MARTIAN HABITAT DESIGN

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1 MARTIAN HABITAT DESIGN MARS OR BUST, INC. UNIVERSITY OF COLORADO, BOULDER AEROSPACE ENGINEERING SCIENCES ASEN 4158/5158 MOB DECEMBER 17, 2003

2 TABLE OF CONTENTS 1 MISSION SUMMARY CONTEXT OF THIS DESIGN EXERCISE SUMMARY OF MISSION CHARACTERISTICS KEY ASSUMPTIONS TOP LEVEL REQUIREMENTS SYSTEMS ENGINEERING AND INTEGRATION SUBSYSTEM OVERVIEW KEY ASSUMPTIONS DESIGN PHILOSOPHY DESIGN OVERVIEW MARS ENVIRONMENT AND IN-SITU RESOURCE UTILIZATION MARS ENVIRONMENT OVERVIEW MARS ENVIRONMENT PARAMETERS FUTURE CONSIDERATIONS IN-SITU RESOURCE UTILIZATION LEVEL 2 REQUIREMENTS INTERFACE DESIGN OPERATIONS SUMMARY OF ISPP PLANT DESIGNS AND PROCESSES BENEFITS OF ISRU FOR FUTURE MISSIONS ADDITIONAL MARTIAN RESOURCES WATER AND SOIL VERIFICATION OF REQUIREMENTS FUTURE CONSIDERATIONS STRUCTURES SUBSYSTEM OVERVIEW LEVEL 2 REQUIREMENTS INPUT/OUTPUT DIAGRAM DESIGN AND ASSUMPTIONS VERIFICATION OF REQUIREMENTS ELECTRICAL POWER DISTRIBUTION AND ALLOCATION SUBSYSTEM OVERVIEW DESIGN AND ASSUMPTIONS VERIFICATION OF REQUIREMENTS FUTURE CONSIDERATIONS: ENVIRONMENTAL CONTROL AND LIFE SUPPORT SUBSYSTEM OVERVIEW REQUIREMENTS ATMOSPHERE SUBSYSTEM WATER SUBSYSTEM WASTE SUBSYSTEM FOOD SUBSYSTEM INTEGRATED SYSTEM CONCLUSION THERMAL CONTROL SUBSYSTEM REQUIREMENTS OVERVIEW OF DESIGN PROCESS Page 2 of 264

3 8.3 THERMAL SUBSYSTEM DESIGN VERIFICATION OF REQUIREMENTS FAILURE MODES EFFECTS ANALYSIS FUTURE CONSIDERATIONS CREW ACCOMMODATIONS CREW ACCOMMODATIONS OVERVIEW CREW ACCOMMODATIONS DESIGN AND ASSUMPTIONS CREW ACCOMMODATIONS VERIFICATION OF REQUIREMENTS CREW ACCOMMODATIONS FAILURE MODES AND EFFECTS ANALYSIS CREW ACCOMMODATIONS CONCLUSIONS COMMAND, CONTROL, AND COMMUNICATION SUBSYSTEM OVERVIEW DESIGN AND ASSUMPTIONS VERIFICATION OF REQUIREMENTS ROBOTICS AND AUTOMATION SYSTEMS AND INTERFACES OVERVIEW DESIGN AND ASSUMPTIONS VERIFICATION OF REQUIREMENTS EXTRAVEHICULAR ACTIVITY INTERFACES SUBSYSTEM OVERVIEW DESIGN AND ASSUMPTIONS REQUIREMENTS VERIFICATION MISSION OPERATIONS MISSION OPERATIONS OVERVIEW MISSION OPERATIONS DESIGN AND ASSUMPTIONS MISSION OPERATIONS VERIFICATION OF REQUIREMENTS MISSION OPERATIONS FAILURE MODES AND EFFECTS ANALYSIS MISSION OPERATIONS CONCLUSIONS MANAGEMENT PLAN OVERVIEW SCHEDULE CONCLUSIONS DESIGN SUMMARY KEY DESIGN DRIVERS KEY CHALLENGES APPENDIX A: REVIEW OF MARS EXPLORATION PAST, PRESENT, AND FUTURE MARS 1960 A/B, USSR (TIM LLOYD) MARS 1, USSR (TIM LLOYD) SPUTNIK 24, USSR (KEAGAN ROWLEY) ZOND 2/3, USSR (TIM LLOYD) MARS 1969 A/B, USSR (JEN UCHIDA) COSMOS 419, USSR (KEAGAN ROWLEY) MARS 2/3, USSR (MERIDEE SILBAUGH) MARS 4, 5, 6, 7, USSR (MERIDEE SILBAUGH) THE VIKING PROJECT, USA (HEATHER CHLUDA) PHOBOS 1/2, USSR (TIM LLOYD) MARS OBSERVER, USA (ERIC SCHLEICHER) Page 3 of 264

4 16.12 MARS 96, RUSSIA (KEAGAN ROWLEY) MARS GLOBAL SURVEYOR, USA (ERIC SCHLEICHER) MARS CLIMATE ORBITER, USA (NANCY KUNGSAKAWIN) MARS POLAR LANDER, USA (TERESA ELLIS) MARS ODYSSEY, USA (NANCY KUNGSAKAWIN) NOZOMI, JAPAN (JEN UCHIDA) MARS EXPRESS, ESA (TERESA ELLIS) MARS EXPLORATION ROVERS, USA (DAX MATTHEWS) MARS RECONNAISSANCE ORBITER, USA (MERIDEE SILBAUGH) REVIEW OF MARS DIRECT: A PROPOSAL BY ROBERT ZUBRIN (TYMAN STEPHENS) HUMAN EXPLORATION OF MARS: THE REFERENCE MISSION OF THE NASA MARS EXPLORATION STUDY TEAM (KEITH MORRIS) MARS EXCURSION MODULE, ESA AURORA STUDENT DESIGN PROJECT (JUNIPER JAIRALA) NASA AIM (CHRISTIE SAUERS) THE MARS SOCIETY (CHRISTIE SAUERS) FLASHLINE MARS ARCTIC RESEARCH STATION (JEFF FEHRING) APPENDIX B: ACRONYMS APPENDIX C: MARS ENVIRONMENT INFORMATION SHEET GRAVITY ORBITAL CHARACTERISTICS ATMOSPHERE TEMPERATURE SOLAR FLUX RADIATION WIND SOIL PROPERTIES MARS FACT SHEET APPENDIX D: REFERENCES APPENDIX D: ACKNOWLEDGEMENTS TABLE OF FIGURES Figure 2.1: Subsystem Archetecture Figure 2.2: Input/Output Diagram Figure 2.3: General Layout of Habitat Figure 3.1: Atmospheric Pressure at Surface of Mars Figure 3.2: Atmospheric Pressure at the Surface of Mars, continued Figure 3.3: Diurnal Temperature Variation Figure 3.4: Diurnal Temperature Variation over Sol Figure 4.1: Input / Output Diagram Figure 4.2: ISRU Functional Subsystem Schematic Figure 4.3: Zirconia Electrolysis Figure 4.4: Sabatier Electrolysis Figure 4.5: Reverse Water Gas Shift to produce Oxygen Figure 4.6: Reverse Water-gas Shift and an Ethylene Reactor Figure 5.1: Input/Output Diagram for Structures subsystem Figure 5.2: Upper floor plan Figure 5.3: Bottom floor plan Figure 5.4: Habitat view from the bottom showing the position of the leg supports Page 4 of 264

5 Figure 5.5: Simple force diagram of the habitat Figure 6.1: Input/Output Diagram Figure 6.2: General Functional Diagram Figure 6.3: Life/Mission Critical Figure 6.4: ECLSS Figure 6.5: C Figure 6.6: Failure Tree Figure 7.1: Subsystem Interactions Figure 7.2: Baseline non-regenerable physical/chemical air ECLSS schematic Figure 7.3: Physical/Chemical Air Life Support System Schematic Option A Figure 7.4: Physical/Chemical Air Life Support System Schematic Option B Figure 7.5: Open Loop Diagram w/flow Rates in kg/day for 6 crewmembers Figure 7.6: Closed Loop Water Management Flow Diagram Figure 7.7: Electronic Nose Equipment Figure 7.8: Ion Specific Electrode Figure 7.9: Total Organic Carbon - Conductivity Diagram Figure 7.10: Actual Total Organic Carbon Device Figure 7.11: Sample of Conductivity Device Figure 7.12: Sample Test Kits Figure 7.13: Order of Monitoring Devices Figure 7.14: Schematic of the Waste Management Subsystem Figure 7.15: Food System Schematic Figure 7.16: ECLSS Integrated Design Figure 7.17: Interfaces between ECLSS and other subsystems Figure 8.1: Input/Output Diagram Figure 8.2: Thermal System Schematic Figure 8.3: A radiator used aboard the ISS Figure 8.4: FMEA Breakdown Figure 9.1: Crew Accommodations Active Equipment Interfaces Figure 10.1: C 3 Subsystem Input Output Diagram Figure 10.2: Command and Control Architecture Figure 11.1: Input/output diagram for Robotics and Automation Figure 11.2: Mars Exploration Rover Figure 11.3: Conceptual Local Unpressurized Rover Figure 11.4: Conceptual Mechanical Arm for the LPR Figure 13.1: Overview MOB Mission Timeline for Mars Stay Figure 13.2: Representative crew timeline for a typical month on Mars during the MOB Mission Figure 13.3: Representative crew timeline for the majority of days on Mars during MOB mission Figure 13.4: Representative crew timeline for days when an EVA is performed Figure 13.5: Representative crew timelines for proficiency training days that occur monthly Figure 14.1: Mars or Bust Schedule Figure 16.1: Mars 1969 A/B Orbital Details Figure 16.2: Aerobraking Map of the Orbiter Page 5 of 264

6 Figure 16.3: Representative Art on Orbiter's Aerobraking Period Figure 16.4: Nozomi Mission Sequence Figure 16.5: Conceptual Drawing of an Operational Rover Figure 16.6: Mars Direct Mission Schedule Figure 16.7: The MTV, the Earth-Mars transit vehicle outlined by Mark Ford (1996); the MEM is on the far right Figure 16.8: Habitat presentation Figure 16.9: Artists concept of the operational Advance Integration Matrix (AIM) facility at NASA, Johnson Space Center Figure 16.10:An aerial photo of the Mars Society Flashline Mars Arctic Research Station (FMARS), located in the Canadian Arctic on Devon Island Figure 16.11: The Mars Desert Research Station (MDRS) located in Hanksville, UT TABLE OF TABLES Table 1.1: Top-Level Habitat Requirements from DRM Table 3.1: Mars Environment Parameters Table 3.2: Atmospheric Composition Table 3.3: Landing sites of Viking 1 and 2 landers and Pathfinder landers Table 3.4: Mars Environment Seasonal Parameters Table 4.1: Level 2 Requirements Table 4.2: Mass, Power, Volume Breakdown Table 4.3: Properties and flow rates of consumables Table 4.4: ISPP Trade Study Table 4.5: Verification of Requirements Table 5.1: Level 2 Requirements Table 5.2: Volume allocation and designed volume of subsystems Table 5.3: Key physical properties of aluminum Table 5.4: Launch and landing load factors Table 5.5: Failure Mode Effects Analysis Table 5.6: Mass and Volume Estimates of Structures Components Table 5.7: Requirements Verification Table 6.1: Level 2 Requirements Table 6.2: Power Profile Table 6.3:Electrical Cabling Mass and Thermal Breakdown Table 6.4: Power System Masses and Volumes Table 6.5: Mass/Volume Breakdown Table 6.6: Requirements Verification Table 7.1: Baseline Non-regenerable Physical/Chemical Air Life Support System Table 7.2: Air Management Life Support Technology Rankings Table 7.3: Physical/Chemical Air Life Support System for Mars Mission Option A Table 7.4: Physical/Chemical Air Life Support System for Mars Mission Option B Table 7.5: Heat, Power, and Volume for ECLSS atmosphere technologies Table 7.6: Water Quality Requirement: Maximum Contaminant Levels Table 7.7: Water Management Parameters Table 7.8: Hygiene & Potable Water Treatment Candidate Technologies Table 7.9: Urine Treatment Candidate Technologies Page 6 of 264

7 Table 7.10: List of Technologies & Associated TRLs Table 7.11: Water Sample Requirement for Off-Line Monitoring (Initial On-Orbit Operations) Table 7.12: Water Sample Requirement for Off-Line Monitoring (Mature Operations). 77 Table 7.13: Heat, Power, and Volume for ECLSS Water Technologies Table 7.14: Waste Product Breakdown for a 6-Person Crew Table 7.15: Heat, Power, and Volume for ECLSS Waste Technologies Table 7.16: Food Technology Specifications Table 7.17: Heat, Power, and Volume for ECLSS Food Technologies Table 7.18: ECLSS Total Mass, Power, and Volume Estimates Table 7.19: Total Mass and Volume Values for Consumables Table 7.20: Water Requirements Table 7.21: Verification of Requirements Table 8.1: Level 2 Requirements Table 8.2: Heat Loads from Subsystems Table 8.3: Thermal System Mass, Power, and Volume Table 8.4: Requirement Verification Summary Table 9.1: Crew Accommodations Top Level Requirements Table 9.2: Crew Accommodations Level 2 Requirements Table 9.3: Crew Accommodations Subsystem Equipment List Table 9.4: Non-Active Crew Accommodations Equipment Table 9.5: Clothing Trade Study Table 9.6: Crew Accommodations Requirements Verification Table 10.1: C 3 Level 2 Requirements Table 10.2: Command and Control Power Table 10.3: Command and Control Mass and Volume Table 10.4: Command and Control Failure Modes Effects Analysis Table 10.5: ECLSS and Power Data for Transmission to Earth Table 10.6: Thermal, Structures, ISRU and Mission Ops Data for Transmission to Earth Table 10.7: Earth-Mars Link Budget Table 10.8: Mars Habitat Link Summary Table 10.9: C 3 Requirements Verification Table 11.1: Automation & Robotics Level 2 Requirements Table 13.1: Mission Operations Requirements Table 13.2: Subsystem Operations List Table 13.3: Mission Operations Requirement Verification Table 14.1: MOB Organizational Chart Table 15.1: Mass Breakdown Table 15.2: Aurora Mass Breakdown Table 16.1: Consumable Requirements for Mars Direct Mission with Crew of Four Table 16.2: Mass Allocations for Mars Direct Mission Plan Table 16.3: Internal heat sources Table 16.4:Summary of power demands Table 16.5:Summary of final HAB mass budget Page 7 of 264

8 1 Mission Summary 1.1 Context of this design exercise Introduction and academic context This report describes the process and findings of a semester-long exercise designing a habitat for the surface of Mars. The mission described in this report is a subset of the NASA Design Reference Mission for Human Exploration of Mars. This design exercise was conducted by the students of the Fall 2003 course on Space Habitat Design at the University of Colorado at Boulder, under the instruction of Dr. David Klaus Overview of the Design Reference Mission For the purpose of this design exercise, we have used the basic mission outlined in versions 1.0 [Hoffman and Kaplan, 1997] and 3.0 [Drake, 1998] of the NASA Mars DRM. In version 1.0, a series of four spacecraft are launched to Mars over two separate launch opportunities to support a 6-person crew. A fully fueled Earth Return Vehicle (ERV) is first sent to Mars orbit. A Mars Ascent Vehicle (MAV) is then sent to land on Mars, carrying power production systems and an In-Situ Resource Utilization unit (ISRU), and begin producing propellant for the ascent from the Mars surface. A surface habitat/laboratory lands next, carrying non-perishable consumables and another power plant. After these three spacecraft are checked out and verified to be fully operational, the next launch opportunity sends the crew, via the Crew Transfer Vehicle (CTV), and two more cargo vessels. The crew travel on a fast 180 day transit to Mars, carrying enough consumables for a contingency stay in their transit habitat, land next to the already checked out habitat, and begin their 600-day surface mission. The two cargo vessels are identical to the ERV and MAV from the first launch opportunity, and are to be used either for the next exploration crew, or for redundancy for the first crew. For this version of the DRM, the Mars base consists of one fully fueled MAV, one habitat/laboratory, and a transit habitat/laboratory, with a fully fueled ERV in low Mars orbit (LMO). Version 3.0 of the DRM incorporates many cost-cutting and simplifying changes to version 1.0. Specifically, it eliminates the need for a separate MAV. The first launch opportunity sends two spacecraft to Mars. One is a fully fueled ERV, and the other is a cargo lander that contains an ISPP, power production systems, an inflatable TransHabstyle habitat, and ascent vehicle. In the second launch opportunity, the crew is launched in a transit habitat, carrying enough consumables for a contingency stay, and lands next to the cargo lander. The Mars base for version 3.0 consists of the cargo lander with fully fueled MAV and inflatable habitat, the transit habitat, and a fully fueled ERV in LMO. Page 8 of 264

9 1.2 Summary of mission characteristics MARS OR BUST, LLC The goal of this class, established by Dr. Klaus, was to design a habitat for the surface of Mars. With this goal in mind, the overall missions outlined in DRM versions 1.0 and 3.0 have been combined with a few modifications. The habitat described in this design exercise is meant to fit within a number of different mission scenarios. For the purposes of this exercise, some assumptions have been made about the mission that will use this habitat. The mission will be similar to DRM versions 1.0 and 3.0 in that the crew will travel to Mars in a vehicle separate from the habitat in which they will live on the surface of Mars. The habitat will also be separate from the laboratory in which the astronauts will perform various experiments. It was decided not to design any aspect of the Earth-Mars-Earth transit or the laboratory, in order to better focus on the design of the habitat. Similar to the DRM version 3.0, the first launch opportunity will send the habitat, encased in a transfer vehicle, as well as a nuclear power plant, several rovers, and an In- Situ Resource Utilization Plant (ISRU). Upon arrival at Mars, the habitat will aerobrake using the transfer vehicle, then be jettisoned from the transfer vehicle, parachute through the Martian atmosphere, and land using retrorockets at a designated landing site. The transfer vehicle, aerobraking, parachutes, and landing were not included as part of this design project, in order to better focus on the design of the habitat. The nuclear power plant, rovers, and ISRU will arrive in a similar manner, and land near the habitat. The rovers will be sent instructions from Earth Mission Control to move the habitat, power plant, and ISRU within 50 meters of one another, and connect and configure these elements of the Mars base. Mission Control will then command the elements of the Mars base to power on and perform self-tests in preparation for the arrival of the astronaut crew. 1.3 Key Assumptions Only the surface habitat was designed. The equipment outside of the habitat was not designed, but interfaces to them were. For example, the EVA suits were not designed, but some basic requirements for the suits were chosen, along with the design of the storage, maintenance, and supplies. The habitat is designed to fully function only on the surface of Mars, as it will not be manned during transit. This design therefore focuses only on the surface operations of the habitat, although aspects of the launch, transit, and Mars landing are considered. 1.4 Top Level Requirements Several top-level requirements were directly taken from the DRM. These requirements are given in Table. Page 9 of 264

10 Table 1.1: Top-Level Habitat Requirements from DRM # Requirement Description Source 1.1 Habitat must support crew of 6. DRM 1.2 Habitat must support crew for 600 days without re-supply. DRM 1.3 Habitat must be deployed 2 years before first crew arrives. DRM 1.4 Habitat shall be in a standby mode for 10 months between crews. DRM 1.5 All systems in Habitat must have a minimum operational lifetime of 15 years. DRM 1.6 All systems in Habitat must have low failure rates. DRM 1.7 Crew health and safety must be maintained. DRM 1.8 In-Situ Resource Utilization System must be integrated with the Habitat where applicable, but cannot be initially relied upon. DRM 1.9 Dependence on support from Earth must be minimized. DRM 1.10 Habitat surface infrastructure must be setup and checked out before crew leaves Earth. DRM 1.11 Total Habitat mass (including all payload) must not exceed 34 metric tonnes. DRM 1.12 All mission critical systems must have 2-level redundancy. DRM 1.13 All life critical systems must have 3-level redundancy. DRM 1.14 Habitat will be launched in an 80 metric ton launch vehicle. DRM 1.15 Habitat must land, deploy, operate, and maintain all systems. DRM 1.16 Where possible, habitat systems must be modular. DRM 1.17 Where possible, habitat systems must be easily repairable. DRM 1.18 Electronic and mechanical equipment must be highly autonomous, self-maintained or crew maintained, and, where possible, self-repairing. DRM 1.19 Habitat shall have auto fault detection and correction for all life-critical and mission discretionary elements. DRM 1.20 Systems must be easy to learn to operate, similar, and use common software and hardware. DRM 1.21 Crew must be able to perform real time science activity planning. DRM 1.22 All systems must survive and/or remain functional during launch and transit to Mars. DRM 2 Systems Engineering and Integration 2.1 Subsystem Overview The responsibilities of the Systems Engineering team are to ensure cohesiveness of the habitat design and fulfillment of all mission requirements. Specific tasks include identifying and deriving requirements from the DRM, delegating those requirements to the subsystem teams, reviewing and reconciling subsystem designs and coordinating subsystem interfaces. This team also worked closely with the Mission Operations to ensure consideration of human factors from the beginning of design. They worked closely with project management to oversee, organize and direct the subsystem teams, develop report and presentation templates, establish comprehensive project schedules, conduct meetings, and provide expertise to individual subsystems. Page 10 of 264

11 2.2 Key Assumptions It was assumed that the mission infrastructure delineated by the DRM would in fact be present upon arrival of the habitat. The Martian base infrastructure includes a nuclear reactor power source capable of providing 160 kwe of power, with 25 kwe allocated to the habitat, and the cabling necessary to transport the power to the habitat, an ISRU plant, 2 large pressurized rovers capable of moving the habitat and one small scientific rover. Other assumed mission infrastructure includes a launch vehicle capable of transporting 80 tonnes from the surface of Earth to Mars and a Martian landing site conducive to landing and all surface operations. The habitat was designed to withstand transportation from Earth to Mars, but a thorough consideration of mission modes other than surface operations was outside the scope of this project. Thus, transit, launch, entry, descent, and landing modes were considered but were not included as key drivers for this design. Other assumptions include: The crew would have the capability to perform EVAS There could be no dependence on the CTV There will be communication satellite(s) in orbit around Mars There will be up to a 40 minute communication delay with Earth (during open communication windows) Each crew member s physical profile is between the 5 th percentile Japanese female and the 95 th percentile American male human profile Environmental factors are within those documented (including wind speeds, dust constituents, temperature, micrometeors, etc) 2.3 Design Philosophy As with all space missions, it was important to minimize mass, power and cost for this project. However, mass was a bigger driver than power for this design because the launch capability was well defined, while the power source has yet to be designed. The goal of this design was to focus on overall system engineering approach, including human factors and infrastructure interfaces. Hardware choices were limited to technologies with high TRL (7 or higher), and subsystems were designed to handle worst-case scenarios (hot-hot, all power on at once, etc) to establish a baseline design. The design met the full redundancy required by the DRM without analysis of reliability. Planetary environmental protection and mission justification were not considered as they are programmatic rather than engineering decisions. The design was based heavily on the key DRM requirements, as reevaluation of these requirements was not within the scope of this project Subsystem Architecture The overall design was split into 12 subsystems at the beginning of the project. These subsystems are listed in Figure 2.1. Page 11 of 264

12 Figure 2.1: Subsystem Archetecture The full names of the subsystems are listed below; the responsibilities of each subsystem are discussed in the corresponding section of this document. MOB Subsystems Program Manager Systems Engineering and Integration Mission Operations (MO) Structures Command, Control, and Communication (C 3 ) Electrical Power Management and Allocation (Power) Environmental Control and Life Support (ECLSS) Crew Accommodations (CA) Robotics and Automation Systems and Interfaces (Robotics) ExtraVehicular Activity Interfaces (EVAS) Thermal Control (Thermal) In-Situ Resource Utilization (ISRU) 2.4 Design Overview The MOB habitat has a pressurized volume of 616 m 3, an unused volume of 211 m 3, an overall mass of ~ kg, and a maximum power consumption of 43 kwe. The overall structural layout is shown in Figure 2.3, and the input/output diagram for the entire habitat system is shown in Figure 2.2. Each subsystem will discuss their individual inputs and outputs in their corresponding section. Page 12 of 264

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