ISSUE : 01 DATE : September 2005emits.sso.esa.int/emits-doc/ESTEC/AO6100_RD14_IHAB... · Alcatel...

AA

DOC : IHAB-ALS-VRP-0006 ISSUE : 01 DATE : September 2005 PAGE : 2 of 51 CLASS : DC

Alcatel Alenia Space Italia S.p.A.

DOCUMENT CHANGE RECORD

ISSUE DATE REASON FOR CHANGE AFFECTED PARAGRAPHS

01 Sept 05 First issue All

AA



TABLE OF CONTENT

1. INTRODUCTION .................................................................................................................................................... 4

2. APPLICABLE AND REFERENCE DOCUMENTS............................................................................................. 4

3. INFLATABLE HABITAT PROGRAMME OVERVIEW ................................................................................... 5 3.1 SPACEHAVEN.................................................................................................................................................. 6

3.1.1 Reference Mission....................................................................................................................................... 6 3.1.2 General description .................................................................................................................................... 6 3.1.3 Functional configuration description ......................................................................................................... 7 3.1.4 Dimensions ................................................................................................................................................. 8 3.1.5 Internal outfitting........................................................................................................................................ 9 3.1.6 Structure ................................................................................................................................................... 15 3.1.7 ECLS......................................................................................................................................................... 21 3.1.8 Airlock....................................................................................................................................................... 23 3.1.9 IBDM ........................................................................................................................................................ 31 3.1.10 Medical equipment.................................................................................................................................... 32 3.1.11 Internal Auxiliary Structure (AUXIS) ....................................................................................................... 33 3.1.12 shower....................................................................................................................................................... 34 3.1.13 Washing machine...................................................................................................................................... 35 3.1.14 Galley equipment ...................................................................................................................................... 36 3.1.15 Dish washer .............................................................................................................................................. 37

3.2 DEMONSTRATORS ....................................................................................................................................... 38 3.3 FLIGHT DEMONSTRATORS ................................................................................................................................. 39

3.3.1 Oxygen Atmosphere Regeneration............................................................................................................ 39 3.3.2 Toilet ......................................................................................................................................................... 40 3.3.3 Medical Monitoring System ...................................................................................................................... 41 3.3.4 Shower (A Kind Of Shower, AKOS).......................................................................................................... 42 3.3.5 Flight Structural Demonstrators............................................................................................................... 43

3.4 GROUND DEMONSTRATORS...................................................................................................................... 44 3.4.1 ECLS Demonstrators ................................................................................................................................ 44 3.4.2 Ground Structural Demonstrators ............................................................................................................ 49

3.5 GSE................................................................................................................................................................... 50 3.5.1 MGSE........................................................................................................................................................ 50 3.5.2 FGSE and EGSE....................................................................................................................................... 51

AA



1. INTRODUCTION Inflatable Habitat project is an ESA study aimed to define a preparatory phase leading to a full flight programme of a space habitation module, operationally autonomous with respect to life support functions. The SpaceHaven will enable Europe to support humans in space, be it in Earth orbit in the near future or in forthcoming planetary missions: transit and planetary base. The SpaceHaven is based on an inflatable structure and has to provide all the needed crew support systems. An effort in developing regenerative systems for life support is requested to minimize the logistic needs of the mission. The study covers two different aspects: The SpaceHaven demonstrator programme. It is aimed to define the SpaceHaven technological demonstrators to a

PDR level. Demonstrators are proposed when the critical technologies needed in the SpaceHaven system are neither available in Europe nor currently covered by a dedicated technological development.

The SpaceHaven system programme. It is aimed to define the SpaceHaven system to a PRR level.

2. APPLICABLE AND REFERENCE DOCUMENTS AD1 IHAB-SYS-ESA-SOW-001, issue 01 - INFLATABLE HABITAT STUDY SOW RD1 IHAB-ALS-VRP-001, issue 02 - INFLATABLE HABITAT MISSION DEFINITION AND ANALYSIS RD2 HUMEX – STUDY ON THE SURVIVABILITY AND ADAPTATION OF HUMANS TO LONG-

DURATION INTERPLANETARY AND PLANETARY ENVIRONMENTS RD3 IHAB-ALS-ARP-0001, issue 01 and 02, SpaceHaven System Concepts RD4 IHAB-HTS-TNO-0005, issue β rev. 01, AUXILIARY INTERNAL STRUCTURES (AUXIS) –

SYSTEM CONCEPT OPTIONS RD5 IHAB-ALS-TNO-0002, issue 01, IHAB CONCEPTS EVALUATIONS FOR PACKAGING ASPECTS RD6 IHAB-ALS-ARP-0003, issue 01, INFLATABLE STRUCTURE SYSTEM CONCEPTS OPTIONS RD7 IHAB-ALS-SYS-0036, issue 01, PRELIMINARY TECHNICAL SPECIFICATION FOR THE

EUROPEAN SPACEHAVEN RD8 IHAB-ALS-TNO-0006, issue 01, PROGRAMMATIC DATA FOR INFLATABLE HABITAT

PROGRAM RD9 IHAB-ALS-VRP-0003, issue 01, 25/05/2005 - ECLSS INPUT FOR THE PROGRAMMATIC DATA

PACKAGE RD10 IHAB-ALS-ARP-0004, issue 1, ECLSS demonstrators concepts for SpaceHaven, Dec. 15, 2004.

AA



3. INFLATABLE HABITAT PROGRAMME OVERVIEW The results presented in this document derive from analyses and trade offs performed in the previous phases of the programme. During the phase 0 together the preliminary functional requirements the mission analysis has been performed and Spacehaven concepts (together their critical technologies) have been also presented and discussed. Mission profiles that have been considered in the analysis include LEO missions (attached to ISS or free flyer) and lunar missions (orbit and surface). For the Spacehaven seven different concepts for o-g environment together with two concepts for Lunar surface have been presented and traded. The Spacehaven configuration selected and presented in this document is addressed to the Moon orbit mission scenario. The Moon orbit has been recommended by ESA as the more realistic mission. The Demonstrators proposed have been selected by ESA as output of the PRR. The demonstrator selection is has been developed and presented in this document. The following figure 3-1 shows the Inflatable Habitat study logic.

Figure 3-1 - Inflatable Habitat study logic.

AA



3.1 SPACEHAVEN

3.1.1 Reference Mission The candidate mission for the Spacehaven is summarized in figure 3.1.1-1

Figure 3.1.1-1 – SpaceHaven lunar orbit mission profile.

3.1.2 General description The selected SpaceHaven concept is based on a telescopic expansion of the rigid part induced by pressure application which causes inflation of the shell and extraction of the cylindrical segments. The deployment of the core is operated through the sliding of the segments on guide rails until the open configuration is reached. When compacted, the packed core and the inflatable structure is integrated inside the Ariane 5 fairing for launch (for packaging capability see RD 5). Once in space, out of the A5 fairing, this structure deploys and expands its volume. For the baseline launch with A5, a Service Module (SM) is located under the folded rigid core and it is fixed to the launcher by means of an A5 standard interface. The SM module dimensions and cylindrical segments partial deployed to reduce outfitting are sized to allow under fairing accommodation (see RD1 and RD 5).. Fixation of the inflatable shell is achieved by interfaces located at the bulkhead rings of the most external segments. Also in this case, in front of a compact launch volume, a considerable on orbit volume gain can be achieved with the expansion of both the core and the inflatable shell. The two bulkheads provide interface rings for the joining with the inflatable shell. The top bulkhead is fitted with IBDM and a hatch door. The bottom bulkhead is connected to a resources segment hosting water and air (see RD 1). The cylindrical segments can be a sandwich design with composite skins to achieve mass optimization while bulkheads and rings are metallic items. The inflatable shell can be shaped to give in deployed configuration a toroidal or toroidal/cylindrical volume and is folded against the core in launch configuration. The internal volume of the Spacehaven is organised in three levels oriented perpendicularly to the longitudinal axis. The lower segment of the central core has the smaller diameter and it is dedicated to host the equipment installed at launch. Crew Quarters are located in the mid- segment of the central core. The upper central core segment (close to the hatch) is a crew passageway to access to all the Spacehaven pressurized volumes. Apart from the equipment installed at launch, the Spacehaven internal equipment are distributed in the racks (~ 0.75 m3 each) and in the upper and lower toroidal volumes. The three levels in the inflated part have different

AA


Alcatel Alenia Space Italia S.p.A. functional destinations mainly dedicated to host services (Hygiene, medical, physical countermeasures) and social environments (recreation, galley and food, storage, general working activities, etc.).

3.1.3 Functional configuration description The Spacehaven central core is composed by three telescopic segments. The inner (lower once deployed) telescopic segment allows the installation of equipment at launch. All the other equipment and structures are installed on orbit. The SpaceHaven cylindrical structure is internally organised in three floors perpendicularly located w.r.t. the longitudinal axis. Each floor is configured with a rigid central core portion (telescopic structural central core) and a volume out of the central core but limited by the inflated structure. Connections between floors is allowed by means of a longitudinal corridor connecting the three inflated level and six circular doors connecting the vestibule to the six crew quarters. Figure 3.1.3-1 shows the SpaceHaven internal distribution functional diagram.

EQUIPMENT INSTALLED AT LAUNCH

FLOOR 1 INFLATED

VESTIBULE

CQ 1 CQ 2 CQ 3 CQ 4 CQ 5 CQ 6 FLOOR 2 INFLATED

FLOOR 3 INFLATED

ENTRANCE HATCH

Figure 3.1.3-1 - SpaceHaven internal distribution functional diagram

The access to the three levels of the SpaceHaven is guaranteed by a longitudinal aisle accessible from the 1st segment of the central core.

The total volume of the SpaceHaven is the following: − Pressurized volume: 379 m3 − Habitable volume: 205 m3

Figure 3.1.3-2 – SpaceHaven, longitudinal section with the connecting aisle.

AA



3.1.4 Dimensions The chosen SpaceHaven dimensions here reported have been selected in order to have a habitable volume compatible with the contemporary presence of a maximum of 6 crew members. The overall volume in packaged configuration at launch shall be compatible with A5 under fairing mounting. The internal volume in deployed configuration shall be subjected to adequate on orbit outfitting to reach the fully operative conditions. Basic dimensions are the following:

CORE SEGMENT INTERNAL DIAMETER INFLATABLE VOLUME INTERNAL DIAMETER 1° floor 3900 7820 2° floor 3970 7820 3° floor 4040 7820

Toroidal volumes located at the extremities of the inflated volume are exploitable volumes for storage and equipment. The assumed packaging factor for these toroidal volumes at the extremities of the inflated cylinder is 0.6.

Figure 3.1.4-1 – SpaceHaven vehicle main dimensions

AA



Volumes of the various equipment (see RD 3, issue 02) considered for the internal outfitting of the Spacehaven have been derived from the equipment list which volumes have been calculated using the ISPR (International Standard Payload Rack) as “volume unit” (corresponding to 1.4 m3). This approach is based on the experience deriving form the fact that most of the equipment have been already integrated in the ISPR in other modules (e.g. MPLM, Nodes). The conversion from ISPR volume to SpaceHaven racks has been then performed taking into account the following considerations: − SpaceHaven “rack” has been designed with a volume of

0.75 m3 (762 mm. width x 2049 mm. height x 482 mm. depth)

− Use of dedicated volumes/rooms (bathroom, gymnasium, infirmary, etc.) for the location of those items which dimensions do not allow their integration inside a SpaceHaven racks. For these activities dedicated functional areas have been allocated.

Figure 3.1.4-2 - Toroidal volumes (coloured in red)

located at the extremities of the inflated volume.

3.1.5 Internal outfitting

PRIORITY EQUIPMENT 1 SYSTEM RACK 2 IPC 3 AMC 4 SYSTEM RACK 5 ARC 1 6 ARC 3 7 ARC 2 8 WPC 2 9 WPC 1 10 WPC 3 11 TOOL STORAGE

A set of Inflatable Habitat outfitting priorities has been identified in order to have installed at launch a number of subsystems able to provide and to guarantee the minimum acceptable environment for the crew for the module ingress and the subsequent start of outfitting activities. Here aside is reported the list of the systems installed at launch for the proposed SpaceHaven configuration and its outfitting capability considering the capability to guarantee the above mentioned minimum life support functions (see RD 1, section 3.1):

12 SPARE STORAGE On the basis of the results of the system concept study and the guidelines included in the previous issue 01 of this document (RD 3, issue 01) presented at the MDR, the internal volume of the Spacehaven has been equipped in accordance with the following criteria: (Functional criteria) − Relationship with the functions and relevant functional areas − Definition of multifunctional areas − Utilisation of unique areas for different functions (reconfiguration) FUNCTIONAL AREA EQUIPMENT System equipment ARC1,2,3-IPC-AMC-WPC1,2,3-SYSTEM RACKS Crew quarter and personal equipment Personal items Personal hygiene Bathroom-Shower-Loundry Food Management Food preparation-Refrigerator/Freezer, Food storage,

Dishware, Dishwasher Recreation and collective activity Wardroom table Infirmary Drugs and health status monitoring items Gymnasium Fitness storage racks Various Tools-Salad machine- Trash management racks

AA


Alcatel Alenia Space Italia S.p.A. (ergonomic criteria) − Crew protection from ionising radiations − Privacy / areas for personal care − Area for collective activities − Habitability / anthropometrics − Windows positioning (“technical” criteria) − Equipment location in accordance with resources (power, data, fluids) needs / availability − Equipment installed at launch − Storage location 1st LEVEL

Figure 3.1.5-1 – SpaceHaven, 1st internal level

The deployed telescopic structure is so functionally organised: 1st internal telescopic segment: − entrance hatch − “vestibule” with 6 racks and 6 half

racks for personal items − 3 openings to allow passage of the

crew from central core to inflated volume

− 6 openings to enter into the Crew Quarters

Total personal racks: 6+6*1/2= 9 Storage volume: ∼ 6,7 m3

Figure 3.1.5-2 – SpaceHaven, longitudinal section of the 1st internal level

AA


Alcatel Alenia Space Italia S.p.A. Inflatable area: − Openings to access to “vestibule” − Passage to lower levels of inflatable volumes through a longitudinal aisle − INFIRMARY area with a volume of 11.9 m3, see RD 3, issue 02 (3 of these dedicated to infirmary equipment

storage) − GYMNASIUM area with a volume of 11.9 m3, (3 of these dedicated to gymnasium equipment storage,) − racks for personal items along the inflated wall. PERSONAL RACKS: 12 INFIRMARY RACKS: 4 GYMNASIUM RACKS: 4 VOLUME STORAGE: ∼15 m3 2nd LEVEL 2nd internal telescopic segment

Figure 3.1.5-3 – SpaceHaven, 2nd internal level

− 6 crew quarters (internal walls in soft material installed on-orbit) − Radiation protection (made by a water mattress) around the inner surface of the mid segment of the central core. − Central longitudinal volume for utilities (power, data, ventilation) − Personal storage Inflatable area:

Figure 3.1.5-4 – SpaceHaven, longitudinal section of the 2nd internal level

AA


Alcatel Alenia Space Italia S.p.A. − Access from the longitudinal aisle − PERSONAL HYGIENE # 1 functional area (16.2 m3, see RD 3, issue 02), with shower, hygiene equipment and

storage 3,7 m3. − FOOD MANAGEMENT functional area (shared with 3rd floor) with a volume of 8,2 m3 free and 6 m3 for food

storage (8 SpaceHaven racks along the inflated wall) − Multifunctional table (for 6 crewmembers contemporarily) positioned longitudinally between 2nd and 3rd level

Figure 3.1.5-5 – SpaceHaven, longitudinal section of the 2nd internal level

BATHROOM & SHOWER RACKS: 5 FOOD STORAGE: 19 VOLUME STORAGE: ∼17.2 m3 3rd LEVEL

Figure 3.1.5-6

SpaceHaven, 3rd internal

level 3rd internal telescopic segment

Multifunctional table

AA


Alcatel Alenia Space Italia S.p.A. − Access through opening on the wall of the 3rd segment − Equipment installed at launch (SYSTEM RACKS, IPC, AMC, see RD 1) − Equipment integrated in 4 ISPR-like racks, 2 containers with a volume of 1.12 m3, 3 containers with a volume of

2.4 m3 and 1 container with a volume of 0.6 m3 SYSTEM RACKS: 10 IPC RACKS: 3 AMC RACKS: 3 STORAGE VOLUME: 16.6 m3

Figure 3.1.5-7 – SpaceHaven, horizontal section of the 3rd internal level

Inflatable area: - Access from the longitudinal aisle - PERSONAL HYGIENE # 2

functional area (8.4 m3, see RD 3, issue 02) with hygiene equipment and storage (3,7 m3).

- FOOD MANAGEMENT (KITCHEN-DISHWARE-DISHWASHER) functional area nwith a volume of 16.8 m3 (4,5 of these for equipment storage)

- FOOD STORAGE RACKS, TRASH MANAGEMENT RACKS, SALAD MACHINE RACKS and LOUNDRY RACKS along the inflated wall

- Multifunctional table (for 6 crewmembers contemporarily) positioned longitudinally between 2nd and 3rd level

Figure 3.1.5-8 – SpaceHaven, longitudinal section of the 3rd internal

level FOOD STORAGE RACKS: 3 TRASH MANAGEMENT RACKS: 2 SALAD MACHINE RACKS: 2 LOUNDRY RACKS: 2 KITCHEN RACKS: 2 DISHWARE RACKS: 2 DISHWASHER RACKS: 2

AA



Window: Two windows are functionally positioned on the inflated membrane on the 3rd level in correspondence of the RECREATION AND COLLECTIVE ACTIVITY volume and the longitudinal aisle.

Figure 3.1.5-9 – Window positions in the SpaceHaven.

Volumes for the routing of the utility lines are foreseen inside the “stand-off” in the 3rd level central core, in the axial cylinder between the crew quarters in the 2nd level central core and in the volumes left free between the racks in every level (see figure 3.1.5-10).

Figure 3.1.5-10 - Volumes for the routing of the utility lines circled in red

WINDOWS

AA


Alcatel Alenia Space Italia S.p.A. 3.1.6 Structure

3.1.6.1 Spacehaven Structure The Spacehaven structure preliminary design & configuration concepts have been established based on the basic assumption that the design solutions for the Spacehaven, with particular reference to the materials and materials configurations, the manufacturing processes, the development and qualification approach as established in the course of the IHAB study passing through the identification of ground and flight demonstrators, are intended to be part of the development path for the final Spacehaven vehicle. For the Spacehaven, based on the very exhaustive demonstration campaign, a proto-flight approach is therefore considered. However due to the different size of the Spacehaven vehicle with respect to the foreseen ground and flight demonstrators a strong effort shall be put in the design and analysis of its rigid and inflatable structural elements. Some local additional testing could however be necessary to support the design and correlate the analyses results.

3.1.6.2 Protoflight Verification Approach The testing campaign in this perspective is supposed to be based on: • Sinusoidal test: this is foreseen to be performed on the collapsed central core with the compacted inflatable shell

on it (or a dummy shell) to simulate the flight load environment and demonstrate the structural integrity of the central core after testing as well as to test its interface with the launcher or the resource module. A resonance search to investigate the vibration modes shall be as well performed.

After vibration testing the structure will be inflated to check integrity of the parts and to perform the following tests: • Proof Test: a pressure of 1.5 MEOP at acceptance level shall be applied to confirm the capability of the restraint

layer and its interfaces to the bulkheads and to the window. Strain gauges shall be placed on the selected more critical areas of the restraint to monitor stresses and to extrapolate the result at ultimate through the prepared mathematical models. Qualification of the restraint and its interfaces has been already performed on a dedicated reduced scale demonstrator at 4 MEOP.

• Leakage: after proof testing the pressure shall be maintained and stabilized at MEOP for 24 hours to check the

daily leakage and to confirm that the measured value is within the requirement. After this test execution the Spacehaven structure could be packaged for flight.

3.1.6.3 Shape The chosen shape for the inflatable shell is composed of a cylindrical part combined with two toroidal ending parts attached to a central rigid core. This configuration has been selected based on the performed IHAB study as the most suitable shape for application to free-flyer and interplanetary transfer missions more than for application as a surface habitat for the following main reasons: - High efficiency from an internal accommodation of subsystems and habitability point view: the volume can be

subdivided in sections (nominally 3) along the module axis to create different functional areas and each area can then be subsequently subdivided in radial sectors to provide crew quarters with direct openings on the translation path originated by the central rigid core

- The presence of an internal rigid core allows easy connection with the standard launchers’ adapters, internal secondary structures attachment, hard support for the deposition and compaction of the folded inflatable structure and load transfer during all the flight phases. In particular the central core after deployment provides attachment for the racks’ supporting frame.

- The cylindrical shape with round shaped domes is typical for vessels application where pressure withstanding is the prevalent load condition

AA


Alcatel Alenia Space Italia S.p.A. 3.1.6.4 Global Structural Configuration The global configuration of the Spacehaven module has been preliminarily identified as reported in the following sketches. The macroscopic elements are given by the inflatable shell, the central collapsible/deployable core with metallic bulkheads and the interface adapter to the IBDM. A complete view of the internal and external structural assembly and the internal rigid core is here represented:

Figure 3.1.6.4-1 – Spacehaven overview with IBDM

Inflatable Structure The inflatable structure configuration can be referenced by RD 6, detail of the design of the interfaces with the central rigid part are examined in the next paragraphs. The composition of the inflatable membrane is represented in the schematic hereafter:

Internal Protective Layer (Fire & Puncture protection)

Redundant Bladder (Air Containment)

Structural Restraint (Pressure Containment)

MLI & Beta Cloth (Thermal Protection)

Inflatable Multi Layer Shell

MMOD (Micro Meteoroids Orbital Debris Protection)

Metallic Bulkheads The baseline material is Al-alloy 2219-T851 for all the bulkheads metallic parts based on Alenia Spazio experience. The metallic bulkheads are composed of the following main parts: FWD and AFT Bulkheads Rings The bulkheads rings represent one of the most critical interfacing areas as they have to provide attachment for: • The structural restraint (through eyelets pinned to clevises) • The bladder fixation and sealing (through a dedicated clamping ring) • The AFT and FWD cylindrical segments of the central core (through a forked connection) • The resource module or the adapter for fixation to the launcher (through a bolted connection) • The conical panels (via hoop welded connection) These rings have therefore to be machined from forgings as represented in the hereafter reported section to provide all the required flanged interfaces:

AA



Figure 3.1.6.4-2– Spacehaven Bulkhead Section with Interfaces

Some details of the structural restraint attachment system to the bulkheads rings are here (Figure 3.1.6.4 – 3) represented: the restraint layer is fixed to the external side of the bulkhead rings by means of discrete metallic clevises. The restraint layer is then fitted with stitched eyelets that are pinned to the clevises. The redundant bladder is sealed and bolted by means of a clamping ring on the internal side of the bulkheads rings. In the figure 3.1.6.4 – 4, the left picture shows adhesion of the bladder onto the bulkhead ring prior to clamping ring bolting (right picture). To allow smooth deposition of the redundant bladder onto the structural restraint and to avoid any damaging induced by the contact with the clevises, foam or rubber blocks are to be inserted in the bulkheads rings areas.

Figure 3.1.6.4 - 3 – Structural Restraint Eyelets Fixation to Clevises

Figure 3.1.6.4 - 4 – Redundant Bladder Sealing by Clamping Ring

Clevis

Cylindrical Segment

Bulkhead Ring

Restraint Eyelets

AA


Alcatel Alenia Space Italia S.p.A. FWD and AFT Bulkheads Conical Panels The conical panels are manufactured from machining of plates followed by brake forming to obtain the desired curvature and subsequent aging to reach the final state of temper. They shall be based on a waffle design to increase their structural performance (both static and buckling) without penalizing the mass (high specific strength). In the AFT Bulkhead the conical panels shall then be welded to an intermediate ring which provides bolted interface for the AFT Access Closure (AAC). The AAC is directly derived from Alenia Spazio ISS metallic modules as it allows easy access during integration and provides a sealed interface (with gask-o-seal) blind bulkhead during all the flight and on orbit phases.

Figure 3.1.6.4-5 – AFT Bulkhead with AAC

Figure 3.1.6.4-6 – FWD Bulkhead with hatch opening

In the FWD Bulkhead the conical panels shall then be welded to an intermediate ring which provides in this case welded interfaces for the hatch bulkhead. The hatch bulkhead provides the hatch opening and the interface with an intermediate adapter to which the IBDM is mechanically fastened. The hatch and its latching system are flight standard hardware as well as the IBDM. MMOD interface to bulkheads rings A preliminary design of the interface with MMOD (external secondary structure) has been performed. This design is based on a discrete number of fixation points for the MMOD and MLI layers onto the bulkheads rings. A through-to thickness bolts is placed in each location to connect the MMOD to the fixation brackets. The fixation is made possible by the removal of a small portion of the foam in the central layer that is compensated by the interposition of thick plastic or metallic washers.

Figure 3.1.6.4-7 – MMOD fixation to bulkheads rings

MMOD Fixation Bracket

MMOD envelope

AA



Central Telescopic Cylinder The central telescopic cylinder is given by 3 segments: they are collapsed and blocked in this position during launch in order to keep the core in compacted configuration during all the ascent phase. Once on orbit, the inflatable shell is released by the pyro-cutting of the restraining chords and the cylindrical segments blocking mechanisms are as well released prior to starting the inflation procedure. No actuation is presently foreseen for the telescopic deployment of the cylinders as even a small pressure acting on the bulkheads during inflation provides a considerable force that is currently considered enough to practically operate the deployment of the cylinders through the sliding on dedicated rail guides.

Figure 3.1.6.4-8– Rail guides sliding on spheres detail

Figure 3.1.6.4-9 – Rail guides assembled and inserted in

adjacent cylindrical segments In open position the rail guides are not fully deployed to allow load transfer from one cylinder to the adjacent one. A superimposition of 500 mm has been estimated to be enough for loads transferring between adjacent cylinders. Three rail guides with spheres at 120 degrees provide interface between adjacent cylinders and sliding during the deployment phase. A snap blocking system provides fixation of the cylinders in open position. This system is considered to be based on a certain number of pins actuated by springs that enter the holes of the adjacent cylinder and block any further sliding. All the cylinders walls are obtained from curved composite panels sectors having a thickness of 30 mm and based on CFRP skins with aluminium alloy honeycomb core. The composite panels sectors are joined in correspondence of the supports for the rail guides and assembled with the aid of C-shaped rings at their ends. The FWD and AFT cylinders are directly interfaced to the bulkhead rings: a fork type connection is realized from the machining of the rings.

Figure 3.1.6.4-10 – Detail of fork junction for cylindrical segments at the bulkheads rings

AA


Alcatel Alenia Space Italia S.p.A. At launch the most internal cylindrical segment of the collapsed assembly shall allow mounting of secondary structures (stand-offs) after deployment the cylindrical segments shall provide interfaces with the internal soft floors and externally with the racks supporting structure.

Figure 3.1.6.4-11 – Detail stand-offs and partition floor

Racks Supporting Structures As appears from the configuration study, a great number of racks have to be accommodated very close to the cylindrical wall. A distance of 100 mm from the inflatable wall has been left between the racks and the inflatable wall. A system of beams concurring to form a supporting frame is therefore necessary as part of the outfitting of the module to fix the racks in that position. Dedicated panels are then connected to this purpose at the extremities of the cantilevered beams to provide fixation points for the racks. The complete structure has to guarantee stiffness to the assembly and sustain the astronauts induced loads. Soft floors are to be fixed by Velcro on the horizontal beams to provide partitioning of the internal ambient.

Figure 3.1.6.4-12 – Racks supporting structures

Standoffs

Partition Floors

AA



3.1.7 ECLS The request of resources and the waste production have been defined to identify the needs of the mission. This first stage has allowed a preliminary sizing of the ECLS hardware. The ECLS of the SpaceHaven will cover following functions:

• Atmosphere Control and Supply (ACS) Main aspects and concepts developed for this subsystem are related to: 1) the definition of the total pressure in the SpaceHaven habitable volume (1 atm), 2) the pressure control (a depressurisation assembly and the PPRV’s are installed in the SpaceHaven, while, instead, the pneumatic NPRV’s are not needed) and 3) the gas storage (realised on the external resource module exploiting the ATV gas tanks).

• Atmosphere Revitalisation System (ARS) In particular this subsystem includes: 1) a system for the CO2 collection from the cabin, its reduction for water generation and the water hydrolysis for oxygen production, 2) a system for methane pyrolysis to increase the conversion from CO2 to oxygen, 3) a trace monitoring device, 4) a trace gas removal device, 5) a strategy for toxic atmosphere management and 6) the identification of the need of a leakage detection and localisation device.

• Fire Detection and Suppression (FDS) • Food Management (FM)

Under this subsystem have been investigated aspects related with: 1) kind of diet, 2) food production with the definition of a salad machine, 3) food storage at ambient at a low temperature, 4) food packaging, 5) food preparation, 6) utensils for food consumption and 6) device for cleaning.

• Radiation Protection (RP) A radiation protection strategy has been identified. At this stage, the shielding capability of the foldable primary structure has been evaluated and the additional water shelter around the area of the crew quarters has been identified (25 cm).

• Temperature and Humidity Control (THC) In particular, this subsystem includes: 1) definition of a control based on an effective temperature, 2) consideration between a single THC loop against a multiple THC loop and 3) definition of options to minimise the on orbit integration effort of the ducts.

• Waste Management (WM) In particular under this subsystem the included activities are: 1) collection of waste production rates from previous missions, 2) definition of the toilet and 3) definition of the stabilisation and compaction device.

• Water Recovery and Management (WRM) Main topics included in this subsystem are: 1) a potable water processor, 2) a urine processor, 3) a water quality monitoring device and 4) a water disinfection device.

The overall schematic of the ECLS of the SpaceHaven is shown in fig. 3.1.7-1 To the maximum possible extent, the configuration has been defined trying to match following rules:

1. Minimise the length of the distribution lines defining suitably the location of the items to connect. 2. Modular definition of the items in accordance with ISPR racks or SpaceHaven specific racks. 3. Active racks and components (i.e. racks and components with fluid or electrical interfaces) located as much as

possible near to the resource module on the aft of the SpaceHaven and in the core volume or in locations easily accessible from the resource module

4. Passive racks (i.e. without fluid or electrical interfaces) located far from the resource module in the forward position and in the inflatable volume

AA


Alcatel Alenia Space Italia S.p.A. Fig. 3.1.7-1 SpaceHaven ECLS functional schematic

Food

Water

Wastes

Oxygen

Nitrogen

Oxygen generator

CO2 removal system

CO2 reduction system

CH4 pyrolysis

TG removal

Dish washer & washing machine

ShowerFace washer

Other hygiene facility

Toilet & waste compactor

Galley

Condenser

Water disinfection

H2O treatment stage II

H2O treatment stage I

Urine pretreatment

Water mineralization

Salad machine

Cabin

Crew

Solid waste

WATER TREATMENT

AIR TREATMENT

STORAGE

Urine

Urine

Solid waste

Oxygen

Carbon dioxide

Trace gas

Carbon dioxide

Hum

idity

Hum

idity

Waste water

Brin

e

Hygiene water

Car

bon

Methane

Potable water

Hyd

roge

n

Food

Food

Food

Technical water

Oxy

gen

Carbon dioxide

Potable water

Nitrogen

Hygiene water

UTILITIES

AA



3.1.8 Airlock Airlock for on-orbit EVA and for surface The materials and materials configurations of the most internal layers (up to the bladder) are so considered to be the same as for IHAB, while for the structural restraint, the MMOD, the MLI and the radiation protection layers, although they can still rely on the same IHAB basic constituent materials, their configuration shall be tuned to meet the environmental requirements for an inflatable airlock to be used for EVA (with modules in free-flyer missions) rather than for an enter/exit airlock fixed to a module on Moon/Mars surface. On the other hand these 2 types of airlock are currently envisaged to have commonality in: - The sealed and mechanical connection of the inflatable shell to the metallic flanges - The deployment mechanism: from a structural point of view the absence of gravity for an on-orbit airlock leads to a

lighter design with respect to a surface airlock. For a surface airlock a system of wheels is furthermore necessary to allow deployment.

- The restraint shell could follow the same design although for the 2 types of airlock but some optimization in thickness is considered to be possible for a surface airlock where the differential pressure between internal and external environment is lower (Mars surface)

- The hatch for ingress and egress of the crew from the airlock The airlock for on orbit EVA in its basic structural configuration is considered to be deployed by 3 telescopic longerons which can operate the deployment of the airlock from inside. The deployment is considered to be operated by pressure acting on the FWD bulkhead or by actuation of the telescopic longerons. After deployment the longerons can be used to provide temporary attachment for equipment and/or secondary structures. In folded configuration or after retraction the AFT bulkhead is latched with by electrically actuated pins to the FWD bulkhead. The latched pins allow load transferring during flight. The same system is adoptable for a surface airlock; in this case the bulkhead with hatch has to be supported by wheels to maintain the correct contact with the ground. An inter-module connection It can be conceptually very similar to a surface airlock, so exploiting the same sealing and mechanical connection of the inflatable shell to the metallic flanges. This airlock is subjected to a permanent pressurization so on one side it not subjected to pressure cycling but on the other hand the daily leakage requirement is even more critical. The development on this item will not therefore include pressure cycling testing. The inter-module connection deployment could be automatically driven again by telescopic longerons. An adapter at one of the bulkheads or at both the bulkheads could allow mating of surface modules with recovering of mismatches and misalignments obtained with a system of 6 electrical actuators as will be shown later. Airlock for on orbit EVA The airlock is basically formed by two segments: a metallic module (Equipment Lock) where the astronauts’ suits and equipment are stored and where the crew can get dressed for EVA and an inflatable Crew Lock for astronauts exiting. The equipment lock is fitted with two hatch bulkheads; one of the hatches allows the access to the inflatable crew lock. The equipment lock can be interfaced with the Spacehaven with the standard CBM interface. The crew lock must be pressurized prior to this hatch opening. The here represented crew lock has a diameter of 1900 mm and a length of 2400 mm.

AA



Figure 3.1.8-1 – Inflatable Crew Lock attached to the Equipment Lock The inflatable crew lock is then formed by these main constituent items: • An AFT Ring which is bolted and sealed to the equipment lock hatch bulkhead ring • 3 telescopic longerons equally spaced at 120 degrees and exploiting the equipment lock bulkhead for bolted

fixation as shown hereafter:

Figure 3.1.8-2 – Extensible Longerons fixation to Equipment Lock

bulkhead

Figure 3.1.8-3 – Longeron fixation to airlock FWD bulkhead

AA



The longerons are then fixed on their opposite side to the crew lock FWD bulkhead which carries a dedicated hatch for astronauts exiting in EVA. The telescopic longerons are pneumatically actuated to operate their distension and they are here represented in the compacted configuration showing also the connection to the vestibule module bulkhead that has to be able to transfer the flight and on-orbit loads.

Figure 3.1.8 - 4 – Longeron compacted & details

The most relevant part of this airlock is however given by the inflatable part that has to be compacted during flight and then deployed once on orbit.

Figure 3.1.8 - 5 – Longeron in deployed configuration

• The inflatable shell is based on the multi-layer concept in which the bladder layer for air containment is bolted and

sealed through a clamping ring made by sectors against the crew lock AFT ring and the FWD bulkhead ring. The structural restraint eyelets are pinned to clevises that are mechanically fastened to the same rings of the crew lock but in an upper position, as shown in below pictures:

AA



Figure 3.1.8 – 6 – Crew Lock inflatable shell fixation details

Restraint Layer clevises Bladder bolting and

sealing onto Crew Lock AFT ring

Bladder bolting and sealing onto Crew Lock FWD bulkhead ring

AA



The MMOD is based on ceramic fabric layers that are kept at the required distance after deployment (ballistic performance) by means of discrete foam blocks (acting as spacers) positioned in the AFT and FWD areas as well as in the middle of the MMOD. The MMOD AFT and FWD blocks are then mechanically fixed with dedicated brackets to crew lock rings. The deployment of the longerons and the consequent movement of the crew lock FWD bulkhead operate (via the MMOD brackets) the distension of the MMOD itself to cover the crew lock inflatable part.

Figure 3.1.8 - 7 – Crew Lock MMOD

Foam Blocks Ceramic layers

MMOD brackets

Crew Lock FWD bulkhead

AA



To obtain the compacted configuration on ground, the bladder and the restraint layers are fixed to the bulkheads rings and then folded in such a way to assume a waved shape. The MMOD can be compacted apart, slipped on the crew lock pre-assembled shell and fixed with the foreseen brackets to the bulkheads rings. In the MMOD the foam blocks are compacted by forcing the ceramic fabric flexible layers to form crests towards the external side.

Figure 3.1.8 - 8 – Crew Lock in folded configuration

A more detailed view is presented in the next picture:

Figure 3.1.8 - 9 – Crew Lock in folded configuration details

AA



Airlock for surface EVA The airlock for surface EVA is considered to exploit the same concept as for the on orbit EVA. In this case the airlock has to be fitted with a wheeled support system to sustain gravity and support the crew lock during extension. The wheeled system is fixed to the FWD bulkhead of the crew lock by means of a shock absorber. The solution with 3 wheels allows ground asperities overcoming. A foldable ladder is then placed on the crew lock FWD bulkhead and is deployable to allow astronauts exit for surface walking. The deployment of the longerons operates also the distension of a tensioned soft floor to support astronauts’ transit.

Figure 3.1.8–10 – Airlock for surface EVA

Figure 3.1.8–11 – Airlock for surface EVA with

unfolded ladder Inter-Module Connection For inter-module connection purposes, the connection tunnel is based on the inflatable deployable concept considered for the airlock. The diameter is so assumed to be the same while the length can be adjusted to the need. The inflatable connection tunnel is not subjected to pressurization/depressurization but it is maintained to constant pressure: the fatigue aspect is not relevant to the design. A very important issue is now related to the connection of 2 facing modules that can represent a big problem due to the misalignment that they surely have on a planet surface. To this purpose an adjustable connection system for recovering these mismatching has been thought based on 6 electrically operated actuators that can move the connection bulkhead to fit it to the position of the module to be attached.

Figure 3.1.8–12 – Inter-Module Connection with adjustable connection system

AA



The adjustable connection system is based on a pressurized bellows that is sealed at the inter-module tunnel bulkhead and to a connection ring that has to be fixed to the other module as represented here below:

Figure 3.1.8–13 – Adjustable Connection System details

The adjustable connection system has to be able to recover both inter-axes as well as angular mismatch as here below represented:

Inter-axes mismatch

Angular mismatch

Figure 3.1.8–14 – Adjustable Connection System mismatch recovering

Inter-module tunnel bulkhead

Connection ring

AA



3.1.9 IBDM The Spacehaven FWD bulkhead has been inherited from the design of analogous bulkheads on MPLM, Columbus, ATV, NODE 2&3 with a reduction in diameter. This reduction structurally works in the direction of increasing its load carrying capability with particular reference to the buckling behaviour under the applied loads. For a traditional ACBM/PCBM berthing system the interface limit loads enveloped are the following:

LOADS AXIAL N (lbf)

SHEAR N (lbf)

MOMENT N*m (lbf*in)

TORSION N*m (lbf*in)

ENVELOPING AT BERTHING FOR ACBM/PCBM

- 31664 (-7000)

+/- 7690 (+/- 1700)

+/- 10737 (+/- 95000)

+/- 7347 (+/- 65000)

ENVELOPING AT BERTHED FOR ACBM/PCBM

+/- 18139 (+/-4010)

+/- 14724 (+/- 3310)

+/- 67816 (+/- 600000)

+/- 65216 (+/- 577000)

Comparing these loads with the one induced by the AIBDM/PIBDM system as specified in RD 7 it results that they are exactly the same. This probably means that the ACBM/PCBM loads have been assumed as the target for the AIBDM/PIBDM system design. The impact loads applied via the IBDM on the Spacehaven FWD bulkhead are therefore acceptable and provided these loads are maintained no need for improvement in the IBDM damping capability is currently envisaged. The current design of the FWD bulkhead does not need modifications to increase the global and local stiffness due to the IBDM interfacing. The IBDM can be quite easily interfaced with the Spacehaven structure by means of a short adapter skirt (support structure) as shown here below:

Figure 3.1.9-1 – IBDM support structure

IBDM support structure

IBDM

AA



3.1.10 Medical equipment In the next table the medical devices resulting necessary to equip a long duration mission habitat are listed. They appear ordered by a ranking obtained as the product of the “total incidence” by HUMEX TN1 (RD2) and of the mission priority. The list resulting from a first passage trough the data collected from the first part of the study when the possible pathologies have been assessed. From the previous analysis the incidence values for some devices have been calculated. This list provides then a ranking and therefore a preliminary overview on the importance of the single medical equipment for future SpaceHaven missions. Table 3.1.10-1: Ranking of identified medical devices

Title Priority Incidence Ranking rate

Blood cell counting and analysing device 1.27 4.0170 5.113 X-ray equipment 0.45 4.0920 1.860 Advanced aerobic capacity measurement device (exercising monitoring)

1.27 0.8070 1.027

Rowing device 1.27 0.8060 1.026 Treadmill 1.27 0. 8060 1.026 Cycling ergometer 1.27 0.8060 1.026 Lower body negative pressure device 1.27 0.8060 1.026 Vibration table 1.27 0.8000 1.018 Short-arm centrifuge 1.27 0.8000 1.018 Flywheel ergometer 1.27 0.8000 1.018 Bone analyzer 1.27 0.8000 1.018 Surgery theater 1 0. 1010 0.101 Biocontamination protection enclosure 1 0.0190 0.019 Defibrillator 1.27 0.0140 0.018 ECG 1.27 0.0140 0.018 Endoscopy 1 0.0170 0.017 Cardiovascular monitor 1.27 0.0100 0.013 Isolated medical room 0.45 0.0240 0.011 Ventilation respirator 1.27 0.0070 0.009 Recuperation room 1.27 0.0070 0.009 Imaging device for internal diagnostics 0.45 0.0140 0.006 Blood chemical analyzer 1.27 0.0050 0.006 Impulse free ergometer 0.45 0.0110 0.005 Body analyser 1.27 0.0030 0.004 Fluids analysis lab 1.27 0.0030 0.004 AKOS 0.45 0.0050 0.002 Kidney stones device 0.45 0.0020 0.001 Water analyzer 1.27 n.a. 0.000 Toxicological monitor 1.27 n.a. 0.000 Radiological monitor 1.27 n.a. 0.000 Microbiological monitor 1.27 n.a. 0.000 Individual dosimeters 1 n.a. 0.000 Bubble-formation monitoring 1 n.a. 0.000 Bio-sensor radiation monitors 1 n.a. 0.000 Hyperbaric life support equipment 1 n.a. 0.000

AA



3.1.11 Internal Auxiliary Structure (AUXIS)

Figure 3.1.11-1

Overview of the IHAB Level-1 defined through the Auxiliary Internal Structures (AUXIS, see RD4).

AA



3.1.12 shower

Figure 3.1.12-1: Preliminary basic configuration of the AKOS stall, with closed and open door

Figure 3.1.12-2: Basic block diagram for the AKOS crew shower

Figure 3.1.12-3: example outfitting of the AKOS’ stall interior, showing a riser bar with different positioning points for the hand-held spray nozzle (or for the suction head), stowage spaces, etc.

AA



3.1.13 Washing machine Conventional earth based cloth washing technologies are mainly based on a two phases air / water process. This process produces a lot of foam and air bubbles. These can easily be handled under 1-g environment, but have been identified as one of the major problems on recent microgravity cloth washer developments: the foam and air bubbles decrease the efficiency of pumps, storage vessels and water reclamation systems considerably. The proposed design overcomes this problems by eliminating all air additions during the wash / rinse cycles. For drying, the use of microwave energy will minimise the power consumption. The cloth washer has the following envelope: Diameter 70 cm Depth 44 cm The current design is rather a rather small unit based on a tub capacity of around 5lt. This allows washing of 2kg textiles per cycle. If required, the washing volume could be increased by scaling up the size of the tub. This should not affect the functionality of the washing technology itself.

Figure 3.1.13-1: Laundry installed in standard SpaceHaven rack unit.

Figure 3.1.13-2: Sectional view of SpaceHaven laundry

AA



3.1.14 Galley equipment

3.1.14.1 Refrigerator freezer The Refrigerator / Freezer Rack developed by EADS ST and Marlow is proposed to be used as refrigerator / freezer for the SpaceHaven galley. The size of the RFR is optimised to fit into the International Standard Payload Rack used on the Space Shuttle and the ISS. Adaptation to the standard SpaceHaven rack or a dedicated SpaceHaven galley area should not cause any difficulties. Figure 3.1.14.1-1 shows a possible arrangement of the RFR (middle) in the SpaceHaven galley, integrated in a standard SpaceHaven rack assembly.

Figure 3.1.14.1-1: RFR integrated in SpaceHaven standard rack assembly

3.1.14.2 Oven The proposed SpaceHaven oven uses forced air convection technology for food heating / warming and microwaves for defrosting. This approach is deemed as the best combination with respect to taste of food, time required for food preparation and power consumption. Adding a small amount of water (steam) to the hot air is a possible option which has to be taken into account. It is known that steam is improving the taste of some food, especially vegetables. The oven has the capacity to heat / keep warm food / drinks for 6 crew members at once. It has the following envelope: Height 52 cm Width 73 cm Depth 48 cm

Figure 3.1.14.2-1: Oven unit

Figure 3.1.14.2-2: Oven

integrated in SpaceHaven standard rack

AA



3.1.15 Dish washer The proposed dish washer technology uses the basic spray wash process which is used in a domestic dish washer. However, instead of having a fixed wash tube and dishes and rotating spray arms as in a domestic unit, the SpaceHaven dishwasher has a rotating tray rack and dishes with stationary spray arms. Another difference between the domestic unit and the proposed design is that the SpaceHaven unit is designed to wash trays instead of individual dishes. The trays are designed so that eating utensils, cooking utensils and drinking cups can be attached for washing. The current dish washer design can accommodate nine trays. The proposed dish washer is a self standing unit mounted on a standard rack in the SpaceHaven galley area. Due to its size the dish washer exceeds the rack front panel by around 30cm. Figure 3.1.15-1 below shows an overview on the dish washer unit installed in the standard SpaceHaven rack. The dish washer has the following envelope: Height 86 cm Width 86 cm Depth 76 cm The tub is 76 cm in diameter. During the entire wash and dry process the tub and trays rotate at 30 rpm. The drain and the drying processes are based on a forced air flow.

Figure 3.1.15-1: Dish washer unit installed in the standard SpaceHaven rack

Figure 3.1.15-2: Details of the tray rack

AA



3.2 DEMONSTRATORS

ARES..

EADS HB20101010

PYROLYSIS..

EADS HB20101020

OXYGEN ATMREGENERATION

.EADS HB20101000

TOILETFLIGHT

.ALENIA HB20102000

MEDICALFLIGHT

.HTS-CSEM HB20103000

SHOWERFLIGHT

.HTS HB20104000

FLECS..

ALENIA HB20105010

ATV LIKE..

ALENIA HB20105020

STRUCTUREFLIGHT

.ALENIA HB20105000

IHAB FLIGHTDEMONSTRATOR

.ALENIA HB20100000

INERTIZATIONAND

COMPACTIONALENIA HB20201010

POTABLE ANDTECHNICAL

WATER PRODUCT.ALENIA HB20201020

URINETREATMENT

.ALENIA HB20201030

WATERMONITORING

.ALENIA HB20201040

TRACEGAS

REMOVALALENIA HB20201050

SALADMACHINE

.ALENIA HB20201060

EMERGENCY H/W(WASTE & POTABL E

WATER)ALENIA HB20201070

WATERDISINFECTION

.ALENIA HB20201080

TEMPERATURE &HUMIDITY

CONTROL SYSTEMEADS HB20201090

ATMOSPHERECONTROL

.EADS HB20201100

NEWDEVELOPMENT AVALVE COMBINEDEADS HB20201110

OVERALLECLSS

.ALENIA HB20201000

WINDOW..

ALENIA HB20202010

RESTRAINT..

ALENIA HB20202020

DEPLOYMENT..

ALENIA HB20202030

INTERNALAUXILIARY

STRUCTUREHTS HB20202040

STRUCTUREGROUND

.ALENIA HB20202000

IHAB GROUNDDEMONSTRATOR

.ALENIA HB20200000

IHABDEMONSTRATOR

GSE / TSEAPCO HB90000000

INFLATABLEHABITAT

DEMONSTRATORALENIA HB20000000

Table 3.2-1: IHAB Demonstrators Product Tree

AA



3.3 FLIGHT DEMONSTRATORS

3.3.1 Oxygen Atmosphere Regeneration

3.3.1.1 Air Revitalisation System (ARES) The Air Revitalisation System (ARES) flight demonstrator has the objective to convert Carbon Dioxide (CO2) back to oxygen. The design environment for the ARES flight demonstrator is a closed manned habitat as e.g. the International Space Station ISS. A brief description of the ARES system is given hereafter. The general task of oxygen provision can be subdivided into:

• To provide breathable oxygen during nominal operation periods • To collect CO2 produced by the crew from the cabin atmosphere and to maintain the CO2 level • To remove the CO2 by conversion into methane and water by means of H2 and to dump excessive CO2 and

methane to the venting system • To generate oxygen and hydrogen from water and to return the oxygen to the cabin atmosphere, whereas the

hydrogen is used for CO2 reduction. These objectives will be achieved for a requirements baseline defined for a 6-men crew within ISS as follows:

• Provision of 0.84 kg O2 / per day and person, i.e. 5.04 kg O2 / day. • Removal and conversion of the CO2 generated by the crew (1kg CO2 / day person), i.e. 6.00 kg CO2 / day at a

maximum CO2 partial pressure of 4 hPa. • Autonomous operation within ISS, with communication with the higher level control system for command and

monitoring. • Operation of the CO2 removal function independent from the oxygen generation function • Cyclic operation such that power consuming operation steps are performed within a day period of 53 minutes

within a ~ 90 minute orbit cycle. In order to meet the objectives and requirements as described above, the ARES flight demonstrator system design consists of the following major constituents:

• The Carbon Dioxide Control Assembly (CCA) • The Carbon Dioxide Reduction Assembly (CRA) and • The Oxygen Generation Assembly (OGA)

These major constituents are amended by other subassemblies. These are:

• The cooling loop • The water supply function • The power supply and Controller • The structure

Due to the modular design of the major constituents these subassemblies can be interconnected in various arrangements in order to also fit into different flight hosts. An IHAB/ARES flight demonstrator in ISPR configuration may be transferred to the ISS via STS/MPLM or Ariane/ATV. Application on a Russian launcher/module may require different configuration due to hedge size. Design loads enveloping the individual launch opportunities may have to be considered. Major issue to be resolved is where on the ISS to install the IHAB/ARES flight demonstrator.

AA



3.3.1.2 Methane Pyrolysis Assembly (MPA) for ARES The Carbon Dioxide Removal Assembly (CRA) of ARES produces as by-product methane, which would be dumped overboard in case that ARES would be operated as self-standing system. With the implementation of an additional stage, this methane product of the ARES/CRA can be de-composed to hydrogen and (solid) carbon. The hydrogen can be returned to be used in the Sabatier process in the ARES/CRA in addition or as complement to the hydrogen from the Oxygen Generation Assembly (ARES/OGA). The carbon has to be stored as waste inside the module and disposed. In order to recover the hydrogen out of the methane produced by the ARES/CRA, the methane is catalytically decomposed at high temperature (Pyrolysis). A brief description of such Methane Pyrolysis Assembly (MPA) is given hereafter. The methane Pyrolysis assembly consists of the following major constituents:

1. Catalyst storage, where the new catalyst is fed from 2. Catalytic Thermal Flow Reactor (CTFR) operated at about 930 °C. The used catalyst and carbon particles are

removed with a screw conveyor. 3. Particle separator, consisting of a membrane filter and particle compactor and storage 4. Gas cleaner, consisting of the filters (HEPA) which are operated alternately 5. Gas separator for the H2 purification. CH4 is fed back into the CTFR.

The following design requirements are considered: For the assembly:

• Low volume and mass • Low power consumption and consumption of consumables • High lifetime, safety and reliability • Operable under microgravity conditions • No leakage of gas and soot

For the reactor: • Resistance to high temperature • Resistance to H2 and solid carbon • High conversion

The scope of a phase B/C/D for SpaceHaven is the design, development and MAIT of a compact, in MPA flight demonstrator for combined in-orbit operation together with the ARES. An IHAB/MPA flight demonstrator in ISPR configuration may be transferred to the ISS via STS/MPLM or Ariane/ATV. Application on a Russian launcher/module may require different configuration due to hedge size. Design loads enveloping the individual launch opportunities may have to be considered. Major issue to be resolved is where on the ISS to install the IHAB/MPA flight demonstrator, as close as possible to the IHAB/ARES flight demonstrator.

3.3.2 Toilet This section is dedicated to a flight demonstrator identified in the frame of the IHAB study for the demonstration of the gravity sensitive critical technologies integrated in the SpaceHaven toilet. The following critical parts needing a flight demonstration have been identified:

• The capability of the air/urine separator to separate urine from air • The capability of the fan to suck air and solid wastes from the commode and to confine the solid wastes in the

faecal bags returning odourless air back to the cabin. The compaction and inertization system, part of the final toilet design, is not considered a microgravity critical technology; therefore it will not be integrated in the toilet flight demonstrator and will follow a separate ground demonstration.

AA



The proposed flight demonstrator is planned for 2 weeks demonstration supporting two crewmembers. Since the return of the demonstrator on ground is desired for the evaluation of the status of hardware mainly to investigate around salt deposition, filter clogging and contamination aspects, the preferred configuration is the launch of the demonstrator in MPLM with the Shuttle. Nevertheless, the current technical specification of the TLD also covers the possibility to launch the demonstrator with Ariane V integrated in the ATV. In this case the capability of the TLD hardware to properly perform will be verified but the starting of long period effect and deterioration will not be investigated being not possible the return on ground of the demonstrator. Since the demonstrator is required to be in line with an ISPR, it can be located in any ISS location. No dedicated fluid or avionic interfaces are required. Only a power interface could be needed whether an independent power supply source (battery) will not be provided in the demonstrator. Possible location for the rack on ISS are in the MPLM itself (for example in any of the free Refrigerator/Freezer location) or in Node 3 in the P3 or P4 location currently dedicated to the W&HC that is at the moment stopped. If the demonstrator were launched in ATV then the demonstrator shall be modified to provide the correct mechanical interfaces to the ATV (that does not foresee interfaces for the ISPR rack). The rack shall also be equipped with an autonomous power supply being no power distribution available at the ATV rack location.

3.3.3 Medical Monitoring System The Medical Monitoring system portable device consists of three portable modules, a first sensor unit measuring the heart rate at the thorax (chest belt), a second sensor unit at the ear-cartilage, measuring the body core temperature and a data acquisition and communication module, processing and recording the sensor data. As an option this module comprises a communication unit in order to send the data to an external base station. The sensor modules SC1 and SC2 are wired to the data processing and communication module. In the following the different modules are detailed: ECG sensor sub-system • 2 dry electrodes (plus reference), integrated in garment • accelerometer sensor (for motion artefact removal) • analogue electronics for signal conditioning • auxiliary sensors for compensation effects Body Core Temperature sensor sub-system • temperature sensor • packaging • analogue electronics for signal conditioning Data processing and storing sub-system • interfaces (wired) to sensor sub-systems • processing unit • memory unit • power supply for all sub-systems • signal processing algorithm to enhance ECG and HR measurement • signal processing algorithm to derive BCT • signal processing algorithm to calculate PSI • wireless communication module to higher-level system The option of integrating a communication module together with an external base station for a possible data access from external is not taken into account for the herein proposed development plan. Therefore, the herein proposed development plan limits to a system with three (3) portable units, the two sensor units with BCT and ECG measurement and a central data processing and recording unit.

AA



The Medical Monitoring System flight demonstrator can be integrated into an ISPR and transferred to the ISS via STS/MPLM or Ariane/ATV. Design loads enveloping the individual launch opportunities may have to be considered. Major issue to be resolved is where on the ISS to install the Medical Monitoring System flight demonstrator.

3.3.4 Shower (A Kind Of Shower, AKOS) The shower demonstrator activities involve the basic shower function, as this covers the widest and most challenging range of parameters, involving:

• transport flow control of a multi-phase medium (air, water, and vapour, plus “contaminants” like detergents, dirt, skin, and fibre particles, etc.)

• temperature control of both air and water flowing through the facility • separation of the liquid-gas phases coming out of the stall • reconditioning of air (temperature, humidity, filtering) and water (filtering) flowing out of the facility

The AKOS stall enclosure shall provide an internal/external diameter of 0.82 / 1.00 m. and an internal (between the main surfaces of base and roof modules) / external height of 2.05 / 2.45 m. The stowed (joined) module accordingly measure 0.5 m in height for a 1-m diameter, with the sidewalls rolled to a diameter of 0.3 m and with a 2.05 m height. The AKOS dry mass shall not surpass 250 kg. The peak power drawn by AKOS shall not exceed 8 kW. Typical air flow through the stall enclosure during operation amounts to 0.25 m3/s. The shower demonstrator shall be based on the AKOS facility concept, which includes the following major components:

• the integrated shower stall, comprising (1) a base module, (2) a roof module and (3) a set of side walls consisting of the semi-flexible walls proper (with a limited life time) and of a “spine” member housing harness (and possibly a pipe for return air)

• a water preparation circuit (partly within the roof module), including (1) interface to operative environment freshwater distribution system, (2) local pressure booster and regulator, (3) water heater (vapour generator) and temperature controller, (4) plumbing and valves

• an air circulation complex (partly within the roof and base module, and encompassing the shower stall enclosure), including (1) inlet interface to the operative environment atmosphere, (2) air flow blowers (roof module) and vacuuming fans (base module), (3) air heater and temperature controller and (4) tubing and valves

• a liquid-gas separator (partly within the base module), including (1) interface to the stall enclosure and to the vacuuming line, (2) liquid-gas separator device, (3) air temperature/ humidity regulator, (4) filters and interface back to the operative environment atmosphere and (5) interface to the waste water circuit

• control panels for (1) primary user functions (water on/off; water jet force; water temperature; water allocation indicator), inside the stall, (2) maintenance user functions (drying cycle, cleaning/vacuuming switches, disinfection cycle, etc), outside the stall, (3) secondary user functions (depending on additional uses), (4) adjustment and checkout (water pressure, air temperature and velocity, etc) and (5) technical parameters collection & transmission

The shower demonstrator is considered gravity sensitive, for which parabolic flights demonstration environment may suffice.

AA



3.3.5 Flight Structural Demonstrators

3.3.5.1 FLECS demonstrator It exploits an MPLM planned mission for the on orbit manned qualification of an inflatable habitat. In fact some modifications of the MPLM Aft Cone (additional hatch and new bulkhead) allow Flecs fixation to the MPLM. Once on orbit the inflatable habitat is deployed / inflated and the crew has access through the MPLM hatch. At the end of the mission the structure is folded again to fly back to Earth with MPLM. Having the HW back to Earth will give the great advantage to have an accurate check of the integrity of the inflatable structure layers.

This mission foresees: • A packaging of the inflatable shell against MPLM Aft Cone • Modification of the Aft Cone bulkhead and introduction of a flight hatch and rails • Accommodation of MPLM and Flecs in the Shuttle cargo bay • On orbit re-packaging • Return to Earth in the Shuttle cargo bay

With the following considerations:

• Very low room available in the Shuttle cargo bay (enough to allow a manned mission) • Limited mission duration (14-15 days): driven by MPLM mission duration • On orbit 3 D expansion • Need for restoring MPLM original conditions at the end of the mission • Availability of MPLM missions

This solution appears to be the best compromise in terms of cost, validity of the technological demonstration and possible on earth check of the flown inflatable demonstrator.

Figure 3.3.5.1-1: FLECS demonstrator concept.

3.3.5.2 ATV-supported demonstrator This mission is initially supposed to be manned with the following ATV modifications:

• A lateral NODE2/3 bulkhead and hatch system has to replace a portion of the ATV cylindrical shell (a preliminary verification has shown compatibility in size of the NODE2/3 bulkhead)

• 2 payload racks out of 8 have to be eliminated to place the bulkhead and hatch • The inflatable flight demo is fixed to the ATV Aft and Fwd rings which have to be modified for this purpose

The first check has been conducted on the available volume between the ATV external cylindrical wall after removal of the MDPS panels (in order to maximize the available volume for packaging) and the A5 internal fairing profile. The

AA



MDPS panels’ removal would imply that the Inflatable Flight with its meteoroids protection can re-establish the same protection level. The distance between the ATV cylindrical shell (external profile of waffle ribs) and the A5 fairing is of 150 mm. Under the next hypothesis and data:

• An inflatable flight demo shell thickness of about 100 mm • Compaction under vacuum of the soft MDPS down to about 30 mm • Folding radius of the shell 100 mm • ATV cylindrical section length: 2597 mm • ATV cylindrical shell (external profile of waffle ribs) diameter: 4267 mm (after metallic MDPS panels) • A5 usable diameter: 4570 mm

A rough evaluation of the final deployed shell arc length based on the number of folds of the packaged shell along the length of the ATV cylindrical section results in about 4000 mm. The maximum height at deployed shell could be around 1000 mm (maximum 1500 mm due to uncertainty on packaging). The very low volume obtained does not allow having a significant manned demonstration with this configuration. An unmanned demonstration in which the shell is inflated and monitored is advised also considering that this would avoid the ATV shell modifications and the reduction in the loading capability. A design revision of the rings will still be necessary to interface the flight demo with ATV. The unmanned mission minimizes the ATV modifications as the bulkhead with hatch can be eliminated. This mission is considered to be feasible.

Figure 3.3.5.2-1: ATV supported demonstrator schematic concept.

3.4 GROUND DEMONSTRATORS

3.4.1 ECLS Demonstrators

3.4.1.1 Overall ECLS Demonstrators In the frame of the SpaceHaven programme, a considerable effort for the development of a large number of advanced life support (ALS) technologies is needed. Considering that many of these technologies are strictly and heavily related each other, the independent design and test of each technology on the basis of the expected interfaces is not considered a complete proof of the adequate performances of the integrated ALS system. The need of an ALS overall demonstrator has therefore been addressed with the intent to evaluate the performances and the closure degree of the system and to optimise the working points of the different parts of the system in order to improve the global efficiency. ESA has identified this demonstrator with a priority class of 1.

AA



3.4.1.2 Inertisation and Compaction Organic and inorganic wastes are produced during any mission from food leftovers, metabolic process, cleaning wipes, hygiene papers, end of life items, packaging, dismissed items, consumables etc. A safe mission requires that the produced wastes are stabilised and inertized to avoid contamination of the habitable environment. Furthermore, the inertized wastes are to be compacted to minimize their storage volume. A dedicated hardware qualified for space application is not currently available on the European market. A dedicated demonstrator, the Compaction and Inertization Demonstrator (CID), has been therefore proposed by Alenia and has an ESA priority of 1 (critical demonstrator). A heat melt compactor has been identified as the basic technology for the CID. It allows to drown in an inert material (plastic) the collected wastes. The device provides heat and compaction force to achieve high volume reduction and sterilize/stabilize the wastes. The final demonstrator shall be a 1:1 model of the flight item. It will provide capability to heat wastes up to about 250 ˚C and 550 kPa. The demonstrator is expected not to be gravity sensitive

3.4.1.3 Urine Treatment During SpaceHaven missions one year long and with six crewmembers on board about 3 ton of urine is expected to be produced that is mixed with about 1 ton of flush water. A urine processor is therefore proposed to recover this waste and produce water at potable quality level or water that can be delivered to the potable water production system for further treatment. The definition of the basic technology for urine treatment is still under evaluation. ESA has questioned the possibility to use the reverse osmosis technology because of the low efficiency of the existing R.O. membranes in retaining both the urea and the ammonium. Possible candidate technologies are:

1) the distillation process in a centrifugal fields already used in the MIR by Russian and under qualification development in USA for integration in the Node 3.

2) the electrolytic oxidation. The system will also provide for pre-treatment or stabilization of the urine flow. No space qualified physic-chemical technology is currently available in Europe.

3.4.1.4 Trace Gas removal Trace gases are generated on board as by-product of biological metabolism (human, animals and plants) and because of materials offgassing. Since each trace gas is to be maintained below a toxic threshold tolerable by the crew, the so-called Space Maximum Allowable Concentration (SMAC), a dedicated device is to be developed to remove the trace gases avoiding their accumulation in a closed environment over the defined SMAC. A dedicated technology has currently not been developed in Europe for space application. ISS performances are based on catalytic oxidation equipped with charcoal bed, thermal catalytic oxidiser and post-sorbent bed. Photocatalysis is the process selected for trace gases removal in the SpaceHaven. This process is used from long time to abate contamination in terrestrial applications (submarines, gallery and closed environment) and appears very promising. Commercial devices are available on the market. The core of the demonstrator is the photocatalytic reactor where, thanks to a dedicated catalyst activated by ultraviolet (UV) light, the contaminants molecules are oxidised to simple and non toxic substances. The demonstrator will be equipped to flow the photocatalytic reactor with the entire set of trace gases experienced in the ISS to verify the capability to control the increase of each possible contaminant. The scope of the demonstration is to evaluate the performances and the life of the photocatalytic reactor. If the case, a study will to be performed to integrate the system with a complementary system (chemisorption, active charcoal, high

AA



temperature catalytic oxidation, low temperature catalytic oxidation) able to remove the contaminants on which the photocatalysis would not be efficient. Possibility to exploit the UV radiation available in the space environment from the sun will also be explored. The technology is not considered to be gravity sensitive and simply a ground demonstration will be required to proof the capability of the system to meet the required performances.

3.4.1.5 Foldable Tank (waste and potable water) The demonstrator is aimed to develop foldable tanks for waste and emergency storage of metabolic wastes, potable, hygiene technical and waste water, condensate, urine and brine from water and urine treatment. This kind of tank is proposed because of the minimum volume when unused and its reduced mass.

3.4.1.6 Temperature and Humidity Control System (THCS) The THCS tasks to be demonstrated with this ground demonstrator are as follows:

• Air distribution to Functional Area (FA) compartments • Ventilation in the FA compartments • Temperature control per FA compartment • Humidity control per FA compartment • Air distribution during empty IHAB phase • Ventilation in empty IHAB

In order to develop and demonstrate the capability to separately control temperature and humidity in numerous volumes the demonstrator will consist of an IHAB mock up which is limited to a section of the inner cylinder and 2 to 3 compartments similar to the FA compartments of the central IHAB section. The mock up provides IHAB interior volumes only which can be furnished for ventilation principle testing. It is assembled from commercial wooden or plastics materials and components. During the first phase of this programme the THCS ducting system and the diffusers for the very first tests will be of commercial hardware. For the final ventilation and temperature/humidity control tests flight representative components / hardware will replace the common components. These flight representative components will be e.g. the CHX, CFA, CWSA, Thermal Control Valve TCV/ Cabin Air Diffuser CAD and Cabin Temperature Control Unit CTCU which have to be designed and manufactured acc. to the IHAB needs. For testing of the early ventilation in the empty IHAB the mock up will be adjusted such that around the outer circumference of the central cylinder section which is not covered by FA compartments the entire volume is simulated with flexible plastic foils. Sensors will be installed for ventilation testing in the compartments, for pressure measurements in the ducting, for temperature measurements in the air, on surfaces and for air humidity measurements.

3.4.1.7 Combined Atmosphere Control Valve (CACV) In this demonstrator the pressure relief (depressurisation) and pressure control (positive and negative pressure relief) functions shall be concentrated in one valve or valve assembly. The aim of the development of such a Combined Atmosphere Control Valve (CACV) is to provide an optimised ratio between the concentrated functions, redundancies and the mass, volume and installation interface area. Details of the design, of the arrangement of functions, still have to be investigated.

3.4.1.8 Potable and Technical Water Production The analysis of the water needs shows that it is possible to save up to 60 tons of water in a 1 year SpaceHaven mission with 6 crewmembers, recycling water coming from condensate and from hygiene facilities. This justifies the

AA



development of a processor capable to regenerate water for the production of potable water, hygiene water (to be used in the hygiene facilities) and technical water (to be used as flush water in the toilet). A system based on a multi stage reverse osmosis process has been studied by ESA with Techno-Membrane. The system has been verified for a long duration test for potable water production and has been recently proposed for the Concordia station for hygiene water production. The core of the proposed demonstrator will be based on the reverse osmosis technology and will continue the development process already started to show the capability of the technology to meet the requested performances in terms of efficiency, flows, quality and microbial contamination. The system will probably be integrated with a mineralization unit to provide water within the needed organoleptic standards. The selected technology is not expected to be gravity sensitive.

3.4.1.9 Water Monitoring Any water stored or produced on board has to be monitored to allow a safe consumption from the crew. Currently a space qualified water monitoring device, the TOCA, has been developed in USA for usage on ISS. This device is quite unsatisfactory and is to be improved to enlarge the measurement range, the accuracy, the precision and to avoid the need of hazardous reagent usage. No European space qualified water monitoring devices are instead currently available. The demonstrator here proposed and identified as priority 1 by ESA is devoted to develop and verify the suitability of a European water monitoring device. At the moment the identification of significant parameters to be monitored to check the water quality and a possible the basic technology for water monitoring has not been performed. The system shall allow to the maximum possible extent the on line and continuous monitoring without the need of periodic water sampling.

3.4.1.10 Salad machine The salad machine is a rack dedicated to a limited food production on board the SpaceHaven. The salad machine proposed for SpaceHaven can be considered as an evolution of many related studies and experiments already performed in micro-gravity environments (see RD 9) and as a first European applicative experiment aimed to produce some food and oxygen to be provided to/exploited by the crew. The system can be optimized on the basis of the experimental results of the EMCS and can exploits hardware developed for EMCS or Biolab. The idea is to develop an autonomous system able to maintain the correct environmental conditions for the growth of lettuce with minimum request of resources from the system. No artificial gravitational field is provided. The salad machine will be equipped with: 1. A growth chamber of about 80 l (50 mm x 40 mm x 40 mm). This is much larger than that one provided by the

EMCS even if not large enough to have a meaningful impact on the system resources. Few kg of lettuce are planned to be produced in the salad machine in one year.

2. A system for lighting. 3. A system for the monitoring of the plant health and environmental conditions (video camera and temperature,

humidity and CO2 monitoring). 4. A system for the temperature and humidity control in the growth chamber. The system shall maintain a temperature

of about 26 °C and a humidity of 75%. 5. A system for the oxygen separation and venting to the cabin (the production will be less than 1 kg in one year). 6. A system for the collection of the plant water transpiration to be re-used for watering of the crop. About 500 kg of

water are planned to be managed by the system. 7. An ethylene removal system (less than 30 ml of ethylene produced in 1 year). The system will be based on sticks of

potassium permanganate (less than 5 g). This system is not available in the SVET experiment. 8. A tank with all the water needed by the plants and the relevant nutrients. The planned quantities are about 40 kg of

water and about 1.5 kg of nutrients.

AA



9. Carbon dioxide can be either provided from the SpaceHaven system (the CCA in the ARES) if feasible or provided by an internal tank (total CO2 need for a 1 year mission of an 80 l growth chamber is about 30 kg).

10. An internal processor to control and command the internal equipment and to exchange data with the external system. The salad machine will receive from the SpaceHaven system: 1. The heat removal capability, via a TCS coolant loop. 2. The monitoring of the trace gas in the growth chamber. It shall be based on the trace gas monitoring system

available in the SpaceHaven via a sampling line. 3. The power and the C&DH. In conclusion: 1. The EMCS is dedicated to collect data about the plant growth in different environment while the SpaceHaven salad

machine wants to exploit all the reached results to provide a system for a little food and oxygen production for the crew. So the SpaceHaven salad machine can be thought as a next generation system capable to provide resources for the crew.

2. The EMCS growth chambers are very small (each less than 0.6 l, total volume lower than 5 l) while the SpaceHaven salad machine will be provided with a 80 l growth chamber. This implies the capability to host a large variety of plants that in the EMCS can hardly or can not be hosted.

3. The SpaceHaven salad machine will not be able to generate a gravitational field on the plants. 4. The SpaceHaven salad machine will cause a minimum impact on the crew activities and will have positive

psychological effect on the crew.

3.4.1.11 Water Disinfection Stored water or purified water from potable water processor and from urine processor has to be added with a proper disinfectant to maintain its microbiological standards in accordance with the requirements. Two alternatives are currently in usage in the ISS: the addition of iodine or the addition of colloidal silver. A trade of the different technologies has shown as preferable the colloidal silver addition for the disinfection of the SpaceHaven water . The silver ionization ground unit is equipped with 4 silver bars of 1250 g wetted by the water flux where the silver is dissolved for electrolysis. The quantity of dissolved silver is regulated controlling the current on the silver electrode. This item is largely oversized even for the need of the most ambitious SpaceHaven mission. It shall therefore be resized to be adapted to the SpaceHaven needs and shall be converted to flight hardware. The technology is considered very critical for each long duration mission. It is not gravity sensitive. The ESA priority level associated to this technology is 2.

3.4.1.12 Atmosphere Control System (ACS) The Atmosphere Control System (ACS) concentrates on following tasks:

• Pressure Monitoring - Total Pressure - Partial Pressure (O2, CO2)

• Pressure Relief - Depressurisation

• Pressure Control - Positive Pressure Relief - Negative Pressure Relief

The monitoring is performed by pressure sensors, a total pressure sensor and sensors for the O2 and CO2 partial pressure. These sensors support the IHAB pressure control system. For the pressure relief which is initiated and controlled by the IHAB pressure control system the demonstrator is a relief valve. For pressure control autonomously acting valves control the IHAB pressure mechanically. The demonstrator consists of a Positive pressure Relief Valve and a Negative Pressure Relief Valve. Sensors and valves of this demonstrator are already existing valves from US suppliers.

AA



3.4.2 Ground Structural Demonstrators

3.4.2.1 Window Demonstrator Although not considered in relatively short missions like the one contemplated for the ASI FLECS (15 days) but apart from FLECS, any other Inflatable Habitat either attached to the ISS or performing an independent mission in LEO as a free flyer shall surely incorporate windows. As a matter of fact a windowing system becomes necessary in prolonged mission in LEO or LLO, in interplanetary transfer missions or permanent planetary bases as it is deemed to be necessary to provide psychologically help to the astronauts whenever they are going to be confined for long periods in a limited volume. The window demonstrator has to prove the load carrying capability of the shell with the window frame included and the leakage at the interface between the window frame and the redundant bladder as well as the leakage between the window frame and the window glass. This contributes to validate good design, workmanship and quality of the parts and the related assembly and sealing processes.

3.4.2.2 Structural Restraint Demonstrator The structural restraint is the part of the inflatable shell whose specific function is to assure safe pressure containment. Validation for this item can be achieved only via dedicated structural testing to really demonstrate its load carrying capability. The restraint layer demonstrator is so aimed to prove and validate the pressure capability up to burst level for the restraint layer and of the related interfaces to the bulkhead and to the window frame. The test on the demonstrator shall completely qualify the design and manufacturing processes involved in the restraint realisation.

3.4.2.3 Packaging and Deployment Demonstrator The packaging and deployment of the inflatable shell is one of the major issues in the inflatable structural shell. The 2 operations are strictly related to each other as an incorrect packaging can lead to an incorrect on orbit deployment and consequently to over-stressing or damaging of the materials (with particular reference to the redundant bladder thin layers). Both packaging and deployment are then affected by the presence of window/s so the demonstration has to include this element as well. The success of every mission is so fully related to these initial aspects of the mission (inflation and deployment) and adequate demonstration is therefore needed. The deployment is strongly dependant on the gravity environment so ground demonstration has to be performed in a thermal vacuum chamber using suspension cables to simulate the absence of gravity. The synergy between packaging and deployment is so based on the assumption of exploiting the same inflatable shell for both. The demonstrator for packaging is aimed to set up the folding procedure for the multilayer shell showing the repeatability of the process and the need for assembly jig and tooling. This demonstration is fundamental to show that the under fairing allocated volume of the selected launcher is able to accommodate the inflatable structure. The presence of window/s makes more complicated this demonstration. The demonstrator for deployment on ground is aimed to prove the correct working of all the mechanisms and functions involved in the unfolding of the inflatable shell. The correct deployment is the condition to have the final foreseen volume and the integrity of the structure. The demonstration will give evidence also of the pressure capability and leakage capability of the shell and the inspection after deployment will show any damaging in the shell layers. The structural shell for packaging & deployment shall be scaled in terms of height but maintain the full diameter as a precursor of the Spacehaven vehicle in order to have the same stress experiencing. The packaging/deployment demonstrator shall have all the layers of the final inflatable structure with the relevant thicknesses (including the MMOD and the MLI) and the restraining straps with pyrotechnic devices. The demo is to be seen in the perspective of ground qualification of the final Spacehaven vehicle: both ATV-supported and Flecs are not supposed to utilize ground qualification unit as they will perform overall technology validation on orbit.

3.4.2.4 Auxiliary Internal Structure (AUXIS) The AUXIS demonstrator consists of a number of objects and technological themes:

AA



• a structural test bed simulating the primary structure's interfaces, allowing the inclusion of floor modules and partitioning walls; also, of tertiary elements, as needed/opportune

• generic secondary-structures test article, including: • flooring members, mechanisms, and interfaces • partitioning walls • tailored secondary-structures test articles for crew private cabin, including partitioning walls • tailored secondary-structures test articles for TBD • generic tertiary-structures test article, including: • storage volumes • generic secondary-structures test article may serve as interface (TBC). In addition to mechanical measurement (e.g. deformation, vibration behaviour), important test objectives include the experimental validation of deployment and connection methods and devices – between secondary and primary structure, between walls and floor, and between tertiary and secondary structures. The demonstration activities will also support the definition of maintenance, repair, and disposal procedures. The proposed AUXIS demonstrator consists on the following main subsystems: • Dummy AUXIS device,

consisting on a mock-up of the lower SpaceHaven core cylinder, a mock-up of the central volume and a curtain simulating the SpaceHaven outer wall

• AUXIS segments first floor, reflection the auxiliary structure segments of the first floor of the SpaceHaven and consists on a fixed structure with the beams and the floor and a movable structure with panels, walls and some flooring elements

AUXIS demonstrators are complete of dedicated MGSE consisting on the required infrastructure to support the tests and, if required, a suspension device for gravity compensation. The proposed AUXIS demonstrator includes a number of stand alone, ground based units, to be tested under ground laboratory conditions.

3.5 GSE

3.5.1 MGSE At this stage of the IHAB phase B study development, the following MGSE have been identified: Windows Demonstrator MGSE For operational and obviously for safety reasons, it is critical to verify by test the design and manufacturing of the window frame to the redundant bladder / structural restraint interfaces. These tests have 2 main goals : To verify the tightness of the sealed interface between the redundant bladder and the window frame To verify the structural integrity and mechanical characteristics of the interface between the structural restraint layer

and the window frame In order to be representative of the real design and in reason of the limited size of the window, the test will be completed on a scale 1:1 model. This model should be MAI identically to the flight model. Tightness Test This test does not require any specific MGSE. It is completed with a sealed bag and a He leak detector. Proof Load Test This mechanical test aims to be representative of the loads the model will encounter in operation. For this, longitudinal and hoop load fluxes should be applied on the model to demonstrate the load capability of the shell. This can be obtained with a simple steel frame acting as a support for hydraulic screwjacks driven and controlled by computer. Load cells should be put in between the screw jacks and the frame to record the level of loads introduced all over the test Another supporting frame separated from the first one should be foreseen to support the displacement recording devices, this to get free of the unavoidable effect of the screwjacks onto their supporting frame whatever its eigen stiffness.

AA



Inflatable Restraint Shell Qualification Demonstrator MGSE The qualification of the inflatable restraint shell is foreseen to be conducted in a pool filled with water to reduce the inherent risk of explosion related to any inflation. In that case, the water will act as a pressure transmission vector without the risk of explosion, the water being considered incompressible. The MGSE required to conduct this test is a steel frame to be bolted at the bottom of the pool. This frame, preferably in stainless steel should be a cross beam design for stiffness reasons and provides 2 steel bulkheads, the FWD and the AFT, featuring the real designed interface foreseen for the full scale shell at its upper side. The top of the frame should accommodate the interface to the pumping system necessary to fill up the shell as well as tight feedthroughs for signal lines. Packaging/Deployment Demonstrator MGSE The unfolding of the shell is considered as a critical phase of the inflatable structure system. This unfolding (deployment) is depending of the material used, of the external conditions and of the way the shell was packed. The test should be representative in term of environmental conditions. This requires in particular to simulate the vacuum and temperature constraints the system will encounter in operation and also the 0-g gravity conditions. The MGSE necessary for this test are the following : A stand to support the system A 0-g simulator gantry

Both MGSE should be compatible with use inside a thermal vacuum chamber. This means that they will be preferably in stainless steel or in aluminium but without protective coating that may pollute the chamber and do not feature any closed areas, greased parts and polymeric equipments. The stand will be a simple support allowing the positioning of the inflatable structure system horizontally. The 0-g gantry will be similar to those usually used for the simulation of the non gravity for solar panels deployment tests. It is composed of an aluminium truss gantry in a reversed L –shape configuration. The horizontal part is fitted with rails and roller. Each of the rollers are supporting a suspender which is basically composed of a very thin cable with a compensating spring.

3.5.2 FGSE and EGSE At this stage of the IHAB phase study development 8 FGSE and 8 EGSE have been also identified: Flight demo FGSE: use for integration and testing of the IHAB flight demonstrator Toilet FGSE: use for integration and testing of the IHAB Toilet flight demonstrator ARES/MPA FGSE: use for integration and testing of the IHAB ARES/MPA flight demonstrators Shower FGSE: use for integration and testing of the IHAB Shower flight demonstrator

Windows FGSE: use for integration and testing of the IHAB Windows ground demonstrator Structural FGSE: use for integration and testing of the IHAB Structural Restraint ground demonstrator Packaging/Deployment FGSE: use for integration and testing of the IHAB Packaging and Deployment ground

demonstrator AOD FGSE: use for integration and testing of the IHAB Advanced life support Overall ground Demonstrator

Flight demo EGSE: use for integration and testing of the IHAB flight demonstrator Toilet EGSE: use for integration and testing of the IHAB Toilet flight demonstrator ARES/MPA EGSE: use for integration and testing of the IHAB ARES/MPA flight demonstrators Shower EGSE: use for integration and testing of the IHAB Shower flight demonstrator Medical EGSE: use for integration and testing of the IHAB Medical flight demonstrator Launch Preparation EGSE (LP-EGSE): use for the launch preparation activities (this GSE is made with the

equipments developed for the AIV campaign: no specific development and equipments forseen). Packaging/Deployment EGSE: use for integration and testing of the IHAB Packaging and Deployment ground

demonstrator AOD FGSE: use for integration and testing of the IHAB Advanced life support Overall ground Demonstrator.

ISSUE : 01 DATE : September 2005emits.sso.esa.int/emits-doc/ESTEC/AO6100_RD14_IHAB... · Alcatel...

Documents

Transcript of ISSUE : 01 DATE : September 2005emits.sso.esa.int/emits-doc/ESTEC/AO6100_RD14_IHAB... · Alcatel...