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The tower-like abort structure is specifically built for deep space missions and to ride on a high-powered rocket. It is positioned with its motors on top of the Orion crew module and designed to pull the crew module away from the rocket, rather than push it away with motors at the base, as some other escape systems are built to do. This design minimizes the mass that aborts in an emergency by leaving the service module behind.
The crew module is the pressurized part of the Orion spacecraft, sometimes referred to as the capsule, where crew will live and work on their journey to the Moon and back. The crew module can accommodate four crew members for up to 21 days, and provides a safe habitat through launch, on-orbit operations, landing, and recovery. The crew module contains advances in life support, avionics, power systems, and advanced manufacturing techniques, and is the only portion of Orion that returns to Earth at the end of flights.
Inside the crew module, environmental control and life support systems maintain cabin temperature, pressure, humidity, oxygen, and carbon dioxide levels, keeping crew healthy and comfortable on long missions. A cockpit with glass displays allows full control of Orion by the crew. The sealed capsule also provides radiation protection needed to safeguard crew and spacecraft systems from cosmic and solar radiation seen in deep space, and micrometeoroid protection from items found in the space environment.
The underlying structure of the crew module is called the pressure vessel. The pressure vessel consists of seven large aluminum alloy pieces that are joined together using friction-stir welding to produce a strong, yet light-weight, air-tight capsule. The seven major structural pieces include the barrel, tunnel, forward and aft bulkheads, and three cone panels. Original designs had 33 welded pieces, but the Artemis I crew module and beyond have seven welded pieces, improving manufacturability and saving more than 700 pounds of excess weight.
The floor structure where the crew seats are attached and where the crew stowage lockers are located is called the backbone assembly, which is a nine-piece bolted structure of crisscrossing beams. The backbone, made of aluminum, also provides additional structural support for the crew module. Most of the equipment the crew needs to live in space, such as food, medical kits, emergency equipment such as masks and fire extinguisher, sleeping bags, and the pressure suits worn for launch and return to Earth are stored in lockers located here.
The crew module includes a number of mechanisms that provide the way to enter and leave the module through hatches. It also includes mechanism that provide docking capability for on-orbit activities with other spacecraft, as well as as mechanisms for the separation or jettison functions from other parts of Orion when the crew module needs to separate for entry and landing.
To push Orion to its destination, the service module is equipped with a total of 33 engines: one main engine (NASA-provided refurbished Orbital Maneuvering System engine (OMS-E); eight auxiliary engines (NASA-provided Aerojet R4D-11), and 24 reaction control thrusters (ESA-provided engines that are the same model as those used on the Automated Transfer Vehicle (ATV). These three types of engines provide the propulsion for lunar orbit injection and return to Earth, as well as attitude control for the crew module. The propulsion system can also be used, during some late phases of the launch, for crew safeguard during potential abort scenarios.
Built by Thales Alenia Space in Italy, the primary structure of the service module is the backbone of the entire vehicle. Like the chassis of a car, the structure holds everything together. It is covered with Kevlar to absorb shocks from micrometeorites and debris impacts.
A crew module adapter connects the capsule to the service module. The crew module adapter houses electronic equipment for communications, power, and control, and includes an umbilical connector that bridges the electrical, data, and fluid systems between the main modules.
A consumable storage system provides potable water, nitrogen, and oxygen to the crew module. Potable water is provided by the water delivery system and stored in four metal bellow tanks, covering usable water needs of the crew for the duration of the mission. Oxygen and nitrogen are provided by the gas delivery system and stored in four tanks, the allocation of the tank to each gas being mission dependent.
The Orion spacecraft houses a number of state-of-the-art avionics units to handle data generated by on-board systems, control the various functions of the spacecraft, execute commands sent from Earth or by the crew, and return systems telemetry for insight into systems status.
The brains of the Orion spacecraft consist of two vehicle management computers (VMC), manufactured by Honeywell. A VMC is a robust system that delivers more computing power to the Orion spacecraft than any
Eight power and data units (PDU) connect the flight computers and the software to the rest of Orion. These PDUs control the power to every component on the vehicle and they control effectors such as valves, thrusters, and heaters. All sensor data such as temperature and pressure are routed through the PDUs as well. The PDUs also play a critical role in communicating with the rocket that launches Orion and puts it on its trajectory to the Moon.
The guidance, navigation, and control (GN&C) system is responsible for always knowing where the spacecraft is and where it is going, and controls the propulsion system to keep Orion pointed in the proper direction and on the correct trajectory.
At the center of this system is the GN&C flight software (FSW) that executes on the VMCs. This software receives inputs from navigation sensors and pilot controls and commands the appropriate effectors on the crew module, service module, and launch abort system to accomplish mission objectives. The Orion GN&C software operates across a variety of mission phases, including pre-launch, ascent, Earth orbit, transit to and from the Moon, loiter, rendezvous, docking, entry, and various abort scenarios. The software must operate in both manual and automated modes, and must handle commands from the crew and the ground. The software must also execute complex guidance and navigation algorithms while controlling highly dynamic configurations during entry, ascent aborts, and orbital maneuvers. The resulting range of algorithm types drives a multi-rate architecture to meet central processing unit usage allocations.
Orion also has a number of cameras inside and outside of the vehicle to help the crew with tasks like docking, interviews and public outreach events, medical conferences, and to help gather engineering pictures and video to make sure the spacecraft is performing properly. Each of the solar array wings has a wireless camera near the tip that can be pointed to inspect the exterior of the spacecraft and to provide some views that are out of this world.
The Orion displays and controls are designed for an intensive amount of crew interaction both in nominal and off-nominal scenarios. Electronic procedures have been developed for Orion that allow direct interaction with the display formats enabling reduced workload on the crew. The electronic procedures efficiently step the crew through planned tasks and reduce crew workload by highlighting various telemetry on a display format or queuing up commands. Additionally, the electronic procedures have built in links to the onboard caution and warning system which alert the crew when onboard faults and anomalies occur. The electronic procedures link provides the ability for the crew to bring up electronic procedures which communicate the urgent actions the crew need to take in order to address the caution and warning condition.
The developmental flight instrumentation (DFI) data system is required to measure unique subsystems performance during all phases of flight from launch, cruise, and return to Earth. The DFI diagnostic instrumentation system is required to measure the response of newly designed components and structures to verify and validate engineering models that will be used to predict their future performance.
The architecture of the DFI system is very robust and relies on proven hardware and software to deliver high reliability. The central components are data acquisition units which have two interfaces: one for the sensor interface, and one for the control interface. The sensor interface communicates with the temperature, strain, accelerometers, and acoustic sensors. The control interface in turn communicates with the power, control, recording, telemetry, and time-sync hardware. The sensors can be changed between flights to allow engineers to make adjustments based on what is learned about a previous flight.
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