The Iron Age 1927-06-09: Vol 119 Iss 23

THE IRON AGE New York, June 1927 ESTABLISHED 1855 VOL. 119, No. Making Automobile License Plates Manifold Chances for Error Being Avoided Newer Methods—Embossing, Painting, Ink- ing and Baking ROBERT VER 22,000,000 automo- biles one kind an- other were registered the United States during 1926. Every car carried least one license plate, and the great majority them carried two. Ac- cording the reports filed with the Bureau Public Roads Wash- ington, the owners these vehicles paid $288,282,352 for these license plates. the manufacture the plates there was used, ervative estimate, not less than 6000 tons The number men employed their manufac- difficult estimate, but manufacture the pairs plates comprising the 1926 schedule State New York, about 100 men were em- ntinuously from Feb. until the last day Superintendent Prison Industries, State and now general manager Bridgeport Brass Co. Ax é | B ad. LOOSE /IUITIES f ~ f > c VA VA (Above)—Male Die for Embossing Plates. The numerals and letters, indi- removable, are accurately “spotted” the two pins fitting top and bottom each. This die used conjunction rubber pad (Right)—Spray Machine for Put- Base Color Automobile License Plates. The traveling conveyor brings the plates predetermined speed under the nozzles spraying enamel upon them the calendar year, and gang additional men were employed night shift for period six months. evident, therefore, that the auto- mobile license plate industry one mean propor- tions. the casual automobile owner, the license plate appears cheap affair, and something that should comparatively easy make. Despite its apparent simplicity, the license plate involves some high-class engineering and some rather complex shop problems. its essential operations the manufac- ture license plate consists the following opera- tions: Cutting the steel blanks, embossing the numerals and letters the blanks, embossing the raised rim bead around the edge the plate, putting the base color one two coats, with baking following each coat, coating the numerals with color contrasting with the base color, one two coats, with baking following each coat, sorting the plates into pairs, in- closing each pair paraffine paper, inserting each pair envelope numbered correspond with the number the plate, assorting the envelopes with their 4-4 4 | | | | | | | | | | | | Air Pine Er qame/ J Anglelron a ' SECTION A-A Lx ai ist f Pe wire Spacer Mo for : ken — plates into series consecutive numbers, and pack- ing each series into correspondingly numbered carton for shipment. Great Chance for Error the output State like New York, there are over 4,000,000 chances make error each opera- tion, and the chance discovering errors any the last few operations exceedingly remote until the driver the car unpacks his new plates the begin- ing the year. evident, then, that high degree organization necessary the shop. the case States that, like New York, use combination letters and numbers for their plates, the various letters being assigned different counties requiring widely varying number plates, definite production schedule must laid out the beginning the production period. this were not done would more than likely that, the time when plates were placed sale for the following year, many counties would find themselves without plates, while others would have more hand than they would need until the season driving for pleasure had opened. general public knows practically nothing the automobile plate industry. The engineering profession knows little more, despite the magnitude this indus- try. The reason for this that, with few exceptions, all the license plates used the United States are made the State prisons, and the opportunity see the plants operation limited few persons. rule, visitors prison are excluded from the shops. Therefore, unless one has some business with the prison industries, there little opportunity learn the magnitude the manufacturing work that goes 1 behind the walls Two Methods Available Although the operations followed are the same general way, there are two distinct methods followed the manufacture license plates. The difference lies the manner embossing the plates, and the method application the base color. The older method embossing consists the use steel male die, the female being heavy rubber pad, con- trasted with the more modern method using all- steel die. Despite this seemingly simple difference, the substitution the all-steel die changes the whole process and effects many economies operations. the application color, the two processes general use are the spray booth, with separate bak- ing ovens, and the dip process, with continuous oven for baking, forming integral part the operation. the end 1926, the State New York the older method. For the current year, mod- ern embossing plant will used, the plans which were under consideration the beginning 1927 are arried out, the dip process and continuous baking will adopted the end the 1927 production schedule. This will give New York the most modern and com- plete plant the country for the manufacture au- tomobile license plates. Plants the type that proposed install New York are use the State prisons New Jersey, Pennsylvania, Maryland, Iowa and several other States. After brief discussion the older method, that was employed the New York plant, Auburn prison, and which still used number other States, the operation the more modern methods taken detail. will then possible point out how study methods and processes even simple product embossed and enameled plate can effect savings that are well worth while. Bright-finished, annealed steel used sufficient ductility withstand the severe treatment which subjected the drawing operation the em- bossing press without breaking through the edges the numerals. Considerable difficulty was experienced 165 1927, The Iron Age the past securing steel that would under this treatment. But all difficulties have been overcome, and trouble from rarely The steel purchased either strips equal the length the finished plate, sheared the size the plate. The the more economical method, but until class shearing equipment than was prison shops was procured the loss due sheared plates was greater than the extra blanks sheared size. The lesson has generally driven home, however, that even can better work properly equipped. tendency provide equipment least equ found similar shops outside the prison practice becoming general buying strips and shearing size the shop. Punching and Shearing Form After the plates have been sheared the fir tion round the corners and punch whereby the plates are attached the car. done ordinary inclined-back punch bination punching and shearing die being die arranged cut the round corners the plate and the same time punch that end. The plate then turned end for end opposite end rounded and punched. New many other States, the operators presses are paid piecework basis. They tremely adept, frequently allowing the press continuously, and punching plate each u the New York State plant Auburn Prison, the plates are embossed presses the Seybold type. These are toggle presses, with platen that moves out front the press the conclusion each stroke, that the dies can changed without the operator The ers, placing his hands the working area the press. dies are steel with removable numerals and lett shown Fig. Only male die used, the femal being replaced with rubber pad. The die mounted the platen, which moved upward against the rubber pad when the working position. With this type equipment, the bead around edge the plate embossed the same time numerals, whereas with the type die later, the embossing the “bead separate t tion. the other hand, with the newer two plates can embossed one time, and each will much sharper and clearer than either single plates embossed against the rubber pad. The die consists body and number pieces, the latter comprising the sections the State designation and year, and the letters, which are changed with each pair plates. pair pins each letter and numeral position locate the characters the die. These are hand after every second plate has been eml Much time and effort has been expended perfect automatic device for changing the acters, but without success. Base Color Applied Sprays present, the plates are given their base the Auburn plant spray booth, sketch shown Fig. The apparatus consists pair link-belt chains, running through compartment, joined together 4-in. interva! wire spacers form continuous open belt. nozzles, operated compressed air, are locate and below the belt apply the color. The nozzle coats the front the plate and applies siderably thicker coat than the lower nozzle plates are piled table, groups 50, ing end the machine, and are fed chain, which carries them between the two = 7 ind 1s J =) iu ra- ra the 4 The regulation the speed the chain with the adjustment the nozzles necessary, just the necessary amount color will the delivery end the machine men required, two whom take the the chain and place them crates for the ns. The third man assists moving the tes from the delivery table and places the position. Two these machines are handle the output plates the Auburn instance, frequently the case indus- trial work, was minor consideration that made high-speed operation possible. When the plant Auburn was first installed, the output ates was less than one-half that 1926. The speed fthe paint machine was low, and was easily possible Machine for Applying the Color Letters and Numerals License Plates. operates the principle the printing press. The held magnetic chuck the platen further increased and thus obviated the purchase additional equipment. the operators were paid piecework basis, there was objection their part the higher rate output. The plates Auburn are baked electrically- heated ovens, each holding 1200 pairs plates. Five such ovens are used Auburn. The time required varies from hr., depending the color. The plates are baked temperature about 225 deg. Fahr., the temperature being controlled thermostats. Numerals Colored Printing Rolls Color applied the numerals rolling, much the same manner ink applied type the print- ing press. fact, the process generally referred inking, and the color ink. Care has ex- ercised the selection the ink, otherwise will not Slot Male top for female Die Spring Handle Fig. 4—Tool Steel Male and Female Em- bossing Dies Hinged Steel Frame Are Used the Latest Process. crank press 150 tons capacity furnishes the neces- sary pressure 4, - Fig. 5—Hinged, All-Steel Parallel Action Dies Position the Embossing Press “catchers” pick the plates their edges ace them the crates. the speed the ma- was increased take care the greater de- the operators were compelled grab the plates way possible, with consequent finger-printing This finger-printing was the cause much aint, and great deal study was given avoiding it, even the extent attempting ign apparatus that would deliver the plates rates directly from the belt. the end, the remedy was simple. lelivery end was furnished pair gloves, the and first two fingers which were provided pins sharpened fine point. The men were enabled grasp the plates any manner that onvenient without making any mark them fine pin prick, which filled with color before plates were baked. valuable by-product this that enabled the speed the machine still ates, Each man adhere the base color. Part the ink specifications read that must constituted that will, after baking adhere firmly and become integral part the base color. must insoluble all the or- dinary solvents, which excludes the cheap inks. Several years ago ink was selected the basis appearance and price. After about 100,000 pairs plates had been made was discovered that the numerals could wiped off the plate cloth pened with gasoline. Before insoluble ink was found, the contract price had increased four-fold. addition, all the plates already made had washed off and reinked. The cost doing this was far more than would have been saved the use the cheaper ink. The cheapest material frequently the most expensive the end. Several types equipment are use for inking plates. the Maryland penitentiary, continuous- table machine employed. The table consists The Iron June 1927—1655 if | | it i "pe < 4 series magnetic chucks, which the plates are placed one end, and which its movement carries the plates under two more sets inking rolls. This machine does first-class work but limited capacity. Auburn the same type machine used the plant the State Prison Anamosa. This machine shown Fig. The plate laid the platen and then elevated means linkage, controlled the foot treadle, into the path the rollers. desired that colored border ap- pear the plate, mask, covering the bead around the edge the plate, set the opening the table. The operators become very expert this machine, and frequently lock the treadle the operating position and remove and replace plates the machine without missing single stroke. Auburn, crew two men operate the machine, one whom handles the | | | Fig. Plates Emerging from Final Baking State Prison. Their position permits immediate inspection and sorting into racks plates and out the machine, while the other sup- plies him with plates, places the inked plates the for baking, and the same time inspects the finished product. Five these machines are required handle the New York State supply. After the plates have received their final baking, they are sorted into pairs, duplicates are spoiled plates replaced and each pair then wrapped paraffin paper and placed envelope bearing number corresponding the number the plates. The plates are finally packed lots pairs each corrugated cartons for shipment. Running Two Plates Pair Simultaneously Possibilities error the process just outlined are many, and was partially with the object min- imizing these possibilities that the extensive changes the Auburn plant were adopted. Some the possi- bilities error the older process were the embossing one three plates given number instead two, the pairing plates dissimilar numbers, and the omission pair altogether from series. The first class errors the most common, and measure responsible for most the others. The 1656—June The Iron Age plates being embossed singly, the embosser sarily keep track the number plates ber has made. Toward the end with high speed operation element operator change the dies too soon enough. With the new method, both are embossed the same time, and the becomes matter routine, occurring troduction pair blanks into the pr: Furthermore, the plates made her which not the case with plates made singly, therefore much easier keep the plates the same number together subsequent process: This extremely important errors packing are avoided. the application the base color the spray booth, almost impossible keep together, due the speed which they pass through the machine, and the fact that the “catchers” each remove only every alternate plate from the con veying belt. attempted keep all the plates group pairs together one crate, however, and the crate becomes the unit from this point on. Even this difficult times, particularly when errors have been made the embossing. The sorters and packers handle single crate time and, all the plates the original group pair are the same crate, the problem sorting and packing comparatively simple. However, this not the case, the packer must hold out those plates that have mate, and locate them before can complete carton. The missing plate may any one crates, that the difficulties attendant the correct pairing over 4,000,000 plates can readily imagined. The new methods manufacture, which are use the Ana- mosa, Iowa, plant, and which will probably used Auburn next year, remove most, not all, these troubles. All-Steel Male and Female Dies The first radical change the improved method the substitution all-steel dies. the hinged, paral- lel-action type, these are shown Fig. With this type die ordinary crank press about 150 tons capacity used. Three Niagara presses this type have been installed Auburn, replace five the old Seybold machines. Three these have been fitted put the beads the plates after the have been embossed. shows one the embossing presses with the dies position under the ram. the right the press the box containing the dies, several each number being assigned each press. The dies are withdrawn from the bottom the box, and after use are replaced the top. this way the dies are given equal use, and wear equally, thus making plates more uniform appearance than possible with the die and rubber pad. The output the present ment over twice that the older type, due part the making two plates each stroke the and part the ability run the crank press higher rate speed. All the presses are with safety devices that make impossible for the get his hand the path the descending ram. Dipping and Baking the base The latest and best method applying color the plates eliminates the spray booth replacing with dipping process and baking that essentially continuation the dip. the plants the New Jersey and Maryland prisons, the plate suspended from cross bars carried pair Belt chains, six eight plates being carried bar. The chains carry the suspended plates a drain tank containing the color, and then over ly, — t il 1, cha > J t l Ty i it} tne the surplus enamel drains off the plates plates still suspended from them, the pass into the continuous baking oven, which gas electricity, with thermostatic Inside the oven, the chains which lead them series vertical passes reach the rear end the oven. Then the led forward along the bottom the oven, current cool air flowing in, and the entering end. They pass under the dip rise the front it, where the baked plates ved and the uncolored plates hung position through the machine. Anamosa plant the apparatus somewhat nt. Here the dipping done separate ma- the plates lifted from and placed the the baking oven. Fig. shows the battery quipment Anamosa, with the delivery from the tank right foreground. This machine oper- There are several advantages this type con- struction. Where the plates are suspended from the conveyor, with certain consistency color, the enamel will flow toward the bottom the plate and the color coating will thinner the top than the bottom the plate. get uniform thickness enamel the plate, often necessary pass them twice through the dip and baking operations, they being suspended the opposite direction during the second pass. When the plates pass through the ma- chine horizontally, there tendency for the enamel thicker one part the plate than another. Thus the speed the operation increased the elimination one pass, and considerable economy material effected. similar type oven used for baking the plates after the numerals are The plates are put the conveyor directly from the inking machines, thus eliminating one more handling operations com- pared with other methods. The plates, they emerge Painting and Inking Equipment Continuous Principle. right foreground, then the first baking oven. The delivery rack from dipping Beyond are the “inking” machines for the letters and numerals and the bead, with their baking equipment the background the same general principle those just de- but construction radically different. the former machines, the plates were suspended the carrier they passed through the oven. \namosa machine the plates are carried fingers assume horizontal position they enter the Instead passing through the oven series tical movements, the plates move along horizontal mechanical device lifts the plate from the the conveyor the end each run and de- the fingers the next run below. The thus pass through the oven entirely hori- position, and emerge the back and bottom employment, which went from Payroll one week meantime advanc Steel Employment and Wages and steel workers 207 identical establish- leclined fraction per cent number March and April, according figures the States Bureau Labor Statistics. The num- payroll March was 277,212 and April 276,- the reduction numbers, there was the amount weekly payroll practicalls ent. advanced from $8,732,626 cast iron pipe foundries there was 1.6 from the ovens, are raised the conveyor fingers vertical position shown Fig. thus permitting immediate inspection and sorting into the racks, from which they are packed. The most approved arrangement plant series units, consisting shear, punch press for round- ing the corners and punching the slots, two embossing presses, rimming press for putting the bead, dip tank with its baking oven, and two inking machines with one baking oven serve them. The operators the various units are usually paid piecework basis, with bonus for exceeding predetermined daily weekly output, and additional bonus for the crew that has the best output for week and for month. per cent, from $351,613 Foundry and machine shop products covered 996 establishments showed reduction employment 1.5 per cent, from $256,460 $252,494. The reduction payroll total was considerably greater, being 3.4 per cent. The amount payroll one week was $7,831,040 March and $7,564,450 April. Machine tool plants showed decline both em- ployment and payroll, slightly greater under each head than with foundry and machine shop products. 156 establishments the drop was from 31,075 hands 30,- 498 and from $958,783 payroll $922,048. 999 1 The Iron Age, June 1927—1657 q ] + until tank dl | 14,38 Available Ore Supply Limited Large Part World Reserves Iron Not Commercial, Owing Transportation Costs, Expense Mining and Chemical Physical Composition DWIGHT WOODBRIDGE HERE plenty iron the worid, and mines last long time. While every ton that won from them depletes the deposits, they continue for hundreds years. Many centuries may required exhaust single deposits iron ore, and the history metallurgy Europe from the dawn civilization full mention mines that are yet active after long periods steady production. Authentic information mines that are now extensively worked dates back the dim ages the past. Areas the island Elba, where the Greeks dug iron about the time Rome was founded, are now being mined, and have been worked almost constantly for more than centuries. Cargoes this ore come occasionally the United States. Ore deposits Styria and Carinthia Austria, what was the old province Noricum, have been mined more less continuously for more than centuries. Today they are among the more important spathic iron mines and are the basis great industry. The supply ore from the famous iron mountains Erzberg and Huttenberg shows sign final exhaustion after 2000 years almost constant mining. Mines Hun- gary that were active the first century our era are still making their annual tonnage. Great antiquity claimed for the mines the Ural Mountains, the province that was known the Romans Sarmantia and where they delved for ores iron. Mines Bil- bao, northern Spain, worked the time Pliny, are unexhausted and contribute yearly the exports Britain, they have for long periods. Old British, Swedish and American Mines scoria, iron cinder, the immediate neighborhood the English mines the Forest Dean indicate that iron was made there when Julius Caesar marched through. The definite mineralogical history the district dates back the Norman con- quest, and still producing small annual tonnage that doubt can maintained for years come. Sweden the mining iron ore antedates the Vikings, and there good reason believe that began least early the time Christ. The miners Norberg, where ore yet being dug, were granted crown privileges the fourteenth Dannemora was opened 1488 and still reck- oned with. Since mineral statistics were first gathered central Sweden, about the year 1300, more than 150 million tons have been won, and some the producers still have place. The High Bridge mines New Jersey were opened 1700 and have been worked continuously the present time. The famous Cornwall ore hills Penn- sylvania have produced almost without interruption since 1740 and single recent season raised about half million tons. Quantities cannon, shot and shell for the Continental armies were made from ore dug this mine. Ore was first taken from the deposits Port Henry, Y., 1804, and today the largest works the United States for the lean ores are these mines. older concentration Present Consumption Ore Threatens Life Mines regions that are opened nowadays, especially the United States, will not last thus. The pace too rapid, the demand too great, for long life. Where 1658—June 1927, The Iron Age the call insistent, the case with the Mes range, this will markedly true. While impossible make accurate estimat the total actual reserves iron ore the world. authorities generally agree maximum mor than billion tons, equivalent about billion tons metal. The world consumes from say 100 abou 125 million tons year, depending business con- ditions. Without any considerable there are known reserves last approximately years. This does not compare with the expected our coal reserves, but sufficient relieve any such anxiety was manifest Sweden some years ago, when the Government limited the annual exportation iron because its fear depletion international reserves the mineral. This figure billion tons means exhausts the possibilities, what are called the potential re- serves; the other hand, does not present true picture available sources iron. Many factors and contingencies enter the perspective. Geochemists tell that nearly twentieth the material composing the crust the earth iron, which few favored spots has been concentrated nature such extent that call ore and mine it. definition the crust, upon which this computation made, includes the solid material the lithosphere depth about miles, together with its liquid and gaseous envelopes the oceans and the atmosphere. know that there are vast areas the iron con- tent whose rocks high permit them classed potential reserves—not rich enough smelted just yet, but amenable concentration before smelting; indeed, perhaps and available their natural state, when higher grade ores are scarcer when methods reduction may cheapened. blast furnace operators become able use leaner ores than they now, greater and greater reserves wheel into line commercial. The field woul greatly increased were iron makers use ores ten points lower iron than now. Eighty Per Cent World Reserves Five Countries } the billion tons commercial iron ore the world, about per cent five countries. the order their tonnages these are United States, standing practically parity; France, Newfoundland and Cuba. The British Isles and many have about per cent each, and Sweden, and Russia about per cent between them. Nor' South America combined contain some per the world reserves, fact slight moment consideration the future civilization. But out the billion tons called cause its quality, very considerable not available. Available ore such can profitably proper mining treatment, used profitably the manufacture article. Hence, ore low iron assay able because cheap transportation, adaptability for concentration beneficiation. worth metallurgical processes, while some ore must wait indefinitely account able location characteristics. High iron assay but one the facto for usefulness. the value unit comparison with that other transportation and other costs govern ta! Tne an } than with copper, lead zinc, and still more with tin, nickel, silver gold. Lake Superior Region Produces Half World’s Ore Output shown from the records leading ore Lake Superior district produces half ore, the Mesabi range two-thirds this preponderance? not because ore comparative ease mining, are not exceptional, and while some mines shovels from near the surface the 3000 ft., and are 4000 ft., into not because nearness markets; miles more from these ore beds the es. due rather the highway sup- Great Lakes and its intelligent improve- the past two generations, and the fur- ore and coal could brought together the Lakes and near market. ld. What has held back the vast stores ore existing the interior Brazil? Not grade nor quantity, for her than any others average iron con- ness the country’s area helps solve the difficulty caused poor quality. Rail and water hauls are short; coal, ore and flux are brought together easily, and the manufactured article need taken but few miles some convenient seaport consuming center. En- gland hard find iron-producing locality where ore and coal are separated more than 100 miles, while the United States distances more than 1000 miles usually intervene between ore and fuel. From the mines the Mesabi the coal fields Pennsylvania and Ohio more than 1000 miles; low-volatile coal taken 500 miles plants the Chicago district. The average length haul for all iron ores consumed the furnaces this country not less than 700 miles, and the haul fuel with which this ore reduced metal about half far. Every ton pig iron made the Pittsburgh district the Valleys pays more than for freights assemblage the required materials. Commercial Reasons Measure Availability Ore short, for every mining region the world there the purely commercial reason governing advance retardation, activity idleness; and resources that are themselves virtual parity are either devel- Minnesota ranges. WOODBRIDGE has had much with points out that much the commercial ore the world not Ore low iron assay may become available because cheap transportation, easy iron ore development, particularly the ng, adaptability for concentration beneficiation, from worth metallurgical while richer ores must wait indefinitely account less favorable location char- pe ore may last forty years. The future the United States great steel-making nation rests the Lake region reserves, especially those the Mesabi range. Without increase mining, commercial Plants for concentrating ores are costly, and will take much mechanical equipment plicate the output even one large Lake region mine. Potential ore reserves reported from various parts the world frequently prove disappoint- The large stores iron ore which China was believed possess could not found geological survey. and suitable fuel, and cost transport. ‘he transportation may said include assemblage all materials and the distri- all products. Distance haul less con- than the rate per mile and the development devices for reducing and quickening han- expense and time. ach Markets Retards Newfoundland Production maintains modest rate output from ‘he mines Newfoundland, where the ores are iron those Lake Superior and lie directly Neither low grade nor transportation nor mining costs, but markets. Until there between the Atlantic and the Great their field along the Atlantic Coast and Over there they have their own ores. The seaboard not yet considerable consumer, sense that Pittsburgh and Lake Erie gulp iron nesfull every month. What has checked produc- rom the three four billion tons chromifer- ores top the ground along the seacoast tern cost manipulation, the lack ind the difficulty handling and moving these ores their natural state. did the rich and easily mined ores Utah emain untouched, that today their develop- but beginning? Transportation over long dis- and across mountain ranges any previously points use, and doubt markets- midity money. ‘hy have the very lean ores England built structure affairs? this country such ores serve only ballast roadways. There the small- oped the utmost limit their opportunity are lying fallow. The growth the iron industry country, relation its consumption iron and steel, depends largely the character, extent and availability its coal resources. Sweden and Spain are rich iron but poor mineral fuel, and they export most their ore countries that have abundant and suitable fuels, themselves making but small amount pig iron proportion their wealth ores and their populations. Great Britain depends considerable extent im- ported ores, but she occupies leading place ufacturer steel. She has the coal. The United States fortunate that has within its boundaries widely distributed and abundant supplies both ore and fuel. will apparent that available iron ore some- thing quite different from total tonnage. So, while the world large may have ore commercial grade last 200 years so, the amount that can depended for carrying vastly less. The six seven billion tons commercial iron ore existing the United States fairly well located for use present, but not for long. Half close Lake Superior, where mines, railroads, harbor facili- ties and ships have been coordinated into smoothly running machine that has equal for efficiency. Any further shift the center steel making from Pitts- burgh toward the west must tend increase propor- tionately the requisitions iron makers upon Lake Superior mines. Most the remaining half commercial iron ore this country the Southern States Alabama, (Continued page 1720) The Iron Age, June 1927—1659 | — . if | | | | Se | 4 mets } 4 Plant Maytag Machine Has Several Un- usual Arrange- ments ESCRIPTION the iron handling and melting arrangements Maytag Co., Newton, maker washing machines, was covered THE IRON AGE June page 1587. new continuous melting unit recently installed that plant was placed between the old foundry and large manufacturing building. The present article continues the story that foundry, and will followed other install- ments frequent intervals. For handling incoming raw materials such sand and coke receiving hopper has been provided under the railroad track the yard, shown Fig. will noticed that this hopper has covers which can placed over when not unloading carloads material. The covers for the flanks outside edges the pit have been arranged that they drop back and form curbs for the sides the pit, when the material being dumped into it. far possible all incoming material brought hopper-bottom cars. the case sand the entire charge dropped directly into the hopper, and pan feeder the bottom feeds the con- veying machinery the building. the case coke the hopper should located slightly one side, that the coke slides into the conveyor slowly and the material raked shoveled into the hopper required The pan feeder under the hopper shown Fig. discharges another and larger pan feeder, shown Fig. This located the tunnel under the foundry yard. The end this conveyor can discharge into the boot elevator that takes sand the top the sand bins under the charging platform. Or, second belt which delivers coke the boot the coke elevator that takes coke into the storage, de- scribed later When sand being unloaded comes the con- veyor shown Fig. and flows over the end into the boot elevator that passes through concrete elevator casing built connection with the sand bins. The head this elevator terminates the passage immediately below the charging floor, shown Fig. the head the elevator being the back- ground. The elevator discharges sand belt from which plowed off the right left into series deep bins silos. These are some ft. depth, and the discharge openings all but one Fig. (At Top Page) Track Hopper Which Handles All In- coming Sand and Coke 1660—June 1927, The Iron Age Designed for terference veyor System usually Complete these bins the ground foundry floor level. There one bin, taking half the width the structure, that has discharge opening the foun- dry floor level. This bin used for fire clay for lin- ing ladles and for cupola daubing. The bins have sufficient capacity take care entire winter’s supply molding sand, core sand and fire clay. the end the belt shown Fig. tailings chute which extends down outside the bin proper and terminates the small tailings bin, which emptied after each run raw material. This arrangement prevents the discharge mixed lot miscellaneous material into the last bin the series, and the smal! amount which lands the tailings bin each case wheeled into the plant and used immediately. The coke used this plant by-product coke which has more less structure. This coke handled through the hopper and conveyors already described elevator the continuous bucket type. This elevator takes the coke point several feet above the charging platform and discharges belt suspended from the trusses above the platform, shown this view the cupola shells are shown the left and the belt the right. This general handling belt passes into the coke storage and terminates shown Fig. Beneath the termination the general incoming belt re- versible shuttle belt conveyor shown Fig. means this, coke can discharged any point into the 1000-ton coke storage located the charg- ing floor level. being careful arrange the coke discharge fairly high face coke very little breakage takes place and the system has been found efficient for ting this material into storage. has already been stated this series, the tion this plant made imperative arrange separate department not interfere with departments and, get the maximum tion from the minimum ground area. was reason that the 1000-ton coke storage was level with the charging platform and over the the plant given locker rooms, wash rooms, core ovens and general supplies. The handling equipment involved this unit Lane Co. served foundry engineer and the work was designed Henry Raeder, architect the entire job. = 4 rounary anc OKe —— 7 7 q Extensive the Parts Maytag Conveyor 2—Pan Conveyor Tunnel nder Yard. This conveyor serves deliver molding sand and coke the track hopper the proper elevator the plant 5 7 q 4 7 | 5—Shuttle Conveyor Over Coke Bins, Which Delivers Part the 1000-Ton Coke Storage the Charging Platform Level ‘ig. 3—Sand Distributing Equip- ment Over Sand Bins. This pas- sage immediately beneath the charging platform. The incoming sand discharged the belt rom the elevator round and then plowed off into the various storage bins Fig. Handling Incoming Coke. Conveyor for Supported charging platform, elevator serves port coke from the coke conveyor over the coke bins The Iron Age, June System G | More About Fluorspar the Cupola Prominent German Makes Rejoinder and Advocates Its Use— Sulphur Reduced Thin Slag, Manganese and Jolting Practice,” Prof. Wilke-Doerfurt and Bucholz, appeared the April issue THE IRON AGE, which the use this mineral deprecated—as even injurious cupola operation certain phases. was expected that the Associated Sellers Fluorspar Germany would make rejoinder, and they are doing through Dr. Osann, international repute. Since the advance copy received contains much that interest connection with the use fluor- spar the foundry, condensed abstract the re- joinder question given herewith. Fluorspar Not Properly Used Doctor Osann, discussing the adverse results ob- tained the co-authors above mentioned, claims that the fluorspar was not used properly, for very good desulphurization was obtained with flux two-thirds limestone and one-third fluorspar. Only when the pro- portion fluorspar went did bad results eventuate, inasmuch the cupola lining was badly attacked. This throws odd light upon the subject large. one the United States would think using much fluorspar his cupola fluxing—the amount sel- dom being above per cent. would seem, however, that organized sales effort the part fluorspar selling combine Germany has succeeded setting the line one-third the total flux charged. Further, the combine has not been anxious increase this pro- portion, excessive cutting the cupola lining vould introduce enough alumina into slag make thick and less able take sulphur. Thin Slag Aids Desulphurization The author further points out that one has ever seriously claimed desulphurization the use fluor- spar per se, but that desulphurization would take place the results thinning down the slag with every advantage for sulphur removal the lime thus brought into more intimate contact with the metal and ash the fuel. That with good limestone and with care and ability the part the cupola operatives, not necessary use fluorspar all for good melting. Only where the foundryman sees advan- tage should use fluorspar. can the same time reduce his total flux two-thirds the normal, and have the added benefit clean melting and dis- turbances slagging-off. Going into the act desulphurization specifically, Doctor Osann states that process segregation. Just holding the molten metal furnace mixer, carrying some distance gives time for the forma- tion sulphur compounds—chiefly same process takes place with cupola iron. both cases this manganese sulphide and other sul- phur compounds, being lighter than iron, will trend upwards and either unite with the slag form layer between metal and slag—just the case lead refining. Manganese the Important Sulphur Remover With high manganese the charges there always proportionally less sulphur the result than where lower manganese ranges are used. fact, manganese the important sulphur remover, for the presence slag vitiates the use soda ash, and the presence iron oxide the cupola slag obstructs the formation calcium sulphide. The latter shown the fact that, the electric furnace, desulphurization can only carried through successfully with white slags, that is, slags free from iron oxide. Prepared from the Germat d mented Richard Moldenke 1662—June 1927, The Iron Age Considering the question sulphur ipol will found that have this element coke and iron charged. burning coke part the converted into sulphur dioxide and part int trioxide, about per cent these gases going stack and the rest being absorbed the melting thus enriching its sulphur content. the drops molten iron descend and reach the pool collecting the bottom, the segregation above referred takes place. and the manganese sulphide formed has time rise under special conditions. Thus, with the pool molten iron kept within the cupola constant height and th: surface just the slag hole, with specially good stone and very thin slag, not difficult with rath high-sulphur charges cut this half. mor difficult effect reduction when the sulphur low the first place. Jolting Action Reduces Sulphur common observation that with very metal this increase manganese sulphide may take place. Hence series shocks may necessary start the action off. This the basis the jolting action the cupola mixing ladle recently brought out. (THE IRON AGE, Aug. 12, 1926, page 413.) the transportation blast furnace metal for long dis- tances, which ends with metal with half the sulphu content. Doctor Osann gives attention this jolting action suggesting that with very thin slag, drops molten metal may project themselves through the slag layer the cupola readily and give the necessary impulse start segregation and the upward movement, whereas with heavy viscous slag, the pellets molten metal may not through with any degree force. well known that thin slag never carries iron shot whereas thick slag, when broken up, usually carries some. Again, with thick slag the melting zone there must retarding tendency the part the drops metal, and hence more time given for sulphur absorption. + + Must Have Proper Proportioning Lime and Fluorspar portioning limestone and fluorspar when the latter used. not necessary prove that fluorspar thins the cupola slag when rightly used, well known. The same observation has been made blast furnace, open-hearth, and electric furnace opera- tion. That fluorine may not found such slags quite possible, for silica takes and the compound formed gas. However, the question fluidity one mixtures component parts, and ver) small percentage one material may have far reach- ing consequences the product. is, cult explain why fluorspar limestone slag fluid, even when the fluorine has been Doctor Osann suggests this possibility that action calcium fluoride and silica, which the formation the gaseous silicon-fluorine with oxide the remainder, has this oxide the nascent state, and hence acting powerfully upon any surplus silica remaining ind. so, then careful adjustment the silica fluorine content the materials charged would order, otherwise excess fluorspar would much calcium oxide the slag, cutting into ing, both. This would mean thick and defective operation. Hence the proper ing fluorspar limestone would remain further research, and this connection with the ganese situation should lead valuable infor! Roller Shell, Left, Receives the Shaft and Stationary Field, Center, and Becomes Motor-Roller, Right Motor-Driven Table Rollers Unique Design Which Roller Shell Houses Driving Motor— Variable Speed May Had Required \BLE rollers for steel mills, each individually leads from the windings are led out through the shaft driven motor housed the roller, the latter disconnecting plug. The shaft supports the roller rming shell for the motor, late development. and mounted frame with other similar rollers The motor for the self-contained power unit, designed form roller table. The shaft held from rotating built especially for roller table use, exceedingly either keyway having squared ends, placed gid. The complete unit called square slot the housing. regularly con- The motor unique that its construction the re- structed, the roller dust-tight and can made water- verse the ordinary induction motor. tight. naft carries the stator core and coils 3-phase a.c. Designed for peripheral speed 130 ft. 3000 tor, while outer shell containing the rotor core ft. per min., the speed the rollers determined squirrel cage revolves, thus providing power unit the number poles used the motor winding and the rves roller. frequency the supply current. Speed adjustment, Mounted its ends anti-friction bearings, the desired, may obtained varying the power cir- revolve freely the shaft. The connecting cuit frequency. This may done the use y 4 | rt | | J Two Forms of the Mo- tor-Roller, That Above Being for Plates Flat Sections While That Left for Rounds Other Shapes. Both are made the same principle, motor contained within the roller shell. Variable speed ob- tainable where needed The Iron Age, June 1927—1663 a \ / _ motor-generator set driven adjustable-speed d.c. motor, having the alternator driven the mill motor. The ordinary 25-cycle power circuit will pro- vide for peripheral speeds low 500 ft. per min. The motor-roller can accelerated quickly, permitting rapid reversal. The motor can designed for fre- quent reversing full voltage, without injury. Motor-rollers may take any heat conditions encoun- tered roller tables. For handling hot and heavy stocks the rollers are built with double shells made one-piece steel casting. Effective insulation against heat provided the air space between shells, diag- onal vanes between shells increasing the free circula- tion air. The rollers may cooled forced air ventilation, water, conditions demand. Present common drives for mill tables are from line shafts through beveled gears. Some mills use rope drives, eliminate the beveled gears. Individual mo- tor drives from motors mounted the table frames are used some plants. the gear-driven table numerous bearings must kept alinement. Misalinement results in- power requirement, which may sufficient burn out motor. With the Motor-Roller type table, each roller being independent unit supported stationary shaft, the difficulties alinement are eliminated, the self-contained power unit cannot get out alinement and there necessity keep the table alinement. the table not put the strains the bevel-gear drive, and not neces- sary keep alinement, pointed out, its cost ‘an reduced using lighter and less expensive table frame construction and lighter foundations. When, case trouble, roller disconnected from the power line, will continue run idler crease ithout stopping the mill. The unit construction per- mits flexibility arrangement, the roller curved desired. The roller can Numerous advantages are claimed for other parts common the ordinary roller Power requirements are estimated one-fourth half those for the ordinary roller table. Only about cent much lubricant required for gear the bearings not require greasing once six months. The tables take than the ordinary roller tables, floor space elimination line shafts, gearing and other parts The total width table need only about in. than the length the rollers. The life the increased and maintenance costs are cut down. Developed Germany, the motor roller the Schloemann Co., Diisseldorf, rolling mill and hydraulic machinery. has been use Germany for more than two years. this coun- try will handled the Schloemann Co., Empire Building, Pittsburgh. About the time that the motor roller was being de- veloped Germany, Willis McKee, engineer and con- tractor, Cleveland, was working le- veloping roller embodying the same principle. Mr. McKee now cooperating with the Schloemann Engi neering Co. putting this equipment the Ameri market. These units are being built for the Schloe- mann company the Reliance Electric Engineering Co., Cleveland. set the motor rollers, now being made for large steel plant, will the first tion this country. exhibit the roller made the meeting the Association Iron and Steel Electrical Engineers Pittsburgh, June Industrial Power Plant Problems Discussed Erie MEETING which paid particular attention in- dustrial power problems was held under the aus- pices the Erie section the American Society Mechanical Engineers Erie, Pa., June and was scheduled Tri-State power meeting, delega- tions from the Cleveland, Buffalo and Pittsburgh sec- tions the society participating. The principal papers presented were the following: “Modernization Industrial Power Plants,” Major Spencer, Baker Spencer, Inc., New York; “Conditions and Effects Electric Drive Compared with Other Methods,” Rogers, in- dustrial engineering department, General Electric Co., and “Some Fundamental Considerations the Design Boiler Furnaces,” Prof. Wohlenberg and Brooks, Sheffield School, Yale Univer- ity, New Haven. The technical sessions were marked active and general discussion and certainly were calculated warrant the holding regional meetings the locality and which are conducive liberal ex- change views and