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Space Suit Development for Orion

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Space Suit Development for Orion 48th International Conference on Environmental Systems ICES-2018-199 8-12 July 2018, Albuquerque, New Mexico Space Suit Development for Orion Shane E. Jacobs1 and Donald B. Tufts2 David Clark Company Incorporated, Worcester, MA, 01604 Dustin M. Gohmert3 Johnson Space Center, Houston, TX, 77058 This paper describes the recent design and development of a launch/entry and contingency space suit for NASA’s Orion spacecraft. The suit is designed to be worn during launch, ascent, and entry, to protect crewmembers from a variety of hazards and contingencies, most notably cabin depressurization. The paper details design efforts to improve shoulder and elbow mobility. Additionally, structural design activities are presented- including multiple rounds of analysis and testing – to ensure significant margins of safety when the suit is pressurized to 8 psid. Two new suits with the latest design features were built and human-tested in multiple vacuum chamber tests, which are described. Nomenclature ACES = Advanced Crew Escape Suit CCA = Communications Carrier Assembly DCCI = David Clark Company Incorporated DSC = Dual Suit Controller ECLSS = Environmental Control and Life Support System EVA = Extravehicular Activity LCG = Liquid Cooling Garment OCSS = Orion Crew Survival System ppCO2 = partial pressure of carbon dioxide psia = pounds per square inch absolute psid = pounds per square inch differential sccm = standard cubic centimeters per minute VPIST2 = Vacuum Pressure Integrated Suit Test 2 I. Introduction HE Orion spacecraft is NASA’s next generation exploration spacecraft. It is designed to transport astronauts to T lunar orbit and other destinations beyond Low Earth Orbit. It will nominally carry four crewmembers, transporting them through launch, ascent, travel through deep space, and reentry back to Earth, with a design mission length of 21 days or greater. Due to the unique requirements of this vehicle and mission, a new launch/entry and contingency space suit was required for Orion. The suit is required to not only protect the crew in the event of short term cabin depressurization emergencies during dynamic phases of flight (launch and landing), but also for deep space contingencies that would require the crew to seek safe haven in the suit during transit back to Earth. This key requirement – long duration survival – is the primary design driver that significantly differentiates this suit from conventional launch/entry suits, or short duration Extravehicular Activity (EVA) suits. David Clark Company Incorporated and NASA have worked together to design and develop this new space suit, part of the Orion Crew Survival System (OCSS). The new suit is termed the S1041 OCSS Suit. The S1041 OCSS Suit evolved from the S1035 [1] Advanced Crew Escape Suit (ACES) worn during the second half of the space shuttle program. While many features of the S1035 ACES have been preserved, most have been 1 Softgoods Design Manager, Research and Development, 360 Franklin St. Worcester, MA 01604 2 Program Manager, Research and Development, 360 Franklin St. Worcester, MA 01604 3 OCSS Program Manager, Johnson Space Center, 2101 NASA Parkway, Houston, TX 77058 Copyright © 2018 David Clark Company, Incorporated redesigned due to new requirements driven by Orion’s operational concepts. For example, the suit is designed to function at an operational manned pressure of 8 psid (the S1035 ACES was designed to an operational requirement of 3.5 psid), and works within Orion’s closed loop, continuous flow Environmental Control and Life Support System (ECLSS) architecture (whereas the S1035 ACES was open loop, demand based). The S1041 OCSS Suit ensemble consists of the coverall, helmet, gloves, footwear and a variety of ancillary equipment. This paper focuses on the coverall. Ongoing design efforts for gloves, helmet, footwear and many other subsystems will be presented in future papers. A new neck seal and gas inlet assembly have been designed, which ensure efficient CO2 washout and allows crewmembers to close the neck seal for contingency water egress operations upon landing. Higher mobility elbows and shoulders have been incorporated to provide crewmembers with much improved two-handed work envelope mobility. Structural analysis and testing have driven new designs and materials in much of the restraint layer. In the following sections, the key driving requirements are outlined, which drove suit architecture and critical design trades. The core architecture is outlined, and the details of each design element are discussed. The design work led up to a series of vacuum chamber tests, which are discussed. Finally, future work and plans are outlined as development activities continue towards the pursuit of the first manned test flight of Orion. II. Suit Requirements The requirements for the OCSS Suit consist of those specific to the Orion vehicle and operations, and those generic to launch and entry suits and spaceflight hardware for maintaining a minimum survivability and crew safety capability. In general, all requirements are either directly from NASA or derived collaboratively by NASA and DCCI. The Orion vehicle-specific requirements are being developed in tandem with those for complementary subsystems. This allows for subject matter experts to negotiate and effectively allocate the physical and functional requirements to best support cross-subsystem integration and mission concept of operations. The key driving requirements are paraphrased and listed in Table 1 below. It should be noted that many of the suit requirements continue to evolve as complementary subsystems mature. Therefore many of these are better categorized as design goals rather than strict requirements. Table 1. Suit Driving Requirements/Design Goals Number Requirement Description 1 Suit Pressure The Suit shall operate at 4.3 psia/psid for long duration contingency operations, and at 8 psia/psid for shorter durations 2 Suit ppCO2 Level The suit must maintain the inhaled partial pressure of carbon dioxide in the oral nasal region at or below acceptable limits. 3 Pressure Drop The suit shall have minimal pressure drop to the extent possible. 4 Unassisted Suit The Suit shall be donnable and doffable by an unassisted crew member. Donning/Doffing 5 Anthropometric The Suit shall accommodate the full anthropometric range from the 1st Dimensions and percentile female to the 99th percentile male. Sizing 6 Long-duration The suit shall operate pressurized at 4.3 psia, in a vacuum, for a period of 144 Pressurized hours Operations 7 Mobility The Suit shall provide significant pressurized mobility in the two-handed work envelope at 4.3 psid 8 Pressurized The Suit shall comply with the applicable performance requirements during and Environment after exposure to oxygen environments of 30% and 100% 9 Minimum The Suit hardware shall be operable by all crewmembers Operational Loads 10 Crew Extraction The Suit shall provide handles, an internal harness, and other crew extraction aids/features To fully understand the genesis of the long-duration pressurized requirement noted above, it is important to understand Orion’s contingency depressurized cabin operations concepts. Orion’s mission profile places it at certain mission points of limited return – up to 144 hours away from Earth. Orion nominally operates at 14.7 psia with a 2 International Conference on Environmental Systems normal 80/20 mix of nitrogen and oxygen, respectively. In the event of a cabin depressurization, the Orion capsule is capable of feeding a 0.25-in. hole for 1 hour while maintaining a minimum 8.0 psia cabin pressure. During this 1- hour interim period, the crew would don the OCSS suit ensemble with all ancillary gear required for long duration survival. To minimize risk of decompression sickness, the OCSS suit will be initially held at 8.0 psia for a period of approximately 9 hours. This allows sufficient time for the suit loop to enrich to greater than 95% oxygen within the first hour and for denitrogenation of the crew during the remaining time. Upon completion of this denitrogenation period, the crew will reduce the suit operational pressure to 4.3 psia. This protocol leverages thousands of hours of historical performance data gathered by NASA in the Extravehicular Mobility Unit to ensure crew safety through minimizing adverse physiological reactions. The crew would remain at 4.3 psia for the duration of the depressurization event until return home. While mobility requirements would be minimal during the initial 8.0 psia denitrogenation phase, the crew will be required to eat, drink, sleep, and generally live within the suits at 4.3 psia for the balance of the 6 day duration. III. Design Overview After a comprehensive review of the requirements and concept of operations, and based on lessons learned from years of suit design, development, test and evaluation activities [2-5], the baseline suit architecture was established. The primary focus of the design effort for the coverall was to preserve unpressurized comfort, mobility and crew survivability, while meeting the challenges associate to 8 psia/psid (assuming the cabin has been completely evacuated to vacuum, the absolute pressure inside the suit of 8 psia will yield an equivalent differential pressure of 8 psid. Both are important, as the differential pressure drives the structural loading of the suit, while the absolute pressure drives mass flow requirements, communications, etc.) and 144 hour contingency requirements. These two goals required delicate balance, as typically efforts to
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