PLC-MDT: A Framework for Detecting Anomalies with Digital Twins of Industrial Control Systems
Abstract
The attack events (such as the Stuxnet and BlackEnergy) that targeted the Industrial Control System (ICS) have validated its vulnerability to cyber intrusions. The prevention of ICS from cyberattacks is undoubtedly important and practical as it operates dangerous equipment and produces products that people need. Traditional anomaly detection methods, which rely heavily on SCADA data, are often unreliable due to the limitation of such data in accurately reflecting real-time system states under attacks. Therefore, we propose PLC-MDT, a novel anomaly detection method based on digital twins (DT), exploiting the modern communication technology and computing resources of ICS. PLC-MDT does not depend solely on SCADA data, instead, it leverages the interaction between DT and real-world ICS, utilizing both DT and field-site data to perform anomaly detection. Specifically, for PLC-MDT, the prediction model in DT is trained based on historical data, and the predicted values are used as input to the mechanism model in DT to generate simulated data. Networked structure of ICS guarantees real-time data collected from field sites for DT. Therefore, PLC-MDT detects attacks by monitoring the difference between the predicted and real-time data, revealing control channel corruption when the difference exceeds a threshold. The effectiveness of PLC-MDT is demonstrated through experiments on real-world systems, showing its potential for real-time detection of anomalies in ICS.
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The PLC-MDT approach could detect not only typical code modification attacks but also coordinated stealthy attacks that forge SCADA history logs, achieving high detection rates and low false positive rates in real time.
“The authors demonstrated that this approach could detect not only typical code modification attacks but also coordinated stealthy attacks that forge SCADA history logs, achieving high detection rates and low false positive rates in real time.”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
Xu et al. [72] designed a hybrid prediction-mechanism model called PLC-MDT that leverages a Digital Twin (DT) using PLC-sensor logs from a self-built temperature control ICS testbed.
“Using PLC-sensor logs collected from a self-built temperature control ICS testbed, Xu et al. [72] designed a hybrid prediction-mechanism model called PLC-MDT that leverages a Digital Twin (DT).”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
In many works, a model predicts the next-step sensor or control-signal values and computes prediction residuals, or derives an anomaly score that functions as a probabilistic or density-based residual, so that small but systematic deviations in process dynamics can be detected even when they are not visible at the network layer.
“In many of these works, a model predicts the next-step sensor or control-signal values and computes prediction residuals, or derives an anomaly score that functions as a probabilistic or density-based residual, so that small but systematic deviations in process dynamics can be detected even when they are not visible at the network layer [67,69,70,72,73,75].”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
Prediction-residual-oriented methods are powerful for detecting subtle and coordinated process anomalies, including multi-point stealthy attacks that forge SCADA histories or slowly drive the system toward unsafe states.
“Third, in terms of detection capability and failure modes, the results indicate that prediction-residual-oriented methods are powerful for detecting subtle and coordinated process anomalies, including multi-point stealthy attacks that forge SCADA histories or slowly drive the system toward unsafe states [69,72,73,75,76].”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
Process data are particularly suitable for attacks that perturb the physical process state while keeping network-level statistics relatively unchanged, such as false data injection, malicious command or parameter manipulation, process-oriented attacks, and stealthy drifts in sensor trajectories.
“First, process data are particularly suitable for attacks that perturb the physical process state while keeping network-level statistics relatively unchanged-such as false data injection, malicious command or parameter manipulation, process-oriented attacks, and stealthy drifts in sensor trajectories [67,69-73,75,76].”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
The distribution of datasets shows a strong reliance on SWaT and WADI for benchmarking prediction-residual-based methods, with additional evidence from custom-built avionics, robotics, temperature-control, offshore wind farm, and simulation-based CPS testbeds.
“Finally, the distribution of datasets shows a strong reliance on SWaT and WADI for benchmarking prediction-residual-based methods, with additional evidence from custombuilt avionics, robotics, temperature-control, offshore wind farm, and simulation-based CPS testbeds [67-73,75,76].”
From AI-Based Anomaly Detection in Industrial Control and Cyber–Physical Systems: A Data-Type-Oriented Systematic Review (2025) · cites this paper as [72]
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References 36 · Cited by 6
- Authors
- Xu, Z., Zhang, Z., & Zheqiu, H.
- Affiliations
- Guizhou University (CN)
- Venue
- IEEE Sensors Journal
- Published
- 2025-05-15
- Volume
- 25
- Issue
- 10
- Pages
- 17739-17749
- ISSN
- 1530-437X (ISSN-L)
- 1558-1748
- 2379-9153
- OpenAlex
- W4409327141
- Cited by
- 6
- References
- 36
- Citations by year
- 2026: 3 · 2025: 3
- FWCI
- 2.22
- Type
- journal article
- Language
- en
- Open access
- closed
- Licence
- Locations
- IEEE Sensors Journal (publishedVersion)
- Funders
- National Natural Science Foundation of China (62303126, 62362008)
- Major Scientific and Technological Special Project of Guizhou Province ([2024]014)
- Topics
- Physical Sciences › Engineering › Control and Systems Engineering › Smart Grid Security and Resilience
- Physical Sciences › Computer Science › Computer Networks and Communications › Network Security and Intrusion Detection
- Physical Sciences › Engineering › Control and Systems Engineering › Fault Detection and Control Systems
- Keywords
- industrial control systems, digital twin, anomaly detection, cyberattack detection, PLC, real-time monitoring, Stuxnet, simulation data generation
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