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Overview of ILC Dover Habitat Programs and Technology Overview of ILC Dover Habitat Programs and Technology FISO Colloquium July, 2010 Phil Spampinato [email protected] W 302-335-3911 x350 C 302-382-2979 ILC Dover Proprietary Information 1 s1 ILC Dover Company Overview ILC Dover Secret Level Facility Clearance Employee Function Registration to ISO 9001:2008 Facilities Engineering 25% NHB-5300.4(1D-2), MIL-Q- Lab, Development, Manufacturing 44% 9858A, and MIL-I-45208A quality Production, Admin Quality 10% and inspection systems 340,000 sq ft AS 9100 Compliant Total Employees ~460 NASA’s George M. Low Award (High Bay Manufacturing for Quality and Excellence, 1998 223,000 sq ft ) (40 at NASA JSC - Houston) ILC Dover Proprietary Information 2 ILC Dover Overview Design & Manufacturing Experience since 1947 Space Lighter-Than-Air Engineered Protective Equipment Industrial Inflatables We leverage our competencies in materials, softgoods design and manufacturing to create highly safe & reliable products that protect people & equipment in hostile environments ILC Dover Proprietary Information 3 Habitat Overview Space Habitats Space Suits Polar Habitats Leveraging our design, materials & manufacturing experience between terrestrial & space habitats SBX Radome NBC Shelters (TCPS/M28) Biological Isolation ILC Dover Proprietary Information 4 Single Occupant Habitats Extravehicular Mobility Unit ILC has leveraged decades of flight heritage in designing, qualifying and manufacturing hundreds of space suits to create robust, safe and reliable inflatable space habitats. Extravehicular Mobility Apollo A7LB and I-Suit Unit Collapsible Hyperbaric Chamber easily transportable lightweight Bends treatment device - 26.5 psi - webbing-restraint and bladder construction - integrated hatch and window - human-rated to NFPA-99 Class B Chamber & ANSI/ASME PVHO-1 Safety Std for Pressure Vessels for Human Occupancy. Collapsible Hyperbaric Chamber ILC Dover Proprietary Information 5 Lawrence Livermore Space Station 1989 inflatable space station design studies low-cost space station and lunar base Livermore concept sketch of LEO space station Inflatable structures selected due to packing efficiency and ability to get large volume structures on existing launch vehicles series of grouped pressurized compartments; modules that could subsequently be joined in space ILC webbing based inflatable Livermore concept sketch of lunar element design base modules enclosed in a secondary containment shell Secondary Pressure Pressurized MMOD/Thermal Shield Central Corridor with Containment Wall Compartment bulkhead doors and covered with an MLI/MMOD blanket Individual compartments 5m diameter by 3.5m length, connected by a 1m central corridor Operational pressure 7.5psi, factor of safety of 4 ILC performed configuration analysis, systems design, material & component design, and structural analysis ILC design layout of inflatable elements ILC Dover Proprietary Information 6 Expandable Lunar Habitat 1996 E xpandable Lunar Habitat Study Goal: lightweight structure that could pack into small volume for launch and provide the necessary living space for extended durations (6 days for 2 crew) on the lunar surface system was designed to land and deploy NASA JSC concept sketch of the Lunar Lander autonomously prior to arrival of the crew habitat consisted of rigid end caps that would contain all the logistical supplies and fixed assets, and a 7.5 ft diameter by 12 ft long expandable / inflatable center section ILC structural design concept examples for the operational pressure 8 psi, with a factor of safety softgoods (webbing restraint & internal cables) of 4 ILC performed configuration analysis, systems design, material & component design, and structural analysis of the lunar habitat softgoods and flooring ILC proposed softgoods design concept ILC Dover Proprietary Information 7 Transhab Transhab study of large scale inflatable structures that could be used for deployable habitation for human exploration of space ILC Dover and NASA signed a Space Act Agreement Renderings of Transhab floor plan and on where ILC participated as technical advisor and component Space Station manufacturer on the Integrated Product Team The full-scale structure was a 27 ft diameter cylinder with toroidal ends and a rigid internal core structure that provided facilities for mounting gear and systems. Operational pressure was 14.7 psi, factor of safety of 4 Short section in hydrostatic test Short section vacuum chamber test Transhab bladder, and Thermal/MMOD cover in vacuum chamber test ILC Dover Proprietary Information 8 Intelligent Flexible Materials (InFlex) Signal Transfer System (Data, Sensing & Power Management) Distributed Sensor System for Structural Health Monitoring Self Healing Bladder Materials Exploration Applications Anti-Microbial Materials Enhanced Radiation Protective Materials Materials development to enhance habitat performance Localized Power Generation & Storage Low Permeation Materials ILC Dover Proprietary Information 9 InFlex Lunar Habitat Intelligent Flexible Materials for Deployable Space Structures Program Lunar Habitat design, analysis and construction of a vertically Hatch sizing studies at ILC oriented cylindrical structure with hemispherical endcaps for application to a lunar lander or surface rover deployable airlock was also constructed and included pressure equalization systems. sized for 9 psid operation (FS=4), but was only tested at 1psid Space suit interface Test with airlock included windows and a collapsible floor for compact packaging. Human and space suit interface studies were conducted at ILC and NASA LaRC, including deployment, packaging, hardware interface, lighting & electrical interfaces, acoustics, and outfitting. Outfitting studies at LaRC System deployed at NASA LaRC ILC Dover Proprietary Information 10 Antarctic Habitat Planetary Analog Antarctic Habitat ILC Dover, NASA, NSF Office of Polar Programs study of inflatable deployable structures inflatable habitation technologies tested in the harsh analog environment of Antarctica for one year. Inflatable Habitat at McMurdo Station Antarctica 24 ft by 16 ft inflatable structure with an insulation package, external airlock, self-contained inflation system and distributed power & lighting systems. A suite of sensors was embedded in the walls of the inflatable and insulation package, as well as inside the habitat, to provide real-time structural health monitoring and internal/external environment monitoring. External wall mounted pouches were used to study in-situ radiation Outfitted at McMurdo Shown without liner at ILC shielding options. The system performed well over its year in Antarctica while it witnessed winds exceeding 80mph, temperatures dipping to -50F, and user traffic. It was deployed at ILC after its polar trip to continue long-term deployment monitoring. Hab at McMurdo in Winter ILC designed,• analyzed and manufactured the system, including the inflation & power distribution sub-systems. Regolith radiation Airlock Entry at McMurdo shielding bag test ILC Dover Proprietary Information 11 X-Hab Lunar Habitat X-Hab Mid-structure expandable space habitat 1m packed expandable section becomes 5m deployed length End caps act as logistics storage for flight. Structure sized for 9 psi operation (FS=4) and made from Vectran Bladder manufactured from a specialized coated fabric for containment of the inflation gas (structural) A non- collapsible, lightweight floor was delivered with the unit Deployment testing at NASA LaRC CAD model of X-Hab Structural evaluation at ILC ILC Dover Proprietary Information 12 Minimum Function Habitat Design study by ILC and subcontractors Hamilton Sundstrand and SICSA a ‘bare bones’ habitat element that incorporates the benefits of flexible materials. Included configuration analysis, systems design, material & component design, and structural analysis of habitat, inflatable airlock, and deployable radiator Sleeping Configuration Multifunctional outfitting schemes were developed for several operational concepts in an effort to minimize system mass, including launch & logistics. System designed to support a crew of 4 for 16 days, have >5m 3 deployed volume per crewmember, provide protection from radiation, Radiation Storm 3.0 m Diameter x 4.5 m Long and support EVA sorties Shelter MFH Concept Reconfigurable internal assemblies allowed the same volume to be used for science activities, recreation, sleeping, and as a safe haven NASA Reference MFH with inflatable side Configuration pod option 4.5 m Diameter x 4.5 m Long MFH Concept ILC Dover Proprietary Information 13 Deployable Thermal Control Inflatable Thermal Chimney Inflatable Thermal Chimney Flexible deployable radiator High conductive flexible heat pipe High conductive flexible fin Use of carbon and carbon nanotube Flexible heat sink (Think 3D) • Efficient thermal management • Simple fan and valves • Deployable heat pipe device lighter and simpler than traditional liquid cooling system Innovative Deployable Thermal Control Simplifies System and Reduces Mass ILC Dover Proprietary Information 14 Flexible Thermal Radiator Development • Radiator panel mass goal around 2 ~ 3 kg/m 2 • Thermal conductivity ranging from 200 to 800 W/m-K • Greater than 99% reliability • Operational life around 10 years • Conduct thermal vacuum chamber test • Generate analytical model and perform data correlation • Make it flexible and deployable to increase and enhance mission possibilities • Better efficiency enables more mission capabilities Design and fabricate a flexible radiator panel using
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