Assembly of Crab Cavities couplers in SM18 clean room Eric Montesinos, Sebastien Calvo, Emile Grospelier, Antoine Boucherie, Frida eriksson on behalf of BE-RF-PM section members

Cleanrooms constraints Compatibility with the Crab assembly process The proposal must match with the existing structure of the cleanrooms

What to be assembled ? HOMS (High Order Modes Suppressors Couplers) RF Field Antenna (Measuring couplers) HOMS RF Field Antenna Length: 239mm Mass: 0.5Kg Length: 205mm Mass: 3.5Kg

What processes ? HOMS assembly HOMS storage box assembly HOMS on storage box HOMS on crab cavity Field Antenna assembly Field Antenna box assembly Field Antenna on storage box Field Antenna on crab cavity

Workflow global ? All parts come from the chemistry (bat. 102) defatted individually wrapped However some will be assembled (soldering or EBW), those always follow a ''clean'' process (packaging and handling with gloves) Those sets are re-washed manually before entering baldaquin/ cleanroom

HOMS (High Order Modes Suppressors Couplers) RF Field Antenna

Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Delivery all part packed by the Chemists experts by 2 layers of plastic bag 1 Blow with pure air the 1 layer Move inside baldaquin 2 Blow with pure air the layer 2 1 All parts come from the chemistry (bat. 102) defatted (with laundry without acids) individually wrapped.

Assembly flowchart HOMS assembly and Field Antenna assembly 3 Description Area Time Cleaning of external faces with clean room tissues and isopropyl alcohol 70% 2 Rinsing with demineralized ultra pure water Drying with pure air + 1 night under laminar flux X + 1 night Blow and particles counting with HACH ANNATEL UP 100 Number of particles < 20p/ml Entrance in sas ? all the components 3 2 SAS 3 HPR Size Channels (μm) 0.1 μm, 0.2 μm (plus 0.5 μm and 1.0 μm optional) Display Resolution 0.01 counts/mL

Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Delivery of accessories-nuts, bolts, washers and copper seals packed by the Chemists experts by layer of plastic bag 1 Blow the layers with pure air Open the layer of accessories 2 Rinsing with demineralized UV ultra pure water 2 1 screws A4.100 M6x45 Washers 6x12 Bolts A4.100 M6 studs A4.100 M6x25

Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Put all pieces on 1er drying support Drying with pure air + 1 night under laminar flux 2 Blow and particles counting with HACH ANNATEL UP 100 Number of particles < 20p/ml 2 Drying support

Assembly flowchart HOMS assembly and Field Antenna assembly 3 Description Area Time Entrance in sas all the components 3 2 SAS 3

Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Entrance in clean room ISO 4 all the components on support 4 Put the assembly all HOMS, feedthrough and field antennas on special 2nd drying support 4

x3 Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Assembled by hands the HOMS seal 4 Put fastening Tighten until no gap between flanges (in cross first and in circle to finish) 4 x3 2eme 1er

x2 Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Assembled by hands the feedthroughs 4 Put fastening Tighten until no gap between flanges (in cross first and in circle to finish) 4 x2

Assembly flowchart HOMS storage box assembly and Field Antenna box assembly Description Area Time Package all the assembly with 2 layers of plastic bags 4 Make a leak detection until < 1x10-10mbar/l/s-1 5 Re-package all the assembly with 2 layers of plastic bags after leak detection 4 5

Stored until the final cavity mounting Assembly flowchart HOMS storage box assembly and Field Antenna box assembly Stored until the final cavity mounting 16

Assembly on cavity CRAB

Assembly flowchart HOMS assembly and Field Antenna assembly Description Area Time Delivery of accessories-nuts, bolts, washers and copper seals packed by the Chemists experts by layer of plastic bag, guide tooling for assembly And HOMs & field antenna with layer of plastic bag 1 Blow the layers with pure air Open the layer of accessories 2 Rinsing with demineralized UV ultra pure water 2 1 Centering tool screws A4.100 M6x45 Washers 6x12 Bolts A4.100 M6 studs A4.100 M6x25

Assembly flowchart HOMS assembly and Field Antenna assembly 3 Description Area Time put in sas all the components 3 Entrance in clean room all the components and put them in to the table 4 Blow with pure air and extract the layers 4 SAS 3

Assembly flowchart HOMS storage box assembly and Field Antenna box assembly Description Area Time Blow with pure air all HOMS and Fields antennas 4 Put Nitrogen N2 pressure in cavity +0.2bars Take off HOMS or Field antenna 4

Assembly detail for HOMs 3.5kg FLIP / FLAP x3

Assembly detail for field Antenna 0.7kg x2

Angle positioning system

Assembly flowchart HOMS storage box assembly and Field Antenna box assembly 5 Description Area Time Put by hands HOMS/Field antenna on the cavity 4 Put the centering device Put the washers and screws Tighten until no gap between flanges (in cross first and in circle to finish) Stop Nitrogen N2 pressure in cavity Go with support outside cleanroom for make a leak detection until < 1x10-10mbar/l/s-1 5 4

Total mounting tolerances Seal RF DN 40 After mounting tolerances hoped: Off-center tolerances DN63 = mini -0.05mm maxi 0.25mm Seal tolerance DN63 : Ø82.4  +/-0.05 Flange tolerance DN63 : Ø82.5 0.1/0 (x2) Total angles tolerances mini -0.15mm maxi 0.1mm  ~0.15° Ungasing slot tolerance : 1.5+/-0.1 (x2) Angle positioning tool tolerance : 1.40/-0.05 Asked positioning for FPC assembly: Axials tolerances +/- 1mm Angles tolerances +/- 1° what we can have with the accumulated tolerances max: Axials tolerances +0.25mm/-0.05mm Angles tolerances +/- 0.15°

Final assembly !

ANNEXES