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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 X/0

1X 01
0/0

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. Fill the tank to level A
from valve A.
2. Fill the tank to level B
from valve B.
3. Start the timer, heat, and
stir for 5 minutes.
4. 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
 S
 H
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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

↑ Motor STOP

Down 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

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