This paper is concerned with the synthesis of a robust and optimal controller for open-loop unstable systems possessing actuator redundancy. The designed linear quadratic state feedback regulator can maintain the close-loop stability in the presence of some certain actuator failures. At the first design stage, a discriminance of actuator functional redundancy is given, which is the precondition to design the robust controller. Then a synthesis method based on a sufficient condition which guarantees the existence of the state-feedback fault-tolerant law is presented. The robust Linear Quadratic (LQ) regulator synthesis is shown to be equivalent to a standard LQ regulator design with a given dynamic performance index of the system. The effectiveness of this method has been verified on the fault control system design for the double electromagnets suspension model of maglev train.Index Terms -optimal control, linear quadratic regulator, state feedback, actuator failure, maglev train.