DIGITAL CONTROL

DIRECT DIGITAL CONTROL SYSTEMS

- a computer or digital controller (microprocessor, microcontroller <Arduinos and PICs>) is used

to implement the control strategy for the control system.
- use of analogue to digital converters (ADCs) and digital to analogue converters (DACs) is
necessary in some direct digital control systems.
Advantages over analogue control systems
- flexible and versatile
- have memory
- can be easily connected to SCADA units and remote terminal units (RTU)
Disadvantages
- expensive to install and maintain

CONTROL OF DISCRETE PROCESSES

- discrete processes involve distinct operations where each operation has a specific condition
that triggers/initiates it.
- the control is achieved by sequencing of operations according to some stored program.
- sequences may be (1) event driven where each operation occurs after some event has
occurred OR (2) time driven where each operation occurs after a set time/for a set period of
time.
- a washing machine is a good example of a discrete process.
Methods of describing discrete processes
1. Statement Lists: these state in words the sequence of actions to be carried out, eg:

Output A to occur when input 1 occurs and to last for 50 seconds

Output B to occur when input 2 occurs and to last for 10 seconds
Output C to occur when input 1 ceases and to last for 10 seconds

2. Process timing diagrams: these are graphs or waveforms which describe sequenced
operations as functions of time.
3. Ladder diagrams: these are viewed as electric circuits with vertical lines/upright posts
representing power rails and each step/sequenced operation is shown as a rung on a
ladder. Each step is made up of symbols. The four most common symbols are (for
schematics please google search similar symbols used in PLC programs):
(1) the normally open contact input symbol which is similar to that of a capacitor. The contact
closes when the corresponding input occurs.
(2) the normally closed contact input symbol which looks like a diagonally struck through
capacitor symbol. the diagonal has a positive gradient. The contact opens when the
corresponding input occurs.
(3) the circular output symbol. The output occurs when it is connected to the upright posts
by inputs.
(4) the square/rectangular specific instruction symbol such as a timer, counter, etc
4. Flow charts: these may use start, end, decision and action blocks as in computer
programming to represent each step/sequenced operation AND lines to show paths from
preceding steps to the next.

NB: Students are expected to be able to interchangeably use these methods to describe
given discrete processes.
PROGRAMMABLE LOGIC CONTROLLER (PLC)

- a PLC is a microprocessor-based controller that can perform logic (NOT, AND, OR, EXOR,etc),
timing and arithmetic operations.
- it can also perform sequenced operations, open loop and closed loop control strategies.
- PLCs are programmed using a simple programming language usually in the form of a ladder
diagram. Students are expected to be able to write and execute a simple PLC program given
the process flow diagram.
- the typical PLC block diagram consists of seven connected blocks ie INPUTS, INPUT
INTERFACES, PROCESSOR, OUTPUT INTERFACES and OUTPUTS blocks. Signal direction is
unidirectional from inputs to outputs through other blocks mentioned above. There is a
MEMORY block that connects to the processor via a bidirectional signal path. The memory
block also connects to the PROGRAMMING DEVICE block via another bidirectional signal path.
The purpose of each block is as follows:
(1) the programming device, eg a desktop computer or laptop, is used to write or modify the PLC
program.
(2) memory is used to store the PLC program, input data, processor data and output data.
(3) the processor continuously runs through the program in cycles, updating outputs as
determined by input conditions and PLC program (ON/OFF, P, PD, I, PI or PID control strategy).
(4) input interfaces such as ADCs and decoders transform input signals, which are mostly
analogue, to a digital form and format compatible with the processor.
(5) inputs such as switches, encoders and transducers measure or detect all control variables
required by the PLC program.
(6) output interfaces such as DACs, motor drives, ESD and PWM modules transform digital control
signals from the processor to a form that is compatible with process actuators.
(7) outputs or actuators such as solenoid valves, relays, heaters and motors interact directly with
controlled process in order to produce the desired controlled variable as determined by the
control signal from the processor.