Diameter Versus Mass in the Development of the Orion Life Support Umbilical: A Case Study in Systems Engineering

Systems engineering could also be called the art of compromise. At its heart, systems engineering seeks to find that solution which maximizes the utility of the system, usually compromising the performance of each individual subsystem. While seemingly straightforward, systems engineering methodology is complicated when the utility to be maximized is unclear and the costs to each individual subsystem are not - or not easily - quantifiable. In this paper, we explore one such systems engineering problem within the Constellation Program as a case study in applied systems engineering. During suited operations, astronauts within Orion will be connected to an umbilical to receive and return breathing gas. The pressure drop associated with this umbilical must be overcome by the Orion vehicle. A smaller umbilical, which is desirable for crew operations, means a higher pressure drop, resulting in additional mass and power for the vehicle. We outline the technical considerations in the development of this integrated system and discuss the method by which we reached the ultimate solution. This paper, while just one example of the kind of problem solving that happens every day, offers insight into what happens when the theories of systems engineering are put into practice.