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OPC UA PubSub and 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.
Abb Process Automation, Process Control Platform, Minden, Germany.
Mälardalen University, School of Innovation, Design and Engineering, Embedded Systems.
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2024 (English)In: IEEE International Conference on Emerging Technologies and Factory Automation, ETFA, Institute of Electrical and Electronics Engineers (IEEE) , 2024Conference paper, Published paper (Refereed)
Abstract [en]

Industrial controllers constitute the core of numerous automation solutions. Continuous control system operation is crucial in certain sectors, where hardware duplication serves as a strategy to mitigate the risk of unexpected operational halts due to hardware failures. Standby controller redundancy is a commonly adopted strategy for process automation. This approach involves an active primary controller managing the process while a passive backup is on standby, ready to resume control should the primary fail. Typically, redundant controllers are paired with redundant networks and devices to eliminate any single points of failure. The process automation domain is on the brink of a paradigm shift towards greater interconnectivity and interoperability. OPC UA is emerging as the standard that will facilitate this shift, with OPC UA PubSub as the communication standard for cyclic real-time data exchange. Our work investigates standby redundancy using OPC UA PubSub, analyzing a system with redundant controllers and devices in publisher-subscriber roles. The analysis reveals that failovers are not subscriber-transparent without synchronized publisher states. We discuss solutions and experimentally validate an internal stack state synchronization alternative. 

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers (IEEE) , 2024.
Series
IEEE Conference on Emerging Technologies and Factory Automation, ISSN 1946-0759
Keywords [en]
Competition, Control system analysis, Office automation, Automation domain, Automation solutions, Continuous control, Hardware duplication, Hardware failures, Industrial controllers, Process automation, Redundant controllers, Single point, Systems operation, Redundancy
National Category
Control Engineering
Identifiers
URN: urn:nbn:se:mdh:diva-69012DOI: 10.1109/ETFA61755.2024.10710940ISI: 001535140200183Scopus ID: 2-s2.0-85207816790ISBN: 9798350361230 (print)OAI: oai:DiVA.org:mdh-69012DiVA, id: diva2:1912923
Conference
29th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2024, Padova, 10 September 2024 through 13 September 2024
Available from: 2024-11-13 Created: 2024-11-13 Last updated: 2026-03-10Bibliographically 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, BjarneForsberg, HåkanNolte, ThomasPapadopoulos, Alessandro

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