Chapter 2

Discrete-State Control
Part I

Content
Definition of Discrete-State Process
Control
Characteristic of the System

Objectives
To understand the nature of discretestate 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, which
evolved from the early use of 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 discretestate 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 aUEEA2413
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) by
Close
the input UEEA2413
valve.Process Control and
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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 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.

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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.
All Switches
1. Hopper valve solenoid
Input
Devices Output
1. Right
box present
2. Feed Devices
stock conveyor motor

2. Left box present

3. Feed conveyor right travel limit
4. Feed conveyor left travel limit
5. Hopper low
6. Feed conveyor center
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3. Right box conveyor motor

4. 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
Construct a narrative statement outline of the
2.1
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 UEEA2413 Process Control and
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Flowcharts of the Event 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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Example
2.2

Construct a state variable description of

the process as 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.
1. Fill tankThe
to LAprocess
using valve VA.
sequence is: 2. Fill tank to LB using valve VB
3.
4.
5.
6.

Start TM, stir S and heater H.

5 min. stop S and H.
Open VC empty tank to LE.
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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Input

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.
Output
Description
6. Reset TM, repeat.

(LA)(LB)(LE)(TU)

(VA)(VB)(VC)(TM)(S)(H)

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

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

A
Complement: If A = 1, then

= 0.

AND, : If A = 1 and B = 1, and C = A

B, t

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

A B A B
A B AB

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Example
Simplify the expression
D A B C (A B C )
A B A B C C.C

A B A B C 0
A B (1 C )

A B

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

Example 2.3
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
Heater : H D T P
temperature below
limit.
Fan : F H D T
2. Fans on when heater
Light : L D S
on, or when
temperature above
limit
and
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Q&A

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