Appliance performance analysis and prediction based on closed-loop control output

A method of operating an appliance, the appliance comprising a user interface, a mechanical component comprising a heating element, a sensor positioned and configured to measure a process variable associated with the mechanical component, wherein the process variable associated with the mechanical component comprises a temperature associated with the heating element, and a controller in communication with the user interface, the mechanical component, and the sensor, the method comprising:

• performing an operating cycle of the appliance, the operating cycle comprising operating the mechanical component according to a closed-loop control algorithm wherein operating the mechanical component according to the closed-loop control algorithm comprises:
• activating the heating element in response to a setpoint value received from the user interface,
• receiving a plurality of temperature measurements from the sensor after activating the heating element,
• generating an output from the closed-loop control algorithm based on the setpoint value and each of the plurality of temperature measurements, wherein each output from the closed-loop control algorithm comprises a control variable, the control variable comprising a valve position for a fuel supply valve coupled to the heating element, and
• adjusting a position of the fuel supply valve in response to each output from the closed-loop control algorithm;
• monitoring each output of the closed-loop control algorithm during the operating cycle of the appliance;
• comparing the monitored output of the closed-loop control algorithm during the operating cycle of the appliance to an output of the closed-loop control algorithm during a previous operating cycle of the appliance;
• and
• determining, based on the comparison of the monitored output of the closed-loop control algorithm during the operating cycle of the appliance to the output of the closed-loop control algorithm during the previous operating cycle of the appliance, that the monitored output of the closed-loop control algorithm during the operating cycle of the appliance is an abnormal output.

A method of operating an appliance, the appliance comprising a user interface, a mechanical component comprising a fan, a sensor positioned and configured to measure a process variable associated with the mechanical component, wherein the process variable associated with the mechanical component comprises a speed of the fan, and a controller in communication with the user interface, the mechanical component, and the sensor, the method comprising:

• performing an operating cycle of the appliance, the operating cycle comprising operating the mechanical component according to a closed-loop control algorithm, wherein operating the mechanical component according to the closed-loop control algorithm comprises:
• activating the fan in response to a setpoint value received from the user interface,
• receiving a plurality of fan speed measurements from the sensor after activating the fan,
• generating an output from the closed-loop control algorithm based on the setpoint value and each of the plurality of fan speed measurements, wherein each output from the closed-loop control algorithm comprises a control variable, the control variable comprising a power level for the fan, and
• adjusting an electrical power level supplied to the fan in response to each output from the closed-loop control algorithm;
• monitoring each output of the closed-loop control algorithm during the operating cycle of the appliance;
• comparing the monitored output of the closed-loop control algorithm during the operating cycle of the appliance to an output of the closed-loop control algorithm during a previous operating cycle of the appliance;
• and
• determining, based on the comparison of the monitored output of the closed-loop control algorithm during the operating cycle of the appliance to the output of the closed-loop control algorithm during the previous operating cycle of the appliance, that the monitored output of the closed-loop control algorithm during the operating cycle of the appliance is an abnormal output.