A Synthetic-to-Real Deep Learning Framework for Two-Phase Probe Signal Processing

Accurate binarization of phase-detection probe signals (gas vs. liquid) is necessary for the estimation of local void fraction, interfacial velocity, and bubble statistics in gas–liquid flows. Classical threshold based methods—single or double level— performs well on clean laboratory signals but degrades under realistic industrial conditions where noise, baseline drift, and clustered (slug-like) events challenge fixed rules. This work investigates whether deep learning (DL) models trained exclusively on synthetic data can deliver robust, generalizable binarization on real probe measurements. We (i) build a parametric generator of realistic time series from bubbly pulse templates, extended to clusters/slug patterns and perturbed with controlled noise, drift, and oscillatory baselines; (ii) train four lightweight DL architectures—one-dimensional U-Net (UNET-1D), Temporal Convolutional Network (TCN), a minimal one-dimensional Convolutional Neural Network (CNN-1D), and a Bidirectional Long-Short Memory network (BiLSTM)—only on synthetic signals; and (iii) evaluate them against classical threshold methods using event-level and sample-level metrics. On synthetic signal evaluation, UNET-1D and TCN achieve near-perfect event detection and sub-millisecond onset errors. On real bubbly and slug flow sensor data, classical threshold based methods remain highly competitive on clean sensor signals, while DL models retain advantages under non-stationary baselines and clustered events, yielding accurate void and timing with no hand-tuned assumptions. Results support DL as a practical, data-driven complement to fixed algorithms, particularly in noisy or drift-dominated measuring conditions.