P19127: XHab Deployable Crew Lock Structure
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Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

During the Detailed Design phase, the team reflected on the feedback given during the preliminary detailed design review given by Dr. DeBartolo on the deployment mechanism and budget problems. Using this feedback, a redesign of the deployment mechanism and bulkheads will be made in order to create a more robust deployment mechanism. A greater focus on ergonomics and the deployment system will be used during this redesign process. In addition, the electrical components and schematics will be further detailed out. Finally, the BOM will be completed with all necessary items, and a budget increase request will be made for the BOM items.

Important Note

All previously displayed feasibility analysis, pictures, and documents in Preliminary Detailed Design involved with the bulkhead, vacuum barrier, and ergonomics are still applicable in this phase. Please download the pre-read design review material in the section at the bottom of this page for a comprehensive package of design documents. The presentation for this phase is also a good representation of everything backing the design of the Crew-Lock up until the Final Detailed Design Review.

Subsystems Design Chart

The updated Subsystems Design Chart for this phase can be seen below:
Subsystem Design Tree

Subsystem Design Tree

Phase IV Technical Changes

Change Management Documentation

Below are the changes made to the Crew-Lock design during this phase. The Change Management Excel sheet can be downloaded in the Design Review Materials Section at the bottom of this page.
Change Management - Phase IV

Change Management - Phase IV

Customer Requirements

The Customer Requirements can be downloaded the Design Review Materials Section at the bottom of this page.
Customer Requirements - MSD I

Customer Requirements - MSD I

Engineering Requirements

The Engineering Requirements can be downloaded the Design Review Materials Section at the bottom of this page.
Engineering Requirements - MSD I

Engineering Requirements - MSD I

Project Requirements Confirmation

Below is a document that outlines the fulfillment of Engineering and Customer Requirements by Subsystems and Test Plans. This Excel sheet can be downloaded the Design Review Materials Section at the bottom of this page.
Engineering and Customer Requirements Confirmation Matrix

Engineering and Customer Requirements Confirmation Matrix

Feasibility: Prototyping, Analysis, Simulation

The first analysis involves the feasibility of the threaded rod deployment system.
Threaded Rod Deployment Analysis

Threaded Rod Deployment Analysis

The next analysis involves the vacuum barrier material selection thought process as outlined in the Pugh chart below. The final selected material, Thermoplastic Polyurethane, balanced all of the best aspects.
Vacuum Barrier Material Selection Pugh Chart

Vacuum Barrier Material Selection Pugh Chart

The final analysis involves the analysis of friction and force needed to push the testing rig and bulkhead.
Testing Rig Friction Analysis

Testing Rig Friction Analysis

Schematics, Drawings, Prototypes, and 3D Models

3D CAD Models of Crew-Lock and Test Rig

Below are various CAD model views of the 1/4th scale Crew-Lock concept and the testing rig. The parts have been given mechanical properties and appearances similar to the actual items to be purchased on the BOM. Inaddition, the Electrical schematics are displayed below, The CAD files for both electrical and mechanical components can be downloaded from the Design Review Materials section at the bottom of this page.
Crew-Lock Undeployed View

Crew-Lock Undeployed View

Crew-Lock Deployed View

Crew-Lock Deployed View

Crew-Lock Deployment Mechanism View

Crew-Lock Deployment Mechanism View

Crew-Lock Preliminary Testing Rig View

Crew-Lock Preliminary Testing Rig View

Electrical and Controls Schematics

Circuit Diagram for Controls and Actuation

Circuit Diagram for Controls and Actuation

Process Flow Diagram

Process Flow Diagram for Crew-Lock

Process Flow Diagram for Crew-Lock

Bill of Material (BOM)

Below is our detailed BOM, BOM breakdown, and Lead Times summary. The information can be downloaded from the Design Review Materials section at the bottom of this page.
Final Crew-Lock BOM

Final Crew-Lock BOM

BOM Breakdown

BOM Breakdown

Lead Time Summary

Lead Time Summary

Test Plans

Below are our test plans for the Crew-Lock subsystems. These test plans will be further fleshed out during the Build and Test prep phase of this project. The Excel sheet can be downloaded from the Design Review Materials section at the bottom of this page.
Test Plans for Subsystems

Test Plans for Subsystems

Risk Assessment

Below is an summary of changes to the risk management file. The full risk management file can be downloaded in the Design Review Materials Section at the bottom of this page.
Phase IV Updates to Risk Assessment

Phase IV Updates to Risk Assessment

Conclusions for this Phase

During this phase, the team was able to receive a budget increase, which increased the project budget to $1500. This new total allowed the team to increase the quality of the electrical system (creation of a PCB), put in more effort into ergonomics (more handles and lighting), and create a new deployment system from scratch (threaded rods). This budget increase did not expand the overall project's scope; in fact, the scope decreased as the team decided that the hatches would not be implemented into the full-scale model due to the lack of air-tightness and actual functionality or worth to the project. Electrical and Mechanical CAD were given more detail, and the BOM was populated to include all required components for the building of the final, scaled Crew-Lock.
Tasks to Complete for MSD II

Below is an image of the MSD II schedule. The Excel sheet can be downloaded from the Design Review Materials section at the bottom of this page.

Master Schedule - MSD II

Master Schedule - MSD II

Detailed Design Phase Review Notes

Starting Date Ending Date Meeting Notes
November 2018 December 2018 Design Review Notes - Detailed Design Phase

Design Review Materials


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