based fault detection with automated reporting, the system can reduce some manual effort, support earlier fault identification, and make maintenance information easier to understand.
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How to Cite This Paper
Kunchapu Hima Bindu, Tinga Prashanth (2026). MACHINE AI AI-BASED MALFUNCTIONING INDUSTRIAL MACHINERY FAULT DETECTION AND MAINTENANCE REPORT SYSTEM. International Journal of Computer Techniques, 13(5). ISSN: 2394-2231.
