Development of the CLAES instrument aperture door system

The design, assembly, and test processes followed in developing a space-qualified aperture door system are described. A blackbody calibration source is mounted inside the door, requiring the assembly to open and close a minimum of 150 cycles for instrument recalibration. Within the door system are four separate mechanisms, three of which are redundant; a pyro launch latch, a hinge bearing assembly, and a pair of pivot mechanisms. Decoupling devices within the pivot mechanisms allow an active drive unit to automatically overdrive a failed drive unit. The door is also stowable for possible Shuttle retrieval and re-entry. Illustrations and photographs of the flight hardware help acquaint the reader with the design. The aim is to pass on lessons learned in all phases of developing this spaceflight mechanism.