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Partible State Replication for Industrial Controller Redundancy
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems. Abb Process Automation, Process Control Platform, Västerås, Sweden.ORCID iD: 0000-0002-5333-3699
Abb Process Automation, Process Control Platform, 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
2024 (English)In: Proceedings of the IEEE International Conference on Industrial Technology, Institute of Electrical and Electronics Engineers (IEEE) , 2024Conference paper, Published paper (Refereed)
Abstract [en]

Distributed control systems are part of the often invisible backbone of modern society that provides utility services like water and electricity. Their uninterrupted operation is vital, and unplanned stops due to failure can be expensive. Critical devices, like controllers, are often duplicated to minimize the service stop probability, with a secondary controller acting as a backup to the primary. A seamless takeover requires that the backup has the primary's latest state, i.e., the primary has to replicate its state to the backup. While this method ensures high availability, it can be costly due to hardware doubling. This work proposes a state replication solution that doesn't require the backup to store the primary state, separating state storage from the backup function. Our replication approach allows for more flexible controller redundancy deployments since one controller can be a backup for multiple primaries without being saturated by state replication data. Our main contribution is the partible state replication approach, realized with a distributed architecture utilizing a consensus algorithm. A partial connectivity-tolerant consensus algorithm is also an additional contribution.

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE) , 2024.
Series
IEEE International Conference on Industrial Technology, ISSN 2641-0184
Keywords [en]
Digital storage, Distributed parameter control systems, Redundancy, Consensus algorithms, Critical device, Distributed architecture, Doublings, High availability, Industrial controllers, Replication approaches, State replications, Uninterrupted operations, Controllers
National Category
Control Engineering
Identifiers
URN: urn:nbn:se:mdh:diva-67699DOI: 10.1109/ICIT58233.2024.10540726Scopus ID: 2-s2.0-85195799486ISBN: 9798350340266 (print)OAI: oai:DiVA.org:mdh-67699DiVA, id: diva2:1874482
Conference
25th IEEE International Conference on Industrial Technology, Bristol, England, 25-27th March, 2024
Available from: 2024-06-20 Created: 2024-06-20 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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