David Graziosi

Phase VI Advanced EVA Glove Development and Certification for the International Space Station

Since the early 1980’s, the Shuttle Extra Vehicular Activity (EVA) glove design has evolved to meet the challenge of space based tasks. These tasks have typically been satellite retrieval and repair or EVA based flight experiments. With the start of the International Space Station (ISS) assembly, the number of EVA based missions is increasing far beyond what has been required in the past; this has commonly been referred to as the “Wall of EVA’s”. To meet this challenge, it was determined that the evolution of the current glove design would not meet future mission objectives. Instead, a revolution in glove design was needed to create a high performance tool that would effectively increase crewmember mission efficiency.

Development of a Space Suit Soft Upper Torso Mobility/Sizing Actuation System

ILC Dover Inc. was awarded a three-year NRA grant for the development of innovative spacesuit pressure garment technology that will enable safer, more reliable, and effective manned exploration of the space frontier. Figure 1: Spacesuit Hammering Motion (NASA Artist Concept) The research is focusing on the development of a high performance mobility/sizing actuation system. This technology has application in two areas (1) a spacesuit soft upper torso (SUT) pressure garment for joint interface geometry repositioning to improve specific joint motion, hammering (Figure 1) vs. hand over hand translation (Figure 2), etc., and (2) as a suit sizing mechanism to allow easier suit entry and more accurate suit fit with few torso sizes than the existing EMU. This advanced soft upper torso will support NASAs Advanced EMU Evolutionary Concept of a two-size fit all upper torso for replacement of the current EMU hard upper torso (HUT). A diagram of the proposed project plan is shown in Figure 3. The research began with a system requirement analysis to identify and categorize actuation system requirements for a multitude of applications (International Space Station, Mars, etc.). An actuation study has also been conducted to identify potential actuators that provide acceptable force and response times, and have limited power requirements. Methods for force multiplication will be researched for application to improve actuation range of motion with reduced power consumption. The actuators will be used to position the SUT shoulder joint interface angles in a designated location and remain Figure 2: Spacesuit Hand Over Hand there until task completion. The joint interface will then be held in this position until it is again activated. The control mechanism will also be modeled and developed. Attention will be given to developing a fail-safe design that provides redundant function in the event of a loss of power or function. The SUT development will include the creation of an algorithm for the conversion of scan or manual human anthropometric data into optimal SUT shape including optimal interface ring positions. The SUT will incorporate the mobility/sizing actuation technology in the form of a system of rapidly sizable structural tendons and softgoods that govern interface angles and allow for compact packaging of the upper torso.

I-Suit Advanced Spacesuit Design Improvements and Performance Testing

The I-Suit has been tested in varying environments at Johnson Space Center (JSC). This includes laboratory mobility testing, KC-135 partial gravity flights, and remote field testing in the Mojave Desert. The experience gained from this testing has provided insight for design improvements. These improvements have been an evolutionary process since 1998 to the present. The design improvements affect existing suit components and introduce new components for systems processing and human/robotic interface. Examples of these design improvements include improved mobility joints, a new helmet with integrated communications and displays capability, and integration of textile switches for control of suit functions and tele-robotic operations. This paper addresses an overview of I-Suit design improvements and results of manned and unmanned performance tests. The performance tests include mobility joint testing, helmet visibility testing, and system level manned testing of the improved suit components.

Micrometeoroid and Orbital Debris Enhancements of Shuttle Extravehicular Mobility Unit Thermal Micrometeoroid Garment

it is expected that astronauts will be required to spend more and more time exposed to the hazards of performing Extra-Vehicular Activity (EVA). One of these hazards includes the risk of the space suit bladder being penetrated by hypervelocity micrometeoroid and orbital debris (MMOD) particles. Therefore, it has become increasingly important to investigate new ways to improve the protectiveness of the current Extravehicular Mobility Unit (EMU) against MMOD penetration. identifying methods of improving the current EMU protection. The first part of this evaluation focused on identifying how to increase the EMU shielding, selecting materials to accomplish this, and testing these materials to determine the best lay-up combinations to integrate into the current thermal micrometeoroid garment (TMG) design. Part of this study included using extensive hypervelocity testing to identify potential candidate materials. The last part of this study expanded on the previous results by conducting a more thorough investigation into the performance of the top three candidate lay-ups for micrometeor protection. The ability to manufacture the candidates into the current TMG and their effects on the torque of a mobility joint were the main focus points. This paper summarizes the findings of this study.

System Considerations for an Exploration Spacesuit Upper Torso Architecture

NASA’s Exploration Architecture announced in September 2005, calls for development and flight of a Crew Exploration Vehicle (CEV) no later than 2014 and return to the moon by 2020 with a goal to reach and explore Mars. Intra-Vehicular Activity (IVA) suit systems will need to comfortably protect the crew during launch entry and abort scenarios. Extra-Vehicular Activity (EVA) suit systems will need to provide the capability to perform contingency zero-gravity EVA from the CEV as well as surface EVA to explore the moon and Mars. Studies currently underway to begin definition of the IVA and EVA suits point to a two suit architecture, the first being a launch, re-entry, and contingency EVA system used from CEV, the second and later being a lunar surface mobility suit only. An important consideration, yet to be determined, is the level of commonality between the early CEV and late Lunar suits. One concept is to have maximum commonality beginning with the architecture of the spacesuit upper torso. The upper torso is the foundation of the spacesuit. The upper torso supports the life support system, displays and controls, the opening for entry and closure, the helmet, and the shoulder and waist mobility joints. Upper torso architecture therefore, has a great affect on life support configuration, don/doff capability, mass and volume, suit sizing, and suit performance particularly in terms of visibility, mobility and comfort. Of prime consideration, is the upper torso material. Historically, hard upper torsos (HUTs) have been made of aluminum or composite, and soft upper torsos (SUTs) have been made of dual layer coated and noncoated fabrics. Architecture concepts have included waist entry, rear entry, and zipper closures. Upper Torso architecture is a key driver for the early CEV and late Lunar exploration spacesuit systems definition. This paper provides a review of probable Constellation Program requirements, existing upper torso architectures, and material candidates. Recent developments in the ILC Dover I-Suit fabric upper torso are discussed in relation to meeting program goals. Trade assessments suggest that fabric upper torsos, common to both Constellation Program spacesuits, provide the best advantage to meet the goals of the program.

Human and Robotic Enabling Performance System Development and Testing

With a renewed focus on manned exploration, NASA is beginning to prepare for the challenges that lie ahead. Future manned missions will require a symbiosis of human and robotic infrastructure. As a step towards understanding the roles of humans and robots in future planetary exploration, NASA headquarters funded ILC Dover and the University of Maryland to perform research in the area of human and robotic interfaces. The research focused on development and testing of communication components, robotic command and control interfaces, electronic displays, EVA navigation software and hardware, and EVA lighting. The funded research was a 12-month effort culminating in a field test with NASA personnel.

Evaluation of a Rear Entry System for an Advanced Spacesuit

The success of astronauts in performing Extra-Vehicular Activity (EVA) is highly dependent on the performance of the spacesuit they are wearing. The Space Shuttle Extravehicular Mobility Unit (EMU) is a waist entry suit consisting of a hard upper torso (HUT) and soft fabric mobility joints. The EMU was designed specifically for zero gravity operations. With a new emphasis on planetary exploration, a new EVA spacesuit design is required. One of the key features of any space suit is the entry method. Historical examples of different entry types include waist entry, rear entry, bi-planar entry, and soft zipper type entry. Suit entry type plays a critical role in defining the overall suit architecture. Some of the critical suit features affected by entry type are suit don/doff capability, suit sizing, suit mass, suit volume, and suit comfort. In general, rear entry designs provide better don/doff capabilities. However, mass and limitations to vertical torso length may be disadvantages of the rear entry design. Entry type is also affected by the vehicle and habitat interfaces such as air locks, hatches, and manned rovers. One concept for planetary exploration is to have an unpressurized vestibule attached to the habitat and have the spacesuit attached to the habitat wall acting as an air lock. This scenario is best supported by a rear entry design minimizing the amount of dust and dirt entering the habitat. ILC has designed a rear entry prototype upper torso for the I-Suit advanced spacesuit. The design facilitates don/doff while minimizing mass and the negative effects on vertical sizing. This paper discusses research performed at ILC Dover to develop the rear entry design and initial evaluations of the prototype.

Development of a Space Suit Soft Upper Torso Mobility/Sizing Actuation System with Focus on Prototype Development and Manned Testing

ILC Dover Inc. was awarded a three-year NRA grant for the development of innovative spacesuit pressure garment technology that will enable safer, more reliable, and effective human exploration of the space frontier. The research focused on the development of a high performance mobility/sizing actuation system for a spacesuit soft upper torso (SUT) pressure garment. This technology has application in two areas (1) repositioning the scye bearings to improve specific joint motion i.e. hammering (Figure 1), hand over hand translation (Figure 2), etc., and (2) as a suit sizing mechanism to allow easier suit entry and more accurate suit fit with fewer torso sizes than the existing EMU. This research was divided into three phases. In phases 1 and 2 SUT actuation technologies were developed and evaluated. In the final phase, which this paper focuses on, a field of previously selected actuation methods was narrowed to one active, pneumatically driven system, and one passive, cable driven system. These systems were developed into fully functioning prototypes which were outfitted to a table top SUT mock-up which was later integrated into a full suit and tested. Both of these systems were shown to be successful in positioning the SUT shoulder joint interface angles in a designated location and holding there until task completion. The control mechanisms used for both the active and passive system was also modeled and developed. The final phase was concluded by collecting video of a manned demonstration of two of the sizing systems in effect. This paper will summarize the findings of this three year research with emphasis on the details of the final phase.

Comparison of Shortened and Standard Liquid Cooling Garments to Provide Physiological and Subjective Comfort During EVA

The shortened liquid cooling/warming garment (SLCWG) developed by the University of Minnesota group was compared with the standard NASA liquid cooling/ventilating garment (LCVG) garment during physical exertion in comfort (24°C) and hot (35°C) chamber environments. In both environmental conditions, the SLCWG was just as effective as the LCVG in maintaining rectal temperature (Tre) in a thermal comfort range; sweat production on the face was less; and subjective perception of overall and local body comfort was higher. The findings indicate that the SLCWG produces the same or greater comfort level as that achieved with the LCVGs total coverage of the body surface.

Enhancing Capability in Launch, Entry, and Abort Style Spacesuits For ISS and Commercial Use

As the pending retirement of the Space Shuttle Transportation System draws closer and the focus on a replacement vehicle to ferry crews to and from the International Space Station increases, requirements for the suit that will be worn by the crew members that will fly this vehicle are also currently being written. These requirements will focus on the suits ability to operate in a variety of nominal and contingency environments which will likely require a high degree of functionality in both pressurized and unpressurized modes of operation. While many of these requirements have yet to be finalized several Launch, Entry, and Abort (LEA) type suits have been designed and fabricated by ILC Dover using requirement sets that focused on different specific suit designs and their accompanying technologies. These design elements serve to minimize suit mass, enhance both pressurized and unpressurized mobility, increase safety, and identify potential operational risks. The purpose of this paper is to introduce several of these design elements and some of their preliminary test and operational results.