The Iron Age 1932-01-21: Vol 129 Iss 3

RON AGE January 21, 1932 Editor Editor Editor Emeritus Managing Markets and News Editor F. J. WINTERS R. E. MILiLer R. A. FISKE BURNHAM FINNEY GERARD F'RAZAR E. F. Cone Chicago Detroit Boston F. L. PRENTISS T. H. GerRKEN L. W. Morretr R. G. McINTosH G. EHRNSTROM, JR. Cleveland Pittsburgh Washington Cincinnati CONTENTS What About 1932 Profits? 217 Connecting Rod Machining and Inspection 221 Heating Stock for Nuts and Rivets 222 Welded Bomb Bodies 225 Crane Motorization and Control 226 Making Large Bells for Carillon 230 Preventing White Rust Zinc Coatings 232 Pipe Line Welding 235 Symposium Steel Melting Methods 236 a New Equipment 239 News 244 Automotive Industry 249 Personals and Obituaries 253 Editorials 255 Markets 257 Construction and Equipment Buying 274 a Products Advertised Index Advertisers (Advertising Section) (Advertising Section) THE IRON AGE PUBLISHING COMPANY, 239 WEST 39th ST., NEW YORK Division United Business Publishers, Inc. FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager Copyright, 1932, ADVERTISING STAFF Emerson Findley, 1362 Hanna Bldg., Cleveland. Herman, 847 Ellicott Sq. Buffalo, H. K. Hottenstein, 1507 Otis Bldg., Chicago IRON AGE PUBLISHING Co, Member, Audit Bureau of Circulations Member, Associated Business Papers Peirce Lewis, 7338 Woodward Ave., Detroit, and 402 Traction Bldg., Cincinnati. Published every Thursday. Subseription Price; Charles Lundberg, 45 Kent Rd., Upper Darby, United States and Possessions, Mexico, Cuba, $6.00; Del. Co., Pa. Canada, $8.50, including duty; Foreign, $12.00 Ober, 239 West 39th St., New York. year. Single Copy Cents. Robinson, 1319 Park Bldg., Pittsburgh. W. C. Sweetser, 239 West 39th St., New York. Cable Address: ‘‘Ironage, Y."’ Warren, Box 81, Hartford, Conn. YEAR SERVICE THE METAL WORKING INDUSTRY | | | n | | a | | } at. | | | A | | | | } 4 | | | | | | | TM | } } } } | | THE IRON AGE....JANUARY 21, 1932 Page replacement plan that paid big dividends The Pittsburgh Gear and Machine Company were using machines over ten years old. The question had been raised: How much could saved replacing them? Warner Swasey engineers were called the work was studied carefully and the estimates showed that time saving 20% was possible. The old machines were replaced with eleven new Warner Swasey turret lathes ... and the result was actual average time saving 25%. You can obtain similar savings your shop! Ask Warner Swasey engineer look over your work. will show you what can done lower costs. This service free ... just call the nearest representative. The Warner Swasey Co. Cleveland, Ohio, One machines the Pittsburgh Gear Machine Company > ..THE IRON AGE.. NEW YORK, JANUARY 21, 1932 ESTABLISHED 1855 VOL. 129, No. WHAT ABOUT 1932 ANSWER REDUCTION COSTS & KNOEPPEL Counsel, Cleveland SSUMING that volume business for most companies will not much higher 1932 than 1931 and that selling prices articles will little, any, higher, the question possible profits the new year becomes paramount importance some business concerns are survive. After two years diminishing actual losses, attention will focused increasing sales volume well decreasing costs. budgeting for 1932, the authcr uses chart based per- centage rather than dollars, order more strikingly illustrate the pernicious influence fixed costs profits. most manufacturers 1931 sion recovery ahead; partly be- profits, many companies which were was hectic year, character- cause “pernicious economic anemia” difficulties 1930 and 1931 will ized reduced sales volume abroad; and partly because 1932 find their way the “industrial and “red ink.” Presidential election year. scrap pile,” due sheer inability Many companies are looking The new year will severely test the withstand further losses. 1932 with misgivings—partly because managements most our indus- therefore imperative that not known with any degree trial concerns because, unless ways more attention than ever before certainty whether continued depres- and means can found better devoted the vital matter profit- Fixed-variable costs are Such costs as of fice expense, Salaries of executives and clerks, advertising, power and the / ke with minimum fixed port ons, then variable Dollars Fixed Portion Shut-down" Fixed Costs Nucleus” fixed costs necessary fo maintain Such taxes, insurance and depreciation minimum organization Sales Capacity, per cent Sales Capacity, percent Chart A—An illustration the different kinds cost—fixed, variable and 217 | Ly ars | | non them | upo e Variable Portion = Parts which vary with | = a terms as direct labor and material ¢ Ons | to salesmen maintenance wid the /ixe = me rb ‘ | 300 | ! 260 + — — | | | | | | VV + = | Sales Capaci scientific na- planning making—attention ture and the basis for profits advance. Industry cannot afford wait un- til February March ascertain what was made lost the pre- vious year, only find that results are disappointing. must develop ways and means for anticipating what the Dec. 31, 1932, showing will look like—and governed accord- ingly. The process must “ante-mortem” nature. Cost Reduction Road Profit Profit anticipation will lead loss prevention, and pound preven- tion worth tons excuses. The question, however, becomes one the procedure employ bettering the profit position. 218—The Iron Age, January 21, 1932 ty, per cent clearly points cost reduction the way out; unless there can creased sales volume higher prices (and these will not easy get during 1932), the attack must made costs. approaching this matter cost reduction, must keep mind that costs are three kinds, indicated graphic manner chart which self-explanatory. Industry needs give more and more attention costs the third classification shown this chart, out which will come some surprising results. bringing together the down” fixed costs No. and the “nucleus” costs No. all costs can then divided into the two great groups—fixed and variable. conclusion that fixed costs must attacked profits are made 1932. The chart has been made from arbitrary figures covering hypothetical portrays costs and income from sales percentage basis (costs percentage sales). And these fixed costs which cause losses business. Fixed Costs Must Attacked The force this conclusion will appreciated referring chart which has been made from arbi- trary figures covering hypothetical case. portrays costs and income from sales percentage basis From this chart will seen that all costs were variable costs, the space between variable cost line and sales income line would represent profit, and this profit would constant all the way across the chart. superimposing the area fixed costs the area variable costs, however, the curve—total cost—is the result. This line total cost crosses the line sales income some point the capacity scale (the “profitless” point) above which and the left losses are sustained, while below and the right profits are the chart mentioned the point practical sales capacity. as- sumed, furthermore, that the 1931 actual results fall the per cent line shown, the assumed figures be- ing: Variable costs..... Fixed costs $1,100,000 $693,000 440,000 Total costs.... 1,133,000 $33,000 will also apparent from study chart even sales volume increased (assuming that prices | JAMA A AA ( 60} — 4 + + + ( Area Variable Costs ‘ HART illustrates what may happen when 1932 budgeted the basis 1931 results after efforts have been made toward cost reduction. study charts and together will show the improve- ment the 1932 picture. For 1932 the point has been brought back 38% per cent, and the profit area considerably deepened. are the same), that there will change the curve total cost, nor lowering the “cross-over” point the capacity scale, which bears out the conclusion that cost reduction the answer our profit problem. This conclusion applies force fixed costs, especially those the “nucleus” variety. The problem before concerns 1932, then, drop the area fixed costs, and the same time re- duce the variable costs where pos- sible, bring the “cross-over” point lower the capacity scale, and deepen well lengthen the profit area. The tool use doing this the budget. Budgeting Answer Problem And the budgeting must “va- riable” nature, because falla- cious measure variable actual re- sults against budget fixed char- acter. principle apropos: the degree which certain fixed costs are transferred the variable classification, profits will start show lower capacity point, and widen full capacity reached. therefore assumed that, with the 1931 results basis, budget has been prepared—after investiga- tion and efforts cost reduction— with anticipated results for 1932 shown chart which the 1931 total cost line, point, and actual results have been trans- 300 280 Q ° G | | | Profitless Point Line Chart Line Sales Income 100 Sales Capacity, per cent ferred for purposes comparison. The improvement the 1932 pic- ture over that 1931 obvious, will seen studying charts and one. For 1932, the “profitless” point has been brought back 38% per cent, and the profit area con- siderably deeper. The assumed figures for the 1932 picture are: Variable costs..... 340,000 $301,250 The Knoeppel “profitgraph” was published THE IRON AGE Jan. 22, 1931. was first used the author Pennsylvania plant 1909, since which time has enjoyed wider ap- plication, with gratifying results. this issue, however, there appears for the first time form charting the basis percentage rather than dollars, order more strikingly illustrate the pernicious influence fixed costs profits. The slant the variable cost line sumed transfer some the fixed cost items the variable costs, and increasing slightly faster than mathematical variability the sales volume increases. How can this done? Reducing Costs single article could not begin exhaust the possibilities explain- ing all that might undertaken, but two suggestions can made which will prove most helpful: Have the department assign assistant the analy- sis all so-called “uncontrol- The Iron Age, January 21, 1932—219 2 an nt q ill S- 100 ne es lable” costs, whether fixed (like insurance (like lu- brication), out which can come standards covering what the costs should be, and incentives paid variable proportion cost reduction. Put salesmen management staff (particularly bo salaries and volume which profits were budg- eted advance? Chart merely illustrates what meant. would take care salaries automatically through the three great cyclical seasonal swings encounter busi- ness: the latter) the same basis 1—Below normal (depression why try reduce what beyond incentive payment that workmen seasonal dips) one’s control? have failed many and many our foremen are 2—Normal cases also isolate the costs the © | Where revised income /ines cross-66.67% a Drawing Account Chart conveys the suggestions for control salaries, one the most important items fixed costs. salaries salesmen and management staff basis incentive payment, with drawing accounts paid when business below normal, usual salaries normal and bonuses the “above periods. present, which the principle drawing account for time pay- ment, with additional rewards proportion One the major items these fixed costs are the salaries management—superintendents, of- fice department heads and all execu- tives, including officials. salaries could put the basis drawing accounts sufficient provide enough incomes which live properly, with the balance vary with re- sults, would mean smaller fixed cost area and curve for the variable part, becoming more rapid swing full capacity was approached. And could there any better gage for management rewards than sales 220—The Iron Age, January 21, 1932 tion, from which would come adjust- ments scientific nature man- agement This field fertile one. are finding, other words, that because have called certain items cost there was nothing that could done about them, for Ss — 40 + -+ Capacity, per cent Sales normal (prosperity seasonal peaks). When below normal, drawing ac- counts would paid. Usual salaries would reached some point the normal range, while above normal bonuses would paid. Generally speaking, the amount bonus “above periods should ap- proximately equal the amount which salaries were reduced draw- ing accounts during “below normal” periods. Focus Salary Setting by-product this way going the task making costs more va- riable nature, insofar manage- ment salaries are concerned, would focus more attention salary set- ting and drawing account determina- Line practical sales capacity 120 130 140 150 His plan put classification and de- termine the fixed portions thereof. Here, again, another fertile field. fact, can promised with as- surance that study costs for the purpose making the division sug- gested will pay real dividends the work involved. companies will further and budget their business affairs the basis herein outlined, using charts along the lines suggested and can safely promised that the showing Dec. 31, 1932, will con- tain more relative profits than would otherwise the case. So, the answer the question— “what about 1932 profits?”—becomes that cost reduction, particularly fixed costs. | | ust- hat ing for ond any the RILLING the center holes the connecting rods. a Some Ford Connecting Rod Machining and Inspection Methods RELIMINARY inspection the finished connecting rod. RANKSHAFT and wristpin ends are bored one time diamond boring machine. INAL inspection connecting The Iron Age, January 21, 5 Ra J = HILE the mechanical phase bolt and rivet manufac- ized, there are many varied types and designs furnaces. Several inter- esting types are used the Vulcan Rivet Corpn., Tarrant, Ala. This company makes rivets ranging size from in., bolts and nuts from 3/16 in., and railroad spikes from 5/16 9/16 in. Rivets, nuts and bolts are cold-pressed in., and hot-forged above that size, while the entire range spikes made the hot process. Raw material principally high and low-carbon steel rods, the form coils. These are unloaded directly from railroad cars, siding that parallels the yard and swing-post cranes. The coils are then transferred the pickle room other swing-post cranes, where they are pickled prior drawing. slight reduction amounting 0.150 in. given the rods the drawing room, correct any defects and make them uniform throughout. This accomplished pulling them 222—The Iron Age, January 21, 1932 4 through dies and coiling them again. Smaller-sized rods are trucked the cold headers, where the bolts are given round, square, flat, cone hexagon head shapes, required. The headers are the conventional type, two dies move back and forth heavy steel frame. The rod automatically fed through station- ary die, the first moving die spread- ing out the end and the second finish- ing the head. tool then cuts the bolt off the right length. Another type has two dies tandem the stationary end, the second being moved just enough, cam, shear off the bolt after the head has been formed. These machines will produce from 35,000 40,000 bolts day. Bolts and rivets are annealed gas-fired cylindrical furnace ft. long and ft. diameter. This furnace consists steel shell which revolves retort lined with refractories, which heated two rows eight gas burners each. The retort hopper fed, the amount material passing through being regulated dipper, which affixed the charging end the retort and revolves with it. each revolution this dipper automatically fills itself with material and charges into the retort, where works through the combined action gravity and rota- tion. Work heated 1600 deg. for about min. The rivets are then discharged into steel pots and are covered and allowed cool slowly. The bolts are cooled the air and, after being finished, are reheated 1000 deg. and quenched oil, blacken. The quench contained steel tank equipped with rotating perforated steel screen with screw the inside. this screen sets angle, the bolts are passed and out the tank after being quenched. Rows automatic machines the trimming division trim the heads various shapes. There are various types machines and several unique feeding devices, and all are motor driven. The work tumbled bar- The machines the pointing division are mechanically driven, but the work mostly chucked hand. NLET sloping, con- tinuous, heat-treating furnace for knuckle pins. left are two rotary, gas-fired annealing fur- naces for bolts and rivets. A 4 4 é & EVANS President, Evans Engineering Co. Birmingham The bolts are then routed the threading machines, where the threads are rolled on. Flat rods coils form the stock for the nuts. This stock fed into machine with two punches and two dies, the first punching the hole and the second forming the crown and shearing off. The nuts are tapped automatic hopper-fed machines the chuck-and-spindle type. and nuts are assembled benches provided for this purpose, and are then sent the shipping department. Gas-Fired Furnaces Used All the stock for the hot-forging process heated forging furnaces installed the Surface Combustion Corpn., Toledo, Ohio. Straight rods are used for spikes, the hot stock being taken from the furnace and pushed into machine roll feed which points and cuts off. gripper then holds the sheared stock while hammer head and dies bump against and form the head, single stroke. The finished spike then re- leased and drops into box. furnaces side side. The inclined fur- continuous heat-treating furnace for knuckle pins. The horizontal furnace background heats rods for continuous rivet machine. EATING straight coiled stock for making rivets, bolts, nuts, spikes and knuckle pins done variety gas-fired furnaces Southern plant. Each furnace for this work, well those used for annealing, has been designed for its specific use. Some are continuous and semi-auto- This machine will produce 25,000 spikes daily. the machine pulls the rod through the furnace, the equipment might called semi-auto- matic. This furnace brick, steel in- cased, and ft. long, ft. high and ft. wide. heated with gas burners, each side. All the burners are used the morning bring the furnace heat quickly; after that, part them suffices maintain the proper forg- ing temperature. High-pressure gas used, together with automatic matic; some heat the ends only. All are controlled automatically temperature regulation and some interior at- mosphere proportioning device which the de- sired ratio gas and air obtained. reducing atmosphere re- quired the furnace, the burners are set for this. Thereafter they automatically maintain the air-gas ratio, regardless the flow gas the variations the volume work passing through the furnace. The finished spikes are weighed, sorted into kegs and trucked the storage room. another set-up for the large sizes spikes, the furnace - brick, steel incased, and ft. long, 4 j - The Iron Age, January 21, ind ion elf the the ta- for id, ta x ft. wide and ft. high. heated with four gas burners, two each side. All the burners these velocity type, equipped with venturi- type gas-air proportioners. This fur- nace holds rods charge; these rods are removed, one time, and pushed into the spike-making machine hand. The finished spikes drop out conveyor which dumps them into steel pots for slow cooling. This the only heat treatment the spikes receive. Two bolt and rivet set-ups are al- most identical, furnace and machine, with the one just described. The hot rivets are dumped conveyor into pots and then sorted and kegged di- rectly scales. These kegs are put 224—The Iron Age, January 21, 1932 skids which are moved storage gasoline-driven high-lift trucks. The bolts, however, are first routed automatic, hopper-fed trim- ming machines, where the flash trimmed punch and die. They are then tumbled, and threaded, the threads being cut special machines instead rolled. different method, used forging bolts in. and more length, con- sists first cutting blanks the correct length from the rods. These are heated slot-type forge, ft. wide and ft. square cross-section, which sets legs. brick, steel incased, and heated with three gas burners, set just below the slot. This slot extends across the for heating ends short rods used the hand-fed bolt ma- chine left. the entire face and just high enough permit the blanks pass readily. Only one end the blanks protrudes into the heating chamber, only about in. the stock heated. boy manipulates the stock the furnace and hands the hot blanks the machine operator needed. The operator puts the hot end into the header, which forms the head with double die, explained earlier. The bolts then pass through the other machines described. pins, made this plant, are given spe- cial heat treatment brick furnace unique design. This furnace ft. long, ft. wide and and ft. high the two ends. The hearth slopes 10-deg. angle and OD-HEATING furnace for continuous rivet machine. Straight rods are pushed through the furnace into the gripper the machine. the foreground the delivery side conveyor re- knuckle from quench tank. AND-FED bolt ma- chine served heat- ing forge which the ends rods are heated. equipped with alloy rails which the work slides gravity from one end the other. There are eight gas burners, four each side, and temperature about 1450 deg. maintained. The pins are dis- charged into oil quench provided with elevator conveyor which moves them through the quench tank the uniform rate ft. minute, and discharges them into tote boxes. All the furnaces here are equipped with nected with indicating pyrometers through multiple-point switchboards. Welded Bomb Bodies Withstand Impact Tests welding forge steel nose and tail sections the cylindrical body, which made single piece plate steel welded longitudinally, were tested recently the United States Army the Aberdeen Proving Grounds Maryland. All welding was done the automatic metallic Smith Corpn., Milwaukee. The object the test was de- termine the strength the demolition bomb when dropped standard hard surface. The bombs were weighed empty, loaded with sand, equipped with tail impact pres- sure gage and again weighed. The cannon pressure cylinders were meas- ured before and after impact the bomb. Seven bombs were dropped from altitude 4000 ft., others from altitude 5000 ft., and sev- bodies manufactured 4 Demolition bomb with fin assembly, showing welded circumferential seams. eral were dropped from altitude 2000 ft. After impacts, the bombs were recovered from the hard sur- face, photographed and the bodies ex- amined for deformation and cracks. The flight the bombs was observed Bomb dropped from tude 4000 ft. after having struck hard surface. from the airplane and ground. Both the longitudinal and ferential welds all bombs withstood these standard tests; none the bomb bodies showed any signs cracking splitting open impact. There was perceptible difference the amount deforma- tion the bomb bodies dropped from 4000 ft. and those dropped from 5000 ft. The flight all bombs was espe- cially good. Demolition bomb after impact hard surface. Dropped from altitude 5000 ft. ) The Iron Age, January 21, 1932—225 | 4 i UA use roller bearings for all.crane bearings becoming more common and the creased friction must given serious consideration when applying the elec- tric equipment, particularly the bridge and trolley motions. Many cranes are powered with direct cur- rent and use series-wound motors which the speed increases rapidly the load decreases. The decreased friction the roller bearings per- mits very high speeds reached unless due care taken selecting the size motors and the gear ratios used with them. Furthermore, the increasing use tapered-tread truck wheels tends eliminate flange friction, thus further reducing the load the bridge motor. Cases are known such cranes where the actual free running speed the bridge has gone well over double the specified free running speed. These high speeds which are attained over-motored cranes impose much greater duty the foot brake, sub- ject the building and crane structures much greater stresses and impact loads, require more control equipment, and generally increase the difficulty handling the load the hook prevent from swinging violently. These operating characteristics make the crane more dangerous piece machinery, increase the maintenance both the crane and building, and give the operator speed which may greater than can use effectively, thus reducing the efficiency the crane. All this can avoided carefully selecting the correct size 226—The Iron Age, January 21, 1932 ELECTRIC FOR CRANES JAMES JACKSON, Industrial Engineering Department, General Electric Schenectady, motors and the right gear ratios used with them. Tendency Over-Motor Cranes strong tendency shown over- motor cranes and, while this not serious the hoist motion, does cause the objectionable operating fea- tures previously mentioned for the bridge and trolley motions, particu- larly roller-bearing cranes. Tests have been made three roller-bear- ing cranes with capacities 250 tons, tons and tons, and complete data such weights, specified speeds, gear ratios and truck-wheel diameters ob- tained that the test data could checked against calculated data. Also new calculations were smaller motors and larger gear ratios determine whether equal im- aspects crane motor- ization and control are introduced the application roller bearings this type them necessary for the crane designer and almost essential for the crane purchaser and user. Mr. Jackson, this article, presents some pioneer investi- gations this subject, and shows how motor sizes may materially reduced for the bene- fit operating efficiency. proved operating characteristics could not obtained without any sacrifice the operation obtained with ex- isting equipment. making the new calculations, due consideration was given the fact that, where two motors are used the bridge motion, one them must able handle the bridge emergency conditions, Also, has been recognized that physical limita- tions frequently prevent the use very large gear ratios the bridge motion and that usually only two re- ductions can conveniently obtained. this connection, the suggestion made that, where large gear ratio seems desirable, might obtained using one the many compact speed reducing units now the mar- ket, and that the additional cost this unit would probably saved the lower cost the smaller motor and control equipment. Comparison Specified and Actual Performance Referring Table the data columns headed are taken from tests are calculated from test data and data supplied the crane manufac- turer the cranes exactly built and installed. the columns headed the same cranes are used except that smaller motors and larger gear ratios are used, the gearing being figured hold down the maximum free-running speed with load per cent above the specified free-run- ning speed. The motors Item the table are all direct-current series mill-type 2 > motors strictly accordance with the standard specifications the Associa- tion Iron and Steel En- gineers except that the half-hour rating and speed used instead the standardized one-hour rating. The two larger cranes have twin motor drive the bridge. Item gives, columns the to- tal gear ratio actually used, while columns give the total calculated gear ratio which, with the motors Item will give the specified bridge speed plus per cent with rated load the hook, the per cent excess speed being margin allow for un- known and variable friction losses. This margin should insure that the crane will meet its specified speed with rated load the hook. Item includes all gearing losses and all bearing losses between the motor pinion and the truck wheel, but does not include losses the truck- wheel bearing, wheel flange and tread friction, truck-wheel hub friction, friction due misalinement the Operating characteristics with resistor layout and relay setting for 150 per cent average torque the resistor. TABLE 250-Ton Loaded Loaded Loaded Item 6.5 8.7 9.6 Item B.... 0.52 0.58 0.52 Item B.... 1.1 1.6 Item B.... 220% 220% 220% Item B.... 150% 150% 150% crane, all which are combined into one value called “rolling friction” and given under Item 18. The efficiencies Item were, two cases, given the crane builders and, all cranes had two gear reductions and about the same number bearings, the same cranes. Overspeeding Increases Brake Duty Item gives the speed specified the owner with full load the hook and assumed that, specifying this speed, expected the maximum speed reached when run- ning level track sufficient length permit the crane reach constant speed with rated load the hook. has also been assumed that, specifying this speed, the owner has sufficient knowledge his requirements know that this speed will his work, and, further, that the crane runway and its supports have been designed stand the stresses produced erane known weight operating this speed. With these assumptions come quite interesting where the load bridge speed actually meas- ured checked tachometer the motor shaft showed the three cranes running 218 per cent, 167 per cent and 172 per cent speed respec- tively, while calculated speeds (using test data basis for the tion) with full load the hook are 178 per cent, 147 per cent and 144 per cent respectively the owner’s speci- fied speed. Now the braking ef- fort required stop equal weights Operating data and efficiency 250, and 15-ton overhead traveling cranes equipped with roller bearings, affected installing smaller motors and higher gear ratios. TABLE BRIDGE MOTION Bridge motion only considered. ROLLER-BEARING CRANES 50-Ft. Span 96-Ft. Span 67-Ft. Span Rated load tons and span.. 250-Ton 50-Ton 15-Ton Half-hour rated horsepower and 2-135 Hp. 2-65 Hp. 2-65 Hp. 2-45 Hp. 1-33 Hp. 1-19 Hp. 387 R.P.M. 430 430 R.P.M. 460 500 R.P.M. 560 Assumed efficiency from motor pinion truck-wheel gear... 90%* 90% 90% 90% 90% Specified bridge speed feet per minute with full load Light Loaded Light Loaded Light Loaded Light Loaded Light Loaded Light Loaded feet per minute.......... 356 286 230 505¢ 440 396 345 432 400 345 Per cent specified 218% 178% 143% 115% 167% 147% 132% 115% 172% 144% 133% 115% Ratio braking effort required stop given distance from speed Braking ef- fort stop equal load from specified speed equals 1.. 4.76 3.17 2.05 1.33 2.80 2.16 1.74 1.33 2.97 2.08 1.78 1.33 11. Time seconds accelerate 3.61 4.24 6.0 8.81 4.8 5.73 8.25 12.3 4.88 7.0 7.32 11.63 12. Average rate acceleration ft. per sec. per sec. from standstill specified free 1.0 0.78 0.55 0.4 1.04 0.87 0.607 0.407 1.02 0.72 0.68 0.405 13. Average rate acceleration ft. per sec. per sec. while mo- 1.0 0.805 0.69 0.54 1.08 0.95 0.9 1.14 Rate acceleration immediate- starting from rest..... 1.6 0.95 1.07 0.56 1.5 1.09 1.32 1.03 1.92 1.28 1.06 15. Approx. maximum torque peak while accelerating. Expressed per cent rated 95% 115% 95% 134% 100% 119% 96% 115% 95% 99% 115% 180% 16. Average per cent rated torque motor while accel- Per cent %-hr. rated motor torque propel constant Rolling friction pounds per A—These columns give data cranes actually installed. Values marked thus were taken from lated directly from them. test data basis wherever possible. assumed the same. All other values were calculated using Efficiencies marked thus were furnished crane builder and all other efficiencies were test readings calcu- B—These columns give all calculated values the same cranes but using smaller motors and larger gear ratios hold down the maximum free running speed with full load hook per cent above the specified speed. The per cent in- crease allow for variable and unknown friction values and insure that the crane will meet its specified speed. The Iron Age, January 21, 1932—227 Me MES j > 4 t . > 7 equal distances varies the square the initial speed, these excessive require large increase and heating duty from the brake shown Item 10, and, un- less the brake has been designed for this duty, the coasting tance the crane will much ex- cess what was expected and dents may occur. the brake has been designed for the excess duty, then the crane track supports and the building structure will subjected greatly increased stresses. If, therefore, was designed for the stresses due the specified speed, speeds torque excess dis- tor—first, the gear ratio, and, second, the control equipment. The torque the smaller motors multiplied factor increased direct proportion the increased gear ratio; conse- quently certain torque delivered the crane truck wheel requires smaller torque from the motor. The the torque delivered the truck wheel; consequently the rate does not decrease proportion the size the smaller motor. With control equip- ment adjusted for the same time relay setting and the resistor laid out for the same percentage current peaks, PEED and torque curves for motor- izing the bridge the roller bearing equipped traveling crane. and larger gear ratios, but study the torque values Items and shows that case were either the larger smaller motors being used efficiently. The highest average ac- celerating torque only per cent the one-half hour rated torque and with the exception the 15-ton crane under columns the maximum stantaneous torque peak only per cent the one-half hour rated torque. generally recognized that crane mill motors can safe- used accelerating duty with average torque 150 per cent, while accelerating the resistor and with maximum instantaneous torque peaks 200 per cent over. If, therefore, Items 11, 12, and columns resistor layout and re- lay setting used which gives 150 per cent average torque the re- sistor (Item 16), the values Items 11, 12, 18, and columns would appear the table shown Table II. Item can changed not desired, depends the initial torque application the ond controller point, which can ad- Close when Plugging tained columns and the total 100 time reach specified speed not 120 unduly longer than found columas 180 the crane get above approximately stance per Division two-thirds specified speed, and large percentage crane movements are relatively short Motor Requirements for Twin Drives rivets and bolts loosening shearing off. Impact loads bad rail joints and when hitting the bumpers will greatly increased and may cause stresses well beyond those for which the building was designed. Items and columns headed show how this situation can cor- rected using smaller motors with larger gear ratio, and each case the gear ratio was calculated give 115 per cent the owner’s specified speed with rated load the hook. Smaller Motors with Increased Gear Ratios With smaller motors, the natural questions ask are: What will the effect acceleration, and will one the motor twin drive handle crane emergency? The answer the first question de- pends two factors besides the mo- Iron Age, January 21, 1932 i | building maintenance will high due the rate acceleration will some- what decreased when the smaller motor. If, however, per- missible use higher percentage current peaks the smaller motor, the acceleration rate can brought back reasonably close the same rate obtained with the larger motor and lower gear ratio. the tabulation, resistor lay- out was used, giving the speed torque characteristics shown the chart accompanying this article, and the same time setting for the accelerating relays was assumed every case order put the data comparable basis. Torque 150 Per Cent Used for Accelerating Duty study the acceleration rates Items 12, and shows re- duced rates for the smaller motors the twin drives, quite ob- vious that one motor can handle the shows that for the smaller motors only 19.3 per cent torque for the 250- ton and per cent torque for the 50-ton crane all that required propel the crane. With one motor out, these figures are doubled 38.6 per cent and per cent the re- maining motor. crane motor can safely used 150 per cent 200 per cent torque during accelera- tion, ample margin left celerate the crane with one motor. With reference the maximum torque peaks columns they are all values calculated from the speed- torque curves, but, when possible, they have been checked taking the max- imum throw the ammeter during acceleration and the test values check the calculated values within reason- able degree accuracy. several cases columns the maximum torque peak given per cent. 100! | | 140} | | . + + + | + + 4 80 + + + > 60 + + + | + + + 4 yard bearings throughout. were motored according the ac- cepted standards for plain bearing design, would overspeed, overrun braking, cause excessive strains the sup- porting structure and present operating hazard. The reason for this that point the controller (point used tor plugging only) laid out give per cent torque standstill, and, had been laid out give lower value would have been lower, the peaks all other controller points are be- low per cent. few words explanation may order with reference Item the table, the use “rolling tion pounds per ton total weight” perhaps somewhat out the or- the gearing and the power require- ments crane. This method has been successful use for many years ments for freight and passenger trains, and great deal reliable data available that field. seems logical apply cranes, bearings, combines into one fac- tor number separate friction losses which are extremely difficult separate into reliable individual values. Undoubtedly more data are re- quired this factor the crane field, but relatively easy ob- tain taking ammeter reading after the crane has reached constant speed determined tachometer the motor shaft and reading the corresponding torque value from the torque curve the motor. This torque value can converted into “pounds per ton (sometimes referred “draw bar pull per the gear ratio, truck-wheel diameter and total weight the crane being tested are all known. should borne mind that erroneous conclusions may reached Table the values given for one crane against those given for crane different load rating. One rea- son for this that the ratio live Close-up trolley 15-ton roller bearing crane shown above. The bridge motor hp.; the trolley motor, hp. Note roller bearing construction. load total load differs greatly for the three cranes, due largely the different spans and the duties for which they were designed. Alternating Motors Have Fixed Maximum Speeds The problems treated this article are not encountered cranes using alternating current motors, these motors have fixed maximum speed within narrow limits regardless the torque load. Also, they not enter any great extent the hoist mo- tion direct-current cranes, the dead hoisting load the predominat- ing factor determining the power requirements rather than accelerating requirements, although light hook speeds may become dangerously high with roller bearings too low gear ratio and too large motors are em- ployed. Almost good case can made out against over-motoring the trolley motion for the bridge motion. While the ratio friction load ac- celerating load not large the bridge motion, the variation the ratio much larger and the length runway usually much shorter than the bridge runway. Further, the operator must control his trolley en- tirely electrically, has foot brake help him out case power failure misjudgment his part. Excessive speeds are, therefore, avoided the trolley motion, and the use worm gearing find- ing some favor for this purpose. An- other way overcoming these high speeds using compound wound motors, but this requires extra trolley wires for the shunt field, which are objectionable. The Iron Age, January 21, MAKING LARGE BELLS FOR CARILLON MODERN structure steel beams and channels supporting thirty fifty more bells. (Below) The tuning large bells painstaking operation requir- ing skill and experience the part the tuner. Metal removed from the interior the bell alter the pitch and vibrating qualities. clear Sunday mornings New York hundreds peo- ple wandering along River- side Drive the Grant’s Tomb dis- trict stop times listen the mellow, reverberating chimes from the Riverside Drive Church. But few these listeners realize that the clear notes they hear were first sounded the hazy atmos- phere humble foundry En- gland. Bells have intrigued the faney foundrymen ever since the earliest records cast metal. Single bells are old history, but groups tuned bells are more recent develop- ment. Ancient spires Holland and Belgium contain octaves bells ac- curately tuned the chromatic scale. The tuning skill the old bell foun- ders Europe was lost for some two hundred years and the art tuning had redeveloped when English firms turned bell casting the late years the nineteenth century. The carillon for the Riverside Drive Church, one the largest the world, was made the Croydon Bell Foundry, Croydon, England. The Bourdon bell largest the group bells weighs tons mounted, with head stock and clapper. The single casting the bell proper weighs over tons, which places 230—The Iron Age, January 21, 1932 among the three four largest bells the werld. may supposed, the casting and tuning such large bells difficult and painstaking task. The molds are built largely hand and are set pits the foundry floor for the pouring. The outer mold signed cast iron case flask. bracket which extends out from the completed bell, thus giving the mold After this initial sweeping, which uniform wall thickness which helps leaves the molds with the first hold the sand place. the rough finish, the molds are thorough- inside, the flask provided with ir- dried before the final surface holding the sand when the mold ovens and the large inverted during pouring. The bells takes from five eight days. The pouring large bells After baking, the models are brought from single ladle through out the foundry floor and coated top gate. different English molding sands se- lected for adhesive properties com- bined with porosity. With the sand mixed cow hair. After the mold has been roughly formed hand strickle board fixed arm and central bar and swept around the sand until the re- quired shape has been formed. The inner mold, which called heavy cast plate. important that this plate sufficiently rigid hold the core without springing when supported four outer lugs, must picked these lugs when lowered into the pit. The body the core consists bricks placed tier upon tier and filled and covered with the same sand mixture used for the cope. smooth, accurate surface secured sweeping with strickle board opposite contour that used the outer mold. The board centered second time with finer mixture loam and are then returned the ovens for further drying. Follow- ing this the final touches are put on. This consists blacking the molds and sleeking the surfaces that the castings will come out clean and smooth. this stage inscriptions and other details are added. Inscriptions are usually made separate form and pressed into the surface the outer mold, which makes the let- ters embossed the outside the finished casting. When the molds are completed the core carefully set position the base the pit and the cope then lowered over and adjusted accurate position means small test pieces clay placed various points the core. When the head molder sure that the space between the surface the core and the inner surface the cope mold uniform all points and that the thickness the casting will planned, has the pouring top clamped place. One central gate used and pouring done slowly and continu- ously from one large ladle. After casting, the metal allowed cool for one two days, depend- page 250) cores for large bells are built heavy cast iron plates facilitate handling and out the bake ovens and into the pouring pit. The cope mold (right) which made specially shaped flask, carefully lowered over the core and accurately adjusted for wall thickness the casting. — . The Iron Age, January 21, ee )- Po ae j « COMMON found the surface zinc-coated products has been called the industry “White has been found under many practical con- ditions, and practically all kinds galvanized products. Specific cases have been noted water pipe stored ware- houses, and out covered racks sheds; range boilers that have stood the warehouse for some time; metalware that has been storage, and where the windows the warehouse have been opened dur- ing rainy weather; metalware ar- ticles that have been hot galvanized, quickly dipped water testing vat, and piled; cross-arm braces that have been cooled water tank and stored; secondary racks; wire that has been coiled and stored damp place, where moisture could condense; sheets that have been stored warehouse where occa- sional dampness might enter; ship- ments galvanized pipe San Francisco and other distant points and destinations foreign coun- tries. fact, may found almost any kind zinc-coated prod- ucts stored damp places, where moisture can condense and set con- ditions favorable corrosion. Consists Several Salts Zinc appreciate fully the conditions under which white rust will form, necessary know what white rust is. Chemical analyses rial show zinc oxide, zinc hydroxide and zine carbonate. the reaction has taken place under condi- tions where sea water has been pres- ent, chlorides may found also, due the action the salt and magne- sium chloride which are present variable quantities sea water. Mix- tures basic salts, also, may found the products corrosion. Just what the corrosion products are depends very large extent upon corrosion conditions. These are end- less number, but for general pur- poses they may grouped into least two major classes, follows:— Conditions very large excess available water, and minimum 232—The Iron Age, January 21, 1932 a am WALLACE IMHOFF Vineland, amount gases, such air, oxygen, ‘arbon dioxide, The products corrosion under this condition consist mainly zine hydroxide, with small amount oxide, zine carbonate and other zinc compounds. Second the general condition large excess gases and con- fined moisture, dampness, dew, and moldy and musty conditions gen- eral. The products corrosion under these conditions are largely car- bonate, oxide, and basic zine ox- ides and hydroxides. Which these materials most abundant depends upon which corrosion factor has the most favorable conditions. water, hydroxides would formed; air, oxides and carbonates formed. common example white rust which almost every practical galva- nizer has seen the white rust often found shipments slab zinc. specific example was seen ship- ment 510 slabs zinc, car re- ceived plant some time ago. The roof the car leaked badly, and just happened that the car came through heavy rain storms. The en- tire carload metal was snow white with this corrosion product, white rust, and the car inside was very musty and moldy. When opened unload the metal, the inside the car had very moldy smell; and un- loading the slabs, much confined water was seen from the rain that had leaked through the roof. These practical facts all il- lustrate that white rust nothing more than the rusting, oxidizing, the metal zinc, forming corrosion products varying according the factors and conditions. Zinc put iron the form coating because the zinc electro-positive iron and cor- rodes, oxidizes, first, thus protect- ing the iron beneath. con- siderable practical interest time look the chemical series ELECTROCHEMICAL SERIES Caesium 23. Nickel Rubidium 24. Cobalt 45. Silicon 46. Titanium Potassium 25. Thallium 47. Columbium Sodium 26. Cadmium 48. Tantalum Lithium 27. Lead 49. Tellurium Barium 28. Germanium 50. Antimony Strontium 29. Indium 51. Carbon Calcium 30. Gallium 52. Boron Magnesium 31. Bismuth 53. Tungsten Beryllium 32. Uranium 54. Molybdenum Ytterbium 33. Copper 55. Vanadium Erbium 34. Silver 56. Scandium 35. Mercury 57. Arsenic Aluminum 36. Palladium 58. Phosphorus Zirconium 37. Ruthenium 59. Selenium Thorium 38. Rhodium 60. Cerium 39. Platinum 61. Bromine Didymium 40. Iridium 62. Chlorine Lanthanum 41. Osmium 63. Fluorine Manganese 42. Gold 64. Nitrogen ZINC 43. Hydrogen 65. Sulphur Iron 44. Tin 66. Oxygen AB g> ga Al 10, 12. 13. 14. 15. 16. 18. 19. 20. and note where both and iron are. Also may note the positions aluminum, tin, cadmium, lead and some the other metals found impurities hot-dipped coatings. The difference the electrochemi- cal properties the common metals zinc, cadmium, lead, copper, nickel, aluminum and tin has been well il- lustrated Rawdon. the corro- sion steel, with small plugs these other metals inserted, all pieces were covered with rust except the pieces containing the zinc and cad- mium plugs. The forces corrosion attack and destroy the first, this fact principle being the reason for applying zinc coatings. studying the conditions and fac- tors that form white rust in- terest compare the mechanism with that iron rust, red rust. The re- sult the corrosion iron and steel rust. Therefore corrosion rust- ing, since the process continuous until the iron steel has been com- pletely destroyed. The same may said for the rust- ing which forms the white oxide instead the red oxide. The process changing the iron from iron rust therefore corrosion, and the result the action rust. The word rust, however, has been generally applied iron that used for the same process which goes the corrosion The oxi- dation products, however, are very much the same, the main difference being that the first iron while the second What Causes Rusting Corrosion The agents corrosion which contains almost per cent oxygen; water, moisture various forms such dampness, dew, and condensed moisture, ice, carbon diox- ide, sulphur gases, chemical solutions, etc. Most common kinds corrosion are atmospheric corrosion and that caused dampness and moldy condi- tions. However, galvanized water pipes and other steel articles, buried under ground for various reasons and purposes, are subjected different conditions. Then, again, these articles are air, ZINC-COATED PRODUCTS NALOGOUS the air-and-moisture oxidation steel similar oxidation zinc-coated products. This white rust, made zinc oxide, zinc hydroxide and zinc carbonate, forms under conditions which can easily av