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May 28

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

Programmable Locking Cells (PLC) for Modular Robots with High Stiffness Tunability and Morphological Adaptability

Robotic systems operating in unstructured environments require the ability to switch between compliant and rigid states to perform diverse tasks such as adaptive grasping, high-force manipulation, shape holding, and navigation in constrained spaces, among others. However, many existing variable stiffness solutions rely on complex actuation schemes, continuous input power, or monolithic designs, limiting their modularity and scalability. This paper presents the Programmable Locking Cell (PLC)-a modular, tendon-driven unit that achieves discrete stiffness modulation through mechanically interlocked joints actuated by cable tension. Each unit transitions between compliant and firm states via structural engagement, and the assembled system exhibits high stiffness variation-up to 950% per unit-without susceptibility to damage under high payload in the firm state. Multiple PLC units can be assembled into reconfigurable robotic structures with spatially programmable stiffness. We validate the design through two functional prototypes: (1) a variable-stiffness gripper capable of adaptive grasping, firm holding, and in-hand manipulation; and (2) a pipe-traversing robot composed of serial PLC units that achieves shape adaptability and stiffness control in confined environments. These results demonstrate the PLC as a scalable, structure-centric mechanism for programmable stiffness and motion, enabling robotic systems with reconfigurable morphology and task-adaptive interaction.

  • 6 authors
·
Sep 9, 2025

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

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

Flight Controller Synthesis Via Deep Reinforcement Learning

Traditional control methods are inadequate in many deployment settings involving control of Cyber-Physical Systems (CPS). In such settings, CPS controllers must operate and respond to unpredictable interactions, conditions, or failure modes. Dealing with such unpredictability requires the use of executive and cognitive control functions that allow for planning and reasoning. Motivated by the sport of drone racing, this dissertation addresses these concerns for state-of-the-art flight control by investigating the use of deep neural networks to bring essential elements of higher-level cognition for constructing low level flight controllers. This thesis reports on the development and release of an open source, full solution stack for building neuro-flight controllers. This stack consists of the methodology for constructing a multicopter digital twin for synthesize the flight controller unique to a specific aircraft, a tuning framework for implementing training environments (GymFC), and a firmware for the world's first neural network supported flight controller (Neuroflight). GymFC's novel approach fuses together the digital twinning paradigm for flight control training to provide seamless transfer to hardware. Additionally, this thesis examines alternative reward system functions as well as changes to the software environment to bridge the gap between the simulation and real world deployment environments. Work summarized in this thesis demonstrates that reinforcement learning is able to be leveraged for training neural network controllers capable, not only of maintaining stable flight, but also precision aerobatic maneuvers in real world settings. As such, this work provides a foundation for developing the next generation of flight control systems.

  • 1 authors
·
Sep 13, 2019

Next-Generation LLM for UAV: From Natural Language to Autonomous Flight

With the rapid advancement of Large Language Models (LLMs), their capabilities in various automation domains, particularly Unmanned Aerial Vehicle (UAV) operations, have garnered increasing attention. Current research remains predominantly constrained to small-scale UAV applications, with most studies focusing on isolated components such as path planning for toy drones, while lacking comprehensive investigation of medium- and long-range UAV systems in real-world operational contexts. Larger UAV platforms introduce distinct challenges, including stringent requirements for airport-based take-off and landing procedures, adherence to complex regulatory frameworks, and specialized operational capabilities with elevated mission expectations. This position paper presents the Next-Generation LLM for UAV (NeLV) system -- a comprehensive demonstration and automation roadmap for integrating LLMs into multi-scale UAV operations. The NeLV system processes natural language instructions to orchestrate short-, medium-, and long-range UAV missions through five key technical components: (i) LLM-as-Parser for instruction interpretation, (ii) Route Planner for Points of Interest (POI) determination, (iii) Path Planner for waypoint generation, (iv) Control Platform for executable trajectory implementation, and (v) UAV monitoring. We demonstrate the system's feasibility through three representative use cases spanning different operational scales: multi-UAV patrol, multi-POI delivery, and multi-hop relocation. Beyond the current implementation, we establish a five-level automation taxonomy that charts the evolution from current LLM-as-Parser capabilities (Level 1) to fully autonomous LLM-as-Autopilot systems (Level 5), identifying technical prerequisites and research challenges at each stage.

  • 6 authors
·
Oct 1, 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

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

LLM4Drive: A Survey of Large Language Models for Autonomous Driving

Autonomous driving technology, a catalyst for revolutionizing transportation and urban mobility, has the tend to transition from rule-based systems to data-driven strategies. Traditional module-based systems are constrained by cumulative errors among cascaded modules and inflexible pre-set rules. In contrast, end-to-end autonomous driving systems have the potential to avoid error accumulation due to their fully data-driven training process, although they often lack transparency due to their "black box" nature, complicating the validation and traceability of decisions. Recently, large language models (LLMs) have demonstrated abilities including understanding context, logical reasoning, and generating answers. A natural thought is to utilize these abilities to empower autonomous driving. By combining LLM with foundation vision models, it could open the door to open-world understanding, reasoning, and few-shot learning, which current autonomous driving systems are lacking. In this paper, we systematically review a research line about Large Language Models for Autonomous Driving (LLM4AD). This study evaluates the current state of technological advancements, distinctly outlining the principal challenges and prospective directions for the field. For the convenience of researchers in academia and industry, we provide real-time updates on the latest advances in the field as well as relevant open-source resources via the designated link: https://github.com/Thinklab-SJTU/Awesome-LLM4AD.

  • 4 authors
·
Nov 2, 2023

Require Process Control? LSTMc is all you need!

Over the past three decades, numerous controllers have been developed to regulate complex chemical processes, but they have certain limitations. Traditional PI/PID controllers often require customized tuning for various set-point scenarios. On the other hand, MPC frameworks involve resource-intensive steps, and the utilization of black-box machine learning (ML) models can lead to issues such as local minima and infeasibility. Thus, there is a need for an alternative controller paradigm that combines the simplicity of a PI controller with the grade-to-grade (G2G) transferability of an MPC approach. To this end, we developed a novel LSTM controller (LSTMc) as a model-free data-driven controller framework. The LSTMc considers an augmented input tensor that incorporates information on state evolution and error dynamics for the current and previous W time steps, to predict the manipulated input at the next step (u_{t+1}). To demonstrate LSTMc, batch crystallization of dextrose was taken as a representative case study. The desired output for set-point tracking was the mean crystal size (L), with the manipulated input being the jacket temperature (T_j). Extensive training data, encompassing 7000+ different operating conditions, was compiled to ensure comprehensive training of LSTMc across a wide state space region. For comparison, we also designed a PI controller and an LSTM-MPC for different set-point tracking cases. The results consistently showed that LSTMc achieved the lowest set-point deviation (<2\%), three times lower than the MPC. Remarkably, LSTMc maintained this superior performance across all set points, even when sensor measurements contained noise levels of 10\% to 15\%. In summary, by effectively leveraging process data and utilizing sequential ML models, LSTMc offers a superior controller design approach.

  • 2 authors
·
Jun 12, 2023

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