Multidisciplinary Design Analysis and Optimisation of Inflatable Stacked Toroid Decelerators

Abstract

Future Mars exploration missions require safe and controlled landing on the planet’s surface. Conventional entry, descent and landing (EDL) technologies, such as parachutes and rigid aeroshells, face limitations in meeting increasing demands for heavier payloads, harsher entry conditions, and desired landing locations due to their limited deployment windows or geometry constraints set by current launchers. The stacked-toroid inflatable aerodynamic decelerator (IAD) has emerged as a promising EDL technology which has the potential to enable new and ambitious applications. Unlike conventional aeroshells, it utilizes flexible, high-temperature resistant materials that can be folded during orbital injection and transportation, and subsequently deployed before entering the Martian atmosphere. To address the complex interdependence of design variables and the multidisciplinary nature of stacked-toroid analysis, this research proposes a novel Multidisciplinary Design Analysis and Optimization (MDAO) framework. The framework integrates aerodynamics, aerothermodynamics, structural analysis, mass estimation, and Flexible-Thermal Protection System (F-TPS) sizing with trajectory simulations for a parametrized stacked-toroid. The major design variables are parameterized to trace model responses back to the design space. An additional novel contribution is the inclusion of a smaller torus on the IAD’s shoulder. For aerodynamics and aerothermodynamics modelling, the local-inclination panel method is implemented, separately addressing the continuum, rarefied, and transitional flow regimes using well-established analytical methods and bridging functions. The scalloping phenomenon of the deflected surface is accounted for through semi-empirical expressions and experimentally-fitted correlations, capturing the additional aerodynamic and aerothermal contribution. F-TPS sizing employs a 1D Finite Difference Method (FDM) with harmonic weighted averaging of material characteristics to accommodate abrupt thickness variations. Results from each discipline are compared to experimental, flight, and high-fidelity numerical data, showing consistent agreement under various conditions. All disciplines present mean percentage errors in the order of 10-20% which are deemed acceptable for early design stages. The framework is applied to the ESA MiniPINS study, to demonstrate its applicability to a novel EDL architecture for a penetrating probe. The proposed environment efficiently evaluates the stacked-toroid optimum design for minimum mass, weighing only 3.72 kg whilst complying with mission requirements and optimisation constraints. The design remains robust against variations in entry parameters and atmospheric density, requiring minor adjustments for the penetrator impact speed. The framework enables design space exploration, revealing trends favoring stacked-toroids with low inner torus radii and large numbers of tori to minimize aerothermal loads while ensuring sufficient aerobraking. The inflated radius remarkably results in a global variable that can further simplify the design space to a single input for near-optimum rapid evaluations. The feasible parameter ranges identified through the design space search expedite the evaluation and optimization of stacked-toroids’ multidisciplinary performance, aiding decision-making in early design stages of future Mars missions.