Cyber-Physical System

Cyber-Physical System (CPS) explained simply

Imagine your favourite toy robot – but a really smart one. It senses when an obstacle is coming, thinks, connects with other robots and makes decisions – all without your involvement. This is exactly how a Cyber-Physical System (CPS) works: a clever combination of physical machines and intelligent software that communicate with each other via networks, exchange data in real time and react independently – so that processes run smoothly and efficiently.

Background information

A CPS is the close integration of physical components (machines, sensors, actuators) with software-based processing and networking via data infrastructure such as the Internet. These systems allow the control, monitoring and optimisation of real processes in real time.

CPS can be found in numerous applications – from autonomous vehicles to smart grids to robots in production. They form the basis for the next stage of digitalisation, as they not only map physical processes but actively control them and synchronise them with digital twins.

Technology building blocks in CPS

A Cyber-Physical System consists of several layers and technologies that are interlinked:

Sensors & Actuators: Sensors record physical variables such as temperature, pressure, speed or vibration. Actuators immediately translate digital decisions into physical movements or interventions – from the robot arm to the valve.
Embedded systems & real-time processing: Microcontrollers and embedded systems analyse data directly on site. They ensure that decisions can be implemented within milliseconds – crucial in safety-critical processes such as autonomous driving.
Network communication & protocols: Data is transmitted via industrial networks and the Internet. Standards such as OPC UA, MQTT or TSN (Time-Sensitive Networking) ensure that machines can communicate reliably with each other, even across different manufacturers.
Software & intelligence: At a higher level, AI algorithms and data analyses come into play. They detect patterns, optimise processes and make predictive or even autonomous decisions.
Integration into digital platforms: CPS are often part of larger IT ecosystems – such as cloud platforms, MES (Manufacturing Execution Systems) or ERP systems – and thus enable end-to-end transparency from the sensor to the management dashboard.

CPS in the context of Industry 4.0Fourth industrial revolution through digitalization and intelligent networking of production facilities.

In Industry 4.0, CPS form the technological foundation. They make it possible for machines no longer to work in isolation, but to act within a networked, self-organising production system.

Specifically, this means:

Decentralised decision-making: Instead of a central control system specifying everything, CPS make decisions locally – based on data, algorithms and direct communication with other systems.
Networking of humans, machines and digital twins: Production environments become interactive. Humans can cooperate with machines, machines coordinate with each other, and digital twins provide additional simulations in real time.
Flexibility and batch size 1: Thanks to CPS, production lines can flexibly respond to new requirements. Even individualised production – such as a product in batch size 1 – can be implemented efficiently.
Smart factories as an application field: Without CPS there would be no smart factoryIntelligent factory with fully networked machines and systems that self-organize and produce autonomously.. They are the driving force that practically realises the vision of the intelligent factory.

This makes it clear: CPS are not abstract concepts, but the enablers of Industry 4.0 – they bring the vision of fully networked, adaptive and autonomous production into practice.

Cyber-Physical System