Smart controller for industrial asset health monitoring

A method of controlling an industrial asset performing an operation of an industrial process, the method comprising:

• providing a setpoint to the asset for controlling the asset, wherein the asset performs the operation of the industrial process based on the setpoint;
• monitoring one or more operating parameters of the asset performing the operation of the industrial process;
• determining a current condition of the asset based on the setpoint and the one or more operating parameters;
• in response to the current condition indicating the asset is operating in an undesired condition, identifying a new setpoint for the asset to address the undesired condition;
• predicting a future condition of the asset as a function of the asset operating based on the new setpoint;
• and
• providing the new setpoint to the asset when the predicted future condition of the asset indicates the asset operating in a desired condition.

An automation system comprising:

• an asset of an industrial process;
• a control processor coupled to the asset, wherein the control processor is configured to generate a control signal for controlling the asset, and wherein the asset performs an operation of the industrial process in response to the control signal;
• one or more sensors configured to monitor the asset during performance of the operation and generate at least one sensor signal representative thereof;
• a memory storing computer-executable instructions that, when executed, configure the control processor for:
• determining a current condition of the asset based on the control signal controlling the asset and the at least one sensor signal;
• generating a modified control signal based on the determined current condition of the asset;
• simulating the asset performing the operation of the industrial process in response to the modified control signal;
• predicting a future condition of the asset as a function of the simulating;
• and
• providing the modified control signal for controlling the asset in response thereto when the predicted future condition of the asset indicates the asset operating in a desired condition.