PROGRESS REPORT ON DEVELOPMENT OF THE EXOMARS 2018 SPDS AND RELATED OHB SAMPLE HANDLING STUDIES ASTRA 2015 Workshop, 11 - 13 May 2015, ESTEC, Noordwijk

OHB System AG Dr. Lutz Richter ASTRA 2015, 11-13 May 2015

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Overview

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Recent results from on-going development of Sample Processing and Distribution Subsystem (SPDS) for ExoMars rover

Programmatic plans for evolutions of SPDS design targeted to other missions

Development activities on regolith sampling devices

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EXOMARS SPDS

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ESA ExoMars 2018 Rover Mission The ExoMars Rover:

carries a drill to collect rock and soil core samples from the Mars surface and underground (depth down to 2m)

accommodates the Analytical Laboratory Drawer (ALD) with the ‘Pasteur’ Payload, a set of instruments for the search of extant and extinct life on Mars, and the Sample Preparation and Distribution System

Credit: ESA

Credit: TAS-I

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The SPDS receives Mars rock and soil drill core samples from the Rover drill tool and prepares and presents them to the various analytical instruments.

The SPDS acts as the interface between the drill which is mounted to the outside of the Rover, and the following ‘Pasteur’ instruments in the Rover Analytical Laboratory Drawer:

Raman Spectrometer (RLS) MicrOmega Infrared Microscope (MICR) Mars Organic Molecule Analyzer (MOMA)

Gas Chromatograph (GC) Laser Desorption Mass Spectrometer (LD-MS)

The sample path and a major part of the SPDS is located within a sealed enclosure in the Rover/ALD (Ultra-clean Zone).

The ExoMars Sample Preparation and Distribution System (SPDS)

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CSHS

PSDDS

CS

PSHS

Drill deposits Mars sample

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What has happened since the last ASTRA conference

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SPDS flight design finalized In particular related to solving the incorporation of the static and dynamic

pressure seals, and with respect to a Vibration & Shock Mechanism now having become part of the

SPDS sample crusher mechanism Completion of critical component testing

Complex questions on the SPDS mechanisms’ materials coatings solved Driven by tribology and the need to sustain the ExoMars 2018 sterilisation and

ultra cleaning processes) Qualification Model MRR has been fully closed

Fabrication of SPDS QM under way, with integration and test activities now starting

Detailed development of the analytical laboratory (ALD) structure (task delegated to OHB by TAS-I) including the ALD pressurized Ultra Clean Zone (UCZ) surrounding the sample path

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System Overview

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ExoMars rover SPDS: sample processing & distribution subsystem is a key element in the rover’s analytical lab (ALD)

ALD ALD structure (with optical windows and depress. valve)

SPDS

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System Overview

Role of Planetary Protection

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ExoMars concept of ALD Ultra Clean Zone (UCZ): sample path at overpressure until after Mars arrival -> keep out terrestrial contamination

SPDS / ALD design drivers: Pressure seals across entire system (static and

dynamic): ca. 60 overall Compatibility with sterilisation & cleaning

methods: DHMR temperature (+125C) resiliciency, surface roughness, coatings No organic materials in UCZ

At OHB: ISO 8 integration & testing only, then delivery to TAS-I

Sample body for coatings investigations ALD metallic C-ring pressure seal

undergoing testing

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Sequence at TAS-I (already for SPDS QM)

10 ExoMars SPDS & ALD Structure

At TAS-I: SPDS (partial) disassembly UB cleaning DHMR sterilisation Introduction into Glove Box System

(GB1) CO2 snow jet cleaning (GB2) Re-integration (GB3 + GB4)

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Core Sample Handling Mechanism (CSHS) Core Sample Transportation

Mechanism (CSTM) input interface for transfer of the

core samples from drill to Rover/ALD

opens/closes the door of the ALD and Ultra-clean Zone

transports and delivers the samples to Crushing Station

Blank Sample Dispenser (BSD) stores six ‘blank samples’ and

dispenses them into the Crushing Station when needed

CSTM breadboard

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Sample container BB

Blister package

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Crushing Station (CS) Miniature jaw crusher, crushes raw

samples from drill to produce powder or small grain samples for further analysis by the Pasteur instruments

If a sample cannot be crushed/processed it will be released by opening the jaws (de-jamming mechanism) and dumped into a ‘waste bin’

Design recently enhanced by addition of a Vibration / Shock Mechanism (VSM)

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EM

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Powdered Sample Dosing and Distribution System (PSDDS) Two (redundant) dosing units are

mounted on a rotating arm, can be positioned either under the Crushing Station or over the carousel.

The dosing units dispense sample powder in amounts of 0.1 ml per dosing step.

The dosing function employs a revolving wheel with hollow pockets of defined volume which are filled with the sample material.

Piezo vibrators are used to ease sample discharging and cleaning

Alternative Sample Container (ATC) added: use to bypass dosing units if clogged

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rotation

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Powder Sample Handling System (PSHS) PSHS receives powder samples from

Dosing Station and presents them to the Pasteur instruments in Refillable container (RC) Pyrolysis ovens (MOMA GC)

Powder sample surface in RC is flattened by passing a flat blade over sample

Samples are positioned with high accuracy, relative to instrument viewing ports (MOMA LD-MS, MICR)

Sample handling under ultra-clean conditions in the Ultra-clean Zone

PSHS carousel

Flattening blade

Cleaning blade

Dosing funnel

Camera

Laser sensor

Orientation point

Waste container

MOMA

Camera

RC

PSHS elegant breadboard

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Effect of Mars Gravity SPDS mechanisms rely on the action of gravity in

the flow of granular samples from one mechanism to the next

Combination of testing on parabolic flights and numerical simulations applied to capture and understand effects of reduced gravity

Modeling approach chosen in simulations: DEM (Discrete Element Method), using measured inter-particle forces

Simulation and testing: agree in trends of sample mass flow as function of hopper shape and dimensions

Still from December 2012 TUM / LRT parabolic flight experiment with 2D hoppers (set of 3 hoppers

of different throat diameters is visible) (credit: P. Reiss, TUM / LRT)

SPDS DS funnel: DEM simulation

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Simulated mass flow at Mars g for different materials

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Some Components Aspects 1/2

Pressure seals: One main requirement for SPDS is to create and

maintain the ALD ultra clean zone (UCZ): at overpressure until after landing on Mars -> relevant SPDS requirements state allowed leakage rate of 5*10-6 std.cc/sec He at UCZ overpressure of 0.1 bar

OHB selected metallic (Inconel) C- and O-ring seals as static seals, and grease seals as dynamic seals (for actuator feed-throughs)

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Inconel C-ring seal used in SPDS

Test of ALD door with metallic pressure seal

Measured leak rate of MCI lid 2 seal during 2014 test campaign, for different temperatures and a delta pressure of 0.1 bar

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Some Components Aspects 2/2

Actuators: Dedicated delta development and qualification by

Maxon Motor for ExoMars (also: rotary encoder)

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Crushing Station De-Jamming QM actuator RE13 units with encoders

(development version)

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SPDS Control SPDS controlled by ExoMars Drill and SPDS Electronics Unit (DSEU / CEU)

(developed by SES)

Command sequences run autonomously

Some SPDS acitivities: require intervention from operators on Earth before committing to a subsequent step in sample processing : Initiation of sample crushing by the CS (assess nature of sample by imaging) Initiation of dosing of sample powder following crushing in the CS (verify

extent of crushing achieved) Initiation of a MOMA pyrolysis sequence on sample powder dosed into one of

the MOMA ovens (verify presence of sample first) Sensors within SPDS to enable autonomous sequences:

Rotary encoders Potentiometers Hall sensors (as proximity sensor to indicate ‘end stop’)

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SPDS Control

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Successful end-to-end test of SPDS breadboard system and DSEU / CEU EM electronics and S/W in early 2014

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SPDS Test Models and Test Campaigns 2007 to 2013: Breadboards of all four SPDS mechanisms and an engineering model

of the Crushing Station have been built for test purposes Functional tests were performed at ambient laboratory conditions, at low temperature

in a thermal chamber and in a simulated Mars environment (-50…-60°C, 5…10 mbar CO2) in the Mars Simulation Laboratory of the University of Aarhus (Denmark).

SPDS end-to-end test (E2E): successfully performed in spring of 2013 involving all SPDS mechanisms into a combined assembly (see ASTRA 2013 paper)

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E2E Test Results

Scenes from E2E ambient

testing (January 2013)

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SPDS Mass Budget

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ALD Structure

Since 2013: detailed development by OHB (delegated from TAS-I)

Incorporates the pressurized UCZ

Interfaces with rover primary structure

Carrying SPDS, the DSEU / CEU, Pasteur science instruments and thermal H/W ALD system overall: ~45 kg mass

Design drivers: mass, envelope, strength and pressure tightness severe shape integrity requirements imposed by MicrOmega

and RLS optical instruments Also part of OHB ALD structure task:

MicrOmega and RLS optical windows (metal to glass solder!) ALD pressure relief valve (to maintain constant overpressure)

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ALD Structure Mass Budget

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System / Subsystem / Component Part Number No.Nominal Mass

per unit [kg]Mass Maturity

Factor [-]FM-Design Mass

(Mbee) [kg]Mass maturity

margin (Mmm) [kg]Mass predicted (Mbee+Mmm) [kg]

Mass Require-ment [kg]

ALD Structure 1 9,667 0,15 9,667 1,437 11,097 9,400Upper Deck EXM-KT-DA-2230000-00 1 3,345 0,15 3,345 0,500 3,844 - Structure EXM-KT-DR-2230000-01 1 3,273 0,15 3,273 0,491 3,764 - MOMA Closure Plate EXM-KT-DR-2130000-02 1 0,035 0,15 0,035 0,005 0,040

- Manifold BracketEXM-KT-DR-2130000-03 (Man.Brck) 1 0,000 0,15 0,000 0,000 0,000

- Fasteners EXM-KT-DR-2130000-00-ENV 0,037 0,10 0,037 0,004 0,040Lower Deck EXM-KT-DR-2210000-00 1 3,165 0,15 3,165 0,468 3,633 - Structure EXM-KT-DR-2210000-01 1 2,690 0,15 2,690 0,404 3,094 - Isostatic Mount EXM-KT-DR-2110000-02 1 0,196 0,15 0,196 0,029 0,225 - Inspection Hole Cover EXM-KT-DR-2110000-03 1 0,017 0,15 0,017 0,003 0,020 - Inspection Hole Cover Seal EXM-GFD-DR-SEAL-S21 1 0,001 0,15 0,001 0,000 0,001

- In and Out Gas ConnectionsEXM-KT-DA-2111000-00EXM-KT-DA-2112000-00 2 0,036 0,15 0,072 0,011 0,083

- In and Out Gas Connections Seals EXM-GFD-DR-SEAL-S22 2 0,0002 0,15 0,0004 0,000 0,000 - UCZ Cover Seal EXM-GFD-DR-SEAL-S16 1 0,059 0,15 0,059 0,009 0,068 - TS Shim EXM-KT-DR-2110000-05 1 0,004 0,15 0,004 0,001 0,005 - Fasteners EXM-KT-DR-2110000-00-ENV 0,125 0,10 0,125 0,013 0,138UCZ Cover EXM-KT-DR-2220000-00 1 2,364 0,15 2,364 0,361 2,717 - Structure EXM-KT-DR-2220000-01 1 2,131 0,15 2,131 0,320 2,451 - PRV Seal EXM-GFD-DR-SEAL-S20 1 0,001 0,15 0,001 0,000 0,001 - CS Metal Seal EXM-GFD-DR-SEAL-S17 1 0,002 0,15 0,002 0,000 0,002 - PRValve EXM-KT-DR-2151000-01 1 0,108 0,20 0,108 0,022 0,130 - MOMA Seal EXM-GFD-DR-SEAL-S26 1 0,008 0,008

- RLS Window (Carrier, Window , seal and Cover)EXM-KT-DA-2121000-00EXM-GFD-DR-SEAL-S18EXM-KT-DR-2711000-02

1 0,030 0,20 0,030 0,006 0,036

- MicrOmega Window (Carrier, seal, Window & Cover)EXM-KT-DA-2122000-00EXM-GFD-DR-SEAL-S19EXM-KT-DR-2120000-03

1 0,047 0,20 0,047 0,009 0,056

- Fasteners EXM-KT-DR-2120000-00-ENV 0,037 0,10 0,037 0,004 0,041Struts EXM-KT-DR-2141000-00 12 0,054 0,14 0,652 0,094 0,746 - CFRP Rods Long EXM-KT-DR-2141000-01 8 0,018 0,15 0,144 0,022 0,166 - CFRP Rods Short EXM-KT-DR-2142000-01 4 0,015 0,15 0,060 0,009 0,069 - Connection 1 EXM-KT-DR-2141000-02 12 0,006 0,15 0,072 0,011 0,083 - Connection 2 EXM-KT-DR-2141000-03 8 0,006 0,15 0,048 0,007 0,055 - Connection 3 EXM-KT-DR-2145000-01 4 0,007 0,15 0,028 0,004 0,032 - Strut Pin Baseplate EXM-KT-DR-2140000-06 6 0,015 0,15 0,090 0,014 0,104 - Strut Pin Upper Panel 1 EXM-KT-DR-2140000-01 4 0,013 0,15 0,052 0,008 0,060 - Strut Pin Upper Panel 2 EXM-KT-DR-2140000-02 2 0,015 0,15 0,030 0,005 0,035 - Strut Pin Upper Panel 3 EXM-KT-DR-2140000-05 4 0,013 0,15 0,052 0,008 0,060 - Fasteners EXM-KT-DR-2141000-00-ENV 0,076 0,10 0,076 0,008 0,084General 1 0,142 0,10 0,142 0,014 0,156 - Rest of fastening 0,142 0,10 0,142 0,014 0,156

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Current Status: SPDS

Flight design of SPDS completed

Combined PDR / CDR for SPDS held and closed

MRR held and closed for build of SPDS QM system Is first build of the flight design

Manufacture of SPDS QM parts fully under way

Long Lead Items procurement for the SPDS QM complete

PSHS QM: First of the SPDS QM mechanisms to be integrated:

integration starting this month (May 2015) Over next 3 months: QM’s of CSHS, PSDDS and CS will

follow in staggered sequence, with qualification testing at OHB

Subsequent shipment of the SPDS QM to TAS-I

Start FM build August 2015

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PSHS QM carousel wheel (top), PSHS QM drive housing (right), SPDS QM potentiometer parts (below)

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SPDS Electromechanical Simulator Delivered

Needed for testing of DSEU / CEU in absence of ‚real‘ SPDS

Consists of sensors, actuators and brakes to simulate actual loads and command and feedback behaviours

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Current Status: ALD Structure

Since mid 2013: performed preliminary and then flight design of ALD / UCZ structure

Combined PDR / CDR held and closed

Pressure relief valve: development model built and under design optimisation

STM: first model: used for mechanical qualification

MRR for STM held and closed; STM parts in manufacture

STM followed shortly thereafter by the QM version

Start FM build November 2015

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Fit check of UCZ seal with ALD STM baseplate structure (top); ALD sample strut (below)

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2013 2014 2015 2016 2017

KO Adv C/D2

SPDS QM

2018

SPDS PDR close-out SPDS QM testing (OHB & TAS-I)

SPDS QR / CDR

SPDS PDR

ALD structure PDR

ALD str. PDR close-out ALD structure STM

ALD str. STM testing

ALD structure QM

ALD str. QM testing

ALD QM harness ALD QM harness delivery

STM delivery

QM delivery

FM manufacture & test

FM delivery

Support of TAS-I AIT & launch campaign FM acceptance

FAR Launch

today

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LUNAR APPLICATIONS

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Lunar Landing Missions

Space agencies preparing new round of robotic landing missions to the Moon, with particular focus on polar regions in pursuit of volatiles (now confirmed by variety of remote sensing techniques and LCROSS impactor experiment)

Roscosmos: Defined a series of lunar landing and sample return

missions – Luna-Glob / Luna-Resurs (LUNA 27) / Luna Sample Return – targeted to the lunar poles

Coordination between ESA and Roscosmos to discuss ESA contributions to new programme : one of them: PROSEED: package of sampling drill and analytical instrument

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LUNA 27 configuration

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Preparatory Studies in ESA Programme

L-GRASP: ‘Lunar Generic Regolith Acquisition / Sampling Paw’ led by SES, OHB Munich as subcontractor Lunar regolith sampling device as part of a rotary- percussive

drill compatible with a lunar polar site and subsurface access down to 2 m of depth, reflecting the requirements of the LUNA 27 mission

Icy lunar regolith simulant defined and produced, sampling device breadboard designed and now built,

Testing upcoming ProsPA: ‚Lunar Polar Prospecting: Processing and Analysis’

led by The Open University, OHB Munich as subcontractor Investigates the analytical instrument proposed for LUNA 27

(analysing the samples acquired by the subsurface drill) OHB responsible for “Sample Inlet System” (SIS): similar to

ExoMars SPDS PSHS carousel: carries ovens to be sequentially filled with samples , includes oven sealing mechanism

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Icy regolith sample following strength testing by penetrometer

Test set-up at OHB for measuring ProsPA oven sealing forces and leak rates

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CONCLUSIONS

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Conclusions OHB Munich (ex Kayser-Threde) developing ExoMars SPDS (sample handling and

distribution S/S) and structure of ExoMars rover Analytical Lab housing the SPDS

Recent major achievements Close-out of SPDS flight design and build of SPDS QM Close-out of ALD structure STM design and build of STM

Critical lessons learned: Reduced gravity, powder adherence (cross contamination), mechanisms in (self-

generated) dusty environment, designing for stringent planetary protection and cleanliness requirements, manufacturing technologies for ‘unusual’ parts with tight tolerances

Lunar polar scenarios: Sampling from, distributing and analysing ice-rich regolith (need to preserve volatile

contents) OHB Munich involved in L-GRASP and ProsPA lunar sampling and analysis studies

targeted to Russian LUNA 27 scenario

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Acknowledgement

The work reported in this paper was performed by OHB System (Germany) under contract to Thales Alenia Space Italia (TAS-I), the ExoMars mission prime, with funding from the European Space Agency. Several external entities contributed as project partners. The authors wish to thank ESA and TAS-I.

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