• assembling
• cryomodule
• design optimization
• fem
• fermilab
• superconducting
• tooling

The work presented here, carried out at the Fermi National Accelerator Laboratory, proposes
a feasible assembly sequence and a tooling system for the final integration of the Single Spoke Resonator (SSR1)
cryomodule.
The SSR1 cryomodule is part of the Proton Improvement Plan PIPII project that Fermilab is
developing in order to upgrade the current accelerator complex.

A preliminary study
of the layout and the equipment of the Fermilab facility where the SSR1 cryomodule
will be assembled is performed in order to define the workstation areas, the
assembly flow and the location of the main tooling.

The whole assembly process is divided into main phases, which are based on the cryomodule sub-assemblies precedence constraints.
The SSR1 cryomodule contains two main sub assemblies: the string cavity and the coldmass.
These sub assemblies include ultra high vacuum (UHV) flexible interconnections (bellows) which are characterized by a
limitated strength to off-axis deformations (torsional and lateral). These aspects influenced the design of the whole tooling system by specifying stringent constraints
on the tooling structural stiffness.

Most of the work is focused on the design of the lifting tooling, which will be used to raise and hold the cavity string in the
first part of the assembly sequence.
The design of this tooling is verified according to United
States structural codes (ASME, AISC, AWS) and the technical drawings are completed.

The conceptual design of the remaining tooling system is also presented.
Finite element analyses (FEM) are implemented in order to estimate relative
displacement between flexible interconnection.

In addition, a performance acceptance test (PAT) of an existing tooling, designed for the cavity string installation, is performed. The test highlighted a possible improvement which is designed, procured and installed.