Patent Document ID: 9563185
Application ID: 13252029
Patent Flag: 1

Claim One:
1. A method for controlling operation of a manufacturing system to produce a manufactured product, comprising: determining, using a controller in the manufacturing system, a predicted error in a controlled variable over a forward-looking control horizon based at least in part on a sensed parameter determined by a sensor during operation of the manufacturing system to produce the manufactured product; determining, using the controller, whether a sustained steady state error in the controlled variable is expected to occur over the forward-looking control horizon; determining, using the controller, whether the predicted error or a value based upon the predicted error is above a tolerance when the sustained steady state error is expected to occur; modifying, using the controller, a model predictive control algorithm as a function of the sustained steady state error to reduce the predicted error when the predicted error or the value based upon the predicted error is above the tolerance, wherein the model predictive control algorithm implements cost or objective functions subject to a system model of the manufacturing system; reducing, using the controller, modification to the model predictive control algorithm as the predicted error or the value based upon the predicted error is reduced; and controlling, using the controller, operation of one or more actuators in the manufacturing system to facilitate producing the manufactured product based at least in part on the controlled variable over the forward-looking control horizon determined after the model predictive control algorithm is modified to drive the sustained steady state error of the controlled variable to within the tolerance; wherein the model predictive control algorithm predicts values of the controlled variable in time steps, and wherein the predicted error and the value based upon the predicted error over the forward-looking control horizon are determined in advance of each time step.