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Precision Assembly Tools for Cryomodule at Fermilab Cleanroom

Explore the meticulous process of preparing, assembling, and disassembling cryomodule parts in a Class 10 Cleanroom at Fermilab. Learn about the essential fixtures, tools, and procedures used for cavity alignment, vacuuming, and assembly.

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Precision Assembly Tools for Cryomodule at Fermilab Cleanroom

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  1. Cryomodule Assembly Facility (CAF) @ Fermilab Cleanroom:Assembly/Disassembly Tools Tug Arkan

  2. Parts / Fixture / Hardware Preparation • Wash/rinse in the ultrasonic bath • Blow clean with ionized nitrogen under the Class 10 hood • Dry under the Class 10 hood • Transport in the Class 1000 ante clean room • Blow clean with ionized nitrogen while monitoring the particulates count in the Class 100 sluice area • Transport into the Class 10 assembly area Class 10 / ISO4 Hood Class 1000 cleanroom US cleaner

  3. Rail for Cavity String Assembly Rail length: 3.65 m, 12 rails aligned to each other to 0.1 mm

  4. 1.3 GHz Cavity Support Posts Fixture Cavity is supported through the alignment ring on the beampipe flange at the field probe end Cavity is supported through the alignment ring on the beam pipe flange at the coupler end

  5. Cavity Lift Fixture

  6. Vacuum / Purge / Backfill Manifold

  7. Adjustable Table Fixture This fixture is used to align the flanges of the parts that will be assembled

  8. Cold End Coupler Assembly

  9. Cavity Alignment in the clean room X-Y Alignment Fixture: Cavities beam line flanges are aligned to ~0.5mm for the interconnect bellows assembly in the clean room Rotational Alignment Fixture: Coupler position: parallel to earth with respect to the cavity helium vessel lugs

  10. Miscellaneous Fixtures Interconnecting Bellows Holder Fixture Gate Valve Holder & Alignment Fixture

  11. String Assembly • Gate Valve to Cavity Assembly: • Sub-assembly of the right angle valve • Installation to the support post and vacuum hose assembly • Leak check • Alignment to the cavity beam line flange • Particulate free flange assembly (PFFA) procedures • Assemble the gate valve to the cavity

  12. String Assembly (cont.) • Cavity to Cavity Assembly with the interconnect bellows: • Assemble vacuum hose to the cavity. Pump down and Leak check or Ensure that the cavity beamline arrived to Class 10 cleanroom under vacuum. Backfill • Align the interconnect bellows to the cavity field probe end beam line flange • Clean bellows / Cavity Blank flanges bolt holes with PFFA

  13. String Assembly (cont.) • Assemble Bellows NR flange to the cavity • Remove the bellows holder fixture and install threaded rods fixture • Align the bellows to the other cavity coupler end beam line flange • Assemble Bellows R flange to the other cavity

  14. Magnet/BPM/Gate Valve Assembly

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