Capture Latch Assembly for the NASA Docking System

Final Paper and not the abstract is attached. a summary of the Design, Development, and Qualification of the Capture Latch Assembly (CLA) for the NASA Docking System Block 1 (NDSB1). The CLA is an integral part of the Soft Capture System (SCS) of the NDSB1, serving the purpose of connecting the mating SCS Rings of two docking vehicles. The paper will present an overview of the function of the CLA and its basic concept of operations, including a summary of the major components of the CLA. The development, qualification, and production of the CLA will then be described. Particular focus will be provided on two major issues that occurred during production and qualification of the CLA. The first issue was failures of the CLA Motor (CLM) during acceptance testing (AT). The failures of the CLM were ultimately determined to be due to design defects and manufacturing errors in the motor commutation sensor assembly. The second issue was failure of the secondary release mechanism, or Contingency Capture Latch Release (CCLR) mechanism during development and qualification testing. The CCLR failures were found to be a result of excess free play in the release mechanism, resulting in wear leading to galling inside the release mechanism. An overview of each failure will be provided, along with a summary of the failure investigation and recovery process. Finally, Lessons Learned from each of the major issues and the overall development of the Capture Latch will be presented.