FIELD OF INVENTION
The present invention relates to a system and method for setting simultaneously
co-ordinates of lower and upper high voltage, insulated stator bars.during its
manufacturing on baking wagon for 600mw and 800 mw turbogenerators.
BACKGROUND OF INVENTION
In 600 MW & 800 MW turbo Generators has 84 stator bars. These
stator bars are of two type. First, lower stator bars & second is upper stator bars.
Each type of stator bars are 42 in quantity.
Lower stator bars has 7 variants & upper stator bars also has 7
variants (6 stator bars are in each variants).
The insulation on these stator bars is done through Vacuum
Pressure Impregnation (VPI) Process. After Impregnation of stator bars, these
are pressed on baking wagon & cured in oven. .
Before pressing of stator bars on wagon, wagon is set for co-
ordinates of variants of stator bars to be pressed. These co-ordinates are 'L', 'H'
&'E'.

As standard practice, wagon is set for either lower bars or for
upper bars, because in standard practice, lower bars are not needed to be
manufactured along with upper stator bars. So, tooling for wagon is designed
accordingly.
In prior practice, following disadvantages were there:
1- In spare order received from customers, lower & upper stator bars are not
equal in quantity. Also, in some cases like endurance testing, rework etc,
either lower or upper stator bars are to be manufactured. So, manufacturing
either lower or upper stator bars may leads to underutilization of the facilities.
2- Separate wagon setting for co-ordinates for lower & upper stator bars
consume considerable time & is also non-productive.
3- Engaging man power in frequent non-productive activity leads to loss of man-
hours to organization.
The possible solution for the above said problems is that, on
wagon, both co-ordinates (Lower & Upper) must be placed simultaneously.
Since, original design of tooling do not consider this peculiar situation, hence,
new tooling is required.

With careful analysis of co-ordinates value for wagon setting as per
table no.-1 & 2 with corresponding Figures, following facts are revealed,

1- Co-ordinate 'H' is considerably high in lower type as compare to upper type
stator bars at each end. Co-ordinate 'H' is shown in fig.-1. The height of
supporting beam (2) had to change to adjust the height of all Lug-Rest. So,
this is one of the co-ordinates due to which, whole wagon setting has to
change for upper & lower type of stator bars.
With above fact it was concluded that, Co-ordinate 'H' can be adjusted for
lower bars with insertion of a 'Height blocks' between the lug rest (4) & base
(3).
2- Co-ordinate 'L' varies for Lower & upper type stator bars at Exciter side &
Turbine side. Co-ordinate 'L' is shown in fig.-l. With available data sheet for
co-ordinates, it was found that variation from tip to tip length of stator bars
(1) in upper & lower is around 60-70 mm.
This length is more in upper bars. So, this is another co-ordinate due to
which, whole wagon setting has to change for upper & lower type of stator
bars.
To incorporate lower bars with upper bars, lug rest (4) of lower bars is to be
placed inward. This is done with the extending surface of base (3) as shown
in fig.-4, so that lug rest (4) can be slide in inward direction as shown in fig.-
4. Threads are shifted accordingly in base plate to hold lug rest by blots.

3- Co-ordinate 'E' can be adjusted independently on wagon for Lower & upper
type stator bars simultaneously in lower & upper stator bars on wagon. For
setting of this co-ordinate 'E', only the lug rest (4) has to shift along the
length of supporting beam (2).
Above arrangements make it feasible to produce lower type stator bars along
with upper type stator bars.
OBJECTS OF THE INVENTION
Therefore, it is an object of the invention to propose a system and method for
setting simultaneously co-ordinates of lower and upper high voltage, insulated
stator bars during its manufacturing on baking wagon for 600 MW and 800 MW
turbogenerator which is capable of manufacturing any of the lower or upper
stator bar as per requirement in the same set up.
Another object of the invention is to propose a system and method for setting
simultaneously co-ordinates of lower and upper high voltage, insulated stator
bars during its manufacturing on baking wagon for 600mw and 800 mw
turbogenerator that is capable of utilizing fully the facility of manufacturing either
lower or upper stator bars according to demand.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.l- Shows a stator bar (1) placed on a wagon with its lugs matching
with lug rest (4).
Fig.2- Shows the lug rest (4), base (3) and mounting of lug rest (4) on
base (3)
Fig.3- Shows
a) base (3) with threaded holes for fixing.
b) extended base plate (3E) with support plate (5) welded to it.
c) new extended base plate (6) with new threaded holes (9) at
required place.
d) shows lug rest (4) on old base (3).
e) shows lug rest (4) on extended base (6)
f) shows lug rest (4) on extended base (6) for lower stator bar
Fig.4- Shows lug rest (4) for lower bar mounted on extended base (6)
clamped on beam (2) and another lug rest (8) for upper bar
mounted on base (3).
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION

Fig.l shows the stator bar (1) on wagon. Its slot portion (straight length)
is placed on wagon and its lug is supported in lug rest (4). This lug rest (4) is
clamped with base (3) mounted on support beam (2) of wagon. Position of co-
ordinate 'L' of stator bar with respect to wagon is shown.
Fig.2 shows the lug rest (4), the base (3) and the mounting of lug
rest (4) on base (3).
Fig.3 shows that a support plate (5) is welded to the base (3) for
extension of base. The extended base (6) is shown in fig.3 (c). The threaded
holes (7) on the old base (3) are now made (9) in new base (6) as per
requirement.
Fig.4 shows the extended base (6) having the lug rest (4) of lower
bar mounted on it. The extended base (6) is clamped on the support beam (2).
On the same support beam (2) another lug rest (8) for upper bar is mounted on
base (3).
When a stator bar (1) is placed on wagon, its lug must match with
lug-rest (4). This lug-rest (4) is mounted on base (3) & this base (3) is clamped
with support beam (2) as shown in fig.-1 & fig.-2.
To ensure and achieve co-ordinate setting for lower bar on wagon
having co-ordinates for upper bar, base (3) is modified through extending its

surface through welding of a plate (5) as shown in fig.-3. Now we have a new
developed base (6) with extended surface.
The threads (7) to hold bolts are according shifted to thread hole
(9) on extended surface. In same fig.-3, it is shown that lug-rest (4) is shifted on
extended surface of base (6) so that lug rest (4) shifted more by required
distance (60-70 mm) is inward direction.
When the developed base (6) is placed on support beam (2) of
wagon, as shown in fig.-4, it is clearly visible that developed base (6) has lug-
rest (4) more shifted in inward direction. This lug-rest (4) is used for lower bars.
On same support beam (2), another lug-rest (8) on base (3) as in standard
practice is mounted for upper bars as shown in fig.-4. Thus, fig.-4 is showing
arrangement for simultaneous co-ordinate setting of lower & upper stator bars
on wagon.
ADVANTAGES
1. Setting of co-ordinates Lower type stator bars along with Upper stator bars at
a time on wagon for 600MW & 800MW TGs .
2. Reduction in numbers of wagon settings for stator bars of different variants.
3. Man-hour saving consumed in wagon setting for spare stator bars.
4. Productivity due to reduction in non-productive set-up activities.

WE CLAIM
1. A system for setting simultaneously co-ordinates of Lower and upper high
voltage insulated stator bars during its manufacturing on baking wagon for
600 MW and 800 MW turbogenerators comprising;
a lug rest (4);
a base (3) with threaded holes (7) for fixing the said lug rest (4);
a support beam (2) for holding the base (3) along with lug rest (4);
characterized in that,
the lug rest (4) is clamped on an extended base (6) made by welding a
support plate (5) to the base (3), the said extended base having new
threaded holes (9) for clamping the lug rest (4) of lower stator bar placed on
Baking Wagon (w) for making the said lug rest (4) matched with the lug of
stator bar and for achieving the co-ordinate setting for lower bar on wagon
(w) having co-ordinates for upper bar.
2. A method for setting simultaneously co-ordinates of lower and upper high
voltage insulated stator bars claimed in claim 1 comprising;

welding a support plate (5) to the base (3) to extend the said base to
form new base (6);
making new threaded holes (9) on the base (6);
mounting the lug-rest (4) on base (6) through threaded holes (9);
clamping base (6) with support beam (2);
disposing the stator bar lower on wagon (w) with its slot portion placed on
wagon; when the lugs of stator bar matches with lug-rest (4) of lower stator
and supported on the said lug-rest (4) to achieve co-ordinate setting for
lower bar on wagon having co-ordinates for upper bar.