An Empirical Study of Architectural Shift from Traditional to AI-Enabled Simulink Controllers
Organizations: University of Michigan-Dearborn Dearborn, USA.
Abstract
Effective AI adoption in cyber-physical systems (CPS) depends on embedding design knowledge into engineering practice. Yet as AI-enabled components increasingly replace analytically derived control laws, this occurs without a systematic understanding of how controller architectures differ or remain similar across paradigms. We address this gap with an empirical study of traditional and AI-enabled Simulink controllers, guided by a literature-derived taxonomy of ten structural categories and nine functional roles. The study analyzes 62 real-world models spanning 8 controller types and 10 application domains, and surveys 13 practitioners, identifying three architectural tensions. First, subsystem organization dominates all controller structures regardless of paradigm, occupying 68-72% of controller footprint, while core control logic occupies minimal space. Second, AI-enabled controllers rely heavily on discrete dynamics and user-defined abstraction, categories largely absent from AI literature, exposing a gap between described and implemented architectures. Third, constraint enforcement blocks largely disappear from AI-enabled models despite practitioner expectations. This reveals a misalignment where safety mechanisms shift from explicit structure to implicit training-time artifacts, breaking traceability.
Figures & tables
| ID | Categories | Block Types |
| C1 | Continuous Dynamics | Derivative, Integrator, PID Controller, State-Space, Transfer Fcn, Transport Delay, Zero-Pole, FOH, etc. |
| C2 | Discrete Dynamics & State | Delay, Difference, Discrete Derivative, Discrete PID Controller, Discrete State-Space, Memory, ZOH, etc. |
| C3 | Discontinuities & Nonlinearities | Coulomb and Viscous Friction, Dead Zone, Hit Crossing, Rate Limiter, Relay, Saturation, Backlash, etc. |
| C4 | Logic, Conditions, & Events | Combinatorial Logic, Compare To Zero, Logical and Relational Operator, Shift Arithmetic, Extract Bits, etc. |
| C5 | Math & Signal Operations | Abs, Algebraic Constraint, Sum, Bias, Divide, Dot Product, Gain, Math Function, Reshape, Sign, etc. |
| C6 | Ports, Interfaces & Subsystems | Enable, Subsystem, If, If Action Subsystem, Inport, Outport, Switch Case, Trigger, In/Out Bus Element, etc. |
| ID | Level Type | Description |
| L1 | Core Control Dynamics | Implements the primary control law that generates control actions from system inputs and states. |
| L2 | Signal Constraint Enforcement | Applies constraints or limits to control signals to ensure safe, stable, and valid operation of the system. |
| L3 | Event/Mode Switching Logic | Enables discrete changes in control behavior based on events, thresholds, or operating conditions. |
| L4 | Signal Preprocessing & Computation | Performs transformations or computations to ensure signal compatibility within the control architecture. |
| L5 | Supervisory Coordination | Manages coordination between multiple control elements or modes, ensuring proper sequencing and integration. |
| L6 | Estimation / Observer Support | Provides state estimation or variable reconstruction to supply information not directly measured. |
| ID | Model Name | Type | Size | ID | Model Name | Type | Size |
| M01 | Abstract Fuel Control | DRL | 400 | M07 | PMSM Control | PID | 2601 |
| M02 | Neural Network | DNN | 699 | M08 | Stochastic Fault Tolerance | SBC | 273 |
| M03 | Temperature Control | FLC | 107 | M09 | Adaptive Cruise Control | MPC | 361 |
| M04 | Artificial Pancreas Control | FLC | 276 | M10 | Missile Guidance System | PID | 396 |
| M05 | Steam Condenser | DNN | 172 | M11 | Rolling Mill | LQR | 211 |
| M06 | Nonlinear Guidance | CLC | 355 | M12 | House Heating System | MPC | 200 |
| Cat | BC(T) | (T) | BC(AI) | (AI) | FRL | BC(T) | (T) | BC(AI) | (AI) |
| C1 | 8 | 25.8% | 0 | 0.0% | L1 | 12 | 38.7% | 10 | 35.7% |
| C2 | 7 | 22.6% | 5 | 17.9% | L2 | 5 | 16.1% | 0 | 0.0% |
| C3 | 6 | 19.4% | 0 | 0.0% | L3 | 2 | 6.5% | 2 | 7.1% |
| C4 | 0 | 0.0% | 1 | 3.6% | L4 | 5 | 16.1% | 8 | 28.6% |
| C5 | 2 | 6.5% | 1 | 3.6% | L5 | 1 | 3.2% | 2 | 7.1% |
| C6 | 3 | 9.7% | 3 | 10.7% | L6 | 0 | 0.0% | 0 | 0.0% |
| Coverage ( , %) | Mean normalized presence ( , %) | Model-level prevalence ( , %) | ||||||||||||||||||||||||||||
| Cat. | Traditional | AI-enabled | All | Traditional | AI-enabled | All | Traditional | AI-enabled | All | |||||||||||||||||||||
| PID | MPC | LQR | SBC | CLC | DNN | DRL | FLC | T | AI | PID | MPC | LQR | SBC | CLC | DNN | DRL | FLC | T | AI | PID | MPC | LQR | SBC | CLC | DNN | DRL | FLC | T | AI | |
| C1 | 0.3 | 0.0 | 13.5 | 0.0 | 0.0 | 0.7 | 0.0 | 0.6 | 0.4 | 0.3 | 5.3 | 0.0 | 16.8 | 0.0 | 0.0 | 1.7 | 0.0 | 0.4 | 3.9 | 0.2 | 45.5 | 0.0 | 75.0 | 0.0 | 0.0 | 33.3 | 0.0 | 20.0 | 25.8 | 6.5 |
| C2 | 0.7 | 0.7 | 0.0 | 3.1 | 0.3 | 0.3 | 5.5 | 0.6 | 0.7 | 3.5 | 1.5 | 0.5 | 0.0 | 1.3 | 0.3 | 1.2 | 5.5 | 0.3 | 0.8 | 4.2 | 63.6 | 33.3 | 0.0 | 33.3 | 28.6 | 33.3 | 100 | 20.0 | 38.7 | 80.6 |
| C3 | 0.6 | 0.0 | 5.8 | 0.8 | 0.0 | 0.2 | 0.0 | 1.2 | 0.5 | 0.2 | 1.4 | 0.0 | 3.6 | 0.3 | 0.0 | 0.4 | 0.0 | 1.2 | 0.9 | 0.2 | 72.7 | 0.0 | 25.0 | 33.3 | 0.0 | 66.7 | 0.0 | 40.0 | 32.3 | 12.9 |
| C4 | 1.1 | 0.0 | 0.0 | 4.6 | 12.5 | 0.0 | 1.4 | 0.3 | 2.5 | 0.9 | 1.5 | 0.0 | 0.0 | 1.9 | 10.5 | 0.0 | 1.4 | 0.2 | 3.1 | 1.1 | 36.4 | 0.0 | 0.0 | 33.3 | 100 | 0.0 | 100 | 20.0 | 38.7 | 77.4 |
| Traditional | AI-enabled | All | ||||||||
| Cat. | PID | MPC | LQR | SBC | CLC | DNN | DRL | FLC | T | AI |
| C1 | 1.1/3.5 | 0.4/2.1 | 1.8/4.7 | 1.3/3.7 | 0.2/1.6 | 0.9/2.7 | 0.3/1.9 | 0.3/1.6 | 1.0/3.1 | 0.5/2.1 |
| C2,C4 | 1.0/3.3 | 1.0/3.5 | 0.3/2.2 | 1.5/3.9 | 1.2/3.9 | 0.9/2.9 | 1.9/4.8 | 0.9/3.1 | 1.0/3.3 | 1.2/3.6 |
| C3 | 0.9/3.1 | 0.4/2.3 | 0.3/1.9 | 1.2/3.5 | 0.2/1.9 | 0.7/2.8 | 1.0/3.2 | 1.0/3.3 | 0.6/2.5 | 0.9/3.1 |
| C8 | 0.5/2.3 | 1.8/4.9 | 1.3/4.0 | 0.6/2.6 | 0.9/3.3 | 1.1/3.3 | 1.6/4.5 | 1.6/4.6 | 1.0/3.4 | 1.4/4.1 |
| C7,C9 | 1.6/4.1 | 1.8/4.5 | 1.2/4.2 | 1.4/4.2 | 1.6/4.2 | 1.8/4.7 | 1.5/4.3 | 1.5/4.2 | 1.5/4.2 | 1.6/4.4 |