Permanent magnet synchronous motor (PMSM)-driven position servo systems in high-speed flight vehicles face severe challenges from extreme thermal environments, which induce significant parameter variations up to 25% (e.g., motor torque constant) and complex multi-scale disturbances. This paper proposes a novel adaptive robust control strategy integrating three key components: (1) an ultra-local model formulation motivated by physically consistent thermal effect analysis of electromagnetic, mechanical, and tribological parameters; (2) a dual-layer disturbance observer architecture comprising a third-order finite-time convergent extended state observer (FTCESO) for fast-varying disturbances and a σ-modification adaptive estimator for slow-varying thermal drifts; and (3) a global nonlinear integral terminal sliding mode controller with a cycloidal reaching law. Stability analysis based on homogeneous system theory and Lyapunov methods establishes practical finite-time convergence with explicit bounds. The experimental results on a TMS320F28335-based servo platform demonstrate that the proposed method reduces the maximum position deviation by 83–94% compared to PID, LADRC, and conventional SMC controllers under the tested disturbance conditions, achieving settling time reductions exceeding 90%. Under combined thermal drift and external loading, the proposed approach limits the maximum tracking error to below 0.45° while maintaining a steady-state error under 0.08°.

Permanent magnet synchronous motor (PMSM)-based servo actuators are fundamental to high-performance electromechanical systems. However, in energy-sensitive aerospace applications, the impact of tracking error on system-level efficiency remains insufficiently quantified. This paper establishes an energy-oriented analytical framework linking PMSM tracking accuracy to vehicle-level energy consumption and flight range. By employing a specific mechanical energy formulation, we demonstrate that tracking deviations modify aerodynamic drag and introduce additional dissipative work. Specifically, the accumulated dissipation is shown to admit a lower bound proportional to the integral of the squared tracking error, from which a range degradation bound is derived. These results reveal that “tracking-error energy” imposes a fundamental limit on achievable flight distance. A Lyapunov-based analysis further proves that minimizing this error energy reduces total aerodynamic dissipation without requiring modifications to propulsion scheduling or guidance laws. Numerical simulations comparing a conventional sliding mode controller with an advanced fuzzy-adaptive nonsingular terminal sliding mode controller confirm that enhanced servo precision directly improves velocity retention and range performance. This framework offers practical insights for designing energy-aware PMSM control strategies in energy-constrained aerospace platforms.