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2021 NASA Break the Ice Lunar Challenge

The Pennsylvania State University - Student Space Programs Laboratory

Design of a system architecture to excavate Icy regolith and deliver acquired resources in extreme lunar conditions

January 2021 - April 2021

This project is a technology development proposal developed for a NASA-run competition. Given the problem, a team of students and I worked to create a solution.

Background

The 2021 NASA Break the Ice Lunar Challenge (BtI) is a competition created by NASA to challenge undergraduate students to solve an icy issue. The mission of the competition is a hypothetical scenario similar to a real-world lunar mission. According to NASA:

Teams will design a system architecture to excavate icy regolith and deliver water based on the locations and sites, environmental conditions, terrain, icy regolith specifications, and hypothetical NASA assets described below.

The Mission Scenario takes place in and around a permanently shadowed region (PSR) near the lunar South Pole. In this scenario, the mission will last 365 Earth days.

The Mission Scenario includes three NASA assets: a NASA Power Plant, NASA Power Distribution, and a NASA Water Extraction Plant. These assets are described in detail below in the NASA Assets section. Teams are not required to use these assets.

Teams’ architectures must:

a. Excavate icy regolith at the Excavation Site

b. Extract water from that icy regolith using the NASA Water Extraction Plant or their own method

c. Deliver that water to the Delivery Site

Although there is no minimum mass of water that must be delivered, NASA is most interested in system architectures that can deliver at least 10,000 kilograms (kg) of water over the duration of the mission.

My Involvement

The PSU Student Space Programs Laboratory BtI Team developed the project far into the brainstorming phase. One of the requirements of the submission was to include a 3-D animation of the technology in motion. The team management could not find an animator to create this, so they canceled further developments of the project.

Despite the unfortunate end of the project, I put a lot of hard work into my tasks and the design of the technology. When I joined the team, I was assigned the task of researching the use of different wavelengths of light to melt ice into steam. I discovered that microwaves could heat water effectively at a distance of 0 to 20 cm away from the waves’ origin. Radio waves are effective for water between 20 and 350 cm away. The proposed design of the payload at the time was a rover that would use a tent to capture steam into a cold trap. Considering that the rover was not intended to break the surface, I proposed we used only radio waves as a heat source.

To do this, I investigated commercial Radio Frequency (RF) heating devices, which are used in large-scale bakeries. RF Heating sources are available in power levels up to 500 kW continuous power output at ISM frequencies in the range of 3 to 30 MHz. References showed that RF heating can be effective to extract water vapor from permafrost using a heating source comprising a 30 kW device operating at a frequency of 27 MHz.

However, several issues came up with this idea. First and foremost, RF heating requires the material to be heated to be placed between two plates. Radio frequencies are bounced in-between to stimulate the water molecules within the material. To use RF heating in a lunar environment, I had to figure out how to put the regolith between two plates. The second problem stood as a question as to how the steam will reach the surface if there is no breach of the ground.

The team took a lot of inspiration, in many parts, from a patent by Trans Astra. They designed a rover that also used RF heating and a cold trap mechanism to gather water on the lunar surface. The patent involved three ground-penetrating probes that are connected in parallel. They used a commercial RF heater for their experiments. The three penetrating probes at one end of the regolith container are connected in push-pull with the three probes at the other end. This will provide strong RF fields from end to end through the simulated regolith. This solved the two-plate issue. Implementing rods into the design would allow the radio waves to flow through the regolith. However, this did not solve the ground breach issue.

While steam could rise through certain materials in certain conditions, I assumed that there could be no guarantee that the regolith on the surface would be that porous. In addition, the region to which NASA would send the payloads is a Permanently Shadowed Region (PSR). This absence of sunlight makes for a very, very cold temperature. According to NASA’s Break the Ice Mission Scenario, the surface temperature ranged from 50K to 200K, with an average summer temperature of 130K and an average winter temperature of 80K. To express how cold these temperatures are, the highest temperature (200K) equals -99.67 degrees F and -73.15 degrees C. This type of temperature guarantees that the surface regolith will be extremely hard and solid. From here, I concluded that my research has led me to a dead-end for the direction the project was going: the steam needed an escape.

It was then that I began to play around with the idea of a drill. I looked at traditional, Earth-based drilling systems to get inspiration. One of the first ideas I had was to replace the six probes with long, thin drills that contained the radio wave generation hardware inside. However, again running into the breach problem, I decided to work on a design for one single drill.

The drill I had in mind was a large auger. I considered perhaps winding the RF probes into the twin helix blades on the auger. However, with concerns about the durability and safety of the probs in such a position, as well as the balance of electric fields within the auger, I decided against it. In the unbeknownst final weeks of the project, I began to develop the design shown below.

My idea is as follows:

  • – A robotic arm holds the entirety of the drill such that the volume of the rover could be reduced
    • – The arm would also allow for more flexible usage of the auger
  • – The arm holds a box that holds the auger to the arm
    • – The box would include rollers/motors to move the auger up and down and to spin it
  • – Attached to the box is a spring and a huge, cone-shaped funnel, which would be made of a solid, inflexible material
    • – As the auger moves down into the regolith, the box and spring would push down onto the funnel
    • – This creates a potential water-tight fitting
  • – Attached to the funnel would be four to six probes
    • – The probes, in theory, would be housed inside long, thin drills

This would result in a large hole that would have the auger mixing the regolith and ice within it. Surrounding the hole will be several probes. The probes will feed radio waves to each other, passing through the larger hole. A mixing auger speeds up this process by not only crushing the ice (if found in larger chunks) into small, fine pieces, but the mixing moves regolith around allowing for steam to rise. The steam will find its way into the large funnel. The water-tight mechanics of the funnel allow for increased efficiency of the process by reducing the amount of steam escaped. From there, a vacuum would be attached to the funnel, sucking up the steam. The steam would be accelerated into a cold trap, storing the water in liquid form.

I also had a few other ideas, including ditching the probe idea and simply mining regolith. The auger would be used to move regolith up into the rover, where a storage container would be hooked up with an RF heater. Since another team member estimated that the rover would only be able to make one trip a day, I figured it would save time to simply heat the ice, turn it into steam, then trap it/store it in liquid form WHILE it was driving to its destination.

This was as far as I got with the design before the plug was pulled on the project.

In addition, I did a lot of mathematical tinkering in the final weeks of the project. NASA was hoping that teams could provide 100,000 kg of water per year and I was curious if or how my system could pull it off.

Considering the auger would make a cylindrical hole in the ground, I looked at the diameter and depth of the hole and cross-referenced it with the amount of water present in the regolith. The amount of ice present in the regolith changed the deeper one would go, so I had to consider that. There were several other factors I had to consider, including porosity and density. You can see my calculations for this below.

Looking at 10,000 kg per year, the rover would need to excavate 27.4 kg of water per day. I set up equations that considered the radius and depth of the hole and put them into a graph. The red line represents the possible configurations of radii and depth to achieve the 27.4 kg goal. However, the equation driving that line only considers the fact that the regolith between .2 m and 1 m is 4%. Past 1 m and up to 3.5 m, there is 10% ice. So once the 1 m depth is reached, a new equation was needed to take the 10% ice into consideration. Thus, after 1 m, the green line is the new line of possible configurations of radii and depth. You can see the graph below.

In the end, I was disappointed to see the project go. I feel as I had a great start to the design. However, I learned a lot about engineering projects while doing Break the Ice. It was a great experience working with research and difficult mechanical problems that relate to real-world problems. And I realize that many projects in the real world get shut down as well, due to funding, interest change, and many other things. I believe it was good practice to feel such defeat as it is a somewhat common workplace emotion. Either way, I am proud of the progress I made and how much I have evolved as an engineer over the scope of the project.

Links

SSPL website: https://sites.psu.edu/sspl/

NASA Break the Ice Challenge website: https://breaktheicechallenge.com/

Trans Astra patent: https://patents.google.com/patent/US20200240267A1/en