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NASA NTRS2016

Portable Life Support System 2.5 Fan Design and Development

NASA is building a high-fidelity prototype of an advanced Portable Life Support System (PLSS) as part of the Advanced Exploration Systems Program. This new PLSS, designated as PLSS 2.5, will advance component technologies and systems knowledge to inform a future flight program. The oxygen ventilation loop of its predecessor, PLSS 2.0, was driven by a centrifugal fan developed using specifications from the Constellation Program. PLSS technology and system parameters have matured to the point where the existing fan will not perform adequately for the new prototype. In addition, areas of potential improvement were identified with the PLSS 2.0 fan that could be addressed in a new design. As a result, a new fan was designed and tested for the PLSS 2.5. The PLSS 2.5 fan is a derivative of the one used in PLSS 2.0, and it uses the same nonmetallic, canned motor, with a larger volute and impeller to meet the higher pressure drop requirements of the PLSS 2.5 ventilation loop. The larger impeller allows it to operate at rotational speeds that are matched to rolling element bearings, and which create reasonably low impeller tip speeds consistent with prior, oxygen-rated fans. Development of the fan also considered a shrouded impeller design that could allow larger clearances for greater oxygen safety, assembly tolerances and particle ingestion. This paper discusses the design, manufacturing and performance testing of the new fans.

Quinn, Gregory↗

NASA NTRS2006

Advanced Space Suit Portable Life Support Subsystem Packaging Design

This paper discusses the Portable Life Support Subsystem (PLSS) packaging design work done by the NASA and Hamilton Sundstrand in support of the 3 future space missions; Lunar, Mars and zero-g. The goal is to seek ways to reduce the weight of PLSS packaging, and at the same time, develop a packaging scheme that would make PLSS technology changes less costly than the current packaging methods. This study builds on the results of NASA s in-house 1998 study, which resulted in the "Flex PLSS" concept. For this study the present EMU schematic (low earth orbit) was used so that the work team could concentrate on the packaging. The Flex PLSS packaging is required to: protect, connect, and hold the PLSS and its components together internally and externally while providing access to PLSS components internally for maintenance and for technology change without extensive redesign impact. The goal of this study was two fold: 1. Bring the advanced space suit integrated Flex PLSS concept from its current state of development to a preliminary design level and build a proof of concept mockup of the proposed design, and; 2. "Design" a Design Process, which accommodates both the initial Flex PLSS design and the package modifications, required to accommodate new technology.

Howe, Robert↗

NASA NTRS2010

Proposed Schematics for an Advanced Development Lunar Portable Life Support System

The latest development of the NASA space suit is an integrated assembly made up of primarily a Pressure Garment System (PGS) and a Portable Life Support System (PLSS). The PLSS is further composed of an oxygen (O2) subsystem, a ventilation subsystem, and a thermal subsystem. This paper baselines a detailed schematic of the PLSS to provide a basis for current and future PLSS development efforts. Both context diagrams and detailed schematics describe the hardware components and overall functions for all three of the PLSS subsystems. The various modes of operations for the PLSS are also presented. A comparison of the proposed PLSS to the Apollo and Shuttle PLSS designs is presented, highlighting several anticipated improvements over the historical PLSS architectures.

Conger, Bruce↗

NASA NTRS2015

Asteroid Redirect Crewed Mission Space Suit and EVA System Maturation

The Asteroid Redirect Crewed Mission (ARCM) requires a Launch/Entry/Abort (LEA) suit capability and short duration Extra Vehicular Activity (EVA) capability from the Orion spacecraft. For this mission, the pressure garment that was selected, for both functions, is the Modified Advanced Crew Escape Suit (MACES) with EVA enhancements and the life support option that was selected is the Exploration Portable Life Support System (PLSS). The proposed architecture was found to meet the mission constraints, but much more work is required to determine the details of the required suit upgrades, the integration with the PLSS, and the rest of the tools and equipment required to accomplish the mission. This work has continued over the last year to better define the operations and hardware maturation of these systems. EVA simulations have been completed in the NBL and interfacing options have been prototyped and analyzed with testing planned for late 2014. For NBL EVA simulations, in 2013, components were procured to allow in-house build up for four new suits with mobility enhancements built into the arms. Boots outfitted with clips that fit into foot restraints have also been added to the suit and analyzed for possible loads. Major suit objectives accomplished this year in testing include: evaluation of mobility enhancements, ingress/egress of foot restraint, use of foot restraint for worksite stability, ingress/egress of Orion hatch with PLSS mockup, and testing with two crew members in the water at one time to evaluate the crew's ability to help one another. Major tool objectives accomplished this year include using various other methods for worksite stability, testing new methods for asteroid geologic sampling and improving the fidelity of the mockups and crew equipment. These tests were completed on a medium fidelity capsule mockup, asteroid vehicle mockup, and asteroid mockups that were more accurate for an asteroid type EVA than previous tests. Another focus was the design and fabrication of the interface between the MACES and the PLSS. The MACES was not designed to interface with a PLSS, hence an interface kit must accommodate the unique design qualities of the MACES and provide the necessary life support function connections to the PLSS. A prototype interface kit for MACES to PLSS has been designed and fabricated. Unmanned and manned testing of the interface will show the usability of the kit while wearing a MACES. The testing shows viability of the kit approach as well as the operations concept. The design will be vetted through suit and PLSS experts and, with the findings from the testing, the best path forward will be determined. As the Asteroid Redirect Mission matures, the suit/life support portion of the mission will mature along with it and EVA Tools & Equipment can be iterated to accommodate the overall mission objectives and compromises inherent in EVA Suit optimization. The goal of the EVA architecture for ARCM is to continue to build on the previously developed technologies and lessons learned, and accomplish the ARCM EVAs while providing a stepping stone to future missions and destinations.

Bowie, Jonathan T.↗

NASA NTRS2012

Next-Generation Evaporative Cooling Systems for the Advanced Extravehicular Mobility Unit Portable Life Support System

The development of the Advanced Extravehicular Mobility Unit (AEMU) Portable Life Support System (PLSS) is currently underway at NASA Johnson Space Center. The AEMU PLSS features two new evaporative cooling systems, the Reduced Volume Prototype Spacesuit Water Membrane Evaporator (RVP SWME), and the Auxiliary Cooling Loop (ACL). The RVP SWME is the third generation of hollow fiber SWME hardware, and like its predecessors, RVP SWME provides nominal crewmember and electronics cooling by flowing water through porous hollow fibers. Water vapor escapes through the hollow fiber pores, thereby cooling the liquid water that remains inside of the fibers. This cooled water is then recirculated to remove heat from the crewmember and PLSS electronics. Major design improvements, including a 36% reduction in volume, reduced weight, and more flight like back-pressure valve, facilitate the packaging of RVP SWME in the AEMU PLSS envelope. In addition to the RVP SWME, the Auxiliary Cooling Loop (ACL), was developed for contingency crewmember cooling. The ACL is a completely redundant, independent cooling system that consists of a small evaporative cooler--the Mini Membrane Evaporator (Mini-ME), independent pump, independent feed-water assembly and independent Liquid Cooling Garment (LCG). The Mini-ME utilizes the same hollow fiber technology featured in the RVP SWME, but is only 25% of the size of RVP SWME, providing only the necessary crewmember cooling in a contingency situation. The ACL provides a number of benefits when compared with the current EMU PLSS contingency cooling technology; contingency crewmember cooling can be provided for a longer period of time, more contingency situations can be accounted for, no reliance on a Secondary Oxygen Vessel (SOV) for contingency cooling--thereby allowing a SOV reduction in size and pressure, and the ACL can be recharged-allowing the AEMU PLSS to be reused, even after a contingency event. The development of these evaporative cooling systems will contribute to a more robust and comprehensive AEMU PLSS.

Makinen, Janice V.↗

NASA NTRS2009

Flexible Foam Protection Materials for Portable Life Support System Packaging Study

This paper discusses the phase I effort in evaluating and selecting a light weight impact protection material for the Constellation Space Suit Element (CSSE) Portable Life Support System (PLSS) conceptual packaging study. A light weight material capable of holding and protecting the components inside the PLSS is required to demonstrate the viability of the flexible PLSS packaging concept. The material needs to distribute, dissipate, and absorb the impact energy of the PLSS falling on the lunar surface. It must also be robust to consistently perform over several Extravehicular Activity (EVA) missions in the extreme lunar thermal vacuum environment. This paper documents the performance requirements for selecting a foam protection material, and the methodologies for evaluating some commercial off-the-shelf (COTS) foam material candidates. It also presents the mechanical properties and impact drop tests results of the foam material candidates. The results of this study suggest that a foam based flexible protection system is a viable solution for PLSS packaging. However, additional works are needed to optimize COTS foam or to develop a composite foam system that will meet all the performance requirements for the CSSE PLSS flexible packaging.

Tang,Henry H.↗

NASA NTRS2009

Flexible Foam Protection Materials for Constellation Space Suit Element Portable Life Support Subsystem Packaging Study

This paper discusses the effort in evaluating and selecting a light weight impact protection material for the Constellation Space Suit Element (CSSE) Portable Life Support Subsystem (PLSS) conceptual packaging study. A light weight material capable of holding and protecting the components inside the PLSS is required to demonstrate the viability of the flexible PLSS packaging concept. The material needs to distribute, dissipate, and absorb the impact energy of the PLSS falling on the lunar surface. It must also be very robust and function in the extreme lunar thermal vacuum environment for up to one hundred Extravehicular Activity (EVA) missions. This paper documents the performance requirements for selecting a foam protection material, and the methodologies for evaluating commercial off-the-shelf (COTS) foam protection materials. It also presents the materials properties test results and impact drop test results of the various foam materials evaluated in the study. The findings from this study suggest that a foam based flexible protection system is a viable solution for PLSS packaging. However, additional works are needed to optimize COTS foam properties or to develop a composite foam system that will meet all the performance requirements for the CSSE PLSS flexible packaging.

Tang, Henry H.↗

NASA NTRS2010

Portable Life Support Subsystem Thermal Hydraulic Performance Analysis

This paper presents the current state of the thermal hydraulic modeling efforts being conducted for the Constellation Space Suit Element (CSSE) Portable Life Support Subsystem (PLSS). The goal of these efforts is to provide realistic simulations of the PLSS under various modes of operation. The PLSS thermal hydraulic model simulates the thermal, pressure, flow characteristics, and human thermal comfort related to the PLSS performance. This paper presents modeling approaches and assumptions as well as component model descriptions. Results from the models are presented that show PLSS operations at steady-state and transient conditions. Finally, conclusions and recommendations are offered that summarize results, identify PLSS design weaknesses uncovered during review of the analysis results, and propose areas for improvement to increase model fidelity and accuracy.

Barnes, Bruce↗

NASA NTRS2014

Mini-Membrane Evaporator for Contingency Spacesuit Cooling

The next-generation Advanced Extravehicular Mobility Unit (AEMU) Portable Life Support System (PLSS) is integrating a number of new technologies to improve reliability and functionality. One of these improvements is the development of the Auxiliary Cooling Loop (ACL) for contingency crewmember cooling. The ACL is a completely redundant, independent cooling system that consists of a small evaporative cooler--the Mini Membrane Evaporator (Mini-ME), independent pump, independent feedwater assembly and independent Liquid Cooling Garment (LCG). The Mini-ME utilizes the same hollow fiber technology featured in the full-sized AEMU PLSS cooling device, the Spacesuit Water Membrane Evaporator (SWME), but Mini-ME occupies only 25% of the volume of SWME, thereby providing only the necessary crewmember cooling in a contingency situation. The ACL provides a number of benefits when compared with the current EMU PLSS contingency cooling technology, which relies upon a Secondary Oxygen Vessel; contingency crewmember cooling can be provided for a longer period of time, more contingency situations can be accounted for, no reliance on a Secondary Oxygen Vessel (SOV) for contingency cooling--thereby allowing a reduction in SOV size and pressure, and the ACL can be recharged-allowing the AEMU PLSS to be reused, even after a contingency event. The first iteration of Mini-ME was developed and tested in-house. Mini-ME is currently packaged in AEMU PLSS 2.0, where it is being tested in environments and situations that are representative of potential future Extravehicular Activities (EVA's). The second iteration of Mini-ME, known as Mini- ME2, is currently being developed to offer more heat rejection capability. The development of this contingency evaporative cooling system will contribute to a more robust and comprehensive AEMU PLSS.

Makinen, Janice V.↗

NASA NTRS2015

Mini-Membrane Evaporator for Contingency Spacesuit Cooling

The next-generation Advanced Extravehicular Mobility Unit (AEMU) Portable Life Support System (PLSS) is integrating a number of new technologies to improve reliability and functionality. One of these improvements is the development of the Auxiliary Cooling Loop (ACL) for contingency crewmember cooling. The ACL is a completely redundant, independent cooling system that consists of a small evaporative cooler--the Mini Membrane Evaporator (Mini-ME), independent pump, independent feedwater assembly and independent Liquid Cooling Garment (LCG). The Mini-ME utilizes the same hollow fiber technology featured in the full-sized AEMU PLSS cooling device, the Spacesuit Water Membrane Evaporator (SWME), but Mini-ME occupies only approximately 25% of the volume of SWME, thereby providing only the necessary crewmember cooling in a contingency situation. The ACL provides a number of benefits when compared with the current EMU PLSS contingency cooling technology, which relies upon a Secondary Oxygen Vessel; contingency crewmember cooling can be provided for a longer period of time, more contingency situations can be accounted for, no reliance on a Secondary Oxygen Vessel (SOV) for contingency cooling--thereby allowing a reduction in SOV size and pressure, and the ACL can be recharged-allowing the AEMU PLSS to be reused, even after a contingency event. The first iteration of Mini-ME was developed and tested in-house. Mini-ME is currently packaged in AEMU PLSS 2.0, where it is being tested in environments and situations that are representative of potential future Extravehicular Activities (EVA's). The second iteration of Mini-ME, known as Mini-ME2, is currently being developed to offer more heat rejection capability. The development of this contingency evaporative cooling system will contribute to a more robust and comprehensive AEMU PLSS.

Makinen, Janice V.↗

NASA NTRS2017

Development Specification for the FN-323/324, Oxygen Ventilation Loop Fan Assembly

This specification establishes the requirements for design, performance, safety, and manufacture of the FN-323/324, Oxygen Ventilation Loop Fan Assembly as part of the Advanced EMU (AEMU) Portable Life Support System (PLSS). Fan development for the advanced Portable Life Support System (PLSS) began in 2009 with the development of Fan 1.0. This fan was used in PLSS 2.0 for circulation of the ventilation loop gas. Fan 2.0 was delivered in 2015 and will be used in the PLSS 2.5 Live Loads test series. This fan used the same motor as Fan 1.0, but had a larger volute and impeller in hopes of achieving lower speeds. The next iteration of the advanced PLSS fan is the subject of the requirements contained within this document, and will be used with the PLSS 2.5 -302 configuration.

Ralston, Russell↗

NASA NTRS1989

Suitport extra-vehicular access facility

In a system for entering and leaving a space station, a bulkhead divides the module into an antechamber and an airlock. A space suit has a portable life support system (PLSS) interface on its back. The suit is removably attached to the bulkhead by the interface at a hatch in the bulkhead. A PLSS is detachably mounted in the hatch cover, which is pivotally mounted to move away from the hatch to allow an astronaut to enter the suit through the open hatch and the PLSS interface. After entering the suit, the astronaut closes the hatch and attaches the PLSS to the suit by the operating control to which the glove portion of the suit is attached. The astronaut initiates pumpdown of the airlock with the control. When the pumpdown is complete, the astronaut opens the hatch, disconnects the PLSS from the hatch cover, pivots the pressure vessels of the control to one side on their supports, disconnects the glove portions from the pressure vessels and goes EVA.

Cohen, Marc M.↗

NASA NTRS2007

Continuously Regenerable Freeze-Out CO2 Control Technology

Carbon dioxide (CO2) removal technology development for portable life support systems (PLSS) has traditionally concentrated in the areas of solid and liquid chemical sorbents and semi-permeable membranes. Most of these systems are too heavy in gravity environments, require prohibitive amounts of consumables for operation on long term planetary missions, or are inoperable on the surface of Mars due to the presence of a CO2 atmosphere. This paper describes the effort performed to mature an innovative CO2 removal technology that meets NASA s planetary mission needs while adhering to the important guiding principles of simplicity, reliability, and operability. A breadboard cryogenic carbon dioxide scrubber (Cryo Scrubber) for a closed loop cryogenic PLSS was developed, designed, and tested, and a conceptual design suitable for a PLSS was developed based on the results of the breadboard testing. The Cryo Scrubber freezes CO2 and other trace contaminants out of expired vent loop gas using cooling available from a liquid oxygen (LOX) based PLSS. The device is continuously regenerable, with solid CO2 being removed from the cold freeze-out surfaces, sublimated, and vented overboard. Duration is limited only by the supply of LOX stored in the PLSS. Simplicity, reliability, and operability are universally important criteria for critical hardware on long duration Lunar or Mars missions. The Cryo Scrubber has no moving parts, requires no additional consumables, and uses no electrical power, contributing to its simplicity and reliability. It is easy to use; no operator action is required to prepare, use, or shut down the Cryo Scrubber, and it does not require charging or regeneration. The versatility of the concept allows for operation on earth, the moon, and Mars, and in microgravity.

Fricker, John↗

NASA NTRS2013

Reduced Volume Prototype Spacesuit Water Membrane Evaporator; A Next-Generation Evaporative Cooling System for the Advanced Extravehicular Mobility Unit Portable Life Support System

Development of the Advanced Extravehicular Mobility Unit (AEMU) portable life support subsystem (PLSS) is currently under way at NASA Johnson Space Center. The AEMU PLSS features a new evaporative cooling system, the reduced volume prototype (RVP) spacesuit water membrane evaporator (SWME). The RVP SWME is the third generation of hollow fiber SWME hardware. Like its predecessors, RVP SWME provides nominal crew member and electronics cooling by flowing water through porous hollow fibers. Water vapor escapes through the hollow fiber pores, thereby cooling the liquid water that remains inside of the fibers. This cooled water is then recirculated to remove heat from the crew member and PLSS electronics. Major design improvements, including a 36% reduction in volume, reduced weight, and a more flight-like backpressure valve, facilitate the packaging of RVP SWME in the AEMU PLSS envelope. The development of these evaporative cooling systems will contribute to a more robust and comprehensive AEMU PLSS.

Makinen, Janice V.↗

NASA NTRS2014

Continued Development of the Rapid Cycle Amine (RCA) System for Advanced Extravehicular Activity Systems

Development activities related to the Rapid Cycle Amine (RCA) Carbon Dioxide (CO2) and Humidity control system have progressed to the point of integrating the RCA into an advanced Primary Life Support System (PLSS 2.0) to evaluate the interaction of the RCA among other PLSS components in a ground test environment. The RCA 2.0 assembly (integrated into PLSS 2.0) consists of a valve assembly with commercial actuator motor, a sorbent canister, and a field-programmable gate array (FPGA)-based process node controller. Continued design and development activities for RCA 3.0 have been aimed at optimizing the canister size and incorporating greater fidelity in the valve actuator motor and valve position feedback design. Further, the RCA process node controller is envisioned to incorporate a higher degree of functionality to support a distributed PLSS control architecture. This paper will describe the progression of technology readiness levels of RCA 1.0, 2.0 and 3.0 along with a review of the design and manufacturing successes and challenges for 2.0 and 3.0 units. The anticipated interfaces and interactions with the PLSS 2.0/2.5/3.0 assemblies will also be discussed.

Papale, William↗

NASA NTRS2014

Continued Development of the Rapid Cycle Amine (RCA) System for Advanced Extravehicular Activity Systems

Papale, William↗

NASA NTRS2016

Results from Carbon Dioxide Washout Testing Using a Suited Manikin Test Apparatus with a Space Suit Ventilation Test Loop

NASA is developing an advanced portable life support system (PLSS) to meet the needs of a new NASA advanced space suit. The PLSS is one of the most critical aspects of the space suit providing the necessary oxygen, ventilation, and thermal protection for an astronaut performing a spacewalk. The ventilation subsystem in the PLSS must provide sufficient carbon dioxide (CO2) removal and ensure that the CO2 is washed away from the oronasal region of the astronaut. CO2 washout is a term used to describe the mechanism by which CO2 levels are controlled within the helmet to limit the concentration of CO2 inhaled by the astronaut. Accumulation of CO2 in the helmet or throughout the ventilation loop could cause the suited astronaut to experience hypercapnia (excessive carbon dioxide in the blood). A suited manikin test apparatus (SMTA) integrated with a space suit ventilation test loop was designed, developed, and assembled at NASA in order to experimentally validate adequate CO2 removal throughout the PLSS ventilation subsystem and to quantify CO2 washout performance under various conditions. The test results from this integrated system will be used to validate analytical models and augment human testing. This paper presents the system integration of the PLSS ventilation test loop with the SMTA including the newly developed regenerative Rapid Cycle Amine component used for CO2 removal and tidal breathing capability to emulate the human. The testing and analytical results of the integrated system are presented along with future work.

Chullen, Cinda↗

NASA NTRS2008

Introduction to the Portable Life Support Schematic and Technology Development Components

Conger presented the operations and functions of the baseline Constellation Program (CxP) Portable Life Support System (PLSS) schematic and key development technologies. He explained the functional descriptions of the schematic components in the fluid systems of the PLSS for multiple operational scenarios. PLSS subsystems include the oxygen subsystem, the ventilation subsystem, and the thermal subsystem. He also presented the operational PLSS modes: Nominal EVA mode, Umbilical - no recharge mode, Umbilical - with recharge mode, BENDS mode, BUDDY mode, Secondary oxygen mode, and the PLSS-removed umbilical mode.

Conger, Bruce↗