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By NASA
3 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
Current brake system technology cool disc brakes with air pulled from inside the vehicle’s body to prevent overheating. The channels cut into the exterior of the disc brakes developed by Orbis Brakes draw in external air, which is cooler, ensure the brakes work more efficiently.Credit: Orbis Brakes Inc Just as NASA needs to reduce mass on a spacecraft so it can escape Earth’s gravity, automotive manufacturers work to reduce weight to improve vehicle performance. In the case of brake rotors, lighter is better for a vehicle’s acceleration, reliable stopping, and even gas mileage. Orbis Brakes Inc. licensed a NASA-patented technology to accomplish that and more. This revolutionary brake disc design is at least 42% lighter than conventional cast iron rotors, with performance comparable to carbon-ceramic brakes.
Jonathan Lee, structural materials engineer at NASA’s Marshall Space Flight Center in Huntsville, Alabama, uses his skills as a mechanical designer backed with material science training on multiple projects including the Space Launch System and the International Space Station. Interested in supporting NASA’s other mission to advance technology to improve life on Earth, he was looking for an innovative way to design a better automobile disc brake.
He started with a single disc with a series of small fins around the central hub. As they spin, these draw in air and push it across the surface of the disc, where the brake pads make contact. This cools the rotor, as well as the brake pads and calipers. He then added several long, curved depressions around the braking surfaces, radiating from the center to create the regular, periodic pattern that gives the new technology, known as Orbis, its PeriodicWave brand name.
The spinning fins and the centrifugal force of the wheel push air into trenches, causing a turbulent airflow that draws away heat. These trenches in the braking surfaces also increase the available surface for air cooling by more than 30% and further reduce the weight of the disc. They also increase friction in the same way that scoring concrete makes steps safer to walk on – the brake pads are less likely to slip, which makes braking more reliable.
The troughs draw away more than just heat, too. Water and road debris getting between the pad and rotor are equally problematic, so the grooves provide a place for the air vortex to push any substance out of the way. A small hole machined at the end of each one creates an opening through which unwanted material can escape.
The expertise developed while solving problems in space has proven useful on Earth, too. Orbis’s brakes are sold as aftermarket modifications for high performance cars like the Ford Mustang, as well as some Tesla models.
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Last Updated Dec 12, 2024 Related Terms
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By NASA
5 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA’s Ingenuity Mars Helicopter, right, stands near the apex of a sand ripple in an image taken by Perseverance on Feb. 24, 2024, about five weeks after the rotorcraft’s final flight. Part of one of Ingenuity’s rotor blades lies on the surface about 49 feet (15 meters) west of helicopter (at left in image).NASA/JPL-Caltech/LANL/CNES/CNRS The review takes a close look the final flight of the agency’s Ingenuity Mars Helicopter, which was the first aircraft to fly on another world.
Engineers from NASA’s Jet Propulsion Laboratory in Southern California and AeroVironment are completing a detailed assessment of the Ingenuity Mars Helicopter’s final flight on Jan. 18, 2024, which will be published in the next few weeks as a NASA technical report. Designed as a technology demonstration to perform up to five experimental test flights over 30 days, Ingenuity was the first aircraft on another world. It operated for almost three years, performed 72 flights, and flew more than 30 times farther than planned while accumulating over two hours of flight time.
The investigation concludes that the inability of Ingenuity’s navigation system to provide accurate data during the flight likely caused a chain of events that ended the mission. The report’s findings are expected to benefit future Mars helicopters, as well as other aircraft destined to operate on other worlds.
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NASA’s Ingenuity Mars Helicopter used its black-and-white navigation camera to capture this video on Feb. 11, 2024, showing the shadow of its rotor blades. The imagery confirmed damage had occurred during Flight 72. NASA/JPL-Caltech Final Ascent
Flight 72 was planned as a brief vertical hop to assess Ingenuity’s flight systems and photograph the area. Data from the flight shows Ingenuity climbing to 40 feet (12 meters), hovering, and capturing images. It initiated its descent at 19 seconds, and by 32 seconds the helicopter was back on the surface and had halted communications. The following day, the mission reestablished communications, and images that came down six days after the flight revealed Ingenuity had sustained severe damage to its rotor blades.
What Happened
“When running an accident investigation from 100 million miles away, you don’t have any black boxes or eyewitnesses,” said Ingenuity’s first pilot, Håvard Grip of JPL. “While multiple scenarios are viable with the available data, we have one we believe is most likely: Lack of surface texture gave the navigation system too little information to work with.”
The helicopter’s vision navigation system was designed to track visual features on the surface using a downward-looking camera over well-textured (pebbly) but flat terrain. This limited tracking capability was more than sufficient for carrying out Ingenuity’s first five flights, but by Flight 72 the helicopter was in a region of Jezero Crater filled with steep, relatively featureless sand ripples.
This short animation depicts a NASA concept for a proposed follow-on to the agency’s Ingenuity Mars Helicopter called Mars Chopper, which remains in early conceptual and design stages. In addition to scouting, such a helicopter could carry science instruments to study terrain rovers can’t reach. One of the navigation system’s main requirements was to provide velocity estimates that would enable the helicopter to land within a small envelope of vertical and horizontal velocities. Data sent down during Flight 72 shows that, around 20 seconds after takeoff, the navigation system couldn’t find enough surface features to track.
Photographs taken after the flight indicate the navigation errors created high horizontal velocities at touchdown. In the most likely scenario, the hard impact on the sand ripple’s slope caused Ingenuity to pitch and roll. The rapid attitude change resulted in loads on the fast-rotating rotor blades beyond their design limits, snapping all four of them off at their weakest point — about a third of the way from the tip. The damaged blades caused excessive vibration in the rotor system, ripping the remainder of one blade from its root and generating an excessive power demand that resulted in loss of communications.
This graphic depicts the most likely scenario for the hard landing of NASA’s Ingenuity Mars Helicopter during its 72nd and final flight on Jan. 18, 2024. High horizontal velocities at touchdown resulted in a hard impact on a sand ripple, which caused Ingenuity to pitch and roll, damaging its rotor blades. NASA/JPL-Caltech Down but Not Out
Although Flight 72 permanently grounded Ingenuity, the helicopter still beams weather and avionics test data to the Perseverance rover about once a week. The weather information could benefit future explorers of the Red Planet. The avionics data is already proving useful to engineers working on future designs of aircraft and other vehicles for the Red Planet.
“Because Ingenuity was designed to be affordable while demanding huge amounts of computer power, we became the first mission to fly commercial off-the-shelf cellphone processors in deep space,” said Teddy Tzanetos, Ingenuity’s project manager. “We’re now approaching four years of continuous operations, suggesting that not everything needs to be bigger, heavier, and radiation-hardened to work in the harsh Martian environment.”
Inspired by Ingenuity’s longevity, NASA engineers have been testing smaller, lighter avionics that could be used in vehicle designs for the Mars Sample Return campaign. The data is also helping engineers as they research what a future Mars helicopter could look like — and do.
During a Wednesday, Dec. 11, briefing at the American Geophysical Union’s annual meeting in Washington, Tzanetos shared details on the Mars Chopper rotorcraft, a concept that he and other Ingenuity alumni are researching. As designed, Chopper is approximately 20 times heavier than Ingenuity, could fly several pounds of science equipment, and autonomously explore remote Martian locations while traveling up to 2 miles (3 kilometers) in a day. (Ingenuity’s longest flight was 2,310 feet, or 704 meters.)
“Ingenuity has given us the confidence and data to envision the future of flight at Mars,” said Tzanetos.
More About Ingenuity
The Ingenuity Mars Helicopter was built by JPL, which also manages the project for NASA Headquarters. It is supported by NASA’s Science Mission Directorate. NASA’s Ames Research Center in California’s Silicon Valley and NASA’s Langley Research Center in Hampton, Virginia, provided significant flight performance analysis and technical assistance during Ingenuity’s development. AeroVironment, Qualcomm, and SolAero also provided design assistance and major vehicle components. Lockheed Space designed and manufactured the Mars Helicopter Delivery System. At NASA Headquarters, Dave Lavery is the program executive for the Ingenuity Mars helicopter.
For more information about Ingenuity:
https://mars.nasa.gov/technology/helicopter
News Media Contacts
DC Agle
Jet Propulsion Laboratory, Pasadena, Calif.
818-393-9011
agle@jpl.nasa.gov
Karen Fox / Molly Wasser
NASA Headquarters, Washington
202-358-1600
karen.c.fox@nasa.gov / molly.l.wasser@nasa.gov
2024-171
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Last Updated Dec 11, 2024 Related Terms
Ingenuity (Helicopter) Astrobiology Jet Propulsion Laboratory Mars Mars 2020 Perseverance (Rover) Explore More
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By European Space Agency
The Copernicus Sentinel-1C satellite is ready for liftoff! Tune in to ESA WebTV on 4 December from 22:00 CET to watch the satellite soar into space on a Vega-C rocket to be launched from Europe’s Spaceport in Kourou, French Guiana. Sentinel-1C is scheduled to liftoff at 22:20 CET.
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By European Space Agency
ESA’s eclipse-making precise formation-flying mission is nearly ready for liftoff! Proba-3 is scheduled for launch on a PSLV-XL rocket from Satish Dhawan Space Centre in Sriharikota, India, on Wednesday, 4 December, at 11:38 CET (10:38 GMT, 16:08 local time).
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By Space Force
CMSSF Bentivegna visited Pituffik Space Base to meet with Airmen and Guardians who operate at the “Top of the World” at the DoD’s most northern and remote installation.
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