The challenge of keeping the development and implementation of real-time control systems reliable and efficient and at the same time, low-cost and low-energy, is getting harder. This is because system designers and developers are faced with the dependability, inflexibility and often high-cost of specialized or custom-built hardware and software components. This research attempts to tackle issues such as the reliability and efficiency of real-time control systems and advance further the current state-of-the-art. For this purpose, a strong emphasis is placed on finding novel efficient solutions based on standardized and commercially available off-the-shelf hardware/software components. In this direction, this research applies credible and feasible methodologies (e.g., model-based design, component-based design, formal verification, real-time scheduling, prototyping, and validation) in an innovative enhanced way. As an important outcome, a versatile integrative design approach and architectural framework (VIDAF) is proposed, which supports the development and implementation of reliable real-time control systems and applications using commercial off-the-shelf (COTS) components. The feasibility and applicability of the proposed system’s architecture are evaluated and validated through a system application in embedded real-time control in manufacturing. The research outcomes are expected to have a positive impact on emerging areas such as the Industrial Internet of Things (IIoT).

The progress of embedded control systems in the last several years has made possible the realization of highly-effective controllers in many domains. It is essential for such systems to provide effective performance at an affordable cost. Furthermore, real-time embedded control systems must have low energy consumption, as well as be reliable and timely. This research investigates primarily the feasibility of implementing an embedded real-time control system, based on a low-cost, commercially off-the-shelf (COTS) microcontroller platform. It explores real-time issues, such as the reliability and timely response, of such a system implementation. This work presents the development and performance evaluation of a novel real-time control architecture, based upon a BeagleBoard microcontroller, and applied into the PWM (pulse width modulation) control of a three-phase induction motor in a suction pump. The approach followed makes minimal use of general-purpose hardware (BeagleBone Black microcontroller board) and open-source software components (including Linux Operating System with PREEMPT_RT real-time support) for building a reliable real-time control system. The applicability of the proposed control system architecture is validated and evaluated in a real case study in manufacturing. The results provide sufficient evidence of the efficiency and reliability of the proposed approach into the development of a real-time control system based upon COTS components.