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Consistency before Availability: Network Reference Point based Failure Detection for Controller Redundancy
ABB Process Automation, Process Control Platform, Västerås, Sweden.
ABB Process Automation, Process Control Platform, Västerås, Sweden.
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems.ORCID iD: 0000-0002-1364-8127
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems.ORCID iD: 0000-0001-6132-7945
2023 (English)In: IEEE Int. Conf. Emerging Technol. Factory Autom., ETFA, Institute of Electrical and Electronics Engineers (IEEE) , 2023Conference paper, Published paper (Refereed)
Abstract [en]

Distributed control systems constitute the automation solution backbone in domains where downtime is costly. Redundancy reduces the risk of faults leading to unplanned downtime. The Industry 4.0 appetite to utilize the device-to-cloud continuum increases the interest in network-based hardware-agnostic controller software. Functionality, such as controller redundancy, must adhere to the new ground rules of pure network dependency. In a standby controller redundancy, only one controller is the active primary. When the primary fails, the backup takes over. A typical network-based failure detection uses a cyclic message with a known interval, a.k.a. a heartbeat. Such a failure detection interprets heartbeat absences as a failure of the supervisee; consequently, a network partitioning could be indistinguishable from a node failure. Hence, in a network partitioning situation, a conventional heartbeat-based failure detection causes more than one active controller in the redundancy set, resulting in inconsistent outputs. We present a failure detection algorithm that uses network reference points to prevent network partitioning from leading to dual primary controllers. In other words, a failure detection that prioritizes consistency before availability.

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE) , 2023.
Series
IEEE Conference on Emerging Technologies and Factory Automation, ISSN 1946-0740
Keywords [en]
Distributed parameter control systems, Maintenance, Redundancy, Active controller, Automation solutions, Detection algorithm, Failure detection, In networks, Network partitioning, Network-based, Node failure, Point-based, Reference points, Controllers
National Category
Computer and Information Sciences
Identifiers
URN: urn:nbn:se:mdh:diva-64700DOI: 10.1109/ETFA54631.2023.10275664Scopus ID: 2-s2.0-85175422976ISBN: 9798350339918 (print)OAI: oai:DiVA.org:mdh-64700DiVA, id: diva2:1810932
Conference
IEEE International Conference on Emerging Technologies and Factory Automation, ETFA
Available from: 2023-11-09 Created: 2023-11-09 Last updated: 2026-02-26Bibliographically 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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Papadopoulos, AlessandroNolte, Thomas

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