New regularization embedded nonlinear control designs are proposed for the temperature control of an ill-conditioned thermal process. A classic nonlinear controller applied to such a process is shown to provide good temperature tracking but generates physically unreasonable actuator solutions. Tikhonov and truncated singular value decomposition (TSVD) methods, embedded in the design of feedback linearizing controllers (FBL) and sliding mode controllers (SMC), also provide good temperature tracking and generate physically reasonable and actuator-constraint-satisfying solutions for the ill-conditioned system, in spite of the modeling errors inherent in applying regularization. These nonlinear controllers are also robust to changes in process parameters of the ill-conditioned process.

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