Space Suit Portable Life Support System Thermal Control Valve Ball Design

A Thermal Control Valve (TCV) has been in development for the Exploration Extravehicular Mobility Unit Portable Life Support System (xEMU PLSS). The xEMU PLSS TCV controls flow going to the liquid cooling and ventilation garment that the crew member wears during extra-vehicular activity to expel waste heat. A previous TCV version with a linear actuator and diverter valve has been tested to attempt to control the flow accurately. The previous valve has a non-linear flow response relative to valve position and has struggled to meet the setpoints desired for precise thermal control. While many diverter valve design variations have been attempted, all previous designs have had difficulty meeting set points. Additionally, high precision machining is required to create a metal-on-metal seal which has its own drawbacks and does not always meet requirements for internal leakage. This metal seal also requires stalling a linear actuator to load the seal in compression or tension which has caused sticking failures when stalled. A new approach and design for a TCV has been developed which uses a rotational ball to control flow and has demonstrated a much more precise and linear flow control. The design functions like a two-way ball valve with two Teflon seats that cradle and compress the ball for sealing. The ball outlet has a unique geometric design to create a set-able orifice like hole which is more predictable at controlling flow. Additionally, the Teflon seat performs much better for preventing internal leakage than the metal seal and prevents sticking by having a large range in which it is sealed without having to stall the actuator. This paper will review a new proposed xEMU PLSS TCV ball design and compare it with previous iterations of the design.