Princess Sumaya Univ.
Electronic Engineering Dept.
3442
Industrial Instruments 2
Chapter 8
Discrete-State Process Control
Dr. Bassam Kahhaleh
Princess Sumaya University
3442 - Industrial Instruments 2
2 / 32
8: Discrete-State Process Control
Definitions
The discrete state of the process at any
moment is the set of all input and output
values.
An event in the system is defined by a
particular state of the system, i.e. particular
values of inputs and outputs.
A discrete-state process control is a
particular sequence of events through which
the process accomplishes some objective
Princess Sumaya University
3442 - Industrial Instruments 2
3 / 32
8: Discrete-State Process Control
Example
Frost-free refrigerator/freezer
Discrete-state I/P
Door open/closed
Cooler temp. high/low
Freezer temp. high/low
Power switch on/off
Frost detector on/off
Frost eliminator timer out/not out
Princess Sumaya University
3442 - Industrial Instruments 2
4 / 32
8: Discrete-State Process Control
Example
Frost-free refrigerator/freezer
Discrete-state O/P
Light on/off
Compressor on/off
Timer on/off
Heater on/off
Baffle open/closed
Princess Sumaya University
3442 - Industrial Instruments 2
5 / 32
8: Discrete-State Process Control
Discrete-State Variables
Continuous Control
Princess Sumaya University
3442 - Industrial Instruments 2
6 / 32
8: Discrete-State Process Control
Discrete-State Variables
Continuous Control
Discrete Control
Princess Sumaya University
3442 - Industrial Instruments 2
7 / 32
8: Discrete-State Process Control
Discrete-State Variables
Continuous Control
Discrete Control
Composite
Discrete/Continuous
Control
Princess Sumaya University
3442 - Industrial Instruments 2
8 / 32
8: Discrete-State Process Control
Process Specifications
Process Objectives
Process Hardware
Input Devices
Limit Switches
Comparators
Push Buttons
Output Devices
Lights
Motors
Solenoids
3442 - Industrial Instruments 2
Princess Sumaya University
9 / 32
8: Discrete-State Process Control
Event Sequence Description
Narrative Statements
Flowcharts
Binary-State
00
X/1
1X
X/0
0/0
01
1/1
Princess Sumaya University
3442 - Industrial Instruments 2
10 / 32
8: Discrete-State Process Control
Event Sequence Description
Flowchart Example
Princess Sumaya University
3442 - Industrial Instruments 2
11 / 32
8: Discrete-State Process Control
Event Sequence Description
Flowchart Example
Princess Sumaya University
3442 - Industrial Instruments 2
12 / 32
8: Discrete-State Process Control
Event Sequence Description
Binary-State Example
1.
2.
3.
4.
Fill the tank to level A
from valve A.
Fill the tank to level B
from valve B.
Start the timer, heat, and
stir for 5 minutes.
Open output valve C
until the empty switch
engages.
Princess Sumaya University
3442 - Industrial Instruments 2
13 / 32
8: Discrete-State Process Control
Event Sequence Description
Binary-State Example
I/P Variables O/P Variables
LA
VA
LB
VB
LE
VC
TU
TM
Princess Sumaya University
3442 - Industrial Instruments 2
14 / 32
8: Discrete-State Process Control
Event Sequence Description
Binary-State Example
State:
LA LB LE TU VA VB VC TM S H
Princess Sumaya University
3442 - Industrial Instruments 2
15 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Control Relays (Relay Sequencer)
Princess Sumaya University
3442 - Industrial Instruments 2
16 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram
Princess Sumaya University
3442 - Industrial Instruments 2
17 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
Princess Sumaya University
3442 - Industrial Instruments 2
18 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
Princess Sumaya University
3442 - Industrial Instruments 2
19 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
Princess Sumaya University
3442 - Industrial Instruments 2
20 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
Princess Sumaya University
3442 - Industrial Instruments 2
21 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
1. When the START button is pushed,
the platform is driven to the down
position.
2. When the STOP button is pushed,
the platform is halted at whatever
position it occupies at that time.
3. When the UP button is pushed, the
platform, if it is not in downward
motion, is driven to the up position.
4. When the DOWN button is pushed,
the platform, if it is not in upward
motion, is driven to the down
position.
Princess Sumaya University
3442 - Industrial Instruments 2
22 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
Start
Stop
Princess Sumaya University
3442 - Industrial Instruments 2
23 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START
STOP
Power
Princess Sumaya University
3442 - Industrial Instruments 2
24 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START
Motor
STOP
Power
Princess Sumaya University
3442 - Industrial Instruments 2
25 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START
UP
Motor
Down
Motor
STOP
Power
Princess Sumaya University
3442 - Industrial Instruments 2
26 / 32
8: Discrete-State Process Control
Relay Controllers & Ladder Diagrams
Ladder Diagram Example
CR
CR
Princess Sumaya University
3442 - Industrial Instruments 2
27 / 32
8: Discrete-State Process Control
Hardwired Programming
Relay Sequencers
Programmable Logic Controllers (PLCs)
Processor
Input Modules
Output Modules
Princess Sumaya University
3442 - Industrial Instruments 2
28 / 32
8: Discrete-State Process Control
Programmable Logic Controllers (PLCs)
Input Module
Princess Sumaya University
3442 - Industrial Instruments 2
29 / 32
8: Discrete-State Process Control
Programmable Logic Controllers (PLCs)
Output Module
Princess Sumaya University
3442 - Industrial Instruments 2
30 / 32
8: Discrete-State Process Control
Programmable Logic Controllers (PLCs)
Logic Programming
Using a NC switch to turn off a
light with relay logic and
with PLC programming:
a) The button turns the light
OFF.
b) With relay logic the button
turns the light ON.
c) With a PLC program the
button turns the light ON
Princess Sumaya University
3442 - Industrial Instruments 2
31 / 32
8: Discrete-State Process Control
Programmable Logic Controllers (PLCs)
Logic Programming
NO switches are
considered INACTIVE
when they are read as
open circuit, and
ACTIVE when they are
read as closed circuit.
In the ladder diagram, 01
must be ACTIVE while
03 must be INACTIVE
to turn 08 ON.
Princess Sumaya University
3442 - Industrial Instruments 2
32 / 32
8: Discrete-State Process Control
End of Chapter 8
