Cyber Physical Systems (CPS) integrate computational intelligence with physical processes, improving efficiency of complex infrastructures. CPS subsystems are prone to faults arising from malfunctions, degradation, and wear and tear. Such faults pose a risk to maintaining system-level performance, particularly by interrupting the subsystem dependencies. This paper presents an online model-based fault-tolerant control framework for CPSs modeled as Finite State Automata (FSA). We introduce fault-tolerant strategies that use quantified FSA-based risk measures. These strategies enable proactive adjustment of the control policy such that solutions that may lead to control infeasibility under subsystem faults are prevented. Unlike approaches reliant on historical fault data, the proposed methods are suitable for systems with no prior fault records or with dynamically evolving requirements. The efficacy of these approaches is demonstrated through two case studies, highlighting their ability to maintain control feasibility in the presence of faults. Additionally, a comprehensive sensitivity analysis on randomly generated FSAs compares the fault-tolerance of the proposed controllers against cost-optimal control design. Results show that FSA-based risk quantification improves fault tolerance in online control.

We address the challenge of sequential data-driven decision-making under context distributional uncertainty. This problem arises in numerous real-world scenarios where the learner optimizes black-box objective functions in the presence of uncontrollable contextual variables. We consider the setting where the context distribution is uncertain but known to lie within an ambiguity set defined as a ball in the Wasserstein distance. We propose a novel algorithm for Wasserstein Distributionally Robust Bayesian Optimization that can handle continuous context distributions while maintaining computational tractability. Our theoretical analysis combines recent results in self-normalized concentration in Hilbert spaces and finite-sample bounds for distributionally robust optimization to establish sublinear regret bounds that match state-of-the-art results. Through extensive comparisons with existing approaches on both synthetic and real-world problems, we demonstrate the simplicity, effectiveness, and practical applicability of our proposed method.

Optimization-based controller tuning is challenging because it requires formulating optimization problems explicitly as functions of controller parameters. Safe learning algorithms overcome the challenge by creating surrogate models from measured data. To ensure safety, such data-driven algorithms often rely on exhaustive grid search, which is computationally inefficient. In this paper, we propose a novel approach to safe learning by formulating a series of optimization problems instead of a grid search. We also develop a method for initializing the optimization problems to guarantee feasibility while using numerical solvers. The performance of the new method is first validated in a simulated precision motion system, demonstrating improved computational efficiency, and illustrating the role of exploiting numerical solvers to reach the desired precision. Experimental validation on an industrial-grade precision motion system confirms that the proposed algorithm achieves 30% better tracking at sub-micrometer precision as a state-of-the-art safe learning algorithm, improves the default auto-tuning solution, and reduces the computational cost seven times compared to learning algorithms based on exhaustive search.

Controller tuning and parameter optimization are crucial in system design to improve closed-loop system performance. Bayesian optimization has been established as an efficient model-free controller tuning and adaptation method. However, Bayesian optimization methods are computationally expensive and therefore difficult to use in real-time critical scenarios. In this work, we propose a real-time purely data-driven, model-free approach for adaptive control, by online tuning low-level controller parameters. We base our algorithm on GoOSE, an algorithm for safe and sample-efficient Bayesian optimization, for handling performance and stability criteria. We introduce multiple computational and algorithmic modifications for computational efficiency and parallelization of optimization steps. We further evaluate the algorithm’s performance on a real precision-motion system utilized in the semiconductor industry applications by modifying the payload and reference stepsize and comparing it to an interpolated constrained optimization-based baseline approach.

In this paper, we study the problem of online tracking in linear control systems, where the objective is to follow a moving target. Unlike classical tracking control, the target is unknown, non-stationary, and its state is revealed sequentially, thus, fitting the framework of online non-stochastic control. We consider the case of quadratic costs and propose a new algorithm, called predictive linear online tracking (PLOT). The algorithm uses recursive least squares with exponential forgetting to learn a time-varying dynamic model of the target. The learned model is used in the optimal policy under the framework of receding horizon control. We show the dynamic regret of PLOT scales with $\mathcal{O}(\sqrt{TV_T})$, where $V_T$ is the total variation of the target dynamics and $T$ is the time horizon. Unlike prior work, our theoretical results hold for non-stationary targets. We implement our online control algorithm on a real quadrotor, thus, showcasing one of the first successful applications of online control methods on real hardware.

Smart manufacturing (SM) systems utilize run-time data to improve productivity via intelligent decision-making and analysis mechanisms on both machine and system levels. The increased adoption of cyber-physical systems in SM leads to the comprehensive framework of cyber-physical manufacturing systems (CPMS) where data-enabled decision-making mechanisms are coupled with cyber-physical resources on the plant floor. Due to their cyber-physical nature, CPMS are susceptible to cyber-attacks that may cause harm to the manufacturing system, products, or even the human workers involved in this context. Therefore, detecting cyber-attacks efficiently and timely is a crucial step toward implementing and securing high-performance CPMS in practice. This paper addresses two key challenges to CPMS cyber-attack detection. The first challenge is distinguishing expected anomalies in the system from cyber-attacks. The second challenge is the identification of cyber-attacks during the transient response of CPMS due to closed-loop controllers. Digital twin (DT) technology emerges as a promising solution for providing additional insights into the physical process (twin) by leveraging run-time data, models, and analytics. In this work, we propose a DT framework for detecting cyber-attacks in CPMS during controlled transient behavior as well as expected anomalies of the physical process. We present a DT framework and provide details on structuring the architecture to support cyber-attack detection. Additionally, we present an experimental case study on off-the-shelf 3D printers to detect cyber-attacks utilizing the proposed DT framework to illustrate the effectiveness of our proposed approach.Note to Practitioners—This work is motivated by developing a general-purpose and extensible digital twin-enabled cyber-attack detection framework for manufacturing systems. Existing works in the field consider specialized attack scenarios and models that may not be extensible in practical manufacturing scenarios. We utilize digital twin (DT) technology as a key enabler to develop a systematic and extensible framework where we identify the abnormality of a resource and detect if the abnormality is due to an attack or an expected anomaly. We provide several remarks on how our proposed framework can extend existing industrial control systems (ICS) and can accommodate further extensions. The presented DTs utilize data-driven machine learning models, physics-based models, and subject matter expert knowledge to perform detection and differentiation tasks in the context of expected anomalies and model-based controllers that control the manufacturing process between multiple setpoints. We utilize a model predictive controller on an off-the-shelf 3D printer to run the process, and stage anomalies and cyber-attacks that are successfully detected by the proposed framework.

Due to the advancements in manufacturing system technology and the ever-increasing demand for personalized products, there is a growing desire to improve the flexibility of manufacturing systems. Multi-agent control is one strategy that has been proposed to address this challenge. The multi-agent control strategy relies on the decision making and cooperation of a number of intelligent software agents to control and coordinate various components on the shop floor. One of the most important agents for this control strategy is the product agent, which is the decision maker for a single part in the manufacturing system. To improve the flexibility and adaptability of the product agent and its control strategy, this work proposes a direct and active cooperation framework for the product agent. The directly and actively cooperating product agent can identify and actively negotiate scheduling constraints with other agents in the system. A new modeling formalism, based on priced timed automata, and an optimization-based decision making strategy are proposed as part of the framework. Two simulation case studies showcase how direct and active cooperation can be used to improve the flexibility and performance of manufacturing systems. Note to Practitioners—An intelligent product is a product in a manufacturing system that is able to make decisions based on a set of specifications and affect its own production process. Intelligent products have often been proposed to address the challenges associated with small-batch manufacturing and highly customized production. Specifically, by using intelligent products, manufacturers would be able to complete small orders without the need to reconfigure or reschedule operations in the manufacturing system. However, one of the major challenges in the implementation of this control strategy is the need to develop methods that allow intelligent products to cooperate with machines, robots, and other products in a manufacturing system. In this work, we propose a novel direct and active cooperation framework that allows intelligent products to communicate and cooperate with other resources and products on the shop floor. Using the proposed cooperation framework, intelligent products can resolve scheduling conflicts and work together to meet individual specifications (e.g., deadlines). Two case studies, a small job shop and a large semiconductor manufacturing system, showcase how the proposed cooperation framework can be leveraged for different types of applications.

In this paper, we consider a cyber-physical manufacturing system (CPMS) scenario containing physical components (robots, sensors, and actuators), operating in a digitally connected, constrained environment to perform industrial tasks. The CPMS has a centralized control plane with digital twins (DTs) of the physical resources, computational resources, and a network manager that allocates network resources. Existing approaches for the allocation of network resources are typically fixed with respect to controller-dependent run-time specifications, which may impact the performance of physical processes. We propose a dynamic network management framework, where the network resource allocation schemes are controller-aware. The information about the controllers of the physical resources is implemented at the DT level, and metrics, such as regret bounds, take the process performance measures into account. The proposed network management schemes optimize physical system performance by balancing the shared resources between the physical assets on the plant floor, and by considering their control requirements, providing a new perspective for dynamic resource allocation. A simulation study is provided to illustrate the performance of the proposed network management approaches and compare their resource allocation performance efficiencies.

In current practice, product developers with customized small batch production needs come across the problem of finding capable and flexible manufacturers, whereas manufacturers face underutilization due to inconsistent demand. This paper presents a Production as a Service (PaaS) framework to connect users (consumers or product developers) who have customized small batch manufacturing needs with manufacturers who have existing underutilized resources. PaaS is a cloud-based, centralized framework based on a service-oriented architecture that abstracts the manufacturing steps of a product as individual (production) service requests. Using PaaS, the user is able to reach many capable manufacturers at once and receive quotations for the production request. On the other end, PaaS reduces the effort required to find new customers and enables the manufacturers to easily submit quotations to increase the utilization of their resources. The functionalities and concepts defined in this paper are illustrated through case studies. Note to Practitioners-In order to transition product fabrication from the design phase to manufacturing, there is a need for identifying capable manufacturers with available resources that could be paired with user requirements. We propose Production as a Service (PaaS) in this paper and present initial implementations of the front-end and back-end components with a customizable optimization algorithm. Proposed abstractions and data structures make PaaS a unique, efficient, and intellectual property preserving framework. The current implementation of the framework has been tested with new designs. The PaaS framework has the potential to scale over a large network of manufacturers to effectively coordinate geo-distributed manufacturers for custom manufacturing needs.