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Manned space laboratories like the US Space Station Freedom or the european COLUMBUS APM are equipped with so-called racks for subsystem and payload accommodation. An important resource is air for cooling the unit internal heat sources, the avionics air. Each unit inside the rack must be supplied with sufficient amount of air to cool down the unit to the allowable maximum temperature. In the course of the COLUMBUS ECLSS project, a thermohydraulic mathematical model (THMM) of a representative COLUMBUS rack was developed to analyse and optimise the distribution of avionics air inside this rack. A sensitivity and accuracy study was performed to determine the accuracy range of the calculated avionics air flow rate distribution to the units. These calculations were then compared to measurement results gained in a rack airflow distribution test, which was performed with an equipped COLUMBUS subsystem rack to show the pressure distribution inside the rack.

The redesign of the international Space Station Freedom (SSF) and funding constraints in the ESA member states caused a redirection of the development effort for the Attached Pressurised Module (APM). For the ECLSS the most important changes are the reduction in length of the module in order to make it compatible with the ARIANE V capabilities and the more severe cost constraints. As a result new concepts for the cabin loop were investigated leading to a decrease in cabin loop power consumption, mass and volume and a reduced development effort due to a lower number of items. In the previous concept a module internal loop with a flow rate of 864m3/hr and an Intermodule Ventilation (IMV) flow rate for air revitalisation to the station with 240m3/hr were installed. The revised boundary conditions with a reduced overall massflow rate of 540m3/hr allows the combination of the cabin loop and the IMV with limited impact on the total power consumption.

This paper presents some of the important aspects of the development work carried out recently in the Hermes ECLSS (since Ref. 1). For various constituent hardware items of the ECLSS, the paper describes and explains the technical constraints which are at the origin of the development work, discusses the design concepts which have been identified and investigated to fulfill the constraints, and presents the technical solution which has been selected. For some hardware items (e.g. cabin fan, toilet assembly), for which the initial design selection has been supported by breadboard tests, the paper presents the rationale behind such tests and the major test results obtained. The consequences derived from the test experience for the further development work are explained.

This paper describes the development, manufacturing and testing of an advanced heat pipe profile possessing separated arteries and small radial grooves for condensate transportation. The objective of the development was to design a heat pipe with improved heat transport capability limited by an outer cross-section of 15 mm square. The concept of the new heat pipe is based on an aluminium extrusion profile with rectangular outer shape. The central vapour core of 9.2 mm diameter is connected via small connection slots with four individual liquid channels located in the corner areas of the profile. So the liquid flow in the four channels is decoupled from vapour flow, both streaming in opposite directions. Decreasing of the pressure drop in the liquid channels and decreasing the entrainment of liquid flow to the vapour flow resulted in improved heat transport capability.