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This paper presents and discusses algorithms, hardware, and software architecture developed by the TEAM CoSTAR (Collaborative SubTerranean Autonomous Robots), competing in the DARPA Subterranean Challenge. Specifically, it presents the techniques utilized within the Tunnel (2019) and Urban (2020) competitions, where CoSTAR achieved 2nd and 1st place, respectively. We also discuss CoSTAR's demonstrations in Martian-analog surface and subsurface (lava tubes) exploration. The paper introduces our autonomy solution, referred to as NeBula (Networked Belief-aware Perceptual Autonomy). NeBula is an uncertainty-aware framework that aims at enabling resilient and modular autonomy solutions by performing reasoning and decision making in the belief space (space of probability distributions over the robot and world states). We discuss various components of the NeBula framework, including: (i) geometric and semantic environment mapping; (ii) a multi-modal positioning system; (iii) traversability analysis and local planning; (iv) global motion planning and exploration behavior; (i) risk-aware mission planning; (vi) networking and decentralized reasoning; and (vii) learning-enabled adaptation. We discuss the performance of NeBula on several robot types (e.g. wheeled, legged, flying), in various environments. We discuss the specific results and lessons learned from fielding this solution in the challenging courses of the DARPA Subterranean Challenge competition., Comment: For team website, see https://costar.jpl.nasa.gov/. Accepted for publication in the Journal of Field Robotics, 2021

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.

A repeatably reconfigurable robot, comprising at least two printed circuit board (PCB) rigid sections, at least one PCB flexible section coupled to the at least two PCB rigid sections, at least one wheel, hybrid wheel propeller, wheel and propeller, or hybrid wheel screw propeller rotatably coupled to at least one of the at least two PCB rigid sections and at least one actuator coupled to the at least two PCB rigid sections, wherein the at least one actuator folds and unfolds the repeatably reconfigurable robot.