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This paper presents a new control methodology based on active disturbance rejection control (ADRC) for designing the tension decoupling controller of the unwinding system in a gravure printing machine. The dynamic coupling can be actively estimated and compensated in real time, which makes feedback control an ideal approach to designing the decoupling controller of the unwinding system. This feature is unique to ADRC. In this study, a nonlinear mathematical model is established according to the working principle of the unwinding system. A decoupling model is also constructed to determine the order and decoupling plant of the unwinding system. Based on the order and decoupling plant, an ADRC decoupling control methodology is designed to enhance the tension stability in the unwinding system. The effectiveness and capability of the proposed methodology are verified through simulation and experiments. The results show that the proposed strategy not only realises a decoupling control for the unwinding system but also has an effective antidisturbance capability and is robust.

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