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Purpose The characteristics of spherical robots, such as under-drive, non-holonomic constraints and strong coupling, make it difficult to establish its motion control model accurately. To improve the anti-interference performance of spherical robots in practical engineering, this paper proposes a spherical robot motion controller based on auto-disturbance rejection control (ADRC) with parameter tuning. Design/methodology/approach This paper considers the influences of the spherical shell, internal frame and pendulum on the movement of the spherical robot during the rotation to establish the multi-body dynamics model of the XK-I spherical robot. Due to the serious coupling problem of the dynamic model, the motion control state equation is constructed using linearization and decoupling. The XK-I spherical robot PSO-ADRC motion controller with parameter tuning function is designed by combining the state equation with the particle swarm optimization (PSO) algorithm. Finally, experiments are performed to evaluate the feasibility of PSO-ADRC in an actual case compared to ADRC, PSO-PID and PID. Findings By analyzing the required time to reach the expected value, the control stability and the fluctuation range of the standard deviation after reaching the expected value, the superiority of PSO-ADRC to ADRC, PSO-PID and PID is demonstrated in terms of the speed and anti-interference ability. Practical implications The proposed method can be applied to the robot control field. Originality/value A parameter-tuning method for auto-disturbance-rejection motion control of the spherical robot is proposed. According to the experimental results, the anti-interference ability of the spherical robot moving on uneven ground is improved. Therefore, it provides a foundation for the autonomous environmental monitoring of the spherical robot equipped with sensors.

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