A framework for designing a degradation-aware controller based on empirical estimation of the state–action cost and model predictive control

Controlling the machine’s state of health (SoH) increases the accuracy of the remaining useful life estimation and enables the control of the failure time by keeping the system operational until the desired maintenance time is reached. To achieve system reliability through SoH control, the system controller must consider the impact of its actions on other parameters, such as degradation. This article proposes a structure for designing degradation-aware controllers for systems with available physical models. A system using this approach can learn autonomously, irrespective of the system’s physical structure and degradation model, and opt for control actions that enhance the system’s reliability and availability. To this end, first, a method is proposed to compute the cost associated with the actions taken by the controller. Second, a new cost function is introduced that incorporates the costs associated with degradation into the cost function utilized in model predictive control. In the third step, dynamic programming and deterministic scheduling are used to calculate the optimal action based on the defined cost function. Finally, the proposed control method is validated through simulation, demonstrating its ability to effectively manage machine degradation and achieve optimal performance according to production and maintenance plans. • Optimize operation and maintenance by making the controller aware of action costs. • Keeping system operational until the desired maintenance time. • A new optimal control cost function, including degradation cost, is proposed. • Eliminating state–actions with high degradation costs keeps the system operational. • A method proposed for empirical estimate of the planned production cost.