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Discrete Control Using Programmable Logic Controllers

The document discusses discrete process control systems that deal with parameters and variables that change at discrete moments in time and can have binary values of 1 or 0 representing ON/OFF. Discrete control uses sensors and actuators that have binary outputs. Logic control systems use logic gates like AND, OR and NOT to determine output values based on input values without considering past inputs. Sequencing control considers time and past input values to perform operations in a defined sequence. Programmable logic controllers are commonly used for discrete control applications.

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71 views12 pages

Discrete Control Using Programmable Logic Controllers

The document discusses discrete process control systems that deal with parameters and variables that change at discrete moments in time and can have binary values of 1 or 0 representing ON/OFF. Discrete control uses sensors and actuators that have binary outputs. Logic control systems use logic gates like AND, OR and NOT to determine output values based on input values without considering past inputs. Sequencing control considers time and past input values to perform operations in a defined sequence. Programmable logic controllers are commonly used for discrete control applications.

Uploaded by

farah naz
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Discrete Control Using

Programmable Logic Controllers


DISCRETE PROCESS CONTROL
Discrete process control systems deal with parameters and variables that
change at discrete moments in time. The parameters and variables
themselves are discrete typically binary. They can have either of two possible
values, 1 or 0.The values mean ON or OFF, true or false, object present or not
present, high voltage value or low voltage value, and so on, depending on
the application. The binary variables in discrete process control are
associated with input signals to the controller and output signals from the
controller.
Input signals are typically generated by binary sensors, such as limit switches
or photosensors that are interfaced to the process. Output signals are
generated by the controller to operate the process in response to the input
signals and as a function of time. These output signals turn on and off
switches, motors, valves, and other binary actuators related to the process.
Binary Sensors and Actuators Used in Discrete Process Control

Sensors One/Zero Interpretation Actuators One/Zero Interpretation

Limit switch Contact/no contact Motor On/off

Photodetector On/off Control Relay Contact/no contact

Push- button switch On/off Light On/off

Timer On/off Valve Closed/open

Control relay Contact/no contact Clutch Engaged /not engaged

Circuit breaker Contact/no contact Solenoid Energized/not energized


The purpose of the controller is to coordinate the various actions of the
physical system, such as transferring parts into the work holder, feeding
the machining work head, and so on.
Discrete process control can be divided into two categories:
(1) Logic control
(2) Sequencing
Logic Control:
A logic control system, also referred to as combinational logic control, is
a switching system whose output at any moment is determined by the
values of the inputs. A logic control system has no memory and does
not consider any previous values of input signals in determining the
output signal. Neither does it have any operating characteristics that
perform directly as a function of time.
To illustrate logic control consider example from robotics. Suppose that in a
machine-loading application, the robot is programmed to pick up a raw workpart
from a known stopping point along a conveyor and place it into a forging press.
Three conditions must be satisfied to initiate the loading cycle. First, the raw
workpart must be at the stopping point; second, the forge press must have
completed the process on the previous part; and third, the previous part must be
removed from the die.
The first condition can be indicated by means of a simple limit switch that senses
the presence of the part at the conveyor stop and transmits an ON signal to the
robot controller.
The second condition can be indicated by the forge press, which sends an ON signal
after it has completed the previous cycle.
The third condition might be determined by a photodetector located so as to sense
the presence or absence of the part in the forging die. When the finished part is
removed from the die, an ON signal is transmitted by the photocell.
All three of these ON signals must be received by the robot controller to initiate the
next work cycle. When these input signals have been received by the controller, the
robot loading cycle is switched on. No previous conditions or past history are
needed
Elements of Logic Control.
The basic elements of logic control are the logic gates AND, OR and
NOT. In each case, the logic gate is designed to provide a specified
output value based on the values of the input(s). For both inputs and
outputs, the values can be either of two levels, the binary values 0 or 1.
For purposes of industrial control, we define 0 (zero) to mean OFF, and 1
(one) to mean ON.
AND Gate
The logical AND gate outputs a value of 1 if all of the inputs are 1, and 0
otherwise. Figure illustrates the operation of a logical AND gate. If both
switches A and B (representing inputs) in the circuit are closed, then the
lamp Y (representing the output) is on.
The truth table is often used to present the operation of logic systems. A
truth table is a tabulation of all of the combinations of input values to
the corresponding logical output values.
Inputs output
X1 X2 Y
0 0 0
0 1 0
1 0 0
1 1 1

Truth Table for the Logical AND Gate Electrical circuit illustrating the operation of the logical
AND gate.
The AND gate might be used in an automated production system to indicate
that two (or more) actions have been successfully completed, therefore
signaling that the next step in the process should be initiated. The interlock
system in previous robot forging example illustrates the AND gate. All three
conditions must be satisfied before loading of the forge press is allowed to
occur.
OR Gate
The logical OR gate outputs a value of 1 if either of the inputs has a value of
1,and 0 otherwise. Figure shows how the OR gate operates. In this case. the
two input signals Xl and X2 are arranged in a parallel circuit, so that if either
switch is closed, the lamp Y will be on. The truth table for the OR gate is
presented .A possible use of the OR gate in a manufacturing system is for
safety monitoring. Suppose that two sensors are utilized to monitor two
different safety hazards. When either hazard is present, the respective sensor
emits a positive signal that sounds an alarm buzzer.
Inputs Output

X1 X2 Y

0 0 0

0 1 1

1 0 1

1 1 1

Truth Table for the Logical OR Gate Electrical circuit illustrating the operation of the logical OR
gate.
NOT gate
The NOT gate has a single input. The logical NOT gate reverses the input
signal: If the input is I, then the output is 0; if the input is 0, then the
output is 1. The truth table for the NOT gate is shown in Table.
Inputs Output

X Y

0 1

1 0

Truth Table for the Logical NOT Gate


In addition to the three basic elements, there are two more elements
that can be used in switching circuits: the NAND and NOR gates.
The logical NAND gate is formed by combining an AND gate and a NOT
gate in sequence. The logical NOR gate is formed by combining an OR
gate followed by a NOT gate.

Truth Table for the Logical NAND Gate Truth Table for the Logical NOR Gate
Symbols used for the Logical Gates

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