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AEROSPACE ENGINEERING
AEE 383 - SYSTEM DYNAMICS
2023 – 2024 FALL SEMESTER
Ayşe Nur GÖK
Abstract - This mini-project delves into the
design and analysis of a PID-controlled rudder
system for aerospace applications, aiming for
precise position control within ±35°. The
interdisciplinary approach involves mechanical
design using SolidWorks, Simmechanics
modeling, and Simulink simulation. The project
encompasses the creation and assembly of a
rudder and shaft, with material properties
assigned using SolidWorks, and subsequent
export to Simulink. The Simulink design
includes the development of a DC motor for
position control, considering the gear train ratio
specified in the project guidelines. The study
explores the impact of PID gain values on system
performance and emphasizes the significance of
precise position control in aerospace engineering.
The abstract underscores the integration of
mechanical and control systems in the pursuit of
optimized rudder functionality for aerospace
applications.
Keywords – PID Controller, gearbox, DC motor,
rudder, MATLAB, SolidWorks, SimMechanics,
Simulink, overshoot, rise time, settling time,
Maxon products
I. INTRODUCTION
In an aircraft, rudder is a primary control surface
that is typically located on the vertical stabilizer,
which is the vertical fin at the tail of the aircraft.
Function of the rudder is to control the yaw motion
of the aircraft. Yaw is the rotation of the aircraft
around its vertical axis, which is an imaginary line
running from the top to the bottom of the aircraft,
passing through its center of gravity [1].
The integration of a PID (Proportional-Integral-
Derivative) controller, coupled with a gearbox and a
DC motor, becomes essential for achieving precise
and responsive rudder control. In this intricate
system, the gearbox facilitates the transformation of
the DC motor's output to finely tune the rudder's
movement. The DC motor, selected based on
specific criteria such as torque and speed
requirements, serves as the driving force in this
control mechanism. The PID controller, a staple in
control engineering, adds a layer of sophistication
by adjusting the rudder's position based on the
difference between the desired and actual positions
[2]. This closed-loop control system ensures that the
aircraft's yaw motion is not only effectively
controlled but also meets design goals such as
desired rise time, settling time, and overshoot.
Overall, the integration of these components
demonstrates the relation between aerodynamics
and control engineering, highlighting the
multidisciplinary nature of aircraft design and
ensuring optimal performance in various flight
scenarios.
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II. METHODOLOGY
1)Software Adjustments
Rudder was designed according to the guidelines
provided in the project instructions file considering
the student ID of 20110111009. RudderL1 is
95.4mm, rudder height is 153.4mm and shaft height
is 193.4mm. Detailed SolidWorks drawing of the
rudder is provided in Appendix A. According to the
ID Rudder mass is taken as 1.6kg and according to
SolidWorks measurement tool volume is
368589.38mm3. Thus, density is calculated as
4340.9kg/m3. In addition, a custom material is
assigned considering the density value.
Secondly, assembly was exported as an xml file
from SolidWorks and opened in MATLAB to
Simulink/Simmechanics environment. Setup was
prepared using block diagrams. Detailed figures of In this configuration (Fig. 3.1), vertical axis of
block diagrams used in this project are provided in the graph represents the position (as degree) of
Appendix B; figure 1 and figure 2. the rudder. Blue line starts from 0° position (0.6
2)DC Motor Selection and Gearbox Design
Fig. 3.1: Motion of the Rudder Graph
In order to get meaningful data, a proper DC
Motor for the rudder assembly was selected. As in vertical). First it goes to the position of -35° (0
criterion, moment of inertia (J), armature resistance in vertical). After it settles down completely
(Ra) and armature inductance (La), armature under 5 seconds, it goes to the position of +35°
voltage (V) and no-load speed (initial speed) was (1.2 in vertical) and again it settles. Each
considered. Values of the criterion are shown in movement lasts for 5 seconds.
Appendix B, figure 4.

DC Motor was expected to move a mass of 1.6kg

(mass of the rudder). Thus, DCX 32L motor was
chosen as it met the requirements. Features of DCX
32L can be seen in Appendix C.

Gearbox was simply designed with MATLAB

function box in the diagram to transmit the torque
with gear ratio of 3.3, code for this purpose is
provided in figure 6.
3)Simulation and Graphs
When the simulation is performed there were
some errors due to the formulation and step input, Fig. 3.2: Rise Time Measurement
after many iterations graphical results became better
and took its final version. Final graphical output of 3.1) Rise Time
the motion can be seen: Using the tools in the graph window (Fig. 3.2),
rise time is measured as 0.884 seconds which is less
than 1 second.
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projection of ±35° in the simulation window.

Changing that would result in different angles.

5)The Effect of PID Gain Values

Final graphical output was provided previously
(Fig 3.1). Final gain values of PID controller are as
following:

Fig. 3.3: Overshoot Measurement

3.2) Overshoot
Also obtaining value of vertical output of blue
line and yellow lines (Fig. 3.2), overshoot is
calculated as 9.33%.
Fig. 5.1: Initial Gain Values of PID

5.1) Changing Proportional (P) Gain Value

Increasing the gain value of the P from 5 to
30 resulted in the graphic below. It decreased the
4)Effect of Step Input Values
overshoot, the rise time and the settling time as
demonstrated.

Fig. 4.1: Step Input Difference

Fig. 5.2: Increase in P

Importance of correctly adjusting step input
value can be seen in figure 4.1. As seen, increasing Decreasing the gain value of the P from 5 to 1
the final value of step input from 1.2 to 3 changes resulted in increase of overshoot, rise time and
the positional behavior of the rudder. Starting graph failed to settle in period of 5 seconds.
position which is 0° corresponds to 0.6. When the
step input is taken as 0.0 final value should be 1.2
due to symmetry. These values result in a true

Fig. 5.3: Decrease in P
5.2) Changing Integral (I) Gain Value
Increasing the gain value of the Integral from
5 to 30 resulted in an increased overshoot. However
it succeeded to decrease the settling time and rise
time.
Fig. 5.4: Increase in I
Decreasing the gain value of the Integral to 1
resulted in significant decrease of overshoot.
However, rise time increased above 1 second.
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Fig. 5.5: Increase in I
5.3) Changing Derivative (D) Gain Value
Increasing the gain value of the Derivative
from 1 to 5 resulted in an instable result in the
motion. It failed to reach the settling point.
Fig. 5.6: Increase in D
Decreasing the gain value of the derivative to
0.1 resulted in a significant decrease in response
time and settling time.
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considerations, including hardware constraints and

communication protocols, present an opportunity
to transition the designed control system from
simulation to practical aerospace applications.

Further refinements in the mechanical design,

incorporating advanced materials and structural
optimizations, could contribute to weight reduction
while maintaining structural integrity.
Experimental validation, integrating the control
system into a physical prototype, is a logical next
step to relate simulation findings with physical
world outcomes. Additionally, exploring adaptive
control strategies, human-in-the-loop simulations,
Fig. 5.7: Decrease in D and integration with broader flight dynamics offer
avenues for a more comprehensive understanding of
the system's behavior in realistic scenarios. Energy
efficiency considerations and the implementation of
III. CONCLUSION system health monitoring further align the rudder
In summary, the PID-controlled rudder system system with emerging trends in aerospace
designed and analyzed in this mini-project technology, emphasizing reliability, efficiency, and
successfully achieves the specified position control adaptability in future works.
objectives within ±35°. The integrated approach
involving SolidWorks, SimMechanics, and
Simulink ensures a seamless connection between
mechanical design and control engineering. The
selection of the Maxon DCX 32L motor, along with
the gearbox, proves effective in meeting torque and
speed requirements. The PID controller, with
carefully tuned gain values, enables precise rudder
positioning, as evidenced by simulation results
meeting the desired rise time, settling time, and
overshoot criteria. This project highlights the
critical interplay between mechanical and control
components in aerospace applications, contributing
to optimized performance and reliability. The
systematic analysis of PID gain sensitivity further
underscores the importance of parameter tuning for
stable and efficient system response.

IV. FUTURE WORKS

Looking ahead, the PID-controlled rudder system
opens avenues for future enhancements and
investigations. Firstly, exploring advanced control
strategies beyond PID, such as model predictive
control or fuzzy logic, could elevate the system's
performance and adaptability to dynamic flight
conditions. Real-time implementation
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Appendix A – SolidWorks Drawing

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APPENDIX B – FIGURES

Figure 1: Complete Diagram of the Design

Figure 2: Detailed Demonstration of PID

Figure 3: Detailed Demonstration Rudder Motion

Figure 4: Parameters of DC Motor

Figure 5: Parameters of Rudder Motion

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APPENDIX C – MOTOR SELECTION AND GEARBOX

Figure 6: DC Motor DataSheet

Figure 7: MATLAB Code of Gearbox

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REFERENCES
[1] W. Zhou, D. B. Cherchas, and S. Calisal,
“Identification of rudder—yaw and rudder—roll
steering models by using recursive prediction
error techniques,” Optimal Control Applications
and Methods, vol. 15, no. 2, pp. 101–114, 1994.
doi:10.1002/oca.4660150203
[2] L. Wang, PID Control System Design and
Automatic Tuning Using MATLAB/Simulink.
Wiley-IEEE Press, 2020.
[3] “Introduction: Pid controller design,” Control
Tutorials for MATLAB and Simulink -
Introduction: PID Controller Design,
https://ctms.engin.umich.edu/CTMS/index.php?
example=Introduction&section=ControlPID
(accessed Jan. 21, 2024).
[4] K. Ogata, “Ch. 8, PID Controllers and Modified
PID Controllers,” in Modern Control
Engineering, Boston etc.: Prentice Hall, 2010
[5] G. F. Franklin, J. D. Powell, and A. Emami-
Naeini, “Ch.4, A First Analysis of Feedback,” in
Feedback control of Dynamic Systems, Upper
Saddle River: Pearson/Prentice Hall, 2010