Systems Engineering Approaches for Building Resilient Cyber-physical Systems

Delfina Concetta^*
*Correspondence: Delfina Concetta, Department of Physics, St. Petersburg State University, Universitetskaya Emb 13B, 199034 St. Petersburg, Russia, Email:

Introduction

In today’s rapidly advancing technological landscape, Cyber-Physical Systems (CPS) plays an increasingly critical role in everything from autonomous vehicles and smart grids to industrial automation and healthcare systems. These systems, which integrate physical components with computational algorithms and networks, are crucial in driving the future of smart cities, industrial operations and interconnected infrastructures. However, with the growing complexity and interdependence of CPS, ensuring their resilience defined as the ability to anticipate, absorb, adapt and recover from disruptions is paramount. Cyber-physical systems are inherently vulnerable to both cyber threats (such as hacking and data breaches) and physical disturbances (such as environmental factors, hardware malfunctions, or component failures). To address these vulnerabilities, a systems engineering approach is essential. Systems engineering, with its holistic and interdisciplinary methodology, provides the framework needed to design, analyze and manage the complexities of CPS. This review explores the role of systems engineering in building resilient CPS, examining the theoretical underpinnings, key strategies and practical applications of resilience engineering in CPS development [1].

Description

Cyber-physical systems are highly interconnected systems where physical processes (e.g., mechanical, electrical, or chemical) are controlled or monitored by computational units (software, algorithms and sensors) embedded in a network. CPS can be found in diverse domains, including transportation, manufacturing, energy, healthcare and smart environments. Despite their immense potential, CPS are vulnerable to a range of risks, both from cyber threats and physical hazards. Cyber threats such as cyberattacks, data breaches, or malware can compromise the data integrity and control mechanisms of CPS. For instance, in an autonomous vehicle, a successful cyberattack could manipulate sensor data or vehicle controls, leading to accidents or system malfunction. Similarly, physical risks like equipment failure, environmental changes, or natural disasters can also disrupt the operation of CPS. Resilience in CPS, therefore, requires that the system be robust against these threats and capable of continuing to function, albeit with reduced performance, or recover quickly from failure. To design CPS with resilience in mind, engineers must account for a variety of factors such as fault tolerance, redundancy, security and adaptability. Systems engineering encourages viewing a system as a whole, considering interactions between components and subsystems. In CPS, this holistic perspective helps engineers to identify potential vulnerabilities, interdependencies and failure modes across both physical and cyber components. Stakeholder Involvement: Successful systems engineering requires input from all stakeholders, including end users, operators and external entities such as regulatory bodies. For CPS, involving stakeholders in the design phase ensures that resilience needs are accurately captured, such as safety requirements, cybersecurity standards and operational constraints. Model-Based Systems Engineering (MBSE) uses graphical models to represent systems and their behaviors, facilitating analysis, verification and validation of CPS designs. This approach allows engineers to simulate different scenarios, such as failures or cyberattacks and test the system’s response before deployment [2].

Systems engineering incorporates systematic risk assessment and management techniques, which are essential for identifying and mitigating potential vulnerabilities in CPS. Risk management tools, such as Failure Mode Effects Analysis (FMEA) or Fault Tree Analysis (FTA), are commonly employed to assess both cyber and physical risks and inform resilience strategies. Prevention is often the first line of defense in building resilient CPS. Systems engineering promotes the incorporation of fault-tolerant and redundant components within the CPS architecture to prevent failures before they occur. Redundancy is a fundamental strategy for ensuring resilience. By incorporating backup components or subsystems that take over in case of failure, CPS can continue functioning without major interruptions. For example, in critical infrastructure such as power grids, multiple power sources or backup communication lines can prevent system failures during emergencies. Fault Isolation and Containment: In systems with complex interdependencies, a fault in one component can cascade through the system, leading to a wider failure. Using design techniques that isolate faults and contain their effects can help prevent this cascading impact. For example, modular system designs can allow for quick isolation and replacement of faulty components [3,4].

Cybersecurity is integral to preventing attacks that can compromise the resilience of CPS. Systems engineering incorporates secure design practices, such as encryption, intrusion detection systems and access control mechanisms, to prevent unauthorized access and tampering with cyber-physical processes. Detection involves the continuous monitoring of CPS to identify anomalies or early signs of failure. Through real-time data collection and advanced algorithms, systems can detect both cyber and physical disruptions. Sensors play a critical role in CPS, enabling continuous monitoring of both the physical environment (e.g., temperature, pressure) and the system’s internal state (e.g., processor load, network traffic). Monitoring systems alert operators to unusual conditions, enabling early intervention. Anomaly detection advanced data analytics and machine learning techniques are employed to identify anomalies in CPS behavior. By comparing real-time data to expected system behavior, it is possible to detect irregularities that may indicate impending system failure or cyberattacks. In the event of an incident, a resilient CPS should be capable of responding and adapting to minimize the impact of the failure. Some advanced CPS designs incorporate self-healing capabilities, where the system can automatically identify and fix certain types of faults without human intervention. Self-adaptation techniques enable the system to change its behavior in response to environmental or operational changes [5].

Autonomous Decision making in critical systems, such as autonomous vehicles or drones, decision-making algorithms enable CPS to adjust their actions in response to unexpected events. For example, an autonomous vehicle may switch to a backup route if it detects a hazard ahead, ensuring that the vehicle can continue operating safely. Even with the best preventative and adaptive measures, some failures are inevitable. Thus, recovery is another essential component of resilient CPS. In case of a catastrophic failure, failover systems automatically switch to a backup mode to restore functionality. This is common in communication networks, where if one server fails, traffic is rerouted to another server to maintain service continuity. Systems engineering emphasizes the importance of setting Recovery Time Objectives (RTOs)—the maximum allowable time that a system can be down before it negatively impacts stakeholders. Defining RTOs helps in designing systems that prioritize fast recovery when disruptions occur.

Autonomous vehicles rely on an intricate integration of sensors, algorithms and actuators to operate safely. Systems engineering approaches, such as redundancy in sensor systems (e.g., LIDAR, radar, cameras), fault detection and cybersecurity, are critical to ensure that these vehicles continue to function in the face of cyberattacks or mechanical failures. Smart grids, which integrate information technology with energy networks, require resilience against both cyber and physical disruptions. Systems engineering ensures the integration of secure communication channels, fault-tolerant power distribution systems and rapid recovery mechanisms to maintain grid stability during incidents. Industrial control systems, which manage manufacturing and other critical industrial processes, depend on resilient CPS to avoid production downtime or hazardous failures. Systems engineering helps ensure the integration of robust control algorithms, real-time monitoring and redundancy strategies to maintain safe and efficient operations. CPS are increasingly used in healthcare for patient monitoring, robotic surgery and even drug delivery systems. Given the safety-critical nature of healthcare, systems engineering ensures resilience by addressing both cybersecurity threats (e.g., data breaches) and physical hazards (e.g., equipment failure), while maintaining regulatory compliance.

Conclusion

As cyber-physical systems continue to permeate every facet of modern life, ensuring their resilience is not just a technical necessity, but a matter of public safety, economic stability and societal trust. Systems engineering offers a comprehensive approach to designing, analyzing and managing CPS resilience, addressing both the cyber and physical challenges inherent in these systems. From preventive measures like redundancy and fault isolation to adaptive techniques like self-healing and recovery, systems engineering principles provide the necessary tools for building CPS that are both robust and adaptable in the face of disruptions. Moving forward, as CPS become more sophisticated and widespread, continued advances in systems engineering methodologies, coupled with emerging technologies such as machine learning, AI and IoT, will further enhance the resilience of these systems. However, engineers and designers must remain vigilant in addressing new risks and complexities as they arise, ensuring that resilience is not merely an afterthought but a foundational design principle. Building resilient CPS is a multidisciplinary challenge that requires ongoing collaboration, innovation and research, but with the right systems engineering strategies in place, these challenges can be met, ensuring that cyber-physical systems serve their intended purpose safely and effectively for years to come.

Acknowledgment

None.

Conflict of Interest

None.

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