| Summary: | Aiming at the problems of strong coupling and time-varying parameters in the tension systems of roll-to-roll coating machines, this paper outlines the design of a parameter self-tuning decoupling controller based on an improved active disturbance rejection controller (ADRC) for tension systems. First, we established a nonlinear coupled model for a global tension system based on the roll-to-roll coating machine tension constituent unit and working principle. Second, we introduced virtual quantities and actual control quantities; then, we applied an ADRC for decoupling control of the tension system based on a nonlinear coupling model, using a genetic algorithm (GA) to achieve parameters tuning in the ADRC. Finally, both the traditional proportional–integral–differential (PID) controller and the designed controller were simulated to evaluate their anti-interference and decoupling performance. Furthermore, the performances of several controllers were compared to the results obtained by other researchers. The result found that the parameter self-tuning decoupling controller based on an improved ADRC for tension systems exhibited better decoupling control performance and that the controller was able to achieve precise control of tension.
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