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Brooks, Sawyer

Publications and source records attributed to Brooks, Sawyer.

11 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗
NASA NTRS2022

First 210 solar days of Mars 2020 Perseverance Robotic Operations – Mobility, Robotic Arm, Sampling, and Helicopter

This paper includes the summary, lessonslearned, and upcoming plans for the first 210 Mars solar days(sols) of the mission. The focus of the paper is on roboticoperations which has the primary responsibility for strategicplanning, uplink commanding and downlink analysis forrover mobility and navigation, robotic arm operation, thesampling and caching capability including coring, theadaptive caching assembly and the 2nd sample handlingrobotic arm, and interface to the Mars helicopter Ingenuity.As of Sol 210 the rover has driven 2663.65 meters, executed20764 robotic arm and sampling commands, and hassuccessfully completed 13 helicopter flights covering 2382meters horizontal distance. It includes the OperationsReadiness Tests in preparation for landing, landing and initialcheckouts, strategic route planning to the science destinationand waypoints, surface checkout of all of the roboticscapability of the rover. It also discusses the strategic planningand tactical agility needed for interleaving scienceinvestigation and technology demonstration of the Marshelicopter flights where a minimum distance had to bemaintained between the rover and helicopter during flights. Itdiscusses the challenges with planning robotic operations andaddressing anomalies with the larger uncertainty presentduring early mission operations. It also discusses the impacton robotic operations from lessons incorporated fromprevious missions.

Ono, Hiro↗
NASA NTRS2022

Testing Mars 2020 Flight Software and Hardware in the Surface System Development Environment

The Mars 2020 (M2020) Perseverance Rover is NASA's most advanced planetary rover mission to date. It includes a novel Sample Caching Subsystem (SCS) which will collect rock cores for possible future return to Earth, as well as an improved mobility system with enhanced autonomous navigation which will enable it to traverse faster and farther than prior rovers. The development of both systems required extensive flight software and flight hardware testing. To support this testing, we developed the Surface System Development Environment (SSDEV) and used it for a wide variety of testing. SSDEV is a bundled subset of M2020 Flight Software which runs on commercially available Linux computers and can be combined with multiple backend options for simulation and hardware control. The SSDEV architecture enabled our teams to perform much more testing of flight software and flight hardware than would have otherwise been possible. As a secondary benefit, the SSDEV-based test campaigns also helped our teams enter the operations phase of the mission with greater readiness of operations products and tools. In this paper, we summarize the motivation for SSDEV, provide an overview of the SSDEV architecture, list several examples of how SSDEV was used, and summarize lessons learned. SSDEV is not a substitute for integrated testing with flight-like avionics, but it enabled substantially more testing than would have otherwise been possible and also provided some unique benefits. We recommend architectures like SSDEV to future projects that need to perform extensive hardware and software testing using a limited set of flight-like avionics.

Wai, Dennis↗
NASA NTRS2022

Docking the Mars 2020 Perseverance Robotic Arm

The Mars 2020 Perseverance Rover includes an innovative Sample Caching Subsystem (SCS). Two key features of SCS are the ability to collect and process rock and regolith samples for possible future return to Earth and the ability to switch between different types of drill bits for coring rocks, abrading rocks, and collecting regolith. These capabilities are enabled by a Corer mounted on the end of a Robotic Arm and a Bit Carousel mounted on the front of the rover body. Beneath the Bit Carousel, a smaller Sample Handling Arm can insert and remove sample tubes from sampling bits in the carousel. For the Corer to interface with the Bit Carousel so that it can exchange drill bits and hand off rock samples, the Robotic Arm must maneuver the Corer to dock with the Bit Carousel. Docking serves two primary purposes: it precisely aligns the Corer with the hardware inside the Bit Carousel, and it applies enough preload between the Corer and the Bit Carousel to make them stay aligned through the process of bit exchange.The docking assembly consists of four concave alignment cones mounted on a large rotating ring, through the center of which the drill can exchange bits and samples with the Bit Carousel. The coring drill includes four alignment posts which mate with the four cones on the dock. Docking uses an algorithm we call “Force-Corrected Docking”, which means it iteratively reads the force/moments reported by the FTS, performs a small motion to reduce sideload and moments while increasing preload, and repeats until reaching a deadband around the target preload. Because docking is a critical function for SCS, the dock hardware and algorithm have been tested thousands of times over 7 years in various stages of development. The culmination of this work is a reliable docking system which has been demonstrated and used in flight.

Warner, Antonia↗
NASA NTRS2022

Robotics Verification and Validation Strategies for Perseverance Rover Sampling and Caching

The Mars 2020 Sampling and Caching Subsystem(SCS) is the most complex robotic system ever fielded on a MarsRover. It includes a 5 degree-of-freedom Robotic Arm, coringdrill, gas Dust Removal Tool, interfaces for two turret-mountedinstruments, and an Adaptive Caching Assembly (ACA). TheACA is itself a complex robotic system, containing hardware tosupport docking and bit exchange, a 3 degree-of-freedomSample Handling Assembly for manipulating sample tubes,storage for several drill bits and sample tubes, and mechanismsto support observing and sealing samples collected by the drill.To successfully verify and validate the SCS hardware andsoftware and its integration with the Mars 2020 flight systemseveral key strategies were employed.The SCS Verification and Validation (V&V) program utilizedmultiple test venues with tiered levels of fidelity. These includedsimulation and visualization software environments, low fidelitydevelopment testbeds, testbeds with high fidelity SCS hardwareand commercial off-the shelf avionics, integrated systemtestbeds with flight-like avionics, and environmental testbedscapable of simulating Martian surface temperature andpressure. Multiple units of each SCS hardware componentmoved fluidly between test venues to accomplish myriadstandalone and coordinated test objectives. Test preparationand executions were performed by a diverse team of engineerswith training and technical ownership tailored for individualexperience and role. Despite significant differences between testvenues, the SCS V&V team established efficient and consistentprocesses and tools for procedure development, test execution,and data review that enabled personnel, as well as technicalproducts such as sequences and parameter configurations, toflow between venues effectively. A series of benchmark testsprovided evidence of performance consistency as elements weretransferred between venues and as system capability evolved.This paper provides an overview of the SCS V&V program andexplores several overarching strategies that enabled successfuloperation in the face of unprecedented complexity. Keyoutcomes of the SCS validation effort are summarized, alongwith lessons learned and beneficial integrations of validationtool and process innovations into Mars surface operations.

Brooks, Sawyer↗
NASA NTRS2022

Perseverance Rover’s Robotic Arm and Turret Mounted Instruments’ Surface Commissioning

The Robotic Arm (RA) on the Perseverance rover is an integral component of the Sampling and Caching System necessary for completing the science goals of the Mars 2020 mission. While the Perseverance rover was based on the Curiosity rover which landed in 2012, the Robotic Arm was redesigned to carry a much larger turret with a new suite of payloads. Shortly after Perseverance landed in Jezero Crater, a series of checkouts was completed with the RA during the first 100 sols of the mission in order to ensure proper functionality of the RA and the instruments mounted on the turret. This period of time in the mission was called Surface Operations Transition (SOX). The objective of SOX was to systematically execute checkout activities for all the basic functionality so that the RA and instruments, as well as other rover components, could be released for scientific exploration.RA activities during SOX can be divided into a few different categories: Mechanism Checkouts, Rover Visual Inspections, Performance Characterization, and Instrument Functional Checkouts. Many of these checkouts built off of each other such that each subsequent activity would verify incrementally complex functionality. Many of the defined activities were executed several times throughout the development of the rover and served as a check that the RA’s performance is consistent with testing on Earth. Other activities were developed uniquely for SOX to respond to challenges discovered during development. They were designed to be verifiable without the help of ground support equipment or previous executions on the flight hardware to compare against.This paper discusses the formulation and conception of the various RA SOX checkout activities, verification and testing required to certify them for flight, execution of the activities on Mars, issues encountered, and finally results and findings as the mission transitioned to nominal science operations. We will be presenting the results and analysis using downlinked imaging and data from the flight vehicle to show how we verified the performance of the Robotic Arm and the turret mounted instruments in order to transition to science operations with a clean bill of health.

Edgett, Kenneth↗
NASA NTRS2018

Software System for the Mars 2020 Mission Sampling and Caching Testbeds

The development of the Sampling and Caching Subsystem (SCS) of the Mars 2020 Rover Mission is highly dependent on testing of prototype hardware and software operating in explicit conditions as part of integrated testbeds. To achieve relevant integration of hardware and software while maintaining rapid algorithm development capabilities and high testing throughput, the Controls and Autonomy for Sample Acquisition and Handling (CASAH) software system was developed. CASAH is an implementation of the Intelligent Robotics System Architecture (IRSA),which mimics JPL Flight Software (FSW) in that it is divided into hierarchical modules that run separate processes that communicate via message passing, each module is assigned an owner that is a single developer, and the operator initiates requests via a text-based interface that interprets sequences of commands.IRSA enables a modular breakdown of CASAH that follows that of 2020 Flight Software,so developers can take an algorithm from a module in CASAH and re-code it into the same module in FSW. As deployment of CASAH has grown to ten testbeds - each with different hardware and objectives - bottom-up design decisions have been intentionally made to keep the system lightweight and maintainable by a very small team. To date, CASAH has been used to run 1393 different tests. This work describes CASAH, the testbeds and functionality it supports, the tools used to manage the development and sharing of code, and the features of the software. Lessons learned over the past three years of development and deployment are provided.

Vieira, Peter↗