Chameleon Suit â€“ Changing the Outlook for EVA

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Chameleon Suit – Changing the Outlook for EVA

November 7, 2003Ed Hodgson

Hamilton Sundstrand

2

Project Basics• Advanced Extra-Vehicular Activity System

Concept• Phase 2 Study

– March 2002 – January 2004• Contract #NAS5-03110 Grant #07605-003-001• HS Project Team – Gail Baker, Allison Bender,

Joel Goldfarb, Edward Hodgson, Gregory Quinn, Fred Sribnik, Catherine Thibaud-Erkey

• External Support – NIAC, NASA JSC, NASA HQ, and many, many more.

3

Why a Chameleon Suit?

• History

• Future Needs

• Technology Opportunities

4

Historical EVA Challenges and Issues

• Pressure Suit Mobility & Comfort• On-Back Weight• EVA Expendables• Durability / Maintainability

5

Future Mission Needs

AccessiblePlanetarySurface

Earth& LEO

Anywhere/ Anytime

Earth’sNeighborhood

• Easier• Lighter• Cheaper• Longer• Adaptable

6

Technology Opportunities – The Shape of Things to Come

• Recursive system evolution• Atomic scale design & manufacture• The imitation of life

Active, optimal multi-functional materials –unconstrained design integration.

7

The Guiding Concept – A Different System Paradigm

Historic EVA Systems

• Functional partition• Environment isolation• Component interfaces

Chameleon Suit

• Functional integration• Environment

exploitation• Human interfaces

8

The Many Shapes of the Chameleon –Concept Implementation Options

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Implementation OptionsTechnology & Logical Choices

Phase 1 StudyIntegrated Passive Thermal Control

Integrated Active Heat Transport

EmphasizeIntegrated CO2 & Humidity Control

Active MobilityMCP SuitMobilityMass Savings

& IntegrationActive Suit Fit

TransportArtificialPhotosynthesis

Energy Harvesting

Distributed Energy Harvesting

O2 RecoveryModule

DistributedO2 RecoveryReactants Energy

10

Integrated Passive Thermal Control(Phase 1 Study)

LCVG Layers (outer layer,transport tubing, liner)

TMG and MEMS louvers

Variable loft layerswith active polymer

spacers and thermallyconductive fiber felt

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Integrated Active Heat Transport

Distributed thin filmmodules or flexible

thermoelectric polymers




12

Integrated CO2 & Humidity Control


thermoelectricpolymers


Selective ChemicalTransport Membranes



13

Active Suit Fit





Active Suit Fit Material



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Energy Harvesting






Flexible solar cell arrays/Photoelectric polymers

Concentrated CO2and H2O vented to

environment

Harvested Energy tobackpack reduces

battery size



15

Artificial Photosynthesis






Selective ChemicalTransport/Catalysis



Harvested energyfrom photo- &

thermoelectrics todrive oxygen

recovery

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Distributed O2 Recovery

Distributed thin film modules orflexible thermoelectric polymers





Oxygen Recovery Process


spacers and thermallyconductive fiber feltCO2, H20 and

O2 Transfer

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Active Mobility - MCP Suit





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Distributed Energy Harvesting -O2 Recovery Module




Active Suit Fit Material for MCP

Flexible solar cell arrays/Photoelectric polymersHarvested energy

from photo- &thermoelectrics to

backpack



Suit atmosphere tobackpack for CO2,H2O removal and

O2 recovery

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Enabling Technologies

• Multi-functional Materials• Bio-mimetic Processes• Advanced Manufacturing Technologies• Information Technologies

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Multifunctional Materials

• Conductive Polymers• Shape Change Materials• Optically Active Materials• Energy Storage and Conversion• Chemically Active Materials

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Polymers and NanocompositesEngineered Materials Revolution

• Driven by, enabled by, and underlying information revolution– Microelectronics > massive complexity > ever smaller features >

MEMS– Computational, imaging and modeling tools at atomic and

molecular scales• Ubiquitous in science, industry & society• Designer molecules

– Multi-functional polymers – conductive, mechanically active, optically active, chemically active

– Biomimetic• Nano-composites

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Conductive PolymersAlternatives to Wiring Harnesses, Switches

and Liquid Electrolytes• Conductive polymers and

composite electro-textiles– Flexibility– Massively parallel

interconnection• Polymeric semiconductors

– Integrated function, structure & control

• Solid polymer electrolytes– Lithium polymer batteries – Fuel cells ~ 1000 W-hr/Kg– Flexible batteries – 160W-hr/Kg

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Shape Change Materials

-

-100

-

60-80

-

Medium to fast

380

7.2

Dielectric

---20 to 40 20 to 40

-150 to150

Temperature range (C)

-

0.3

30-35

107

100

20

0.35

HumanMuscle

-

120

1

[email protected]% strain

3

2

40

MIT CP

2002

N

Very low

1

105

Low

2

5-10

insulation

-

>4

20

106

36

25

0.5

MIT target

Y

40

20

106

100

25

40

MCP/assisted mobility

20Tensile strength (MPa)

Y

low

1000

Low

25

20

Active fit

O2 compatibility

Efficiency (%)

Life cycle

Strain rate (%/s)

Strain (%)

Force output (MPa)

Characteristics

-

-100

-

60-80

-

Medium to fast

380

7.2

Dielectric

---20 to 40 20 to 40

-150 to150

Temperature range (C)

-

0.3

30-35

107

100

20

0.35

HumanMuscle

-

120

1

[email protected]% strain

3

2

40

MIT CP

2002

N

Very low

1

105

Low

2

5-10

insulation

-

>4

20

106

36

25

0.5

MIT target

Y

40

20

106

100

25

40

MCP/assisted mobility

20Tensile strength (MPa)

Y

low

1000

Low

25

20

Active fit

O2 compatibility

Efficiency (%)

Life cycle

Strain rate (%/s)

Strain (%)

Force output (MPa)

Characteristics

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Optically Active Materials

• Electrochromicmaterials– Inorganic– Polymers

• Electroemissivematerials– OLED

• MEMS• Photoelectric materials

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Energy Storage & Conversion

• Thin film & polymeric devices

• Increasing conversion efficiency

• Lower cost & more flexible manufacture

• Emerging applications

Progress of Thermoelectic Improvements

012345

1930 1950 1970 1990 2010Year

Figu

re o

f Mer

it,

ZT

Thin Film State of the Art

Polymer state of the art

Commercially available material

ElectrolytePlastic (PET)Platinum Catalyst

Transparent Conductor

0.010 inches

Plastic (PET) TiO2 & DyeTransparent Conductor

Photovoltaic

Polymer Batteries

Thermoelectric

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Chemically Active Materials

O2

CO2

H2O

CO2

e-load

H2O

O2

H2

e-power

H+

CO3=

O2

CO2

H2O

CO2

e-load

H2O

O2

H2

e-power

H+

CO3=

Porous substrate

Liquid containing facilitators

Hydrophilized surface

Vent flowCO2 ,O2,

H2O H2O

CO2

Vacuumor

Sweep gas

Passive transport selective membranes

Active transport – polymer electrolytes

Chemical conversion – integrated catalysis

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Bio-mimetic Processes

• Membranes• Bio-catalysts• Artificial Photosynthesis• Self-Assembling Systems

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Membrane Technologies

• Biological membranes– Self organizing– Selective transport– Active transport

• Enzyme membranes• Biomimetic liquid

crystal membranes– CO2 transport &

selectivity comparable to lung tissue

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Bio-catalysts

Biocatalytic Processes• Efficient reactions at

useful rates and modest temperatures

• High specificity• Enzymes - organic -

stereochemical

Historical Processes• Efficient reactions at

high rates , high temperatures

• Limited specificity• Inorganic metals &

salts

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Artificial Photosynthesis

• Find alternate chemicals / chemical sequences to achieve photosynthetic functions recognizing photosynthesis specificity of– Fast kinetics– Highly specific pathways– Molecular level assembly

• For example, mimicking chlorophyll’s light conversion process (PSII)– Carotene/Porphyrin/Fullerene sequence (Arizona

State University)– Development of Ru-Mn complexes (Uppsala

University, Sweden)

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Self-Assembling Systems

• The essence of biology• Complexity (apparently) without

cost• Genetic codes – molecular templates• Understanding Practice

– Natural systems Modes of operation Engineered analogs

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Advanced Manufacturing Technologies

• Photo-Lithography• Stereo-Lithography• Self-Assembling Systems

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Photolithographic ProcessesKeys to Practical Complexity at Any Scale

• Design and manufacturing approaches are proven

• Extension to multi-disciplinary systems has been made

• Extension to large scale planar structures

• Further growth in scale and range of materials

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Stereo-Lithography

• Photo-lithographic process extended to 3D• Direct computer control

– Design flexibility– Responsiveness– Small lot economics

• Increasing materials possibilities

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Self-Assembling Systems (again)

• Becoming a practical reality in engineering practice

• One key to mastering massively parallel, repeating systems of very small parts …Like the Chameleon Suit

Nanolitho effort harnesses self-assembly

PORTLAND, Ore. — Nanoscale patterning of silicon substrates with regular, repeatable, atomically perfect application- specific templates could enable manufacturable nanoscale chips within the decade, according to scientists at the University of Wisconsin'sMaterials Research Science and Engineering Center (Madison).

By R. Colin Johnson

EE TimesAugust 5, 2003 (2:54 p.m. ET)

http://www.eetimes.com/

http://www.eetimes.com/

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Information Technologies

• Underlying Technology• Information Processing• Connectivity• Recursive Design• Advanced Interfaces

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Underlying Technology Base

• Silicon as a designer material– Flexible, easily controlled functionality– Consistent continuous structure

• Photolithographic manufacturing– Progressive evolution to smaller scales– Consistent, local control of microscale

composition• Automated design, manufacturing processes

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Information Processing

• Dealing with massive complexity essential for and enabled by information revolution enables:– Design of complex structures and networks– Complex control algorithms and networks– Practical coordinated interaction of large numbers of

sensors and effectors– Analysis and understanding of complex natural systems

– designer molecules & biomimetic design

Chameleon Suit practicality

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Connectivity

• Data bus structures and approaches to enable flow of information among large numbers of cooperating devices with practical overhead– Data bus Ethernet Internet

• Wireless adaptations flexible geometry and topology

• Smaller, lower power access devices “smart dust”

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Recursive & Extensible Processes

• N-1th generation capabilities enable Nth generation design

• Progressive change in scale (smaller), complexity (greater)

• Extensible to additional degrees of freedom & new domains– MEMS– Microchannel systems

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Advanced Information Interfaces –Toward Thought Controlled Systems• Progress in sensors and signal processing

Robust research in thought controlled systems– Military systems & assistive systems and devices

• Complex spatial and temporal patterns of very low level signals– Noise, individual variability

• Extensive training, user concentration• Limited channel bandwidth < 10 Hz• Continued progress and research interest

Chameleon Suit applications potential

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Application Analyses and Results – Is the Concept Real?

• Thermal Control• Transport• Mobility• Mass Reduction• System Energy Balance• Implications for System Robustness• Artificial Photosynthesis Integration

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Thermal Control Viability –Passive & Beyond

CollapsedLayers

ThermoelectricModules

Heat Spreading LayerCarbon Velvet

Plastic

Heat Spreading Layer

Plastic Carbon Velvet

Gap (Vacuum) AluminumThread

Skin

Ambient Environment

Passive heat rejection from suit surface in most environments and at most work rates

Thin film thermoelectric devices in suit walls allow no expendables heat rejection at maximum work rate and lunar noon – worst case thermal environment – 250 W power input.

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Transport Membrane Integration

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Hole Spacing (in)

Req

uire

d Fl

ow A

rea/

Tota

l Sui

t Are

a

Laminar

Sharp-Edged Orifice

Analyses show that CO2 and humidity transport through suit insulation is consistent with thermal control design

0.0E+00

2.0E-06

4.0E-06

6.0E-06

8.0E-06

1.0E-05

1.2E-05

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

Hole Spacing (in)

Pre

ssur

e D

rop

per S

uit L

ayer

(psi

d)

Pressure drop component for flow through felt is negligible compared to the pressure drop through the holes in the suit which is ~0.008 psid per layer

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Assisted and Enhanced Mobility

• Active Fit, Assisted Mobility, Mechanical Counter Pressure

• Required performance parameters separately demonstrated in active materials

• Combined characteristics & environmental tolerance in sight

• Energy harvesting essential for assisted mobility & mechanical counter pressure

WristBearing

ScyeBearing Bearing

Arm

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System Mass Reduction

0

20

40

60

80

100

120

140

On Back Mass (Kg)

basephase1

2 3 4 5 6 7 8 9

Concept

On-Back Mass Reduction With Chameleon Suit Concepts

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System Energy Balance Current Phase 1

Suit Concept 1 2 3 4 5 6 7 8(W-hr) (W-hr) (W-hr) (W-hr) (W-hr) (W-hr) (W-hr) (W-hr) (W-hr) (W-hr)

DCM/CWS 80 80 80 80 80 80 80 80 80 80Radio 90 90 90 90 90 90 90 90 90 90Pump 40 20 N/A N/A N/A N/A N/A N/A N/A N/AFan/Separator Motor Ass'y 304 304 254 N/A N/A 254 N/A N/A N/A 254Circulation Fan N/A N/A N/A 125 125 N/A 125 125 125 N/AElectrochromics N/A 2 2 2 2 2 2 2 2 2Actuators N/A 150-300 150-300 150-300 150-300 150-300 150-300 150-300 150-300 150-300MEMS Louvers N/A 5 5 5 5 5 5 5 5 5Thermoelectrics N/A N/A 122-80 122-81 122-82 122-83 122-84 122-85 122-86 122-87Photovoltaics N/A N/A N/A N/A N/A N/A 0 to 3456 0 to 3456 0 to TBD 0 to 3456Oxygen Recovery N/A N/A N/A N/A N/A N/A N/A 2350 N/A 2350Net Energy Balance - MAX 514 801 853 724 724 853 724 3074 724 3203Net Energy Balance - MIN 514 651 501 372 372 501 3084 734 TBD 605

Phase 2 Concepts

ENERGY BALANCES FOR CHAMELEON SUIT CONCEPTS

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Implications for System Robustness

• Current reliability and life issues are eliminated:sublimator, gas trap, filters.

• Fewer duration limiting resources• Massively parallel systems graceful failure

responses (gradual performance loss)• Inherent environmental sensitivity• Central control or common power failures (design

mitigation)• Local thermal extremes possible with failures

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Artificial Photosynthesis Integration

• Materials and energy transport problem– Energy (light) available outside suit– Materials available (CO2, H2O), and

needed (O2), inside suit– Both must be together for O2

recovery• Energy transport

– As electricity (low efficiency)– As energetic intermediates?

• A satisfactory solution path has not been identified yet.

Suit Pressurized Volume

Unpressurized SuitInsulation Space

WasteCO2, H2O

O2Need

AvailableLight Energy

Transport?

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Summary – Vision for the Future • The seed has been planted and it will grow!

– The path is clear to revolutionary change– The required technologies are ripening for harvest– Targeted research is being explored with many

investigators – The vision of possibilities has been shared– The Chameleon Suit is on our technology roadmap

• Today’s unsolved problems are not insoluble• Perhaps the Chameleon Suit really will look like

those Star Trek images after allThe best possible space suit will be invisible

Documents

Chameleon Suit â€“ Changing the Outlook for EVA