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Industrialization Studies in the KEK Cavity Fabrication Facility (CFF)

The 2nd workshop on SCRF Cavity Technology and Industrialization for the ILC @Chicago,July 2011. Industrialization Studies in the KEK Cavity Fabrication Facility (CFF). H. Hayano 07242011. S. Yamaguchi, K. Ueno, T. Saeki, H. Inoue, Y. Ajima, Y. Watanabe, K. Enami, S. Koike,

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Industrialization Studies in the KEK Cavity Fabrication Facility (CFF)

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  1. The 2nd workshop on SCRF Cavity Technology and Industrialization for the ILC @Chicago,July 2011 Industrialization Studies in the KEK Cavity Fabrication Facility (CFF) H. Hayano 07242011 S. Yamaguchi, K. Ueno, T. Saeki, H. Inoue, Y. Ajima, Y. Watanabe, K. Enami, S. Koike, S. Kato, E. Kako, Y. Yamamoto, A. Yamamoto; KEK

  2. KEK Cavity Fabrication Facility(CFF): main R&D KEK initiative on mass-production technology R&D in CFF KEK also like to invite industry participation in CFF Center cell R&D ✓ EBW Quality Control Technology ( multi-dumbbell, multi-cell, multi-cavity Jigs for EBW ) it will start soon. End-group R&D ✓ Deep Drawing Technology Fine-blanking (Water-jet cut) and Press-forming Technology ( End-group Jigs for EBW ) ✓ it will start soon.

  3. KEK Cavity Fabrication Facility 19m x 14m clean room STF Building inside ATF Press Machine Chemical Room EBW Trimming Machine KEK Cavity Fabrication Facility Inspection area Plant clean room Crane range

  4. EBW delivery on April 12, 2011 12th April 2011

  5. Main Machines in the facility EBW Press Trim MORI VKL-253 Vertical CNC lathe SST EBOCAM KS-110 – G150KM Chamber (Stainless Steel chamber) AMADA digital-survo-press SDE1522 150t, 50stroke/min, 225mmstroke Tape-cut Ceremony on July 13,2011 for EBW operation start. Chemi-room

  6. Center Cell Fabrication R&D KEK 9cell cavity #0 (w/o HOM couplers) fabrication

  7. Press, Trim, EBW R&D before KEK-EBW delivery by using EBW Job-shop Cell Press at KEK Trimming at KEK Stiffener Press at KEK BCP at KEK EBW at Tosei-electrobeam co., Tokyo (SST-EBW)

  8. Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011) Total 13 dumbbells were fabricated. 8 of them went to cavity fabrication

  9. Stiffener Insertion and EBW stretching of dumbbell stiffener insertion after insertion After Stiffener EBW EBW setting Stiffener EBW

  10. 2 - Dumbbell EBW at Job-shop (Dec.2010 – Feb.2011)

  11. 4 – Dumbbell, 8 - Dumbbell EBW at Job-shop (June.2011 – July 2011) Beam 30 June 2011 6 July 2011 Beam 8 July 2011

  12. 8 - Dumbbell EBW-Seam inspection Center cell equater: typical seam Center cell equater: seam end * End-group fabrication will be done in September – October, 2011, right after delivery of Nb pipes. KEK –EBW machine will be used there.

  13. End Group Fabrication R&D

  14. KEK-End-Group, KEK-HOM-coupler At First, we started HOM coupler fabrication study (4) Press cut-out from thick plate, (5) Press cut-out of slope region, (6) Press forming into design shape (1) Deep Drawing of HOM-cup, (2) Cut-out of holes, or Burring of holes. (3) Develop cost effective shape of tuning knob.

  15. One press-action Deep drawing First step study : Using existing press-setup, 1.5mm Nb sheets were deep-drawn into cup, by one press-action. Blank diameter: 120mm Inner diameter : 40mm Cup height : 65mm

  16. HOM-cup Tuning-Knob forming First step study : Using existing press-setup, deep-drawn cup bottom shape and knob were formed, by two press-action. Knob: 10mm diameter, 6mm height

  17. HOM Antenna forming Study of Press-forming is underway Water-Jet cut Press forming of Nb HOM Antenna press forming

  18. Mass-production R&D, others

  19. Conceptual design of automated cell-press KEK-Shinohara Press Idea of Multi-action Press for cell forming *Automated product transfer mechanism in the press machine are also under design.

  20. KEK-MHI Estimation of cavity production plant Plant Simulation study using CFF housing area（53m x 30m） EBW EBW CP Eddy-current scan reception Press forming stock Inspection Trimming parts delivery shipping of jacketed cavity Stock area anneal Tuning machine Bulk EP AC power area Jacket Inspection Assuming Nb plates for cell, fabricated end-group parts are input, 200 working days/year, 2 shifts/day with 30 people times 2 shifts Max. production rate will be ~530 cavities/year, ~2650 cavities for 5years. Assuming that final treatment and vertical test will be done in other place.

  21. KEK-Hitachi Estimation of cryomodule assembly plant Assembly Plant Analysis using KEK assembly hall area（120m x 50m） Cold-mass, thermal shield cavities Vacuum vessel, themal shield Assuming VT-passed cavity, fabricated cold-mass parts, vaccum cessel are input, 200 working days/year, 2 shifts/day with 37 people times 2 shifts Max. production rate will be ~57 cryomodules/year, ~285 cryomodules for 5years. Assuming that cryomodule power test will be done in other place.

  22. Conceptual Design Study Concept of rotational jig for multi-dumbbell and end-parts EBW

  23. Conceptual Design Study Concept of EBW rotational jig for multi 9 cell cavities

  24. Schedule Plan

  25. CFF schedule planfor industrialization 2011 2012 2013 1,2,3 4,5,6 7,8,9 10,11,12 4,5,6 10,11,12 1,2,3 7,8,9 7,8,9 EP, VT KEK-#0 w/o HOM EP, VT KEK #1 EP, VT KEK #2 EP, VT 2011 materials procurement KEK #3 2012 materials procurement Jacketing EP, VT HPV application KEK #4 HPV inspection EBW fixture development KEK #5 Design of multi-dumbbell fixture fabrication operation and upgrade KEK #6 Design of multi 9-cell cavity fixture fabrication operation and upgrade Design of endgroup EBW fixture fabrication operation and upgrade CFF industrial production Trim fixture development operation and upgrade Design fabrication Design fabrication Automated BCP operation and upgrade Deep-drawing, Forming press development operation and upgrade Design of press-shape deep drawing jig fabrication Basic R&D Hayano’s proposal; June 2011

  26. STF Plans for cavity production and test CY2011 CY2013 CY2012 CY2014 CY2015 CY2016 S1-Global cryomodule operation disassembly operation finished Start beam operation Phase2 Injector part operation as “Quantum-Beam Project” Phase-2 Injector construction operation ILC Cryomodule operation 1st Cryomodule operation 4 cavities/year from Industries Phase2 CM-1 cryomodule construction cavity replace cavity replace Phase2 CM-2 construction or cavities replacement of CM-1 operation operation STF phase-2 Cavity Fabrication Facility Startup & EBW jig construction CFF Industrialization Operational (4 cavities/year) KEK EBW operational 1st cavity 2nd cavity, 3rd, 4th, …. Cavity Industrialization Start

  27. Summary R&D status of KEK Cavity Fabrication Facility Center cell R&D 1. EBW Technology Experience through KEK-#0 9-cell cavity (w/o HOM) production. 2. By using EBW job-shop, center cell part was finished its fabrication. 3. After Nb pipes delivery, end group fabrication will be done in September – October, 2011, by using KEK EBW. End-group R&D 1. R&D on Deep Drawing Technology, Press forming technology are on-going. 2. Using existing press setup, possibility of end group parts fabrication from Nb sheet and from Nb thick sheet is under demonstration. Mass-production Studies 1. Conceptual Design Studies on Press-forming and EBW is started. 2. Cavity production plant and Cryomodule assembly plant are in study. Cavities by CFF, and cavities from industries, will be tested in cryomodule. End

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