Sustainable Control of Large-Scale Industrial Systems via Approximate Optimal Switching with Standard Regulators

Large-scale production systems (LSPS) operate under growing complexity driven by digital transformation, tighter environmental regulations, and the demand for resilient and resource-efficient operation. Conventional control strategies, particularly PID and isodromic regulators, remain dominant in industrial automation due to their simplicity and robustness; however, their capability to achieve near-optimal performance is limited under constraints on control amplitude, rate, and energy consumption. This study develops an analytical–computational approach for the approximate realization of optimal nonlinear control using standard regulator architectures. The method determines switching moments analytically and incorporates practical feasibility conditions that account for nonlinearities, measurement noise, and actuator limitations. A comprehensive robustness analysis and simulation-based validation were conducted across four representative industrial scenarios—energy, chemical, logistics, and metallurgy. The results show that the proposed control strategy reduces transient duration by up to 20%, decreases overshoot by a factor of three, and lowers transient energy losses by 5–8% compared with baseline configurations, while maintaining bounded-input–bounded-output (BIBO) stability under parameter uncertainty and external disturbances. The framework provides a clear implementation pathway combining analytical tuning with observer-based derivative estimation, ensuring applicability in real industrial environments without requiring complex computational infrastructure. From a broader sustainability perspective, the proposed method contributes to the reliability, energy efficiency, and longevity of industrial systems. By reducing transient energy demand and mechanical wear, it supports sustainable production practices consistent with the following United Nations Sustainable Development Goals—SDG 7 (Affordable and Clean Energy), SDG 9 (Industry, Innovation and Infrastructure), and SDG 12 (Responsible Consumption and Production). The presented results confirm both the theoretical soundness and practical feasibility of the approach, while experimental validation on physical setups is identified as a promising direction for future research. © 2025 by the authors.