CASE STUDY MSC Software: Case Study - NASA/JPL-Caltech Only One Chance to Get it Right Adams Simulations Help Curiosity Rover Make Perfect Touchdown on Mars Based on an interview with Dr. Chia-Yen design more robust. The simulation was Key Highlights: Peng, Principal & Lead Engineer for the Loads also used to validate the landing sequence and Dynamic Simulation team at JPL. and determine loads on subassemblies and components. The controls software code Mars Science Laboratory is a robotic space Industry probe mission that successfully landed Curiosity, that guides the mission through the sky crane a Mars rover, in Gale Crater on Mars on August landing sequence was integrated into the Aerospace 5th, 2012. The sky crane landing sequence Adams environment to validate and tune its required the rover to transform from its stowed performance. The accuracy of these simulations Challenge flight configuration to landing configuration while was proven by the success of the mission. Validate the landing sequence and determine being lowered to Mars wheels down from the loads on subassemblies and components on descent stage. The final entry, descent, and Complex Landing Sequence the Curiosity Rover during its historic landing sky crane landing phase was called “seven sequence on Mars. minutes of terror” by NASA engineers because The Curiosity rover is about twice as long and of its complexity and the fact that human five times as heavy as previous Mars Spirit intervention from earth was impossible. and Opportunity rovers. Landing such a large MSC Software Solutions payload on Mars is challenging because the Adams NASA Jet Propulsion Laboratory (JPL) atmosphere on Mars is too thin for parachutes engineers simulated this final sky crane and aerobraking to be effective yet still thick landing sequence using MSC Software’s enough to create the potential for stability and Benefits Adams multibody dynamics software. The impingement problems when decelerating with • Optimize the design of every component to simulation identified problems with the initial rockets. Also at 900 kg the Curiosity rover is too ensure their ability to withstand loads and concept design and guided engineers as heavy to use airbags to cushion the shock of successfully perform their mission they resolved these issues and made the • Determine the bounding limit design loads that could be expected on every component. • Ensure that there was no possibility of contact between the flight hardware Case Study: NASA/JPL-Caltech CASE STUDY MSC Software: Case Study - NASA/JPL-Caltech “The engineers at JPL were not able to test most of the critical mission events on Earth so they had to rely upon MSC Software simulation technology to design most of the hardware and control sequences for this mission.” landing. One additional challenge is that the 14 surface. As the bridles unreeled, the rover’s simulation from the very beginning and devoted minute trip required for a radio signal to travel six motorized wheels snapped into position an average of three people working with from Mars to earth means that the vehicle must to prepare for landing. After landing, the multibody dynamics over the life of the project. act autonomously without interactive control rover fired explosive devices activating cable The rover, the most critical part of the from Earth for the entire landing sequence. cutters to free itself from the descent stage simulation, was modeled to a high level of NASA engineers addressed these challenges and the descent stage crash landed hundreds fidelity including many flexible elements some by developing a unique entry-descent-landing of meters from the rover. At 6:33 a.m., the of which incorporated nonlinear stiffness and system. The aeroshell containing the heat rover confirmed a successful landing. damping. The descent stage model is much shield, rover, descent stage, backshell and simpler, consisting entirely of rigid bodies. In parachute, separated from the cruise stage Only One Chance to Get it Right the beginning of the project, separate models ten minutes before entering the Martian were used for the rover separation, mobility atmosphere and fired thrusters to orient There was only one chance to get it right. The deployment, and touchdown phases. During the heat shield facing Mars. The aeroshell complex sequence either works perfectly or the later stages of the project, all of the slowed to about 578 meters per second the entire mission goes up in a cloud of Martian models were emerged into one. The combined at about 10 kilometers from Mars at which dust as the rover is destroyed. Engineers model runs between 17 to 93 minutes on a point a supersonic parachute deployed. cannot test the landing sequence on Earth four-CPU Hewlett Packard Unix workstation. because they can’t duplicate Martian gravity, atmosphere, and the landing conditions on At about 1.8 kilometers altitude with the Earth. They can test individual components but Determining Loads aeroshell traveling at 100 meters per second, the only way to test the complete sequence for Structural Design the rover and descent stage dropped out. and determine the loads on the individual The descent stage fired its rocket thruster to Optimizing the design of every component components is with simulation. The program in the payload was critical because of the slow to less than 1 meter per second and engineers recognized the importance of lowered the rover with a 7.6 meter tether consisting of three bridles and an umbilical cable carrying electrical signals to the Martian 2 | MSC Software MSC Software: Case Study - NASA/JPL-Caltech CASE STUDY need to ensure their ability to withstand much higher than expected. The original The flight control software was written in loads and successfully perform their expectations also were that the rover would be C++. The people who wrote the controller mission while at the same time minimizing in a quiescent state when it touched down on software required a detailed mechanical their weight because of the high cost of the Martian surface but the Adams simulation model to accurately predict the system transporting incremental weight to Mars. showed that the rover was actually rotating performance. The engineers overcame Adams was used to predict the loads on and swinging as it landed. As a result, the rover this issue by compiling the controller with components and subassemblies and these structure was stiffened to mitigate these issues. the Adams solver. This made it possible to loads in turn were used as input to structural Later studies provided the additional surprise validate the system performance and tune analysis that optimized the design to provide that the deployment of the rover’s wheels the controller parameters with a detailed the strength to withstand mission loads while and struts as originally planned generated mechanical model. JPL engineers validated minimizing size and weight. The philosophy even greater loads on some of the rover and updated the Adams model by correlating of the modeling was not to try and predict components than the touchdown. Simulation the simulation results to the test data. every event to 100% accuracy but rather to showed that the end of wheel deployment The engineers at JPL were not able to test determine the bounding limit design loads generated hammer-like blows on the rover most of the critical mission events on Earth that could be expected on every component. suspension so they had to rely upon simulation to design Prior to the Adams simulation, JPL engineers and frame. most of the critical hardware and control believed that the projected 1 meter per second JPL engineers addressed this problem by sequences for this mission. The accuracy maximum speed during touchdown would changing the timing of the wheels and struts and thoroughness of the simulation results not induce particularly high loads on the rover. deployment. Changing the timing of the wheels helped make it possible to successfully and However, simulation showed the loads were and struts deployment also reduced the swing precisely place the rover onto the Red Planet. rate and swing angle before touchdown. Image Credit: NASA/JPL-Caltech Checking Other Aspects of the Landing Sequence The most critical aspect of the separation between the rover and descent stage is the need to avoid contact between the flight hardware. The Adams simulation was used to check the clearance and ensure that there was no possibility of contact. In the final design there is very small clearance but no contact issues. Case Study: NASA/JPL-Caltech 3 CASE STUDY About MSC Software About Adams MSC Software is one of the ten original software companies and the Multibody Dynamics Simulation worldwide leader in multidiscipline simulation. As a trusted partner, MSC Adams is the most widely used multibody dynamics and motion Software helps companies improve quality, save time and reduce costs analysis software in the world. Adams helps engineers to study the associated with design and test of manufactured products. Academic dynamics of moving parts, how loads and forces are distributed institutions, researchers, and students employ MSC technology throughout mechanical systems, and to improve and optimize the to expand individual knowledge as well as expand the horizon of performance of their products. simulation. MSC Software employs 1,000 professionals in 20 countries. For additional information about MSC Software’s products and services, Traditional “build and test” design methods are expensive, time please visit www.mscsoftware.com. consuming, and impossible to do sometimes. CAD-based tools help to evaluate things like interference between parts, and basic kinematic motion, but neglect the true physics-based dynamics of complex mechanical systems. FEA is suited for studying linear vibration and transient dynamics, but inefficient at analyzing large rotations and other highly nonlinear motion of full mechanical systems. Adams multibody dynamics software enables engineers to easily create and test virtual prototypes of mechanical systems in a fraction of the time and cost required for physical build and test.