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System-level actuator testing for mars rover application

The Mars 2020 mission utilizes heritage designs from the Mars Science Laboratory rover, while integrating new actuators for the Sample Caching Subsystem (SCS). The Motion Control Subsystem system-level test program was executed to identify potential areas of risk as well as qualify actuators and the Rover Motor Controller Assembly (RMCA). Actuators were tested in a flight-like configuration in a thermal chamber at ambient temperature, +70 °C, and −70 °C. The tests performed include Winding Resistance, Brake Disengage/Engage, Startup/Halt Sensitivity, No Load, Cogging Profile/Powered Torque Ripple, and Dynamometer. The test setups and methods for understanding results were outlined. Early test results identified areas of risk which resulted in an engineering change: a new RMCA FPGA rate estimator algorithm and changes to the controller conductance loop. The continuation of this testing and future work will inform development of flight software and operational procedure.