The Mars Exploration Rover was designed to be stowed atop a
Delta II rocket. Each spacecraft consists of several components: • Rover: • Lander: • Backshell / Parachute: • Heat Shield: • Cruise Stage: • Propellant: • Instruments: Total mass is .
Cruise stage The cruise stage is the component of the spacecraft that is used for travel from Earth to Mars. It is very similar to the Mars Pathfinder in design and is approximately 2.65
meters (8.7 feet) in
diameter and tall, including the entry vehicle (see below). The primary structure is aluminium with an outer ring of ribs covered by the solar panels, which are about in diameter. Divided into five sections, the solar arrays can provide up to 600
watts of power near Earth and 300 W at Mars. Heaters and
multi-layer insulation keep the electronics "warm". A
freon system removes heat from the flight computer and communications hardware inside the rover so they do not overheat. Cruise avionics systems allow the flight computer to interface with other electronics, such as the
Sun sensors, star scanner and heaters.
Navigation The star scanner (without a backup system) and
Sun sensor allowed the spacecraft to know its orientation in space by analyzing the position of the Sun and other stars in relation to itself. Sometimes the craft could be slightly off course; this was expected, given the 500-million-kilometer (320 million mile) journey. Thus navigators planned up to six trajectory correction maneuvers, along with health checks. To ensure the spacecraft arrived at Mars in the right place for its landing, two light-weight, aluminium-lined tanks carried about 31 kg (about 68 lb) of
hydrazine propellant. Along with cruise guidance and control systems, the propellant allowed navigators to keep the spacecraft on course. Burns and pulse firings of the propellant allowed three types of maneuvers: • An axial burn uses pairs of thrusters to change spacecraft velocity; • A lateral burn uses two "thruster clusters" (four thrusters per cluster) to move the spacecraft "sideways" through seconds-long pulses; • Pulse mode firing uses coupled thruster pairs for spacecraft
precession maneuvers (turns).
Communication The spacecraft used a high-frequency
X band radio wavelength to communicate, which allowed for less power and smaller
antennas than many older craft, which used
S band. Navigators sent commands through two antennas on the cruise stage: a cruise
low-gain antenna mounted inside the inner ring, and a cruise medium-gain antenna in the outer ring. The low-gain antenna was used close to Earth. It is omni-directional, so the transmission power that reached Earth fell faster with increasing distance. As the craft moved closer to Mars, the Sun and Earth moved closer in the sky as viewed from the craft, so less energy reached Earth. The spacecraft then switched to the medium-gain antenna, which directed the same amount of transmission power into a tighter beam toward Earth. During flight, the spacecraft was
spin-stabilized with a spin rate of two
revolutions per minute (rpm). Periodic updates kept antennas pointed toward Earth and solar panels toward the Sun.
Aeroshell The aeroshell maintained a protective covering for the lander during the seven-month voyage to Mars. Together with the lander and the rover, it constituted the "entry vehicle". Its main purpose was to protect the lander and the rover inside it from the intense heat of entry into the thin Martian atmosphere. It was based on the Mars Pathfinder and Mars Viking designs. ;Parts The aeroshell was made of two main parts: a
heat shield and a backshell. The heat shield was flat and brownish, and protected the lander and rover during entry into the Martian atmosphere and acted as the first
aerobrake for the spacecraft. The backshell was large, cone-shaped and painted white. It carried the
parachute and several components used in later stages of entry, descent, and landing, including: • A parachute (stowed at the bottom of the backshell); • The backshell electronics and batteries that fire off pyrotechnic devices like separation nuts, rockets and the parachute mortar; • A Litton LN-200 Inertial Measurement Unit (IMU), which monitors and reports the orientation of the backshell as it swings under the parachute; • Three large
solid rocket motors called RAD rockets (Rocket Assisted Descent), each providing about a ton of force (10
kilonewtons) for nearly 4 seconds; • Three small solid rockets called TIRS (mounted so that they aim horizontally out the sides of the backshell) that provide a small horizontal kick to the backshell to help orient the backshell more vertically during the main RAD rocket burn. ;Composition Built by
Lockheed Martin Space in Denver, Colorado, the aeroshell is made of an aluminium honeycomb structure sandwiched between
graphite-epoxy face sheets. The outside of the aeroshell is covered with a layer of
phenolic honeycomb. This honeycomb is filled with an
ablative material (also called an "ablator"), that dissipates heat generated by atmospheric friction. The ablator itself is a blend of
cork wood,
binder and many tiny
silica glass spheres. It was invented for the heat shields flown on the Viking Mars lander missions. A similar technology was used in the first US
crewed space missions
Mercury,
Gemini and
Apollo. It was specially formulated to react chemically with the Martian atmosphere during
entry and carry heat away, leaving a hot wake of gas behind the vehicle. The vehicle slowed from in about a minute, producing about 60 m/s2 (6
g) of
acceleration on the lander and rover. The backshell and heat shield are made of the same materials, but the heat shield has a thicker, , layer of the ablator. Instead of being painted, the backshell was covered with a very thin aluminized
PET film blanket to protect it from the cold of deep space. The blanket vaporized during entry into the Martian atmosphere.
Parachute The parachute helped slow the spacecraft during entry, descent, and landing. It is located in the backshell. ;Design The 2003 parachute design was part of a long-term Mars parachute technology development effort and is based on the designs and experience of the Viking and Pathfinder missions. The parachute for this mission is 40% larger than Pathfinder's because the largest load for the Mars Exploration Rover is 80 to 85
kilonewtons (kN) or when the parachute fully inflates. By comparison, Pathfinder's inflation loads were approximately 35 kN (about 8,000 lbf). The parachute was designed and constructed in
South Windsor, Connecticut by
Pioneer Aerospace, who also designed the parachute for the
Stardust mission. ;Composition The parachute is made of two durable, lightweight fabrics:
polyester and
nylon. A triple bridle made of
Kevlar connects the parachute to the backshell. The amount of space available on the spacecraft for the parachute was so small that the parachute had to be pressure-packed. Before launch, a team tightly folded the 48 suspension lines, three bridle lines, and the parachute. The parachute was loaded in a special structure that then applied a heavy weight to the parachute package several times. Before placing the parachute into the backshell, the parachute was heat set to
sterilize it. ;Connected systems s and lander is dropped to the surface in this computer generated impression. After the parachute was deployed at an altitude of about above the surface, the heatshield was released using 6 separation nuts and push-off springs. The lander then separated from the backshell and "rappelled" down a metal tape on a
centrifugal braking system built into one of the lander petals. The slow descent down the metal tape placed the lander in position at the end of another bridle (tether), made of a nearly long braided
Zylon. Zylon is a fiber material, similar to Kevlar, that is sewn in a webbing pattern (like shoelace material) to make it stronger. The Zylon bridle provides space for airbag deployment, distance from the solid rocket motor exhaust stream, and increased stability. The bridle incorporates an electrical harness that allows the firing of the solid rockets from the backshell as well as provides data from the backshell inertial measurement unit (which measures rate and tilt of the spacecraft) to the flight computer in the rover. Because the atmospheric density of Mars is less than 1% of Earth's, the parachute alone could not slow down the Mars Exploration Rover enough to ensure a safe, low landing speed. The spacecraft descent was assisted by rockets that brought the spacecraft to a dead stop above the Martian surface. A
radar altimeter unit was used to determine the distance to the Martian surface. The radar's antenna was mounted at one of the lower corners of the lander tetrahedron. When the radar measurement showed the lander was the correct distance above the surface, the Zylon bridle was cut, releasing the lander from the parachute and backshell so that it was free and clear for landing. The radar data also enabled the timing sequence on airbag inflation and backshell RAD rocket firing.
Airbags Airbags used in the Mars Exploration Rover mission are the same type that
Mars Pathfinder used in 1997. They had to be strong enough to cushion the spacecraft if it landed on rocks or rough terrain and allow it to bounce across Mars's surface at highway speeds (about 100 km/h) after landing. The airbags had to be inflated seconds before touchdown and deflated once safely on the ground. The airbags were made of
Vectran, like those on Pathfinder. Vectran has almost twice the strength of other synthetic materials, such as Kevlar, and performs better in cold temperatures. Six 100
denier (10 mg/m) layers of Vectran protected one or two inner bladders of Vectran in 200 denier (20 mg/m). Using 100 denier (10 mg/m) leaves more fabric in the outer layers where it is needed, because there are more threads in the weave. Each rover used four airbags with six lobes each, all of which were connected. Connection was important, since it helped abate some of the landing forces by keeping the bag system flexible and responsive to ground pressure. The airbags were not attached directly to the rover, but were held to it by ropes crisscrossing the bag structure. The ropes gave the bags shape, making inflation easier. While in flight, the bags were stowed along with three gas generators that are used for inflation.{{cite web|title=Mars Exploration Rovers - How to Land Softly on a Hard Planet|url=https://mars.nasa.gov/mer/spotlight/airbags01.html|website=NASA
Lander The spacecraft lander is a protective shell that houses the rover, and together with the airbags, protects it from the forces of impact. The lander is a
tetrahedron shape, whose sides open like petals. It is strong and light, and made of beams and sheets. The beams consist of layers of
graphite fiber woven into a fabric that is lighter than aluminium and more rigid than steel. Titanium fittings are glued and fitted onto the beams to allow it to be bolted together. The rover was held inside the lander by
bolts and special nuts that were released after landing with small explosives.
Uprighting After the lander stopped bouncing and rolling on the ground, it came to rest on the base of the tetrahedron or one of its sides. The sides then opened to make the base horizontal and the rover upright. The sides are connected to the base by hinges, each of which has a motor strong enough to lift the lander. The rover plus lander has a
mass of about . The rover alone has a mass of about . The gravity on Mars is about 38% of Earth's, so the motor does not need to be as powerful as it would on Earth. The rover contains
accelerometers to detect which way is down (toward the surface of Mars) by measuring the pull of gravity. The rover computer then commanded the correct lander petal to open to place the rover upright. Once the base petal was down and the rover was upright, the other two petals were opened. The petals initially opened to an equally flat position, so all sides of the lander were straight and level. The petal motors are strong enough so that if two of the petals come to rest on rocks, the base with the rover would be held in place like a bridge above the ground. The base will hold at a level even with the height of the petals resting on rocks, making a straight flat surface throughout the length of the open, flattened lander. The flight team on Earth could then send commands to the rover to adjust the petals and create a safe path for the rover to drive off the lander and onto the Martian surface without dropping off a steep rock.
Moving the payload onto Mars The moving of the rover off the lander is called the egress phase of the mission. The rover must avoid having its wheels caught in the airbag material or falling off a sharp incline. To help this, a retraction system on the petals slowly drags the airbags toward the lander before the petals open. Small ramps on the petals fan out to fill spaces between the petals. They cover uneven terrain, rock obstacles, and airbag material, and form a circular area from which the rover can drive off in more directions. They also lower the step that the rover must climb down. They are nicknamed "batwings", and are made of Vectran cloth. About three hours were allotted to retract the airbags and deploy the lander petals. ==Rover design==