Actuator and Motor Control End-to-End V&V on the Mars 2020 Rover

The Mars 2020 Perseverance rover is the most advanced robotic exploration system ever sent to another planet. To support the complex scientific and mobility needs of the mission, the rover utilizes 33 actuators, three multi-degree-of-freedom force-torque sensors, fifteen single or dual-speed resolvers, two solenoid valves, and twelve contact switches. The control for these actuators and sensors is achieved by several levels of flight software, coordinated between two computers with varying bandwidth control loops. Furthermore, the actuators and sensors were integrated into multiple larger robotic mechanisms that were delivered by different organizations at various points in the Integration and Test (I&T) timeline. All of this created a very complex Verification and Validation (V&V) scenario involving multiple subsystems and teams, several hardware and software testbeds with varying levels of fidelity, and significant systems engineering to ensure the overall I&T schedule could be maintained while ensuring system hardware safety.This paper details the integrated V&V effort across multiple teams and venues to provide full coverage of all necessary functionality, performance, and fault protection. First, it provides an overview of how the V&V campaign was subdivided among teams and venues and provides descriptions of the various hardware configurations used to support the testing. The Mars 2020 implementation of the plan incorporates many of the lessons learned from Mars Science Laboratory’s test campaign, and these value-added modifications are discussed here. Also included in this section is the system-level environmental testing approach used for mechanisms. Second, the paper describes the phased approach used by the teams to support new hardware and software deliveries to testbed and Systems I&T. In this approach the test campaign was built upon higher-level mechanism needs for performance, functionality, and safety at specific times in the campaign. Finally, the paper discusses lessons learned from the V&V campaign that should be applied to future large-scale motion control testing efforts.