Abstract The fault-tolerant control issue of aircraft engines with actuator dynamics and faults is investigated in this paper. By proposing a novel intelligent sliding mode fault-tolerant control (ISMFTC) method, which combines an adaptive dynamic programming (ADP) sliding surface with Grey Wolf Optimizer (GWO) for controller parameter optimisation, the goal is to achieve quality steady-state and dynamic performance in aircraft engines while maintaining strong fault-tolerance properties. Firstly, by considering not only actuator dynamics but also actuator faults, an uncertain nonlinear cascaded model of aircraft engines is developed according to characteristic of aircraft engines and their actuators. Secondly, an ADP-based sliding surface is proposed for considered aircraft engine uncertain nonlinear cascaded system. It can obtain a certain sense of optimised performance, and could be solved by ADP strategy off-line as well. Thirdly, fault-tolerant controller is obtained on the basis of sliding mode theory and adaptive fault estimation law, namely, ADP-based ISMFTC controller. Meanwhile, GWO is integrated into the investigation of ADP-based ISMFTC controller, optimised designable control parameters are obtained subsequently. Besides, robustness analysis is elaborated according to Lyapunov theory, fault estimation error is bounded and states of closed-loop system are uniformly ultimately bounded. Simulation on a twin-shaft turbofan aircraft engine, indicates the effect of proposed ADP-based ISMFTC method.
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