Automatic Recovery Planning and Execution Architecture for IEC 61131-3 Controlled Machinery

This paper presents an architecture for automated fault recovery in special-purpose machinery using standard IEC 61131-3 PLC control software. Building upon the MAPE-K paradigm (Monitor, Analyze, Plan, Execute with Knowledge), the proposed three-level architecture integrates runtime control via a previously presented modularization concept called Control Primitives, high-level reasoning using Regionalized Resource Process Dependence Graphs (RRPDGs), and an intermediate Resource Agent that bridges field-level execution and recovery planning. The architecture supports fully automated dynamic recovery and seamless resumption of productive operations while maintaining real-time reliability. Experimental evaluation demonstrates the scalability and low resource demands of the planning system across simulated scenarios and validates the concept on a lab-sized real-world demonstrator. The architecture and interfaces build a modular foundation for future research and industrial applications.