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Actuators
Volume 15
Issue 9
10.3390/act15090454
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

RPI-Based Robust Fault-Tolerant Predictive Asynchronous Switching Control with Disturbance Input for Multi-Phase Batch Processes

by
Wei Xiang
1,
Anfan Zuo
2,*,
Chunwei Shi
3,*,
Huiyuan Shi
1,
Wei Gao
4,
Hanwen Ye
1,
Yuting Li
5 and
Tze Jin Wong
6
1
School of Information and Control Engineering, Liaoning Petrochemical University, Fushun 113001, China
2
School of Artificial Intelligence and Software, Liaoning Petrochemical University, Fushun 113001, China
3
School of New Energy and Advanced Materials, Liaoning Petrochemical University, Fushun 113001, China
4
PetroChina Jinzhou Petrochemical Company, Jinzhou 121001, China
5
Institute of Systems Engineering, Macau University of Science and Technology, Taipa, Macau SAR, China
6
Faculty of Humanities, Management and Science, Universiti Putra Malaysia, Bintulu 97008, Malaysia
*
Authors to whom correspondence should be addressed.
Actuators 2026, 15(9), 454; https://doi.org/10.3390/act15090454
Submission received: 3 July 2026 / Revised: 13 August 2026 / Accepted: 21 August 2026 / Published: 23 August 2026
(This article belongs to the Section Control Systems)
Versions Notes

Abstract

A robust fault-tolerant predictive asynchronous switching control method based on robust positively invariant sets is proposed for multi-phase batch processes subject to actuator faults, unknown disturbances, and asynchronous switching. To attenuate the effect of unknown disturbances, a min–max performance index is constructed, by which the robust control problem is formulated as a min–max optimization problem under worst-case disturbance conditions. To improve fault tolerance, robust positively invariant sets are introduced into the controller design so that the system states can remain within a constraint-satisfying feasible region under admissible actuator faults. Moreover, an online pre-switching mechanism is developed to address the phase mismatch between the system phase and controller. By updating the switching timing according to the real-time operating state, the controller can be adjusted to the corresponding control law before the system enters the next phase, thereby reducing the mismatched interval and suppressing state deviation. A case study on the injection and holding phases of the injection molding process shows that the proposed method improves tracking accuracy and operational smoothness under actuator faults, unknown disturbances, and asynchronous switching, demonstrating its effectiveness and applicability.
Keywords: multi-phase batch process; robust positively invariant set; fault-tolerant control; min–max optimization; asynchronous switching; predictive control multi-phase batch process; robust positively invariant set; fault-tolerant control; min–max optimization; asynchronous switching; predictive control

Share and Cite

MDPI and ACS Style

Xiang, W.; Zuo, A.; Shi, C.; Shi, H.; Gao, W.; Ye, H.; Li, Y.; Wong, T.J. RPI-Based Robust Fault-Tolerant Predictive Asynchronous Switching Control with Disturbance Input for Multi-Phase Batch Processes. Actuators 2026, 15, 454. https://doi.org/10.3390/act15090454

AMA Style

Xiang W, Zuo A, Shi C, Shi H, Gao W, Ye H, Li Y, Wong TJ. RPI-Based Robust Fault-Tolerant Predictive Asynchronous Switching Control with Disturbance Input for Multi-Phase Batch Processes. Actuators. 2026; 15(9):454. https://doi.org/10.3390/act15090454

Chicago/Turabian Style

Xiang, Wei, Anfan Zuo, Chunwei Shi, Huiyuan Shi, Wei Gao, Hanwen Ye, Yuting Li, and Tze Jin Wong. 2026. "RPI-Based Robust Fault-Tolerant Predictive Asynchronous Switching Control with Disturbance Input for Multi-Phase Batch Processes" Actuators 15, no. 9: 454. https://doi.org/10.3390/act15090454

APA Style

Xiang, W., Zuo, A., Shi, C., Shi, H., Gao, W., Ye, H., Li, Y., & Wong, T. J. (2026). RPI-Based Robust Fault-Tolerant Predictive Asynchronous Switching Control with Disturbance Input for Multi-Phase Batch Processes. Actuators, 15(9), 454. https://doi.org/10.3390/act15090454

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