L04 Discrete-State Process Control

04 /11/2019 Eng. Said Ibrahim

 OBJECTIVES
• Define the nature of discrete-state process-control systems.
• Give different examples of applications of discrete-state process
control in industry.
• Explain how a discrete-state process can be described in terms
of the objectives and hardware of the process.
 INTRODUCTION
• The majority of industrial process-control installations involve
more than simply regulating a controlled variable.
• The requirement of regulation means that some variable tends
to vary in a continuous fashion because of external influences.
But there are a great many processes in industry in which it is
not a variable that has to be controlled but a sequence of
events.
 Discrete State
• The term discrete state expresses that each event in the
sequence can be described by specifying the condition of all
operating units of the process.
• Such condition descriptions are presented by expressions such
as: valve A is open, valve B is closed, conveyor C is on, limit
switch is closed, and so on.
• A particular set of conditions is described as a discrete state of
the whole system.
 Discrete-State Process Control
• Figure 1 is a symbolic representation of a manufacturing process and the
controller for the process.
• Let us suppose that all measurement input variables and all control output
variables of the process can take on or be assigned only two values.
• Now we define a discrete state of the process at any moment to be the set of
all input and output values.

• Each state is discrete in the sense that there is only

a discrete number of possible states.
• If there are three input variables and three output
variables, then a state consists of specification of all
six values.
• Because each variable can take on two values, there
is a total of 64 possible states. Figure 1
 Discrete Event
• An event in the system is defined by a particular state of the
system—that is, particular assignment of all output values and a
particular set of the input variables.
• The event lasts for as long as the input variables remain in the
same state and the output variables are left in the assigned state.
• For a simple oven, we can have the temperature low and the heater
on. This state is an event that will last until the temperature rises.
 discrete-state process control
• discrete-state process control is a particular sequence of events
through which the process accomplishes some objective.
• For a simple heater, such a sequence might be:-
1. Temperature low, heater off
2. Temperature low, heater on
3. Temperature high, heater on
4. Temperature high, heater off
• The objective of the controller of Figure 1 is to direct the discrete-
state system through a specified event sequence.
EXAMPLE 1
Construct a description of the frost-
free refrigerator/freezer shown in
Figure 2 as a process with a
discrete-state control system.

Define The input variables, output

variables, and sequence of
serial/parallel events.

Figure 2
 Solution
The discrete-state input variables are
1. Door open/closed
2. Cooler temperature high/low
3. Freezer temperature high/low
4. Frost eliminator timer time-out/not time-out
5. Power switch on/off
6. Frost detector on /off

The discrete-state output variables are

1. Light on/off
2. Compressor on/off
3. Frost eliminator timer started /not started
4. Frost eliminator heater and fan on/off
5. Cooler baffle open/closed
Figure 2
This is a total of 11 two-state variables. In principle, there are possible
states or events. Of course, only a few of these are necessary. 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.

The events of (a) can occur in parallel with any of the others. The events
of (b) and (c) can occur in parallel. Event (d) can only be serial with (b)
or (c).
 Discrete-State Variables
• It is important to be able to distinguish between the nature of
variables in a discrete-state system and those in continuous
control systems.
• To define the difference carefully, we will consider an example
contrasting a continuous variable situation with a discrete-state
variable situation for the same application. Later it will be shown that
continuous variable regulation can be itself a part of a discrete-state
system.
 Continuous Control
Figure 3 shows a tank with a valve that controls
flow of liquid into the tank and some unspecified
flow out of the tank.
A transducer is available to measure the level of
liquid in the tank.
Also shown is the block diagram of a control
system whose objective is to maintain
the level of liquid in the tank at some preset or
setpoint value.

Figure 3
 Discrete-State Control
The variables, level and valve settings, are discrete
because they can take on only two values. This
means that the valves can only be open 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. To do this, we specify an event sequence:
1. Close the output valve.
2. Open the input valve and let the tank fill to the
desired level, as indicated by a simple switch.
3. Close the input valve.

Figure 4.
 Composite Discrete/Continuous Control
• It is possible for a continuous control system to be part of
a discrete-state process-control system.
• The outlet valve is to be closed and the tank filled to the
required level as in Figure 4.
• Periodically a bottle comes into position under the outlet
valve, as shown in Figure 5. The level must be maintained
at the setpoint while the outlet valve is opened and the
bottle filled. This requirement may be necessary to ensure
a constant pressure head during bottle filling.
• This process will require that a continuous-level control
system be used to adjust the input flow rate during bottle-
fill through the output valve. The continuous control
system will be turned on or off just as would a valve or
motor or other discrete device. Figure 5.
 Process Specifications
• 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.
• The first part consists of the objectives of the process.
• and the second is the nature of the hardware assembled to
achieve the objectives.
 Process Objectives
The objectives of the process are simply statements of what the process is
supposed to accomplish.

The overall objective can be broken down into many secondary objectives. Figure 6
suggests some of the secondary objectives that might be involved.

Figure 6
 Process Hardware
• Process hardware design is closely tied to the nature of the industry, and its design
must come from the joint efforts of process, production, and control personnel.
• For the control system specialist, the essential thing is to develop a good
understanding of the nature of the hardware and its characteristics.

FIGURE 7
FIGURE 7
 Process Hardware two basic categories.
1. Input devices provide inputs to the control system. The operation of these devices is
similar to the measurement function of continuous control systems. In the case of discrete-
state process control, the inputs are two-state specifications, such as
• Limit switches: open or closed
• Comparators: high or low
• Push buttons: depressed or not depressed

2. Output devices accept output commands from the control system. The final control
element of continuous control systems does the same thing. In discrete state process
control, these output devices accept only two-state commands,such as
• Light: on or off
• Motor: rotating or not rotating
• Solenoid: engaged or not engaged
Example 2
Study the pictorial process of Figure 7. Identify the input and output devices and
the characteristics of each device.

FIGURE 7
 Example 2 Solution
1. Input Devices (All Switches)
• Right box present
• Left box present
• Feed conveyor right travel limit
• Feed conveyor left travel limit
• Hopper low
• Feed conveyor center
2. Output Devices
• Hopper valve solenoid
• Feed stock conveyor motor right
• Feed stock conveyor motor left
• Right box conveyor motor
• Left box conveyor motor
Important note
• It is not enough simply to identify the input and output devices. In
addition, it is important to note how the two states of the devices
relate to the process
• if a level-limit switch is open, does that mean the level is low or at the
required value? If a command is to be used to turn on a cooler, does
this require a high- or low-output command?
 Event Sequence Description
• A sequence of events must be described that will direct the system
through the operations to provide the desired end result.
 Narrative Statements
• Specification of the sequence of events starts with narrative
descriptions of what events must occur to achieve the objective.
• describes in narrative form what must happen during the process
operation.
 Narrative Statements Example
• In systems that run continuously, there are typically a startup, or
initialization, and running phase
• As an example, consider the system described by Figure 7. The start-
up phase is used to place the feed conveyor in a known condition.
This initialization might be accomplished by the following
specification: a running phase.
I. 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
Completion of this phase means that the feed
E. Open hopper-feed valve conveyor is positioned at the left limit position and
F. Test for left limit switch the right half of the conveyor has been filled from the
1. If engaged, go to G feed hopper.
2. If not, go to F The system is in a known configuration, as shown in
G. All motors off, hopper-feed valve closed Figure 8.
H. Go to running phase
I. 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
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
II. Running
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, go 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
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 Note that the system cycles from step M to step A.
K. Test center switch The description is constructed by simple analysis of what
1. If engaged, go to L events must occur and what the input and outputs must
2. If not, go to K be to support these events.
L. Open hopper-feed valve
M. Test left limit switch
1. If engaged, go to II.A
2. If not, go to M
EXAMPLE 3
Construct a narrative statement outline of the event sequence for the system
shown in Figure 5. The objective is to fill bottles moving on a conveyor.

Figure 5.
 Solution
I. Initialization (prefill of tank)
A. Conveyor 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 reached
C. Go to the running phase
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
 Flowcharts of the Event Sequence
• It is often easier to visualize and
construct the sequence of events if a
flowchart is used to pictorially present
the flow of events.
• Although there are many sophisticated
types of flowcharts, the concept can be
presented easily by using the three
symbols shown in Figure 9.

Figure 9.
 Figure 10 shows part of the initialization phase
of the conveyor system of Figure 7 expressed
in the flowchart format.

Figure 10 Figure 7
 Binary-State Variable Descriptions
• Each event that makes up the sequence of events described by the narrative scheme
corresponds to a discrete state of the system.
• Thus, it is also possible to describe the sequence of events in terms of the sequence of
discrete states of the system.
• To do this simply requires that for each event the state, including both input and output
variables, be specified.
• The control system works like a look-up table. The input state variables with the output
become like a memory address, and the new output state variables are the contents of that
memory.
 EXAMPLE 4
• Construct a state variable description of the process shown in Figure 11.
• The timer output (TU) is initially low when its input (TM) is low.
• When TM is taken high the output stays low for five 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 the tank to level A (LA) from valve A (VA)

2. Fill the tank to level B (LB) from valve B (VB)
3. Start the timer (TM), stir (S), and heater (H)
4. When five minutes are up take stir (S) and heater (H) off
5. Open output valve (VC) until the tank is empty (LE)
6. Take the timer low (TM) and go to step 1.

Figure 11
Solution
• To provide the solution, we first form the state variable
representation of the system by assignment of binary states.
• There are four input variables (LA, LB, LE, TU) and six output
variables (VA, VB, VC, TM, S, H).
• A discrete state of the system is defined by specifying these
variables. Because each variable is a two-state variable, we use
a binary representation: true = 1 and false = 0.
• 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)
• The sequence of events is now translated into an expression of the discrete state as a
binary word per state.
• The system is processed through the proper sequence by having the input state
uniquely select an output state. The following table shows the states of the machine
along with brief descriptions. The bit order is the same as previously given.
 Boolean Equations

• Because the discrete state of the system is described by

variables that can take on only two values, it is natural to think
of using binary numbers to represent these variables.
• It is also natural to consider use of Boolean algebra techniques
to deduce the output states from the input states.
• Although this technique is used, there are generally easier
ways to view and solve the problems than with traditional
Boolean techniques.
 EXAMPLE 5
Figure 12 shows a pictorial view of an oven, along with the associated input and
output signals. All of the inputs and outputs are two-state variables, and the relation
of the states and the variables is indicated. Construct Boolean equations that
implement the following events:

1. The heater will be on when the power-switch is

activated, the door is closed, and the
temperature is below the limit.
2. The fans will be turned on when the heater is on
or when the temperature is above the limit and
the door is closed.
3. The light will be turned on if the light switch is on
or whenever the door is opened.

Figure 12
 Solution
The solution for problems of this type is
developed by simply translating the
narrative statements
of the events into Boolean equations. In
this case, referring to the variables defined
in Figure 12, you can see that the solution
is
 EXAMPLE 6
The operation of a microwave oven in terms of a discrete state system is
described in two phases.
Phase 1 is to identify the operational elements of the system (input and
outputs)
Phase 2 is to define the sequence of events necessary to employ the oven.
•Phase 1 :

Generator (source of microwaves)

Fan (for cooling)
Light inside oven
Safety switch on door
Main power switch
Time switch
This is basic set, others could be added.
•Phase 2:

Open door and put in food

Close door
Set timer
Turn main power on
Open and close door to take a look
Time up (cooking finish)
Batch processing cookie machine
 System Description
• Suppose that chocolate-chip cookies are made in the first production run. First, the oven is turned
on to the desired temperature.
• Next, the required ingredients in proper quantities are dispensed into the sealed mixing chamber.
A large blender then begins to mix the contents.
• After a few minutes, vanilla is added, and the mixing process continues. After a prescribed period
of time, the dough is the proper consistency, the blender stops turning, and the compressor turns
on to force air into the mixing chamber.
• When the air pressure reaches a certain point, the conveyor belt turns on. The pressurized air
forces the dough through outlet jets onto the belt. The dough balls become fully baked as they
pass through the oven.
• The cookies cool as the belt carries them to the packaging machine.
• After the packaging step is completed, the mixing vat, blender, and conveyor belt are washed
before a batch of raisin-oatmeal cookies is made.
• Products from foods to petroleum to soap to medicines are made from a mixture of ingredients
that undergo a similar batch process operation.
Coffee Vending Machine