This paper presents a novel auto-tuning subsystem-based fault-tolerant control (SBFC) system designed for robotic manipulator systems with n degrees of freedom (DoF). It initially proposes a novel model for joint torques, incorporating an actuator fault correction model to account for potential faults and a mathematical saturation function to mitigate issues related to unforeseen excessive torque. This model is designed to prevent the generation of excessive torques even by faulty actuators. Subsequently, a robust subsystem-based adaptive control strategy is proposed to force system states closely along desired trajectories, while tolerating various actuator faults, excessive torques, and unknown modeling errors. Furthermore, optimal SBFC gains are determined by tailoring the JAYA algorithm (JA), a high-performance swarm intelligence technique, standing out for its capacity to optimize without the need for meticulous tuning of algorithm-specific parameters, relying instead on its intrinsic principles. Notably, this control framework ensures uniform exponential stability (UES). The enhancement of accuracy and tracking time for reference trajectories, along with the validation of theoretical assertions, is demonstrated through the presentation of simulation outcomes.

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