AI-Driven Predictive Maintenance with Environmental Context Integration for Connected Vehicles: Simulation, Benchmarking, and Field Validation
Predictive maintenance for connected vehicles offers the potential to reduce unexpected breakdowns and improve fleet reliability, but most existing systems rely exclusively on internal diagnostic signals and are validated on simulated or industrial benchmark data. This paper presents a contextual data fusion framework integrating vehicle-internal sensor streams with external environmental signals -- road quality, weather, traffic density, and driver behaviour -- acquired via V2X communication and third-party APIs, with inference at the vehicle edge. The framework is evaluated across four layers. A feature group ablation study on a physics-informed synthetic dataset shows contextual features contribute a 2.6-point F1 improvement; removing all context reduces macro F1 from 0.855 to 0.807. On the AI4I 2020 benchmark (10,000 samples), LightGBM achieves AUC-ROC 0.973 under 5-fold stratified cross-validation with SMOTE confined to training folds. A noise sensitivity analysis shows macro F1 remains above 0.88 at low noise and degrades to 0.74 at high noise. Most critically, the pipeline is validated on real-world telemetry from five vehicles across three countries (India, Germany, Brazil), comprising 992 trips and 11 evaluable service events identified from component wear resets in the trip logs. Across six wear-driven events spanning four vehicles, the model achieves 100% detection with mean MAE of 12.2 days. A fine-tuning ablation shows the base synthetic model already achieves 6/6 binary detection; per-vehicle adaptation reduces wear-driven MAE from 25.9 to 12.2 days. SHAP analysis confirms contextual and interaction features rank among the top 15 predictors. Edge-based inference reduces estimated latency from 3.5 seconds to under 1.0 second relative to cloud-only processing.