US 12,111,634 B2
Systems and methods for using intermediate data to improve system control and diagnostics
Jacob Lindley, St. Louis, MO (US); Miranda Pizzella, St. Louis, MO (US); Jeremy Quandt, Winona, MN (US); Philip Schmidt, St. Louis, MO (US); John Bergen, San Jose, CA (US); Hanwen Yuan, St. Louis, MO (US); and Daniel Gander, St. Louis, MO (US)
Assigned to Watlow Electric Manufacturing Company, St. Louis, MO (US)
Filed by Watlow Electric Manufacturing Company, St. Louis, MO (US)
Filed on Jul. 27, 2021, as Appl. No. 17/443,595.
Claims priority of provisional application 63/056,810, filed on Jul. 27, 2020.
Prior Publication US 2022/0026881 A1, Jan. 27, 2022
Int. Cl. G05B 17/00 (2006.01); G05B 11/42 (2006.01); G05B 19/4155 (2006.01); G05D 23/19 (2006.01)
CPC G05B 19/4155 (2013.01) [G05B 17/00 (2013.01); G05B 11/42 (2013.01); G05B 2219/50333 (2013.01); G05D 23/1917 (2013.01)] 27 Claims
OG exemplary drawing
 
1. A method of controlling a thermal system of an industrial process, the thermal system including a heater system and a process control system configured to generate an output control for the heater system based on intermediate data generated by the process control system, the method comprising:
monitoring the intermediate data;
associating the intermediate data with correlation data, wherein the correlation data is associated with the output control, and wherein the intermediate data comprises one or more of: proportional gain data, integral gain data, or derivative gain data;
generating a supervised learning model that defines a relationship between the intermediate data and the correlation data;
predicting a state of the heater system based on the supervised learning model; and
selectively performing a corrective action based on the predicted state of the heater system, wherein the corrective action includes controlling power to the heater system based on the predicted state of the heater system.