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An interactive learning approach on digital twin for deriving the controller logic in IEC 61499 standard
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Computer Science.ORCID iD: 0000-0003-3371-6075
Independent researcher.
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Computer Science.ORCID iD: 0000-0003-2936-4185
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Computer Science. Department of Electrical Engineering and Automation, Aalto University, Espoo, Finland.ORCID iD: 0000-0002-9315-9920
2022 (English)In: 2022 IEEE 27th International Conference on Emerging Technologies and Factory Automation (ETFA), IEEE, 2022Conference paper, Published paper (Refereed)
Abstract [en]

In this paper, we describe a method to automatically derive the controller for an automated process by an interactive learning approach using a simulation model developed in Visual Components 3D simulation software. The latter is used to record the events of the processes and the controller is generated as an IEC 61499 function block. To create different process scenarios, the actuator signals are triggered manually in appropriate order. The controller logic in Petri net is derived by process discovery algorithms with help of recorded events and conversion of Petri net to IEC 61499 function blocks is done by a software tool configured with a set of transformation rules.

Place, publisher, year, edition, pages
IEEE, 2022.
Keywords [en]
cyber-physical automation systems, IEC 61499, Process discovery, Visual Components
National Category
Computer Sciences
Research subject
Dependable Communication and Computation Systems
Identifiers
URN: urn:nbn:se:ltu:diva-94175DOI: 10.1109/ETFA52439.2022.9921602ISI: 000934103900156Scopus ID: 2-s2.0-85141370199OAI: oai:DiVA.org:ltu-94175DiVA, id: diva2:1712201
Conference
27th International Conference on Emerging Technologies and Factory Automation (ETFA 2022), Stuttgart, Germany, September 6-9, 2022
Projects
1-SWARM
Funder
EU, Horizon 2020, 871743
Note

ISBN för värdpublikation: 978-1-6654-9996-5

Available from: 2022-11-21 Created: 2022-11-21 Last updated: 2025-10-21Bibliographically approved
In thesis
1. Enabling dependable flexibility in industrial automation with formal methods integrated to development toolchains
Open this publication in new window or tab >>Enabling dependable flexibility in industrial automation with formal methods integrated to development toolchains
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Enabling dependable flexibility in industrial automation requires architectures that can adapt to evolving system requirements without compromising safety, reliability, or performance. One of the major challenges in this context is balancing dependability with flexibility. As systems evolve, rapid revalidation becomes essential. Automatic testing plays a crucial role in addressing this by enabling quick verification after changes. However, in safety-critical systems, automatic testing alone is insufficient. To ensure correctness and reliability, formal verification techniques are required. Closed-loop verification helps mitigate state-space explosion by integrating plant models with the control logic, allowing for more rigorous analysis. Another key challenge lies in obtaining appropriate models of the physical plant for verification. One practical solution is to leverage existing simulation models, discretize them, and inject non-determinism to represent execution uncertainties. Process mining techniques facilitate the construction of plant models by analyzing event logs from digital twins, providing an accurate representation of system behavior. This approach ensures robust validation, verifying system performance under diverse conditions and operational uncertainties. 

Within this context, IEC 61499 provides a modular and event-driven framework for designing control systems, enabling distributed control through function blocks (FBs). This architecture enhances reusability, interoperability, and scalability, making it well-suited for cyber-physical automation systems and reconfigurable manufacturing. Blockchain based traceability enhances security and ensures verification in flexible production system. AI-driven automation further optimizes industrial control by enabling intelligent decision-making, real-time adjustments, and process adaptation. AI agents, leveraging large language models (LLMs) and knowledge graphs (KGs), enhance human-machine collaboration by analyzing tasks and executing actions via OPC UA. These agents can interpret operator instructions, generate and validate execution sequences, and ensure conformance with specified requirements to support reliable and adaptive industrial automation. 

Place, publisher, year, edition, pages
Luleå: Luleå University of Technology, 2025
Series
Doctoral thesis / Luleå University of Technology 1 jan 1997 → …, ISSN 1402-1544
Keywords
Formal verification, Process mining, Agentic AI, IEC 61499
National Category
Computer Systems
Research subject
Dependable Communication and Computation Systems
Identifiers
urn:nbn:se:ltu:diva-114743 (URN)978-91-8048-901-0 (ISBN)978-91-8048-902-7 (ISBN)
Public defence
2025-10-21, C305, Luleå University of Technology, Lulea, 13:00 (English)
Opponent
Supervisors
Available from: 2025-09-18 Created: 2025-09-17 Last updated: 2025-10-21Bibliographically approved

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Xavier, MidhunPatil, SandeepVyatkin, Valeriy

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