About the Author
• BE Electrical Engineering• BS Physics• BA Visual Arts• Electrician (USA, AU)• Explosives, confined spaces, heights• Off Road Racer• Potential Martian
Onsite Repairs
• Redundant critical systems• Easily replaceable systems• Standardized materials • Multipurpose tools• Manufactured onsite pats• Compatible multipurpose parts • Easy to fix systems
Standardization: Regulation
• Organized standardization• Body to define and regulate• No government affiliations• Could draw on relevant practices• NEC or AS/NZS • Fire safety or OHS• Industry designed best practice
Standardization: Theory
• Metric only• Standard practice• Standard nomenclature• Standard color code• Standardized wiring• Standardized connections• Standard size hatches• Standard size containers
Standardization: Practice
• Metallurgy• Equipment Color Codes• Wire Color Codes• Connectors• Hardware• Software • Formats • Containers, access ways
Computer Hardware
• Power Sources• Batteries• Processor• Storage / Hard Disks• Video cards• Networking cards / Connections• I/O Devices
Software
• Operating systems: Dos, Unix, Java• Drivers: USB, Buses, printers, cameras• Networks: Bluetooth, G3, G4• Images: Vector, Rastor• Displays: Web Page, Video, Images• Editors: Video, Graphics, Text• GUI: Inputs, Links, Active listening
Formats
• J-Peg, GIF, PNG• Doc, Docx, Pdf• AVI, MP3, MP4• 1080i, 720p• 16:9, 4:3, Anamorphic• 48kHz, 16kHz
Design Principles
• No planned obsolescence• No disposable equipment• Repairable equipment• Accessibility• Identifiable components• Identifiable systems• Easy to maintain systems
Nuts, Bolts and Screws
• Standardized sizes, grades• Nuts with edges• Keyed screws• No security hardware• Standardized thread pitch• Course or fine thread• No reverse threads (even fuel hoses)• Standardized plumbing• Pressure fittings• High quality materials
Electrical
• Adjustable components (digitally/manually) • Standardized rules/colors• Connectors, compatible parts• Visible schematics • Non-destructive connectors• Robust parts in assembly
Robust Methods of Assembly
• Dielectric grease • Brass in place of copper• Teflon coated wire, not
thermal plastic• Solder connections• Avoid hard to trace
splices• Ensure mechanical
protection to wire in bulkhead pass through
Batteries
• Universal connections• Standardized battery configuration• Standardized voltages• Compatible with vehicles• Easy to recharge
Heat
• View systems as interconnected• Lower weight • Use novel approaches• Transfer heat efficiently
Assembly
• Design for repair• Joints/connections critical• Identifiable connections• Plan for vibration• Plan for replacement• Plan for maintenance• Soft coat threats• Minimize sharp edges
Sharp Edge Protection
• Round edges on covers, hatches and corners• Gusset frames, ground down protruding welds• Round cable ties (new tool needed)• Use tape over cable ties (possibly reusable)• Avoid cuting steel ties, hose clamps (new tool
needed)• Wire mesh hose is high risk unless coated
Tool Design
• Start early, over many iterations• Design for ease and robustness• Standardize designs and parts• Limit size, volume and weight• Design attachments, not specialty tools• Design spacecraft for available tools• Design spacecraft for easy and quick access in
high risk environments
Repair Tools Spare Materials• Crescent wrenches• Ratchets (extensions , breaker
bar & torque wrench) • Screwdrivers (flat, Phillips &
square)• Saw (with multiple blades)• Drill (polishing brush, metal step
bits, screw bits, etc.)• Pry bar, bolt cutters• Claw, rubber & sledge hammer• Ruler, feeler gauge • Grips: Vice grips, pliers, dykes,
needle nose pliers (extended), linesman's, wire strippers, pipe wrench, hose/cable cutters
• Magnet on a stick• Box knife, pocket knife, razors
• Duct tape / gaffer tape• Electrical tape• Aluminum foil / plastic wrap• Rubber gloves• Zip ties (plastic & metal)• Tie-wire• Hose clamps• Sheet metal (beer can)• Length of hoses & wires • 2 part epoxy / JB weld• Gasket material (paper, rubber,
carbon fiber), • O-rings• Steel cable & rope• Ratchet straps