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Replacement Controller for IoT-Enabled Dependable Control Systems

The one-layer architecture for operational technology systems with a ‘private machine-cloud’ together with self-reliant controllers has been presented in previous work. The dependability of the new control system can be quantified thanks to the fault-tolerant structure of multiple processors and the IoT connectivity within the private machine-cloud. As an essential part of this work, a Replacement Controller is developed for the associated self-reliant controller running the model predictive control (MPC) algorithm (called self-reliant MPC). Comprehensive simulation results for three multi-variable systems comprising a paper machine, a helicopter, and a railway wheel set with bogie technically illustrate the effectiveness of the presented Replacement Controller. The Replacement Controller has significantly improved the control performance of the self-reliant MPC when the switching-over between the duty and standby MPCs takes a relatively long time to complete. The one-layer architecture is necessarily modified with embedded Multivariable Stations for installing the Replacement Controllers to ensure that the control performance of the self-reliant MPC is maintained in the presence of sustained communication interruptions between the duty and standby processors.