AI-Driven Hybrid Deep Learning and Swarm Intelligence for Predictive Maintenance of Smart Manufacturing Robots in Industry 4.0

Abstract

Advancements in Industry 4.0 technologies, which combine big data analytics, robotics, and intelligent decision systems to enable new ways to increase automation in the industrial sector, have undergone significant transformations. In this research, a Hybrid Attention-Gated Recurrent Unit (At-GRU) model, combined with Sand Cat Optimization (SCO), is proposed to enhance fault identification and predictive maintenance capabilities. The model utilized multivariate sensor data from cyber-physical and IoT-enabled robotic platforms to learn operational patterns and predict failures with enhanced reliability. The At-GRU provides deeper temporal feature extraction, thereby improving classification performance. The robustness of the proposed model is validated through analysis of a benchmark dataset for industrial robots, and the results demonstrate that the proposed model exhibits impressive predictive capacity, surpassing other prediction methods and predictive maintenance approaches. Additionally, the performance evaluation indicates a lower computational cost due to the lightweight gating architecture of GRU, combined with attention. The robotic motion is further optimized by the SCO algorithm, which reduces energy usage, execution delay, and trajectory deviations while ensuring smooth operation. Overall, the proposed work offers an intelligent and scalable solution for next-generation industrial automation systems. Furthermore, the proposed model demonstrates the real-world applicability and significant benefits of incorporating hybrid artificial intelligence models into real-time robot control applications for smart manufacturing environments.