Systems Engineering Evaluation

of a Mars Habitat Design

Klaus, D., Chluda, H., Ellis, T., Fehring,
J., Howard, H., Jairala, J., Lloyd, T.,
Matthews, D., Morris, K., Rowley, K.,
Sauers, C. and Stephens, T.
Aerospace Engineering Sciences Department
University of Colorado, Boulder, CO

Published as SAE paper 04ICES-187, Copyright ©2004 SAE International

Space Habitat Design Class Project
CU Aerospace Engineering Sciences
ASEN 4158/5158, Fall 2003

Develop Martian habitat per NASA’s Design

Reference Mission (DRM)
[Hoffman and Kaplan, 1997; Drake, 1998]

• Overall plan for a human Mars mission

• Top level requirements, little detail

DRM modified to narrow scope of project

• Less than one semester to complete
Presentation Focus

- Primary design drivers

- Integration complexities

- Some ‘not so obvious’ challenges

Overall Project Goal
Establish a Martian Habitat
capable of supporting humans

Level 1 Requirements
• Support crew of 6
• Support 600 day stay without re-supply
• Maintain health and safety of crew
• Minimize dependency on Earth
Key ‘Level 1’ Design Drivers
80 metric ton launch vehicle
• Recommended total habitat mass < 36,154 kg
Habitat deploys 2 years before first crew
Standby mode for 10 months between crews
Mission critical: 2-level redundant
Life critical: 3-level redundant
Integrate In Situ Resource Utilization (ISRU)

[Hoffman and Kaplan, 1997; Drake, 1998]

Organizational Breakdown
Project-level Design Drivers
Rationalize the design by Trade Study
Plan for crewed operations & automation
Governing Documents
• DRM [Hoffman and Kaplan, 1997; Drake, 1998]
• Man-Systems Integration Standards (MSIS)
[NASA-STD-3000 rev. B, 1995]

Coordinate with Auburn Univ. Design Class to

develop common IRD for a Cargo Carrier
Key Assumptions Made
Only first surface habitat (Hab-1) designed
• Mars surface ops only
Focus on surface operations
• Launch, transit, Mars landing considered
Define interfaces with external equipment
• Rovers, power supply, ISRU unit
Crew will use habitat on arrival (not transit)
Systems Engineering and
Integration Responsibilities
Identify and derive subsystem requirements
Ensure requirements met (verification matrix)
Control subsystem interfaces
Review and reconcile subsystem design issues
Integrate mission operations
DRM Mass Recommendations
Subsystem Mass Estimate [kg]
Structures 20,744
Power 3250
ECLSS 4661
Thermal 550
Crew Accommodations 5000
C3 320
EVAS 1629
Total 36,154
 Mars Environment
ISRU
Plant
Legend
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

 Mission Ops Responsibilities
Establish hardware operational needs
Identify crew ops (vs. automated)
Develop schedule templates
Identify status data to provide crew
Characterize failure scenarios (FMEA)
and address off-nominal conditions
Structures Key Design Drivers
Fit within the dynamic envelope of the launch vehicle†
• Launch Shroud (7.5 m D X 16.3 m L)*
Structurally sound in all load environments†
• Launch, transit, landing, surface
Mass limit 20,744 kg*
Radiator

Pressure shell
Horizontal Orientation† Radiator Radiator
Airlock
• Stability
• Expansion Radiator
• Emergency exits

* [DRM] † Derived
Historic Volume Comparison

MOB

Aurora

[Larson and Pranke, 2000]

C3 Key Design Drivers

Allow checkout of habitat prior to crew arrival†

Include audio/visual caution and warning
alarms†
Facilitate Earth-based control and monitoring†
Provide local area communication with rovers
and EVA crewmembers†
Mass limit of 320 kg*

* [DRM] † Derived
C3 Design Overview
Command and control subsystem
• Based on ISS C3 subsystem
• Habitat interfaces:
• 3 tiered architecture
• Mil-Std-1553B data bus (old, but proven)
• User interfaces: personal workstations, file server,
caution and warning subsystem
External communications subsystem
• Based on ISS, Shuttle and Mars probes
• High gain communications via Mars orbiting satellite
• DSN comm with Earth
• Local area UHF communications
 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

Power Key Design Drivers
Supply and transfer power to the habitat from
the surface nuclear reactor*
Supply power with 3-level redundancy†
• Reactor, batteries, solar panels
Distribute power on a multi-bus system†
Provide an emergency power cutoff†

Subsystem mass limit 3250 kg (including in-

transit power supply)*

* [DRM] † Derived
 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

ECLSS Key Design Drivers
Provide a physiologically acceptable environment for
humans to survive and maintain health

Heat 0.1 kW/p/d

O2 0.636 – 1 kg/p/d
Potable H2O CO2 0.726 – 1.226 kg/p/d
2.27 – 3.63 kg/p/d
Respired & Perspired H2O 2.28 kg/p/d
Food (dehydrated)
0.5 – 0.863 kg/p/d Sweat Solids 0.02 kg/p/d
(2200 kCal/p/d)

Urine (solid & liquid) 1.27 – 2.27 kg/p/d

Feces (solids & liquids) 0.12 kg/p/d

Hygiene H2O Atmosphere System

1.36 – 9 kg/p/d Water System
N2 Waste System
Food System

[Eckart, 1994]
ECLSS Subsystem Design Crew Accommodations
(shower, washer, etc.)
& EVA (EM U cooling)

Food Water
Ultra Filtration
S ystem S ystem
Hygiene Water RO AES Brine water
Food Iodine Removal VCD
M onitoring M illi Q
Preparation Bed
Pretreated Urine
Food ISE M onitoring M CV Iodine
Trash Pretreatment Ozone,
Potable Water Sulfuric Acid

Atmosphere Waste
S ystem Fecal S ystem
TCCA SPWE Urine
H2
Vent
to Compactor
Atmospheric
Condenser M ars Solid Waste
EDC Atm. Compactor Storage

(From ASEN 5116 Study)

 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

Crew Accommodations Key Design Drivers
http://www.robots.org/images/CyberArts/hablower1.jpg

Crew hygiene
Hab cleanliness
Psychological support
Crew physical health
• exercise & monitoring history.nasa.gov/ SP-4213/ch4.htm
• medical services
John Frassanito & Associates

Human Factors
• comfortable
• efficient

[Larson and Pranke, 2000]

http://msis.jsc.nasa.gov/sections/section03.asp

liftoff.msfc.nasa.gov/academy/
astronauts/exercise.html
gospelcom.net/rbc/ ds/cb922/point8.html
Trade Study Example
Clothes/Linens Options:
• Bring All
• Hand wash
• Washing Machine

Trade-offs: www.sears.com

Bring All Hand Wash Washing Machine

Total Mass: 2250 to 5400 kg Total Mass: 1554 kg Total Mass: 1604 kg
Washing Ops: 0 hrs/month Washing Ops: 12 hrs/month Washing Ops: 1 hr/month

Decision: Washing Machine

[http://theguardians.com/space/orbitalmech/stationoutput.html]
[http://www.shoalwater.nsw.gov.au/1yourwater/audit.html]
[Larson and Pranke, 2000]
Robotics and Automation
Provide for interfaces for local transportation†
• Minimum of two small rovers for scientific exploration
• One medium rover for local transportation
• Two large pressurized rovers for long exploration

Deploy and operate various mechanisms on habitat†

• Automated hatches in case of depressurization
• Deployment of communications hardware and radiator panels
• External monitoring of systems and scientific equipment
• Leveling of habitat and deployment of airlocks
Extravehicular Activity Systems

EVA Systems (EVAS)

• EVA suit
• Pressurized Rover
• Airlock

NASA
EVAS – EVA Suit
Requirement drivers
• Minimize mass and storage volume
• Maximize mobility and dexterity
• 4.3 lbs/in2 internal operating pressure
• Regenerable, durable, reliable, maintainable
• 430 hours of cumulative use
- 13 suits (6 primary, 7 backup)
- 2x2 crew EVA’s / week
Interfaces with habitat
• Water
• Potable
• Non-potable
• Oxygen
• Waste water
• Power
• Data/Comm
EVA - Key Design Driver

EVA is a primary driver of ECLSS

•Suit P  Base P
•Prebreathe time
EVAS – Pressurized Rover
• Nominal crew of 2
– 4 in emergency*
• Rover airlock capable
of surface access and
direct connection to
habitat*
• Per day, rover can
support 16 crew hours
of EVA*
• 20 day maximum excursion*
• Facilities for recharging PLSS
and minor repairs to EVA suit† [Larson and Pranke, 2000]

• Interfaces with Hab

– ECLSS, C3, Power, Structures

* [DRM] † Derived
EVAS - Airlock
Independent element capable of being relocated [DRM]

10% air loss per sortie (after initial cycle) [DRM]

Three airlocks
• Two operational
• One emergency/back up
Sized for three crew members
• Two operational EVA suits
• One emergency/back up EVA suit
Airlock interfaces with habitat
• ECLSS, C3, Power, Physical
 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB EVAS Subsystem Functional Diagram

Thermal System Key Design Drivers
Maintain a heat balance with all subsystems over all
Martian temperature extremes within operating limits†
• Heat Load / Rejection Capacity Balance
• Average / Peak Power

Accommodate transit period and surface of Mars †

Auto-deployed and activated†

Report status for communication to Earth†

Mass shall not exceed 5000 kg†

• originally 550 kg*

* [DRM] † Derived
Worst Case Thermal Scenarios
• Hot - Hot
– Occurs on hottest day
– Peak power usage
– No structure heat losses / heat gain
– Crew highest metabolic output
• Cold - Cold
– Occurs on coldest night
– Minimal power usage
– Maximum structure heat losses
– No crew
 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

 In-Situ Resource Utilization (ISRU)
Demonstrate potential use of Martian resources
Interface between habitat and ISRU plant
Non-critical system (i.e. no backups)
Provide additional oxygen, nitrogen, and water*
All interfaces shall tolerate leaks within limits†
Acceptable temperatures shall be maintained†
Storage interfaces must be compatible with
habitat†
Pumping systems shall have adequate power to
[NASA/JSC image ]
transport O2, N2, and H2O to habitat†
Piping must have adequate protection for Mars Environment†
Interfaces to habitat storage tanks and ISRU tanks can be
connected using robots or humans †

* [DRM] † Derived
ISRU (Mars Environment)

Provide consistent data set specific to hab site

• Thermal, Radiation, Pressure, Light Levels,
Atmosphere, Wind, etc.

Carbon Dioxide
Nitrogen
Argon

2.7 Oxygen
95.32 Carbon Monoxide
1.6 Water Vapor
Neon
Krypton
Xenon
0.24 Ozone
 Mars Environment
ISRU
Plant
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

 Mars Environment
ISRU
Plant
Legend
Oxygen
Nitrogen
CO2 Robotics/
Cabin Air Structures
Trace Contam. Automation
H20 Vapor
H2
Potable H20
Non-Pot. H20
Solid Waste
Liquid Waste ISRU
Food
Thermal
Telemetry
Video
Audio ECLSS
Packet. Data
TCP/IP C3
Command
Heat Power EVAS
Electric. Power

Nuclear
Reactor
Crew
Crew
Accommodations
Mars
Com
Satellites Habitat Boundary

MOB Habitat Overall Subsystem Functional Diagram

Habitat Design Summary

Mass = 67,910 kg
- Exceeds DRM by 31,756 kg
Total Volume = 405 m3
- 210 m3 of usable volume
- Meets DRM max allowable
Maximum Power = 42.6 kW
- Exceeds DRM by 17.6 kW
- Overall Reactor = 160 kW
Key Future Challenges
EVA Suit P / Habitat P  ECLSS Selection & Prebreathe Ops
Transit (0g) vs. Surface (1/3 g)  ECLSS Selection
ISRU  systems cost-benefit analyses  ECLSS Selection
Mission Ops  C3 Bandwidth  DSN capacity oversubscribed
Orientation trade study  Vertical landing / Horizontal setup
Crew Accommodations  Incorporate ‘Crew FMEA’ into Design
Waste disposal  Hab Sanitation and Mars contamination concerns
Heat Rejection  subsurface heat sink vs. panel dust accumulation,
structural thermal analysis inputs
Parting Thoughts…
Mars Hab Design demands a unique merger of:
- Systems Engineering (trade studies and mass flows)
- Architecture (mission and structural)
- Human Factors (and physiological deconditioning)

Start with the Human ‘subsystem’

Consider TRL (vs. Phase C/D) and End-of-Life
Performance (degradation factors)
Potential concern re. health maintenance
Acknowledgements
Professor: David Klaus, Ph.D.
Graduates: Heather Chluda, Bronson Duenas, Teresa Ellis, Jeff
Fehring, Keric Hill, Heather Howard, Juniper Jairala, Nancy
Kungsakawin, Tim Lloyd, Dax Matthews, Keith Morris, Keagan
Rowley, Christie Sauers, Eric Schleicher, Meridee Silbaugh, Tyman
Stevens and Jennifer Uchida
Undergraduates: Sam Baker, Eric Dekruif and Tom White

Lockheed Martin Reviewers: Calvin Craig, Tim

Gasparrini, Stephen Price, Ben Clark (and Steve Jolly)

Mars Society Reviewers: Dewey Anderson, Ray McCall,

Tony Muscatello

Course URL: http://www.colorado.edu/ASEN/asen5158/