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Jul 9

Agents4PLC: Automating Closed-loop PLC Code Generation and Verification in Industrial Control Systems using LLM-based Agents

In industrial control systems, the generation and verification of Programmable Logic Controller (PLC) code are critical for ensuring operational efficiency and safety. While Large Language Models (LLMs) have made strides in automated code generation, they often fall short in providing correctness guarantees and specialized support for PLC programming. To address these challenges, this paper introduces Agents4PLC, a novel framework that not only automates PLC code generation but also includes code-level verification through an LLM-based multi-agent system. We first establish a comprehensive benchmark for verifiable PLC code generation area, transitioning from natural language requirements to human-written-verified formal specifications and reference PLC code. We further enhance our `agents' specifically for industrial control systems by incorporating Retrieval-Augmented Generation (RAG), advanced prompt engineering techniques, and Chain-of-Thought strategies. Evaluation against the benchmark demonstrates that Agents4PLC significantly outperforms previous methods, achieving superior results across a series of increasingly rigorous metrics. This research not only addresses the critical challenges in PLC programming but also highlights the potential of our framework to generate verifiable code applicable to real-world industrial applications.

  • 8 authors
·
Oct 18, 2024

ProvICS: A Provenance-based Intrusion Detection for Industrial Control Systems

The convergence of Information Technology and Operational Technology has exposed Industrial Control Systems (ICS) to multi-stage cyberattacks that traverse software, network, and physical process layers simultaneously. Although Provenance-based Intrusion Detection Systems (PIDS) are effective in Information Technology (IT) environments, their applicability to Industrial Cyber-Physical Systems (CPS) remains largely unexplored because of the absence of datasets that jointly capture host-level causal behavior, industrial network semantics, and physical process state. To address this gap, we design an open-source, Hardware-in-the-Loop (HIL) CPS testbed that replicates an industrial chemical reactor control architecture across the Purdue model layers. Using this testbed, we propose ProvICS, a multimodal provenance dataset purpose-built for CPS intrusion detection, which synchronously captures four streams: whole-system provenance graphs from the supervisory host and the resource-constrained PLC, decoded Modbus deep-packet inspection records, and physical process telemetry. The collection comprises a 48-hour benign phase and a 22-hour attack phase across four campaigns covering 20 ICS ATT&CK techniques over 32 attack events, ranging from reconnaissance to physical process manipulation. Comparative analysis shows that ProvICS is among the few existing ICS/CPS benchmarks with multi-host kernel-level provenance, real PLC hardware-in-the-loop execution, decoded Modbus traffic, physical process-state measurements, and auxiliary raw PCAP traces in a time-synchronized collection. Baseline detection further confirms that cross-modal fusion can detect all 32 labeled attack events (F1 = 0.913, false-positive rate (FPR) = 1.40%), demonstrating the dataset's ability to expose complementary attack signals across modalities and addressing a gap not covered by prior benchmarks.

  • 2 authors
·
Jul 6

LLMPot: Automated LLM-based Industrial Protocol and Physical Process Emulation for ICS Honeypots

Industrial Control Systems (ICS) are extensively used in critical infrastructures ensuring efficient, reliable, and continuous operations. However, their increasing connectivity and addition of advanced features make them vulnerable to cyber threats, potentially leading to severe disruptions in essential services. In this context, honeypots play a vital role by acting as decoy targets within ICS networks, or on the Internet, helping to detect, log, analyze, and develop mitigations for ICS-specific cyber threats. Deploying ICS honeypots, however, is challenging due to the necessity of accurately replicating industrial protocols and device characteristics, a crucial requirement for effectively mimicking the unique operational behavior of different industrial systems. Moreover, this challenge is compounded by the significant manual effort required in also mimicking the control logic the PLC would execute, in order to capture attacker traffic aiming to disrupt critical infrastructure operations. In this paper, we propose LLMPot, a novel approach for designing honeypots in ICS networks harnessing the potency of Large Language Models (LLMs). LLMPot aims to automate and optimize the creation of realistic honeypots with vendor-agnostic configurations, and for any control logic, aiming to eliminate the manual effort and specialized knowledge traditionally required in this domain. We conducted extensive experiments focusing on a wide array of parameters, demonstrating that our LLM-based approach can effectively create honeypot devices implementing different industrial protocols and diverse control logic.

  • 5 authors
·
May 9, 2024

6G-Enabled Digital Twin Framework for Real-Time Cyber-Physical Systems: An Experimental Validation with Industrial Bearing Fault Detection

Current Cyber-Physical Systems (CPS) integrated with Digital Twin (DT) technology face critical limitations in achieving real-time performance for mission-critical industrial applications. Existing 5G-enabled systems suffer from latencies exceeding 10ms, which are inadequate for applications requiring sub-millisecond response times, such as autonomous industrial control and predictive maintenance. This research aims to develop and validate a 6G-enabled Digital Twin framework that achieves ultra-low latency communication and real-time synchronization between physical industrial assets and their digital counterparts, specifically targeting bearing fault detection as a critical industrial use case. The proposed framework integrates terahertz communications (0.1-1 THz), intelligent reflecting surfaces, and edge artificial intelligence within a five-layer architecture. Experimental validation was conducted using the Case Western Reserve University (CWRU) bearing dataset, implementing comprehensive feature extraction (15 time and frequency domain features) and Random Forest classification algorithms. The system performance was evaluated against traditional WiFi-6 and 5G networks across multiple metrics, including classification accuracy, end-to-end latency, and scalability. It achieved 97.7% fault classification accuracy with 0.8ms end-to-end latency, representing a 15.6x improvement over WiFi-6 (12.5ms) and 5.25x improvement over 5G (4.2ms) networks. The system demonstrated superior scalability with sub-linear processing time growth and maintained consistent performance across four bearing fault categories (normal, inner race, outer race, and ball faults) with macro-averaged F1-scores exceeding 97%.

  • 2 authors
·
Oct 4, 2025

Hybrid Reasoning for Perception, Explanation, and Autonomous Action in Manufacturing

Industrial processes must be robust and adaptable, as environments and tasks are often unpredictable, while operational errors remain costly and difficult to detect. AI-based control systems offer a path forward, yet typically depend on supervised learning with extensive labelled datasets, which limits their ability to generalize across variable and data-scarce industrial settings. Foundation models could enable broader reasoning and knowledge integration, but rarely deliver the quantitative precision demanded by engineering applications. Here, we introduceControl and Interpretation of Production via Hybrid Expertise and Reasoning (CIPHER): a vision-language-action (VLA) model framework aiming to replicate human-like reasoning for industrial control, instantiated in a commercial-grade 3D printer. It integrates a process expert, a regression model enabling quantitative characterization of system states required for engineering tasks. CIPHER also incorporates retrieval-augmented generation to access external expert knowledge and support physics-informed, chain-of-thought reasoning. This hybrid architecture exhibits strong generalization to out-of-distribution tasks. It interprets visual or textual inputs from process monitoring, explains its decisions, and autonomously generates precise machine instructions, without requiring explicit annotations. CIPHER thus lays the foundations for autonomous systems that act with precision, reason with context, and communicate decisions transparently, supporting safe and trusted deployment in industrial settings.

  • 2 authors
·
Jun 10, 2025

Securing AI Agents: Implementing Role-Based Access Control for Industrial Applications

The emergence of Large Language Models (LLMs) has significantly advanced solutions across various domains, from political science to software development. However, these models are constrained by their training data, which is static and limited to information available up to a specific date. Additionally, their generalized nature often necessitates fine-tuning -- whether for classification or instructional purposes -- to effectively perform specific downstream tasks. AI agents, leveraging LLMs as their core, mitigate some of these limitations by accessing external tools and real-time data, enabling applications such as live weather reporting and data analysis. In industrial settings, AI agents are transforming operations by enhancing decision-making, predictive maintenance, and process optimization. For example, in manufacturing, AI agents enable near-autonomous systems that boost productivity and support real-time decision-making. Despite these advancements, AI agents remain vulnerable to security threats, including prompt injection attacks, which pose significant risks to their integrity and reliability. To address these challenges, this paper proposes a framework for integrating Role-Based Access Control (RBAC) into AI agents, providing a robust security guardrail. This framework aims to support the effective and scalable deployment of AI agents, with a focus on on-premises implementations.

  • 1 authors
·
Sep 14, 2025

PyScrew: A Comprehensive Dataset Collection from Industrial Screw Driving Experiments

This paper presents a comprehensive collection of industrial screw driving datasets designed to advance research in manufacturing process monitoring and quality control. The collection comprises six distinct datasets with over 34,000 individual screw driving operations conducted under controlled experimental conditions, capturing the multifaceted nature of screw driving processes in plastic components. Each dataset systematically investigates specific aspects: natural thread degradation patterns through repeated use (s01), variations in surface friction conditions including contamination and surface treatments (s02), diverse assembly faults with up to 27 error types (s03-s04), and fabrication parameter variations in both upper and lower workpieces through modified injection molding settings (s05-s06). We detail the standardized experimental setup used across all datasets, including hardware specifications, process phases, and data acquisition methods. The hierarchical data model preserves the temporal and operational structure of screw driving processes, facilitating both exploratory analysis and the development of machine learning models. To maximize accessibility, we provide dual access pathways: raw data through Zenodo with a persistent DOI, and a purpose-built Python library (PyScrew) that offers consistent interfaces for data loading, preprocessing, and integration with common analysis workflows. These datasets serve diverse research applications including anomaly detection, predictive maintenance, quality control system development, feature extraction methodology evaluation, and classification of specific error conditions. By addressing the scarcity of standardized, comprehensive datasets in industrial manufacturing, this collection enables reproducible research and fair comparison of analytical approaches in an area of growing importance for industrial automation.

  • 2 authors
·
May 16, 2025

Effective control of two-dimensional Rayleigh--Bénard convection: invariant multi-agent reinforcement learning is all you need

Rayleigh-B\'enard convection (RBC) is a recurrent phenomenon in several industrial and geoscience flows and a well-studied system from a fundamental fluid-mechanics viewpoint. However, controlling RBC, for example by modulating the spatial distribution of the bottom-plate heating in the canonical RBC configuration, remains a challenging topic for classical control-theory methods. In the present work, we apply deep reinforcement learning (DRL) for controlling RBC. We show that effective RBC control can be obtained by leveraging invariant multi-agent reinforcement learning (MARL), which takes advantage of the locality and translational invariance inherent to RBC flows inside wide channels. The MARL framework applied to RBC allows for an increase in the number of control segments without encountering the curse of dimensionality that would result from a naive increase in the DRL action-size dimension. This is made possible by the MARL ability for re-using the knowledge generated in different parts of the RBC domain. We show in a case study that MARL DRL is able to discover an advanced control strategy that destabilizes the spontaneous RBC double-cell pattern, changes the topology of RBC by coalescing adjacent convection cells, and actively controls the resulting coalesced cell to bring it to a new stable configuration. This modified flow configuration results in reduced convective heat transfer, which is beneficial in several industrial processes. Therefore, our work both shows the potential of MARL DRL for controlling large RBC systems, as well as demonstrates the possibility for DRL to discover strategies that move the RBC configuration between different topological configurations, yielding desirable heat-transfer characteristics. These results are useful for both gaining further understanding of the intrinsic properties of RBC, as well as for developing industrial applications.

  • 6 authors
·
Apr 5, 2023

Verified Synthesis of Optimal Safety Controllers for Human-Robot Collaboration

We present a tool-supported approach for the synthesis, verification and validation of the control software responsible for the safety of the human-robot interaction in manufacturing processes that use collaborative robots. In human-robot collaboration, software-based safety controllers are used to improve operational safety, e.g., by triggering shutdown mechanisms or emergency stops to avoid accidents. Complex robotic tasks and increasingly close human-robot interaction pose new challenges to controller developers and certification authorities. Key among these challenges is the need to assure the correctness of safety controllers under explicit (and preferably weak) assumptions. Our controller synthesis, verification and validation approach is informed by the process, risk analysis, and relevant safety regulations for the target application. Controllers are selected from a design space of feasible controllers according to a set of optimality criteria, are formally verified against correctness criteria, and are translated into executable code and validated in a digital twin. The resulting controller can detect the occurrence of hazards, move the process into a safe state, and, in certain circumstances, return the process to an operational state from which it can resume its original task. We show the effectiveness of our software engineering approach through a case study involving the development of a safety controller for a manufacturing work cell equipped with a collaborative robot.

  • 8 authors
·
Jun 11, 2021

Reinforcement Learning of Display Transfer Robots in Glass Flow Control Systems: A Physical Simulation-Based Approach

A flow control system is a critical concept for increasing the production capacity of manufacturing systems. To solve the scheduling optimization problem related to the flow control with the aim of improving productivity, existing methods depend on a heuristic design by domain human experts. Therefore, the methods require correction, monitoring, and verification by using real equipment. As system designs increase in complexity, the monitoring time increases, which decreases the probability of arriving at the optimal design. As an alternative approach to the heuristic design of flow control systems, the use of deep reinforcement learning to solve the scheduling optimization problem has been considered. Although the existing research on reinforcement learning has yielded excellent performance in some areas, the applicability of the results to actual FAB such as display and semiconductor manufacturing processes is not evident so far. To this end, we propose a method to implement a physical simulation environment and devise a feasible flow control system design using a transfer robot in display manufacturing through reinforcement learning. We present a model and parameter setting to build a virtual environment for different display transfer robots, and training methods of reinforcement learning on the environment to obtain an optimal scheduling of glass flow control systems. Its feasibility was verified by using different types of robots used in the actual process.

  • 3 authors
·
Oct 11, 2023

Analog and Multi-modal Manufacturing Datasets Acquired on the Future Factories Platform V2

This paper presents two industry-grade datasets captured during an 8-hour continuous operation of the manufacturing assembly line at the Future Factories Lab, University of South Carolina, on 08/13/2024. The datasets adhere to industry standards, covering communication protocols, actuators, control mechanisms, transducers, sensors, and cameras. Data collection utilized both integrated and external sensors throughout the laboratory, including sensors embedded within the actuators and externally installed devices. Additionally, high-performance cameras captured key aspects of the operation. In a prior experiment [1], a 30-hour continuous run was conducted, during which all anomalies were documented. Maintenance procedures were subsequently implemented to reduce potential errors and operational disruptions. The two datasets include: (1) a time-series analog dataset, and (2) a multi-modal time-series dataset containing synchronized system data and images. These datasets aim to support future research in advancing manufacturing processes by providing a platform for testing novel algorithms without the need to recreate physical manufacturing environments. Moreover, the datasets are open-source and designed to facilitate the training of artificial intelligence models, streamlining research by offering comprehensive, ready-to-use resources for various applications and projects.

  • 11 authors
·
Feb 7, 2025

Leveraging Cloud-Fog Automation for Autonomous Collision Detection and Classification in Intelligent Unmanned Surface Vehicles

Industrial Cyber-Physical Systems (ICPS) technologies are foundational in driving maritime autonomy, particularly for Unmanned Surface Vehicles (USVs). However, onboard computational constraints and communication latency significantly restrict real-time data processing, analysis, and predictive modeling, hence limiting the scalability and responsiveness of maritime ICPS. To overcome these challenges, we propose a distributed Cloud-Edge-IoT architecture tailored for maritime ICPS by leveraging design principles from the recently proposed Cloud-Fog Automation paradigm. Our proposed architecture comprises three hierarchical layers: a Cloud Layer for centralized and decentralized data aggregation, advanced analytics, and future model refinement; an Edge Layer that executes localized AI-driven processing and decision-making; and an IoT Layer responsible for low-latency sensor data acquisition. Our experimental results demonstrated improvements in computational efficiency, responsiveness, and scalability. When compared with our conventional approaches, we achieved a classification accuracy of 86\%, with an improved latency performance. By adopting Cloud-Fog Automation, we address the low-latency processing constraints and scalability challenges in maritime ICPS applications. Our work offers a practical, modular, and scalable framework to advance robust autonomy and AI-driven decision-making and autonomy for intelligent USVs in future maritime ICPS.

  • 7 authors
·
Jun 22, 2025

IndustryBench-MIPU: Benchmarking Multi-Image Attribute Value Extraction for Industrial Products

Industrial products such as valves and circuit breakers are defined by dense technical specifications that govern procurement, compatibility, and safety across supply chains. These specifications are scattered across multiple heterogeneous product images, including specification tables, nameplates, and technical drawings, yet whether Multimodal Large Language Models (MLLMs) can reliably recover them remains underexplored. To fill this gap, we introduce IndustryBench-MIPU, the first large-scale benchmark for multi-image industrial product understanding, built around structured attribute extraction -- recovering property-value pairs from product images. This task jointly probes text recognition on specification tables and nameplates, visual reasoning over technical drawings, domain knowledge to decode industrial terminology, and cross-image evidence integration to assemble scattered specifications. Concretely, the benchmark comprises 4,559 products across 27,652 images with 103,703 annotations spanning 18 industrial categories, constructed through multi-model consensus and three-tier quality assurance. Evaluating nine MLLMs under both single-image and product-level multi-image settings reveals a stark completeness gap: models achieve high precision (86--94%) but the best recovers only 49.9% of product-level attributes; moving from single-image to multi-image extraction costs 15--34 percentage points of recall. Multi-image completeness, not single-image accuracy, is the core bottleneck. Dataset and code are publicly available.

Reachable Set Estimation for Neural Network Control Systems: A Simulation-Guided Approach

The vulnerability of artificial intelligence (AI) and machine learning (ML) against adversarial disturbances and attacks significantly restricts their applicability in safety-critical systems including cyber-physical systems (CPS) equipped with neural network components at various stages of sensing and control. This paper addresses the reachable set estimation and safety verification problems for dynamical systems embedded with neural network components serving as feedback controllers. The closed-loop system can be abstracted in the form of a continuous-time sampled-data system under the control of a neural network controller. First, a novel reachable set computation method in adaptation to simulations generated out of neural networks is developed. The reachability analysis of a class of feedforward neural networks called multilayer perceptrons (MLP) with general activation functions is performed in the framework of interval arithmetic. Then, in combination with reachability methods developed for various dynamical system classes modeled by ordinary differential equations, a recursive algorithm is developed for over-approximating the reachable set of the closed-loop system. The safety verification for neural network control systems can be performed by examining the emptiness of the intersection between the over-approximation of reachable sets and unsafe sets. The effectiveness of the proposed approach has been validated with evaluations on a robotic arm model and an adaptive cruise control system.

  • 4 authors
·
Apr 25, 2020

Artificial intelligence in cyber physical systems

This article conducts a literature review of current and future challenges in the use of artificial intelligence (AI) in cyber physical systems. The literature review is focused on identifying a conceptual framework for increasing resilience with AI through automation supporting both, a technical and human level. The methodology applied resembled a literature review and taxonomic analysis of complex internet of things (IoT) interconnected and coupled cyber physical systems. There is an increased attention on propositions on models, infrastructures and frameworks of IoT in both academic and technical papers. These reports and publications frequently represent a juxtaposition of other related systems and technologies (e.g. Industrial Internet of Things, Cyber Physical Systems, Industry 4.0 etc.). We review academic and industry papers published between 2010 and 2020. The results determine a new hierarchical cascading conceptual framework for analysing the evolution of AI decision-making in cyber physical systems. We argue that such evolution is inevitable and autonomous because of the increased integration of connected devices (IoT) in cyber physical systems. To support this argument, taxonomic methodology is adapted and applied for transparency and justifications of concepts selection decisions through building summary maps that are applied for designing the hierarchical cascading conceptual framework.

  • 5 authors
·
Mar 11, 2019