Validation of the Mars 2020 Fault Protection Design: Navigating the Infinity of the Off-Nominal

On July 30th 2020, the Mars 2020 mission successfully launched out of Cape Canaveral, Florida, passed through the Earth's shadow, and began its short cruise to Mars. Less than seven months later, the Perseverance rover touched down safely in Jezero Crater to begin its ambitious mission that includes looking for signs of ancient life and collecting samples for future return to Earth. Getting to the successful landing, or “Tango Delta Nominal,” could not have been achieved without also considering the off-nominal. One of the teams supporting this ambitious mission is the fault protection (FP) team. This team is tasked with assessing the various failures, or faults, that could prevent mission success and with ensuring that the autonomous behaviors built into the software and hardware can detect faults and recover the vehicle to a safe state. As part of its charter, the FP team designed a test campaign to provide confidence in the system's robustness to off-nominal scenarios across all of Mars 2020's mission phases. The greatest challenge associated with designing such a validation campaign was reducing the infinite number of anomalous scenarios into a finite test suite. In addition, the tests needed to be executed efficiently in order to utilize the team's limited test venue access, but still needed to maintain a level of rigor that guaranteed confidence in the test outcomes. Given that each test scenario generated massive amounts of data, the team also developed methods for quickly ascertaining whether the autonomous fault protection behaviors maintained vehicle safety in the presence of an anomaly. This paper summarizes the processes that the Mars 2020 fault protection team employed to execute its off-nominal validation campaign. It captures both the methods of generating a suite of off-nominal tests, as well as reducing it to a subset that can be realistically executed within schedule and resource constraints. It also describes the various processes and philosophies that the team utilized to execute the tests efficiently, including creating a standardized procedure template, keeping the test cases modular so that they could be easily interchanged, and capturing common fault injections in a change-controlled database. Finally, it will describe the tools and processes for assessing the test data, focusing in particular on a tool that evaluated vehicle state using “secondary” sources of data to validate that the software had truly configured the spacecraft to the expected safe state.