Fault detection in autonomous VTOL aircraft is critical because even minor component degradations can rapidly destabilize multirotor vehicles operating in complex, safety-critical environments, motivating robust fault detection and estimation strategies capable of identifying early signs of rotor damage; however, real-flight fault detection remains challenging due to sensor noise, environmental disturbances, and the nonlinear aerodynamics of multirotor platforms. This study proposes a comprehensive machine-learning framework for rotor fault detection, isolation, and severity prediction using real flight data. A convolutional neural network (CNN) architecture is developed to learn spatio-temporal patterns from multivariate flight dynamics, enabling direct inference of both the faulted rotor and its damage level. The framework is first validated using simulated data generated by a data-generative model, and experimental validation is then performed on a hexacopter by introducing controlled blade-tip breakage. The trained model achieves rotor-wise fault classification accuracies above 99% and severity estimation accuracy of 96% within a 1% tolerance in experimental data, demonstrating strong generalization and supporting real-time health monitoring for autonomous VTOL systems.

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