Princess Sumaya Univ.

Electronic Engineering Dept.

3442
Industrial Instruments 2
Chapter 8
Discrete-State Process Control
Dr. Bassam Kahhaleh

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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

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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

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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

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8: Discrete-State Process Control

Discrete-State Variables
Continuous Control

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8: Discrete-State Process Control

Discrete-State Variables
Continuous Control
Discrete Control

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8: Discrete-State Process Control

Discrete-State Variables
Continuous Control
Discrete Control
Composite
Discrete/Continuous
Control

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8: Discrete-State Process Control

Process Specifications
Process Objectives
Process Hardware

Input Devices
Limit Switches
Comparators
Push Buttons

Output Devices

Lights
Motors
Solenoids

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8: Discrete-State Process Control

Event Sequence Description
Narrative Statements
Flowcharts
Binary-State
00
X/1

1X

X/0

0/0

01
1/1

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8: Discrete-State Process Control

Event Sequence Description
Flowchart Example

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8: Discrete-State Process Control

Event Sequence Description
Flowchart Example

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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.

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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

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8: Discrete-State Process Control

Event Sequence Description
Binary-State Example
State:

LA LB LE TU VA VB VC TM S H

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Control Relays (Relay Sequencer)

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

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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.

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

Start

Stop

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START

STOP

Power

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START

Motor
STOP

Power

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example
START

UP
Motor

Down

Motor
STOP

Power

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8: Discrete-State Process Control

Relay Controllers & Ladder Diagrams
Ladder Diagram Example

CR

CR

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8: Discrete-State Process Control

Hardwired Programming
Relay Sequencers
Programmable Logic Controllers (PLCs)
Processor
Input Modules
Output Modules

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8: Discrete-State Process Control

Programmable Logic Controllers (PLCs)
Input Module

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8: Discrete-State Process Control

Programmable Logic Controllers (PLCs)
Output Module

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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

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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.

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8: Discrete-State Process Control

End of Chapter 8