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Kubernetes Orchestration of High Availability Distributed Control Systems
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems. Abb, Västerås, Sweden.ORCID iD: 0000-0002-5333-3699
ABB, Västerås, Sweden.
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems.ORCID iD: 0000-0001-6132-7945
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems.ORCID iD: 0000-0002-1364-8127
2022 (English)In: Proc IEEE Int Conf Ind Technol, Institute of Electrical and Electronics Engineers (IEEE) , 2022Conference paper, Published paper (Refereed)
Abstract [en]

Distributed control systems transform with the Industry 4.0 paradigm shift. A mesh-like, network-centric topology replaces the traditional controller-centered architecture, enforcing the interest of cloud-, fog-, and edge-computing, where lightweight container-based virtualization is a cornerstone. Kubernetes is a well-known container management system for container orchestration in cloud computing. It is gaining traction in edge- and fog-computing due to its elasticity and failure recovery properties. Orchestrator failure recovery can complement the manual replacement of a failed controller and, combined with controller redundancy, provide a pseudo-one-out-of-many redundancy. This paper investigates the failure recovery performance obtained from an out-of-the-box Kubernetes installation in a distributed control system scenario. We describe a Kubernetes based virtualized controller architecture and the software needed to set up a bare-metal cluster for control systems. Further, we deploy single and redundant configured containerized controllers based on an OPC UA compatible industry middleware software on the bare-metal cluster. The controllers expose variables with OPC UA PubSub. A script-based daemon introduces node failures, and a verification controller measures the downtime when using Kubernetes with an industry redundancy solution.

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE) , 2022.
Series
IEEE International Conference on Industrial Technology, ISSN 2641-0184
Keywords [en]
Cluster computing, Containers, Distributed parameter control systems, Fault tolerance, Fog computing, Middleware, Network architecture, Redundancy, Bare metals, Container management, Edge computing, Failure recovery, High availability, Management systems, Metal cluster, Network-centric, Paradigm shifts, Virtualizations, Controllers
National Category
Computer and Information Sciences
Identifiers
URN: urn:nbn:se:mdh:diva-62523DOI: 10.1109/ICIT48603.2022.10002757Scopus ID: 2-s2.0-85131518888ISBN: 9781728119489 (print)OAI: oai:DiVA.org:mdh-62523DiVA, id: diva2:1761053
Conference
Proceedings of the IEEE International Conference on Industrial Technology
Available from: 2023-05-31 Created: 2023-05-31 Last updated: 2026-02-27Bibliographically approved
In thesis
1. Revisiting Spatial Redundancy in Industrial Controller Architectures: A Network-Centric Perspective
Open this publication in new window or tab >>Revisiting Spatial Redundancy in Industrial Controller Architectures: A Network-Centric Perspective
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Automation solutions are omnipresent in modern society as a part of the infrastructure that provides utility services such as water and power. At the core of these systems is the controller, a specialized computer designed to operate in harsh environments where unplanned downtime can be costly. High-quality hardware, software, and spatial redundancy (i.e., hardware multiplication) are commonly employed to mitigate disruptions. 

Industrial control systems are evolving into more interconnected and interoperable architectures, marking a shift toward network-centric designs where the network, rather than the controller, becomes the central part of the system. Concepts traditionally associated with information technology, such as edge and cloud computing, containerization, and orchestrators, are entering the operational technology domain. New standards, such as OPC UA, with its information model and communication protocols, are gaining traction to facilitate interoperability.

This evolution presents redundancy challenges, such as adapting failure detection and state transfer mechanisms needed by standby redundancy to a network context, and opportunities, such as utilizing systems previously confined to the information technology domain. This shift toward a network-centric control system architecture is the overarching motivation for this thesis's revisit of spatial redundancy.

Specifically, this thesis investigates orchestrator-aided failure recovery as a complement to traditional redundancy. It also proposes a failure detection mechanism that maintains consistent control during network partitioning between redundant controllers. The thesis also examines the behavior of OPC UA PubSub in a standby redundancy context. It introduces a method for processing priority based on information embedded in incoming network frames. Additionally, the thesis proposes an architecture that enables the distribution of redundancy-related state data. It also investigates checkpointing solutions and communication protocols to identify a suitable mechanism for transferring state data between redundant controllers.

Place, publisher, year, edition, pages
Västerås: Mälardalens universitet, 2025
Series
Mälardalen University Press Dissertations, ISSN 1651-4238 ; 443
National Category
Computer Sciences
Research subject
Computer Science
Identifiers
urn:nbn:se:mdh:diva-73223 (URN)978-91-7485-723-8 (ISBN)
Public defence
2025-11-06, Kappa och digitalt, Mälardalens universitet, Västerås, 13:15 (English)
Opponent
Supervisors
Funder
Knowledge Foundation
Available from: 2025-09-10 Created: 2025-09-10 Last updated: 2025-10-16Bibliographically approved

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Johansson, BjarneNolte, ThomasPapadopoulos, Alessandro

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