Next‐generation safety‐aware cyber‐physical system integration: A proton exchange membrane water electrolysis demonstration

Abstract Next‐generation cyber‐physical process systems demand unified safety and control design protocols that seamlessly integrate hazard prevention with operational optimization. Here, we present a comprehensive safety‐aware cyber‐physical system that integrates dynamic risk assessment with multiparametric model predictive control for real‐time process operation and safety management. Our framework features a novel risk index formulation for use as a safety barrier within decision‐making. This enables automatic transitions between normal operation and safety‐critical control modes. The system architecture incorporates real‐time state estimation, dynamic risk assessment, and explicit control across the operational space. We demonstrate the implementation of this framework on a proton exchange membrane water electrolyzer, where thermal management is required to prevent membrane damage. The safety ‐ aware controller automatically activates protective cooling protocols when risk thresholds are exceeded. The controller successfully maintains safe operation while regulating hydrogen production, achieving temperature difference tracking with less than 3% overshoot and steady‐state errors below 0.3 K. The safety‐aware controller automatically activates protective cooling protocols when risk thresholds are exceeded. This work establishes a generalizable framework for safety‐aware process control that moves from reactive safety systems to proactive hazard prevention across chemical and energy systems.