Manufacturing Systems of the Mars Homestead Project Local Steel, Aluminum, and Glass Damon Ellender...
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Transcript of Manufacturing Systems of the Mars Homestead Project Local Steel, Aluminum, and Glass Damon Ellender...
“Manufacturing Systems of the Mars Homestead Project”
Local Steel, Aluminum, and Glass
Damon Ellender
MHP Programming Team
Manufacturing
• Local Manufacturing is key to long-term planetary settlement
Requirements
• Steel Processing 400kg/day 1500K
• Aluminum Processing 25kg/day 1000K
• Glass Processing 200kg/day 1200K-1400K
• Manufactured Products as needed for construction(i.e. Structural, wire,…)
• Dual use or Flexible equipment used where possible
Glass Process
• Floated on Tin, Pilkington Process, 2mx4m float tray, made from local brick, covered to protect from dust
• Cooled using CO2 in Lehr, 2mx2m, made from local brick. Rollers imported.
• Cut into 1m x 1mx5mm glass panels for transport and further cutting.
• Located Outdoors
Cooling Lehr 2mx2mx1m (built from local Bricks,
Refractory) 200K
200kg/day
Glass Supply(Molten)1200-1400C200kg/day
Float Bath (Pilkington Process)Required a 20mm layer of
Sn(.16m3(1166kg))2mx4mx1m (built from local Bricks,
Refractory)1200-1400C200kg/day
Diamond Glass Cutter
1m2 (200kg)
18 cuts/day
Coo
ling
CO
22.
5 kW
Transport and Storage
Stacked on Trailer and
Moved by Rover18 1mx1mx5mm panes per day
1kW
Pow
er R
equi
rem
ent
Hea
ting
Met
hane
/O2
?? k
W
LCC Steel Process
• Low Carbon Content (LCC) Steel is better for low temperature application
• All products made of 6mm Sheet or cast directly• Provision for Rolling ‘Strip’ depending on size of Steel
Batch• Located Outdoors
Cooling Oven 2mx2mx1m (built from local Bricks,
Refractory) 200K
400 kg/day
Steel Supply(Molten)1500C
400kg/day
Strip Caster(3mx3m, 1000kg)1500-1000K
2mx6mm Strip~4m/day
Coo
ling
CO
24
kW
Transport and Storage
Rolled orStacked on Trailer and
Moved by Rover
Strip Caster
• 6mm thick x2m wide• Can be outdoors
though dust may require enclosed(not pressurized) areas
• Pickling could also be done in enclosed area to ensure recovery of acids/caustics.
Typical Strip Casting Process
• All products made of 6mm Sheet or cast directly• Provision for Rolling ‘Strip’ depending on size of
Steel Batch
Reference Earth Installations
Slab Caster
• For Context• Not practical for
amount of steel manufactured unless larger sections needed(i.e. rails)
• Batch Casting or Direct Chill better alternative
Aluminum Process
• Strip Casting possible using same process as Steel
• Direct Chill is also possible for Aluminum, not sure for Steel.
Cooling Oven 2mx2mx1m (built from local Bricks,
Refractory) 200K
25 kg/day
Aluminum Supply(Molten)1000C
25 kg/day
Strip Caster(3mx3m, 1000kg)1000-800K
2mx6mm Strip~4m/ 5day
Coo
ling
CO
2.3
5 kW
Transport and Storage
Rolled or Stacked on Trailer and
Moved by Rover
Aluminum Direct Chill Casting
• Ingots Poured Vertically
• Continuous Quench with Water or CO2
• Once Mold is full, valve shuts, and ingot is rotated and pressed out by ram.
• Other material could use this process(i.e steel)
Annealing Furnace
• Located Outdoors
• Capable of 1000K Temperatures
• Capable of Controlled Cooling(using CO2)
• Approximately 5mx1mx1m made from local Refractory
• Heat Exchanger Imported(1m3, 100kg)
• Uses Steam from Nuclear Reactor for Controlled Heating
Material Transport
• Need Glass, Steel, and Al transported from Refining to Manufacturing Airlock
• Need Steel Rolls transported to Annealing Oven
• Need Finished Products transported from Manufacturing Airlock to Area of Use
• Rover or Automated Robot Carrier could easily be programmed to perform this function.
Products Processing (Indoors)• Sheet Metal
– Foil Foil Mill (8m2,1000kg)– Ducting 4m brake(4m2, 200kg), Resistance Welder(.25m2,50kg), Rivets– Piping/Tubing Tube Mill(4m2,500kg)– Wire/Cable Stripper(4m2,200kg), Wire Mill(6m2, 500kg)– Mesh Expander(3m2,200kg)– Stamped
• Housings Press and Dies(4m2, 200kg), Castings(.5m2, 50kg)• Structural Members Press and Dies(4m2,200kg), Castings(4m2,100kg)• Rover Wheels Castings(.5m2,50kg), Press and Dies(4m2, 200kg)
– Roll Winder/Unwinder (4m2, 400kg)• Cast Metal
– Structural Beams Direct Chilled, Castings(4m2, 100kg)– Castings Castings(1m2, 100kg)
• Valves• Sprinklers• Rover Parts
• Glass Glass Cutter(2mx1m, 100kg)• Coatings
– Zinc Galvanizing Use Locally Made PE Tank, and Zinc– Powder Coating Line Includes Oven, 3mx3m, 400kg– Electroplating Use Locally Made PE Tank, and appropriate Eplating solution
• Shop– One Off Manufacture Drill Press, CNC Lathe, CNC Milling Machine (H&V), Grinders, Cutters– Prototyping Rapid Prototyping System, Wax or Plastic Investments Minimum
• Robots/Automation– 6 DOF Motoman Handles Resistance Welder, Plasma Cutter, and Manipulator– Crane Loading and Unloading of Heavy Items
Import ListingEquipment Floorspace Area Volume Weight
Foil Mill 4mx2m 8m3 1000
4m Brake 4mx1m 4m3 200
Resistance Welder .5mx.5m .125m3 50
Tube Mill 2mx2m 4m3 400
Stripper 2mx2m 4m3 200
Wire Mill 3mx2m 6m3 500
Mesh Expander 3mx1m 3m3 100
Press and Dies 4mx1m 4m3 200
Castings 4mx1m 5m3 250
Glass Cutter 2mx1m 2m3 100
Powder Coat Line 3mx3m 9m3 400
Galvanizing Tank 6mx1m 6m3 Locally Made
Electroplating Tank 6mx1m 6m3 Locally Made
CNC Lathe Mill Drill 5mx2m 20m3 1500
Laser or Water Cutter 6mx2m 12m3 500
Plasma Arc Cutter .5mx.5m .125m3 50kg
Rapid Prototyping Machine 1mx1m 2m3 100kg
6DOF Robot 1mx1m 2m3 250kg
Crane 3m radius 3m3 200kg
Heat Exchangers Annealing Furnace
5mx2m 1m3 100kg
Valving for CO2 Cooling .5mx.5m .25m3 200kg
Rollers(50mmRx3m) 3mx6m 3m3 500kg
Slitter
• May be used for making wire ribbon as well.
Cutting device
• Diamond Saw
• Cuts both steel and glass
Tubing Mill-Formers
• Rolls strips into a tube and welds.
• Tubing out can be rolled or cut in lengths.
Coiler/DeCoiler
• Roll and Unrolls Tubing, Strip, Wire, and Cable.
• 200kgs per unit
• ~1mx2m floorspace
Steel Mill Control Room
• For Context• Supervision of
Process– Video– Instruments– Visual
• Programming of new process
Powder Coat Oven
• Finished Products• Durable Epoxy
Coating• Can be used on Steel
and Aluminum