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A Closed Loop Feedback Method for a Manual Bar Straightener Robert J. Miklosovic, Zhiqiang Gao Department of Electrical and Computer Engineering Cleveland State University Cleveland, Ohio, USA Abstract—Automation of a unique manually controlled industrial bar straightener is proposed. A continuous-time closed loop model is constructed in Simulink for an event-driven process through the use of asynchronous timers. The system is simulated with linear and nonlinear PD controllers. A nonlinear filter,called the tracking differentiator, is introduced as an alternative to a linear approximate means of providing accurate derivative feedback in the presence of noise. In both cases, the nonlinear techniques outperformed their linear counterparts while retaining tuning simplicity. I. BACKGROUND Precision straightening of a cylindrical metal bar is largely based on the ability to precisely measure its geometry. A few fundamental measurements and how each influences the tolerance specification on straightness should first be understood. Methods for measuring roundness and straightness are covered to lay the groundwork for the problem formulation. The basic operation of the machine is outlined in Section II, and its fundamental limitations and need for automation are discussed. Section III addresses the task of closing the loop through block diagrams and the role of new hardware in the process. Section IV contains descriptions of all of the blocks that are modeled in Simulink. The linear and nonlinear controller designs are discussed in Section V, the system is simulated in Section VI, and concluding remarks are made in Section VII. A. Measuring Roundness Roundness is a quantity derived from comparing the shape of a cross-sectional area at one distinct point along a cylinder’s length against a circle. A round metal bar that is arbitrarily long with respect to its diameter has to be checked for roundness in many locations lengthwise and averaged to insure overall consistency. Rou
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