1. 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

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

3. 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

4. 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

5. 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

6. HOMS (High Order Modes Suppressors Couplers) RF Field Antenna

7. 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.

8. Assembly flowchart HOMS assembly and Field Antenna assembly3
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

9. 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

10. 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

11. Assembly flowchart HOMS assembly and Field Antenna assembly3
Description
Area
Time
Entrance in sas all the components 3 2
SAS 3

12. 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

13. 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

14. 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

15. 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

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

17. Assembly on cavity CRAB

18. 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

19. Assembly flowchart HOMS assembly and Field Antenna assembly3
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

20. 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

21. Assembly detail for HOMs
3.5kg
FLIP / FLAP x3

22. Assembly detail for field Antenna
0.7kg x2

23. Angle positioning system

24. Assembly flowchart HOMS storage box assembly and Field Antenna box assembly5
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

25. 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°

26. Final assembly !

27. ANNEXES