1
FIELD OF INVENTION
The present Invention relates to a Form Impregnation fixture adaptable to continuous resin poor Insulation system for group of stator Bars of Hydro generators.
BACKGROUND OF THE INVENTION
In power generating machines, type of Insulation plays a vital role In the optimization of design of the machine, Its reliability and availability for operation. Further, considering the modern trend, emerging market demand and to meet the specific customer requirements, continuous thrust has been given for optimisation and improvement in the Insulation system of the machine. In this perspective, and adapting the advantages which a VPI Insulation system offers, prior art system of continuous resin rich thermosetting Insulation has been upgraded by introducing a continuous resin poor (VPI) Insulation features in Hydro generators. To introduce the new feature of Insulation and to establish a process therefore, an imperative need arises to first develop, manufacture and provide a suitable Form Impregnation Fixture having features for Impregnation and Curing a group of Stator Bars of Hydro generators in a single charge.

2 OBJECTS OF THE INVENTION
It is therefore, an object of the present invention to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which eliminates the disadvantages of prior Art.
Another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which imparts overall improvement in quality of stator Bars and strict control of stator Bar size within specific tolerances.
A still another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which controls the winding pitch distance and angular pitches on Turbine END (TE) and Exciter END (EE) and Adequate pressing force to ensure uniform pressing of all the stator Bars In a single charge.
An yet another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which enables ease in assembly and disassembly of various components of fixture and winding Bar and consistently repeatability of quality out put.

3
A further object of the present Invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which imparts in enhancement of productivity by accommodating 15 nos of stator Bars In the fixture.
A still further object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which enables perfect matching of ends of upper and lower stator Bars on (TE) and (EE) after laying in the wound stator.
An yet further object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which ensures specified and uniform gap, in overhang profile of two adjacent stator Bars after lying in the stator core and optimum resources utilization.
SUMMARY OF THE INVENTION
Form Impregnation Fixture is a rectangular C shaped box structure, open from the top and is made up of plurality Columns, which are rigidly fixed on a steel Base plate. To ensure straightness of the box, Columns are housed in 2 parallel grooves machined in Base plate. The Columns, on each side of the box are fastened longitudinally with plurality Rods. These Rods also

4
accommodates the plurality Fixed wedges during assembly, which in turn also ensures perfect right angle in all sides of rectangular box. The inside configuration of the box is such that it provides plurality independent channels for accommodating width, thickness and full length of slot portion of Stator Winding Bars of Hydro generator in disposed layers one after another. After placing all the Stator Winding Bars in the Fixtures along with Side Pressing Rules and Middle plates. Now plurality Fixed Wedges are assembled with Rods and Sliding Wedges are then inserted between Upper Pressing plate and plurality Fixed Wedges to bring about uniform and sufficient compressive force on all the Insulated Stator Winding Bars in a single charge during Impregnating and curing operation.
Further to support ends of overhang portion of Stator Bars of Turbines and Exciter sides, steel Brackets are rigidly fastened to Base plate on front and rear sides of the fixture. On these Brackets accurate racks/shelves to support end of different layers of Stator Winding Bars are made up with the help of plurality Pressing plates, Mandrel and Bushes.
After completion of loading and pressing of Stator Bars in the fixture, it is overturned to horizontal position, by putting lifting slings in the Rods. The fixture is now placed in Micalastic Tank, where vacuum is created and resin is poured for Impregnation process. After completing the Impregnation cycle, the fixture is transferred to Baking oven for heating and curing operation for specified time.

5
All parts of the Fixture which control slot size of the Stator Bars were treated with special compound to avoid any wear due to repetitive cleaning during use.
In the development of this Fixture, due emphasis have been given on critical quality requirements, ease of manufacturing, reduction in cost, increased productivity with consistent quality and reliability, beside optimum utilization of resources.
All parameters in the Fixture which are critical to quality were achieved by precision machining on Jig Boring Machine and by grinding operation. The total assembly is with the help of Fasteners only to avoid any distortion because of welding etc.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig-1- Shows a schematic diagram of the Form Inpregnation Fixture Fig-IA Show a schematic diagram from A-A view of Fig-1.

6
BRIEF DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION.
As shown in Flg-1 &. 1A, Form Impregnation Fixture (F) comprising of a rectangular C shaped box structure, open from the top and is made up of plurality Columns (3 & 10), which are rigidly fixed on a steel Base plate (27). To ensure straightness of the box, Columns are housed In 2 parallel grooves machined in Base plate. The Columns, on each side of the box are fastened longitudinally with plurality Rods (26). These Rods also accommodates the plurality Fixed wedges (5) during assembly, which in turn ensures perfect right angle in all sides of the rectangular box. Plurality Mandrels (7) are permanently fixed in Jig Bored holes in Base plate. The Inside configuration of the box Is such that is provides 15 no. of independent channels for accommodating width, thickness and full length of slot portion of Stator Winding Bare of Hydro generator in 5 disposed layers one after another with the help of plurality Mandrels (7), plurality Middle plates (8) and plurality Side Pressing Rules (9) After placing all the Stator Winding Bars in the Fixtures along with Side pressing Rules and Middle plates, the entire box of the Fixture is covered with a Upper Pressing plate (15). Then plurality Fixed Wedges (5) are assembled with Rods and Sliding Wedges (4) are inserted between Upper Pressing plate and plurality Fixed Wedges to bring about uniform and sufficient compresslve force on all the 15 Insulated Stator Winding Bars in a single charge during Impregnating and curing operation.

7
Further to support end of overhang portion of Stator Bars of Turbine and Exciter sides, specially designed steel Brackets (28 & 30) are rigidly fastened to Base plate on front and rear sides of the Fixture. Winding pitches on Turbine and Exciter side are achieved by controlling heights of these Brackets. On these Brackets 5 accurate racks/shelves to support ends of different layers of Stator Winding Bars are made up with the help of plurality Pressing plate (13 & 18), Mandrels (16) and Bushes (19). Angular slots as per angular pitches in Stator Bars on Turbine and Exciter sides are machined in these pressing plates. To firmly hold, end of Stator Bars in position, plurality Glass Textolite Wedges (14 & 20) are sued.
Plurality Lugs (31 & 32) are fixed to ends of Middle plate and Side Pressing rules for lifting purpose, during assembly and disassembly o these parts In the fixture.
Plurality Plugs are fixed on one side of Columns (10) to keep the fixture in horizontal position in Micalastic tank during impregnating and in Baking oven during curing operations.
After completion of loading and pressing of Stator Bars in the fixture, it is overturned to horizontal position, by putting lifting slings in the Rods. The fixture is now placed in Micalastic Tank, where vacuum is created and resin is poured for Impregnation process. After completing the Impregnation

8
cycle, the fixture is transferred to Baking oven for heating and curing operation for specified time.

11
WE CLAIM
1. The form inpregnation fixture to introduce continuous resin
poor Insulation system for group of stator bars of the hydro
generator comprises:-
- a rectangular C shape box structure made up of plurality columns
(3, 10) rigidly fastened to a steel base plate (27), for holding and
pressing of slot portion of plurality of stator bars in five disposed
layers, one after another with the help of plurality mandrels,
middle plates and side pressing rules (7,8,9)
- steel brackets (28,30) fitted with plurality mandrels (16), are
fixed to base plate (27) which act as holders for end of stator bars
in 5 accurate racks/shelves made up with the help of plurality steel
pressing pates (13,18) and bushes (19).
2. The fixture as claimed in claim 1, achieved uniform box size in
full length, to control insulated stator bar size with the help of
plurality columns (3,10), mandrels (7), side pressing rules (9),
middle plates (8) and accurate grooves machined in base plate
(27).

12
3. The fixture as claimed in claim 1, ensured winding pitches on
turbine and exciter sides of stator bars with the help of
controlled heights of specially designed/developed brackets on
(TE)&(EE). (28&30)
4. The fixture as claimed in claim 1, ensured angular pitches on
turbine and exciter sides with the help of angular slots
machined in plurality pressing plates (TE) &(EE) (18 & 13).
5. The fixture as claimed In claim 1, comprising of plurality fixed
wedges (4) and plurality sliding wedges (5), and a upper
pressing plate for ensuring uniform pressing of slot portion of all
the plurality stator bars in a single charge.
6. The fixture as claimed in claim 1, comprising of plurality rods
(26) and their position ensured lifting and overturning of
assembled fixture with stator bars in horizontal position to
vertical position for loading in micalastic tank during
impregnation process and in baking oven during curing.
7. The fixture as claimed in claim 1, all parameters which are
critical to quality were achieved by precision machining of Jig
Boring Machine and by grinding operation. The total assembly
is
3.
13 accomplished with the help of fasteners only.
8. The fixture as claimed in claim 1, all parts which control slot
size of the stator bar were treated with special compound to
avoid any were due to repetitive cleaning during usage.
9. The fixture as claimed in claim 1, is specially designed glass
textolite wedges (14,20) having been used for firmly
holding/pressing of ends of stator bars.
10. The Form Impregnation fixture to introduce continuous
resin poor Insulation system for groups of stator bars of the
Hydro-generator as described and illustrated herein with
reference to accompanying drawing.

1
FIELD OF INVENTION
The present Invention relates to a Form Impregnation fixture adaptable to continuous resin poor Insulation system for group of stator Bars of Hydro generators.
BACKGROUND OF THE INVENTION
In power generating machines, type of Insulation plays a vital role In the optimization of design of the machine, Its reliability and availability for operation. Further, considering the modern trend, emerging market demand and to meet the specific customer requirements, continuous thrust has been given for optimisation and improvement in the Insulation system of the machine. In this perspective, and adapting the advantages which a VPI Insulation system offers, prior art system of continuous resin rich thermosetting Insulation has been upgraded by introducing a continuous resin poor (VPI) Insulation features in Hydro generators. To introduce the new feature of Insulation and to establish a process therefore, an imperative need arises to first develop, manufacture and provide a suitable Form Impregnation Fixture having features for Impregnation and Curing a group of Stator Bars of Hydro generators in a single charge.

2 OBJECTS OF THE INVENTION
It is therefore, an object of the present invention to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which eliminates the disadvantages of prior Art.
Another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which imparts overall improvement in quality of stator Bars and strict control of stator Bar size within specific tolerances.
A still another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which controls the winding pitch distance and angular pitches on Turbine END (TE) and Exciter END (EE) and Adequate pressing force to ensure uniform pressing of all the stator Bars In a single charge.
An yet another object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which enables ease in assembly and disassembly of various components of fixture and winding Bar and consistently repeatability of quality out put.

3
A further object of the present Invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which imparts in enhancement of productivity by accommodating 15 nos of stator Bars In the fixture.
A still further object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which enables perfect matching of ends of upper and lower stator Bars on (TE) and (EE) after laying in the wound stator.
An yet further object of the present invention is to propose a Form Impregnation Fixture for continuous Resin poor Insulation system for hydro generator which ensures specified and uniform gap, in overhang profile of two adjacent stator Bars after lying in the stator core and optimum resources utilization.
SUMMARY OF THE INVENTION
Form Impregnation Fixture is a rectangular C shaped box structure, open from the top and is made up of plurality Columns, which are rigidly fixed on a steel Base plate. To ensure straightness of the box, Columns are housed in 2 parallel grooves machined in Base plate. The Columns, on each side of the box are fastened longitudinally with plurality Rods. These Rods also

4
accommodates the plurality Fixed wedges during assembly, which in turn also ensures perfect right angle in all sides of rectangular box. The inside configuration of the box is such that it provides plurality independent channels for accommodating width, thickness and full length of slot portion of Stator Winding Bars of Hydro generator in disposed layers one after another. After placing all the Stator Winding Bars in the Fixtures along with Side Pressing Rules and Middle plates. Now plurality Fixed Wedges are assembled with Rods and Sliding Wedges are then inserted between Upper Pressing plate and plurality Fixed Wedges to bring about uniform and sufficient compressive force on all the Insulated Stator Winding Bars in a single charge during Impregnating and curing operation.
Further to support ends of overhang portion of Stator Bars of Turbines and Exciter sides, steel Brackets are rigidly fastened to Base plate on front and rear sides of the fixture. On these Brackets accurate racks/shelves to support end of different layers of Stator Winding Bars are made up with the help of plurality Pressing plates, Mandrel and Bushes.
After completion of loading and pressing of Stator Bars in the fixture, it is overturned to horizontal position, by putting lifting slings in the Rods. The fixture is now placed in Micalastic Tank, where vacuum is created and resin is poured for Impregnation process. After completing the Impregnation cycle, the fixture is transferred to Baking oven for heating and curing operation for specified time.

5
All parts of the Fixture which control slot size of the Stator Bars were treated with special compound to avoid any wear due to repetitive cleaning during use.
In the development of this Fixture, due emphasis have been given on critical quality requirements, ease of manufacturing, reduction in cost, increased productivity with consistent quality and reliability, beside optimum utilization of resources.
All parameters in the Fixture which are critical to quality were achieved by precision machining on Jig Boring Machine and by grinding operation. The total assembly is with the help of Fasteners only to avoid any distortion because of welding etc.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig-1- Shows a schematic diagram of the Form Inpregnation Fixture Fig-IA Show a schematic diagram from A-A view of Fig-1.

6
BRIEF DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION.
As shown in Flg-1 &. 1A, Form Impregnation Fixture (F) comprising of a rectangular C shaped box structure, open from the top and is made up of plurality Columns (3 & 10), which are rigidly fixed on a steel Base plate (27). To ensure straightness of the box, Columns are housed In 2 parallel grooves machined in Base plate. The Columns, on each side of the box are fastened longitudinally with plurality Rods (26). These Rods also accommodates the plurality Fixed wedges (5) during assembly, which in turn ensures perfect right angle in all sides of the rectangular box. Plurality Mandrels (7) are permanently fixed in Jig Bored holes in Base plate. The Inside configuration of the box Is such that is provides 15 no. of independent channels for accommodating width, thickness and full length of slot portion of Stator Winding Bare of Hydro generator in 5 disposed layers one after another with the help of plurality Mandrels (7), plurality Middle plates (8) and plurality Side Pressing Rules (9) After placing all the Stator Winding Bars in the Fixtures along with Side pressing Rules and Middle plates, the entire box of the Fixture is covered with a Upper Pressing plate (15). Then plurality Fixed Wedges (5) are assembled with Rods and Sliding Wedges (4) are inserted between Upper Pressing plate and plurality Fixed Wedges to bring about uniform and sufficient compresslve force on all the 15 Insulated Stator Winding Bars in a single charge during Impregnating and curing operation.

7
Further to support end of overhang portion of Stator Bars of Turbine and Exciter sides, specially designed steel Brackets (28 & 30) are rigidly fastened to Base plate on front and rear sides of the Fixture. Winding pitches on Turbine and Exciter side are achieved by controlling heights of these Brackets. On these Brackets 5 accurate racks/shelves to support ends of different layers of Stator Winding Bars are made up with the help of plurality Pressing plate (13 & 18), Mandrels (16) and Bushes (19). Angular slots as per angular pitches in Stator Bars on Turbine and Exciter sides are machined in these pressing plates. To firmly hold, end of Stator Bars in position, plurality Glass Textolite Wedges (14 & 20) are sued.
Plurality Lugs (31 & 32) are fixed to ends of Middle plate and Side Pressing rules for lifting purpose, during assembly and disassembly o these parts In the fixture.
Plurality Plugs are fixed on one side of Columns (10) to keep the fixture in horizontal position in Micalastic tank during impregnating and in Baking oven during curing operations.
After completion of loading and pressing of Stator Bars in the fixture, it is overturned to horizontal position, by putting lifting slings in the Rods. The fixture is now placed in Micalastic Tank, where vacuum is created and resin is poured for Impregnation process. After completing the Impregnation

8
cycle, the fixture is transferred to Baking oven for heating and curing operation for specified time.

11
WE CLAIM
1. The form inpregnation fixture to introduce continuous resin
poor Insulation system for group of stator bars of the hydro
generator comprises:-
- a rectangular C shape box structure made up of plurality columns
(3, 10) rigidly fastened to a steel base plate (27), for holding and
pressing of slot portion of plurality of stator bars in five disposed
layers, one after another with the help of plurality mandrels,
middle plates and side pressing rules (7,8,9)
- steel brackets (28,30) fitted with plurality mandrels (16), are
fixed to base plate (27) which act as holders for end of stator bars
in 5 accurate racks/shelves made up with the help of plurality steel
pressing pates (13,18) and bushes (19).
2. The fixture as claimed in claim 1, achieved uniform box size in
full length, to control insulated stator bar size with the help of
plurality columns (3,10), mandrels (7), side pressing rules (9),
middle plates (8) and accurate grooves machined in base plate
(27).

12
8. The fixture as claimed in claim 1, ensured winding pitches on
turbine and exciter sides of stator bars with the help of
controlled heights of specially designed/developed brackets on
(TE)&(EE). (28&30)
9. The fixture as claimed in claim 1, ensured angular pitches on
turbine and exciter sides with the help of angular slots
machined in plurality pressing plates (TE) &(EE) (18 & 13).
10. The fixture as claimed In claim 1, comprising of plurality fixed
wedges (4) and plurality sliding wedges (5), and a upper
pressing plate for ensuring uniform pressing of slot portion of all
the plurality stator bars in a single charge.
11. The fixture as claimed in claim 1, comprising of plurality rods
(26) and their position ensured lifting and overturning of
assembled fixture with stator bars in horizontal position to
vertical position for loading in micalastic tank during
impregnation process and in baking oven during curing.
12. The fixture as claimed in claim 1, all parameters which are
critical to quality were achieved by precision machining of Jig
Boring Machine and by grinding operation. The total assembly
is
3.
13 accomplished with the help of fasteners only.
10. The fixture as claimed in claim 1, all parts which control slot
size of the stator bar were treated with special compound to
avoid any were due to repetitive cleaning during usage.
11. The fixture as claimed in claim 1, is specially designed glass
textolite wedges (14,20) having been used for firmly
holding/pressing of ends of stator bars.
10. The Form Impregnation fixture to introduce continuous
resin poor Insulation system for groups of stator bars of the
Hydro-generator as described and illustrated herein with
reference to accompanying drawing.
Form Impregnation Fixture is a rectangular C shaped box structure, open from the top and is made up of plurality Columns, which are rigidly fixed on a steel Base plate. To ensure straightness of the box, Columns are housed in 2 parallel grooves machined in Base plate. The Columns, on each side of the box are fastened longitudinally with plurality Rods. These Rods also

accommodates the plurality Fixed wedges during assembly, which in turn also ensures perfect right angle in all sides of rectangular box. The inside configuration of the box is such that it provides plurality independent channels for accommodating width, thickness and full length of slot portion of Stator Winding Bars of Hydro generator in disposed layers one after another. After placing all the Stator Winding Bars in the Fixtures along with Side Pressing Rules and Middle plates. Now plurality Fixed Wedges are assembled with Rods and Sliding Wedges are then inserted between Upper Pressing plate and plurality Fixed Wedges to bring about uniform and sufficient compressive force on all the Insulated Stator Winding Bars in a single charge during Impregnating and curing operation.