# US 2024/0201678 A1 · Smart controller for industrial asset health monitoring > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2024/0201678 A1 - Document ID: US20240201678A1 - Status: Published application - Kind: A1 - Application number: 18/214,809 - Filed: 2023-06-27 - Published: 2024-06-20 - Earliest claimed: 2022-12-15 - Assignees: Schneider Electric Systems USA, Inc. - Applicants: Schneider Electric Systems USA, Inc. - Inventors: Amitabha Bhattacharyya; Srisuhasini Gottumukkala; Prashant Chandanapurkar; Bhaskar Sinha - Web page: https://patentgrep.com/patent/US20240201678A1 ## CPC - G05B 23/0243: {model based detection method, e.g. first-principles knowledge model} - G01M 99/005: {Testing of complete machines, e.g. washing-machines or mobile phones (testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50)} - G06Q 10/06: Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) - G01M: TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR - G06Q: INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR ## Abstract A smart controller continuously monitors data for determining in real time if there is a likelihood that an asset will be shut down and, if so, recommends a new setpoint at which the asset will continue to operate but will not lead to tripping of the system. The smart controller executes a simulation engine to test the new setpoint before implementation to optimize performance while avoiding a shutdown. In this manner, the smart controller provides early warning of possible shutdowns and ensures that key assets are less likely to be shut down. ## Claims ### Claim 1 A controller comprising: a control processor coupled to an asset of an industrial process, 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; an asset condition monitor coupled to the control processor, wherein the asset condition monitor is configured to determine a current condition of the asset based on the control signal controlling the asset and at least one sensor signal generated by one or more sensors monitoring the asset during performance of the operation, and wherein the control processor is further configured to generate a modified control signal based on the determined current condition of the asset; and a simulation engine coupled to the control processor, wherein the simulation engine is configured to simulate the asset performing the operation of the industrial process in response to the modified control signal and to predict a future condition of the asset as a function thereof; and wherein the control processor is further configured to provide 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. ### Claim 2 (depends on 1) The controller of claim 1, wherein the asset condition monitor is configured to execute at least one of the following to determine the current condition of the asset: a vibration analysis, a current signature analysis, a voltage signature analysis, and a frequency domain pattern analysis. ### Claim 3 (depends on 1) The controller of claim 1, wherein the control signal specifies an operating setpoint for the asset and wherein the modified control signal specifies a new operating setpoint for the asset. ### Claim 4 (depends on 3) The controller of claim 3, wherein the control processor is configured to execute an iterative process for setting the new operating setpoint. ### Claim 5 (depends on 3) The controller of claim 3, wherein the control processor generates the modified control signal when the predicted future condition of the asset indicates the asset operating in an undesired condition, and wherein the new operating setpoint reverts to a previous setpoint when the asset last operated in the desired condition. ### Claim 6 (depends on 1) The controller of claim 1, wherein the asset comprises a motor or a pump and the new operating setpoint is related to operation of the motor or the pump, respectively. ### Claim 7 (depends on 1) The controller of claim 1, wherein the control processor generates the modified control signal when the determined current condition of the asset indicates the asset operating in an undesired condition. ### Claim 8 (depends on 1) The controller of claim 1, wherein the undesired condition is indicative of excessive vibration or an anomalous motor current signature or both. ### Claim 9 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. ### Claim 10 (depends on 9) The method of claim 9, wherein determining the current condition of the asset comprises executing at least one of the following: a vibration analysis, a current signature analysis, a voltage signature analysis, and a frequency domain pattern analysis. ### Claim 11 (depends on 9) The method of claim 9, wherein identifying the new setpoint comprises executing an iterative process for setting the new operating setpoint. ### Claim 12 (depends on 9) The method of claim 9, wherein identifying the new setpoint comprises reverting to a previous setpoint when the asset last operated in the desired condition. ### Claim 13 (depends on 9) The method of claim 9, wherein predicting a future condition of the asset comprises executing a simulation of the asset operating based on the new setpoint ### Claim 14 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. ### Claim 15 (depends on 14) The system of claim 14, wherein determining the current condition of the asset comprises executing at least one of the following: a vibration analysis, a current signature analysis, a voltage signature analysis, and a frequency domain pattern analysis. ### Claim 16 (depends on 14) The system of claim 14, wherein the control signal specifies an operating setpoint for the asset and wherein the modified control signal specifies a new operating setpoint for the asset. ### Claim 17 (depends on 16) The system of claim 16, wherein the control processor is configured to execute an iterative process for setting the new operating setpoint. ### Claim 18 (depends on 16) The system of claim 16, wherein generating the modified control signal is responsive to the predicted future condition of the asset indicating the asset operating in an undesired condition, and wherein the new operating setpoint reverts to a previous setpoint when the asset last operated in the desired condition. ### Claim 19 (depends on 14) The system of claim 14, wherein the asset comprises a motor or a pump and the new operating setpoint is related to operation of the motor or the pump, respectively. ### Claim 20 (depends on 14) The system of claim 14, wherein generating the modified control signal is responsive to the determined current condition of the asset indicating the asset operating in an undesired condition. ### Claim 21 (depends on 14) The system of claim 14, wherein the undesired condition is indicative of excessive vibration or an anomalous motor current signature or both.