Chapter 2

Discrete-State Control
Part I
 Content

Definition of Discrete-State Process Control

Characteristic of the System

Objectives

To understand the nature of discrete-state
process-control system.

Describe a discrete-state process in terms
of the objectives and hardware.
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 Introduction
 Many industrial processes are controlled in sequence.
 A discrete state expresses that each event in the
sequence can be described by specifying the condition of
all operating units of the process.
 For example:
# valve A is open # valve B is closed,
# conveyer C is on # limit switch S1 is closed
 A technique for designing and describing the sequence of
process events, call ladder diagram represents the
electromechanical relays to control the sequence in such
process.
 The most common control system for discrete control is
implemented by a programmable logic controller (PLC).
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 Discrete State Process Control

 The figure shows a manufacturing process and the

controller. Input variables (S1, S2, S3) and output
variables (C1, C2, C3) can only be in two value.

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 • For example: valves are open / closed, motors are on / off,
temperature is high / low, limit switches are closed / open.
• If there are 3 input variables and 3 output variables, the
possible states are 64 since each variable can take on two
values (2 × 2 × 2 × 2 × 2 × 2).
• An event in the system is defined by a particular state of the
system, as long as the input variables remain in the same
state and the output variables are left in the assigned state.
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 Characteristics of the System
 Industrial processes involve many operations and
steps:
– some steps occur in series,
– some steps occur in parallel,
– some events involve regulation of continuous
variable over the duration of event (eg. Water
level- up and down).

 The discrete-state process control system functions as

the master control system for the entire plant
operation.

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 Frost Free Refrigerator/Freezer

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 Frost Free Refrigerator/Freezer
 The discrete-state input variables are
– door open/closed,
– cooler temperature high/low,
– freezer temperature high/low,
– frost eliminator timer time-out/not time-out,
– power switch on/off,
– frost detector on/off.
 The discrete-state output variables are
– light on/off,
– compressor on/off,
– frost eliminator timer started/not started,
– frost eliminator heater and fan on/off,
– cooler baffle open/closed.
 There is a total of 11 two-state variables giving 211 = 2048
possible events.
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 Frost Free Refrigerator/Freezer
 The event sequences are
(a) If the door is opened, the light is turned on.
(b) If the cooler temperature is high and the frost eliminator
is off, the compressor is turned on and the baffle is opened
until the cooler temperature is low.
(c) If the freezer temperature is high and the frost
eliminator is off, the compressor is turned on until the
temperature is low.
(d) If the frost detector is on, the timer is started, the
compressor is turned off, and the frost eliminator heater/fan
are turned on until the timer times out.
 Events of (a) can occur in parallel with any of the others.
 The event of (b) and (c) can occur in parallel.
 Event (d) can only be serial with (b) and (c).
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 Discrete-State Variables
It is important to be able to distinguish between
the nature of variables in a discrete-state system
and continuous control system.
An example that constrasting a continuous
varible situation with a discrete-state variable
situation for the same application will be
considered.
It will be shown that continuous variable
regulation can be itself a part of a discrete-state
system.
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 Continuous Control
 A transducer measures the
level of liquid in the tank.
 The objective is to maintain
the level of liquid in the tank
at the setpoint value.
 If the outflow increases, the
control system will increase
the opening of the input valve
to compensate by increasing
the input flow rate. The level
is thus regulated.
 This is a continuous variable
control system because both
the level and the valve
setting can vary over a range.
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 Discrete-State Control
 For the same problem shown
here; the variables, level and
valve settings, are discrete. They
can take on only two values.
 The valves can only be opened or
closed, and the level is either
above or below the specified
value.
 The objective is to fill the tank to
a certain level with no outflow.
The event of sequence:
i) Close the output valve.
ii) Open the input valve and let
the tank fill to the desired
level, as indicated by a switch.
iii) Close the input valve.
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 Discrete-State Control
 The level is certainly not
going to change until, at
some later time, the output
valve is opened to let the
liquid flow out.
 Notice that the variables
(level measurement, input
valve setting, and output
valve setting) are two-state
quantities.
 There is no continuous
measurement or output over
a range.

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 Composite Discrete/Continuous Control

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 Composite Discrete/Continuous Control
 In this case, we specify that the outlet valve is to be
closed and the tank filled to the required level.
 Periodically, a bottle comes into position under the
outlet valve, as shown in the figure.
 The level must be maintained at the setpoint while
the outlet valve is opened and the bottle filled.
 This process will require that a continuous-level
control system to be used to adjust the input flow
rate during bottle-fill through the output valve.
 You can see that the continuous control process is
but a part of the overall discrete-state process.

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 Process Specification
Specification of the sequence of
events in some discrete-state process
is directly tied to the process itself
The process is specified in two parts:
1. process objectives
2. process hardware

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 Process objectives
A statement of what the process is supposed to accomplish.
Global objective is the end result. It is broken in to many
secondary objectives.
Each sub objective may be independent in the whole
operation.
A discrete-state control system then be applied to each
independent part.

The overall objective can be broken

down into many secondary objectives
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 Process Hardware
 Design the hardware such as conveyor system, mixing tank,
oven, etc. so that these hardware can carry out the
designed process in order to achieve the objectives.
 Determination type of components such as sensor, relay,
motor, etc. used in the hardware design.

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 Hardware analysis
 Two basic categories:
a)Input devices – limit switches,comparators,
push button
b)Output devices – Light, Motor, Solenoid

 Study the pictorial process of feed hopper. Identify

the input and output devices.
Input Devices Output Devices
1. Right box present 1. Hopper valve solenoid
2. Left box present 2. Feed stock conveyor motor off
3. Feed conveyor right travel limit 3. Feed stock conveyor motor right
4. Feed conveyor left travel limit 4. Feed stock conveyor motor left
5. Hopper low 5. Right box conveyor motor
6. Feed conveyor center 6. Left box conveyor motor

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 Event Sequence Description
 A process-control engineer may not have been involved
in the development of the system hardware, but must
understand the characteristics of each element.
 Then, only he can decide how the hardware will be
manipulated to accomplish the objective.
 A sequence of events must be described that will direct
the system through the operations to provide the
desired end result.
 Examples: (a) Narrtive Statements
(b) Flowcharts of the Event Sequence
(c) Binary-State Variable Description
(d) Boolean Equation
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 Narrative Statements
Narrative statements specifying the sequence
of events start with descriptions of what
events must occur to achieve the objective.
This specification describes in narrative form
what must happen during the process
operation.
In systems that run continuously, there are
typically a startup, or initialization phase and
a running phase.

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 Initialization Phase
A. All motors off, feed valve solenoid off.
B. Test for right limit switch
1. If engaged, go to C.
2. If not, set feed motor for right motion.
3. Start feed-conveyor motor.
4. Test for right limit switch.
a. If engaged, go to C.
b. If not, go to 4.
C. Set feed motor for left motion and start.
D. Test for center switch
1. If engaged, go to E.
2. If not, go to D.

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 Initialization Phase
E. Open hopper-feed valve.
F. Test for left limit switch:
1. If engaged, go to G.
2. If not. go to F.
G. All motors off, hopper-feed valve closed.
H. Go to running phase.

 Completion of the initialization phase means that

the feed conveyor is positioned at the left limit
position and the right half of the conveyor has been
filled from the feed hopper.

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 Running phase
A. Start right box conveyor.
B. Test right box present switch:
1. If set, go to C.
2. If not, go to B.
C. Start feed-conveyor motor, right motion.
D. Test center switch:
1. If engaged, g to E.
2. If not, go to D.
E. Open hopper-feed valve.
F. Test right limit switch:
1. If engaged, go to G.
2. If not, go to F.
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 Running phase
G. Close hopper-feed valve, stop feed conveyor.
H. Start left box conveyor.
I. Test left box present switch:
1. If set, go to J.
2. If not, go to I.
J. Start feed conveyor, left motion.
K. Test center switch:
1. If engaged, go to L.
2. If not, go to K.
L. Open hopper-teed valve.
M. Test left limit switch:
1. If engaged, go to A.
2. If not, go to M.
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Example 2.1
Construct a narrative statement outline of the event sequence
for the system shown, the objective is to fill bottles moving on
a conveyor.
I. Initialization (prefill of tank)
A. Converyor stopped, output valve closed
B. Start the level control system
1. Operate for a sufficient time to reach the
setpoint, or
2. Add another sensor so that the system
knows when the setpoint has been reach

II. Running
A. Start the bottle conveyor
B. When a bottle is in position (BP true)
1. Stop the conveyor (M1 off)
2. Open the output valve
C. When the bottle is full (BF true)
1. Close the output valve
D. Go to step II.A and repeat
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Flowcharts of theEvent Sequence
 It is often easier to visualize and
construct the sequence into
flowchart.
 The narrative statements are
reformatted into flowchart symbols.

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 Binary-State Variable Description
Used to describe the sequence of events in
terms of the sequence of discrete states of
the system.
Each of the state, including both input and
output variables be specified.
The input variables cause the state of the
system to change because operations within
the system cause a change of one of the state
variables.
The output variables are changed in the
system state that are caused by the control
system itself.
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 Construct a state variable description of the process as
Example 2.2 shown. The timer output (TU) is initially low when its
input (TM) is low. When TM is taken high the output
stays low for 5 minutes and then goes high. It resets to
low when TM is taken low. All level sensors become true
when the level is reached. The process sequence is:

1. Fill tank to LA using valve VA.

2. Fill tank to LB using valve VB
3. Start TM, stir S and heater H.
4. 5 min. stop S and H.
5. Open VC empty tank to LE.
6. Reset TM, repeat.

Input:
(LA, LB, LE, TU)

Output:
(VA, VB, VC, TM, S, H)

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 Solution
Because each variable is a two-state variable, we
use a binary representation: true = 1 and false = 0.
Thus, for input, if level A has not been reached,
then LA = 0, and vice versa.
Let us take the binary “word” describing the state
of the system to be defined by bits in the order:
LA,LB,LE,TU,VA,VB,VC,TM,S,H

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 1. Fill tank to LA using valve VA.
2. Fill tank to LB using valve VB
3. Start TM, S and H.
4. 5 min. stop S and H.
5. Open VC empty tank to LE.
6. Reset TM, repeat.
Input Output Description

(VA)(VB)(VC)(TM)(S)(H
(LA)(LB)(LE)(TU)
)
0000 → 100000 Starting state, open valve A

0010 → 100000 Reaches level E, continue with A fill

1010 → 010000 Reaches level A, close valve A, open valve B

1110 → 000111 Reaches level B, close valve B, start timer, heater, stir

1111 → 001100 Time up, stop stir and heater, open valve C to empty

1011 → 001100 Reaches level B, continue with empty

0011 → 001100 Reaches level A, continue with empty

0001 → 000000 Tank empty, turn off timer, go to first state

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 Logic gates

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 Boolean algebra
Variable A (e.g. temperature),
if the temperature is high A = 1, if it is low A = 0.

Equality: If A = B, and A = 1, then B = 1.

Complement: If A = 1, then A = 0.

AND, • : If A = 1 and B = 1, and C = A • B, then C = 1.

OR, + : If C = A + B, C = 1 if A or B or both A/B = 1.

DeMorgan:
A⋅ B = A + B
A+ B = A⋅B
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 Example
Simplify the expression
D = A⋅ B + C ⋅ (A⋅ B + C )

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 Boolean Equations
We may use Boolean algebra techniques to
represent the process flow since the variables
are binary.
The equation will then determine when that
variable is taken to its true state.
The equation may depend not only on the set
of input variables, but on some of the output
variables.

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Example 2.3 Heater: H, Fans: F, Light: L.

Figure beside shows a pictorial

view of an oven. All the inputs
and outputs are two-state
variables. Construct Boolean
equations that implement the
following events:
1. Heater on when switch
activated, door is closed and
temperature below limit.
2. Fans on when heater on, or
when temperature above
limit and door closed.
3. Light on if light switch on or
when door is opened.
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 Q&A

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