This research investigates the impact of actuator faults on the formation control of multiple-wheeled mobile robots—a critical aspect in coordinating multi-robot systems for applications such as surveillance, exploration, and transportation. When a fault occurs in any of the robots, it can disrupt the formation and adversely affect the system’s performance, thereby compromising system efficiency and reliability. While numerous studies have focused on fault-tolerant control strategies to maintain formation integrity, there is a notable gap in the literature regarding the relationship between controller gains and settling time under varying degrees of actuator loss. In this paper, we develop a kinematic model of wheeled mobile robots and implement a leader–follower-based formation control strategy. Actuator faults are systematically introduced with varying levels of effectiveness (e.g., 80%, 60%, and 40% of full capacity) to observe their effects on formation maintenance. We generate data correlating controller gains with settling time under different actuator loss conditions and fit a polynomial curve to derive an equation describing this relationship. Comprehensive MATLAB simulatio
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