The Iron Age 1938-03-03: Vol 141 Iss 9

duty modern spindle chucker featuring open end con- struction and hydraulic chucking Other models both and spindles MACHINE THE NEW BRITAIN MACHINE CO. NEW BRITAIN, CONNECTICUT, U.S. — Everything make has something with heat, and high any the things shown here fit into you are invited let show how This Type Electric Pot, used for lead Here one several Box Furnaces used the and salts, temperatures 1600° Textile Machinery for carburizing and pot made our No. treating textile machine uses this 502 enameling fixture Whitman use Lead Pots for hardening all their drills. Hoskins Electric Furnaces have They have Box this tip for you? through this Hoskins Type Gos Hoskins,Type HE, Py- compensation, and cclibrated for Couples. Hoskins, Type OM-102, Oil for light eccasional use. For production use the Type OH. 2—THE IRON AGE, March 1938 THE IRON AGE, published every Thursday the CHILTON. CO. Publication Office, Chestnut 56th Sts., Philadelphia, Pa. Editorial and Executive Offices, 239 39th St., New Entered second class matter November the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, $12.00. Vol. 141, No. q NUFACTURING COMPANY, DETROIT, MICHIGAN | | PLUG ont = TURES Editorial under FRITZ FRANK President J. H. VAN DEVENTER Editor Cc. E.WRIGHT J. A. ROWAN A. 1. FINDLEY Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ROUNTREE, Jk. Toronto, Ontario Birmingham Newark, N. J. St. Louis TURNER Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE EVERIT TERHUNE, WILLIAM BARBER, ‘Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY BAUR, General Advertising Manage) DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index Published every Thursday. tion Price: United States and Pos sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 a year Single copy, 25 cents. Cable Address, ‘‘Ironage, N. Y."' 1DVERTISING STAFF Emerson Findley, 621 Union Bidg., Cleveland B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St.. New York Peirce Lewis, 7310 Woodward Ave., Detroit ¢. H. Ober, 239 W. 39th St.. New York W. B. Robinson, 428 Park Bldg., Pittsburgh D. C. Warren, P. O. Box 81, Hartford. Conn MARCH 1938 Industry Must Accept This Challenge Natural Gas the Open Hearth Application and Control Variable Speed Transmissions Recent Developments Metal Finishing Processes. Modern Heat Treating Boiler Tubes Economics and the Purchasing Agent Statistics Metal Working Activity Rate Activity Capital Goods Automotive Industry Washington News NEWS CONTENTS Plant Expansion and Equipment Buying New Industrial Literature Just Between Two Products Advertised Index Advertisers Copyright 1938 Chilton Company 128 178 how peratur Goo =, light » The New Era Steel 1842, when Industry’s problem was availability steel, Ryerson built large and complete stocks. Later, when speed gained importance, Ryerson developed new, faster methods hand- cutting and shipping. Today, when greater uniformity and higher quality needed meet the requirements high speed automatic machinery and mass production methods, Ryerson again ready with large stocks Certified Steels—steels known uniform high quality. Principal products stock for Imme- diate Shipment include—Bars, Struc- turals, Shafting, Plates, Alloy Steel, Tool Steel, Spring Steel, Iron and Steel Sheets, Stainless, Babbitt, Strip Steel, Welding Rod, Tubing, etc. addition, special plan has been oped for the alloys. Entire heats alloy steel, ideal analyses, grain size, etc., are selected. from these heats are accurately identified thoroughly tested. Special data sheets chemical analysis, grain size, cleanliness and heat treatment characteristics are Ryerson sends this complete data with every shi ment alloy steel. The heat treater then guide help him secure the best possible Let send you the new Ryerson Steel Book which tells the complete stor Joseph Ryerson Son, Inc. Plants at: Milwaukee, St. Louis, Cincinnati, Detroit, Buffalo, Boston, Philadelphia, Jersey MARCH 1938 ESTABLISHED 1855 Vol. 141, No. Industry Must Accept Challenge firmly believe, and Government statistics prove so, that over the long run, technological improvement creates better paying jobs for more people. But what about the short run? What private industry going bridge the gap for the man men who temporarily are deprived jobs because machine improvement? This question particularly important period recession, such the pres- ent. During upturn, when demand for skilled semi-skilled labor greater than the supply, the problem solves itself without much help. young industrial engineer came recently with personal problem. Said he: job seems that getting rid men. Getting work done with smaller number people. And why should necessary that when the XYZ Corp., for whom work, has satisfactory surplus and made fair profit the last quarter. Why cannot the company content has been doing and suspend technological said him: that the XYZ Corp., which has been business for years, had adopted that policy the beginning. that time employed some men. you think that would now employ 5000 men, Technological improvement created 4950 additional jobs this one corporation. True enough, the interim, perhaps 1000 men had find other jobs, either with- outside the company, being dislodged from their previous tasks tech- nological improvements. But 3950 men found working opportunity that they would not have found otherwise. cannot stop technological progress. But must, the private system ery enterprise endure, soften the damaging effects such progress upon the in- dividual. And this not job for Government private charity but respon- sibility management. want keep Government out business, and most do, this one the problems that private management must solve. Particularly times de- pression when the loss job may equivalent forcing the victim become rsey dependent Government. Let's have your views regarding the solution this problem. Perhaps put- ting our heads together may find the answer. AS m 4 q ts ‘ | ATURAL gas has been used metallurgical fuel for years more. has long been considered the cleanest, richest fuel obtainable gaseous form. Yet there not single shop using natural gas where tonnages produced, length furnace campaign, expenditure B.t.u.’s per ton steel made, heat times, are good enough prove the statement that natural gas the ideal fuel. Quite the contrary. McKune, Hamilton, Canada, has furnaces burn- ing coke gas and blast furnace gas with non-luminous flame which give results better than any hear natural gas. shop the Chicago district burning the same gases with 34—THE IRON AGE, March 1938 Photo courtesy Steel Corp. luminous flame also puts out figures which far exceed anything record about natural gas. Another Chicago plant has made records with producer gas that have not been duplicated with natural gas. All this naturally causes the question arise, “Why are not better results obtained from the use natural gas?” Before that question can an- swered, seems indicated that answers must found more questions which the will raise. This one significant fact stands out—of the six types open-hearth furnaces burning natural gas Amer- ica today, five work with non-lumi- nous nearly non-luminous flame, the Open Hearth RALPH VAILL Open Hearth Combustion Co., Chicago while only one secures the full lumi- nosity inherent natural gas. This proportion contrasts rather oddly with the division existing between furnaces using other gaseous fuels. With other fuels, only one, the McKune furnace, spectacular performer non- luminous flame; all others use lumi- nous flame. The predominant use non-luminous flame natural naces without doubt simply trib- ute the worth natural gas and conservative adherence the tradi- tions its use. Furthermore, most open-hearth operators heart prefer luminous flame, and this makes the picture more puzzling. Nowadays known how secure luminosity, and the new furnaces there trouble securing it. One aspect this problem cannot escaped, namely, natural gas seems work nearly well with non- luminous flame does the new luminous flame furnaces. Therefore, with modern insulated, air-tight, scien- tifically controlled furnaces, there available fine old gas play with, one that does what other gases | well; produces acceptable re- sults from both luminous luminous flames. other words, nat- ural gas should the fuel from which get some real open-hearth records. date, the luminous-flame natural- gas furnace has not been better than the non-luminous-flame the proportion that the theoretical su- periority radiant heat over heat convection conduction would lead one expect. The luminous-flame furnace suffers under the curse all such furnaces. upside down; this the writer means the hottest part the flame that part the fuel column which contact with the overhead air for combustion. Here this zone the little flames that off toward the roof have tempera- ture from 3300 deg. 3500 deg. these temperatures were down the zone adjacent the slag-metal line, more useful work would ob- tained from the gas, but instead the temperature there damaging the roof. the other hand, non-luminous- flame furnaces there such strati- fication flame temperature. all them (which work well) the air and gas are premixed before entering the melting chamber, and the mixture with great turbulence and considerable velocity forced down into direct contact with the slag and metal. The resultant flame temperature time the cycle relatively higher than the walls and roof will withstand, ex- cept with natural gas. The latter, hav- ing some luminosity inherent due ethane, does, this type fur- nace, give trouble this respect. This particular phase the problem seems important the use natural gas, for experience has taught that these so-called non-luminous-flame natural-gas furnaces, practically impossible maintain the full heat input certain parts the heat cycle, for when one zone gets too hot the whole combustion chamber too hot. conceivable that this one the factors which prevent high tonnage rates with natural gas the non- luminous furnaces. Luminous and Non-Luminous Natural gas being what is—a high powered gas with extremely high flame temperature, especially the luminous-flame type furnace—it seems that again the investigator balked. Thus the question brought up, “If furnace could operated certain periods the heat cycle with luminous flame and other periods (with less decrease than normal heat input for the period question) could converted will non-luminous flame furnace, re- taining either case the full benefits the flame used, would that not the answer the natural gas prob- There are luminous natural-gas fur- naces available. They are doing well, but not well enough. Briefly, this type furnace built quite similarly ATURAL gas now being used open-hearth fuel Colorado, Mexico, Ala- bama, and the Pittsburgh, Ohio River, St. Louis and Chicago steel making districts. least five distinct furnace designs are employed. The use natural gas and the use certain type luminous flame are very live issues, and for this reason the author's discussion herein just why certain results are (or are not) obtained particularly timely. Particularly interesting the author's contention that gas furnace switching from luminous non-luminous flame has potent possibilities. producer-gas furnace, that has two checker chambers each end, two slag pockets, and three uptakes, one discharging into through water-cooled port. Natural gas admitted into this uptake about floor level and low pressure the neighborhood oz. this point the gas encounters preheated air supplied controlled amount the checker chamber that used for passage incoming producer gas. For luminous flame this air would about one-fourth one- third the total air supplied, and moment encounter with the gas would have about one inch W.G. pres- sure and temperature about 2500 deg. The velocity the air and gas from the point admission gas the knuckle the furnace probably about 120 ft. per sec., which means that the ft. travel the point where this partial mixture meets the overhead air, one-eighth second elapses. that one-eighth second, the phenomenon cracking breaking down the methane (CH,), which per cent the gas, into hydrogen and carbon particles occurs, and thoroughly luminous flame emerges from the gas port. believed that the ethane which ordinarily breaks down ahead the methane, illuminant matter how in- troduced into the furnace. Presum- ably the conversion the methane into hydrogen and carbon particles progressive reaction, greatly influ- enced the temperature and quantity the incoming air, and the pre- heating mixed gas, function the temperature which and the time during which the raw gas travels confined medium. increase the amount air without decrease its temperature, decrease the time the raw gas remains the up- take and port, would cause cracking and then partial combustion and would not only deliver very hot blow torch flame, but probably would damage the port lining. increase air, with decrease temperature, and decrease the time period the mixture remains the port and up- take, would result incomplete crack- ing and discharge non-luminous flame. The above presumptions conjec- tures follow closely the claims made for this furnace Boynton, who has patented the process which natural gas made luminous (Open Hearth Combustion Co., patent No. 1,942,682). four widely separated sections this country, furnaces have been constructed according the principles this patent. far comparative performance with other natural gas furnaces concerned, they seem improvement. They have extremely luminous They give far less trouble with foam- ing periods during the heat cycle, and are preferred where desired take extraordinary measures “shap- ing the However, far answers the above presumptions are concerned, this type furnace still the experimental stage. Since natural gas there avail- able fuel that has given equally good results with either type flame, since there has been proved ability design furnaces that will produce, each its own way, good results from that type flame for which was designed but which will not work properly other than that flame, and since believed that the maximum efficiency has not been obtained from natural gas strict adherence either principle combustion, seems reasonable explore the possi- bilities and probabilities purposely designed combination furnace—one THE IRON AGE, March 1- l- |- t which will incorporate the possibilities each furnace. This seems most feasible the luminous flame venturi furnace used the basic construc- tion. the first place, the only one use that gives 100 per cent luminous flame. the second place, the velocity and direction incoming gases can controlled venturi con- tours well any other known furnace construction. Thirdly, the use two separate gas systems there results versatility double that the single system furnaces. Furnace Versatility Because the versatility this luminous flame furnace possible fore long the use natural gas, results which will come through the use luminous flame during peri- ods when serves best, and non- luminous flame when turn most useful. When melting down, flame with high luminosity can used, and the combustion can governed wished the conventional supply overhead air. After the scrap becomes heated point where its glazed- over outer surfaces are beginning reach absolute temperature close that which softens silica brick, then the luminous flame will abandoned sending per cent the air through the gas system, higher pressure, and per cent through the air system. This will give blow torch flame with short luminous core and long non-luminous tip which will carry heat across the furnace, but will not possess the verted characteristics that certain times the heat cycle compel the operator check total heat input. Air-Conditioning Research Under Way Cornell tal importance efficient air-con- ditioning, involving temperature, hu- midity, purity, and velocity, are being studied the Sibley College Me- chanical Engineering Cornell Uni- versity. The study “Heat Trans- mission from Radiators” Rubert, recently published Bulletin No. the Cornell University En- gineering Experiment Station, the latest important series that will continued with greater frequency when the proposed heat-transfer lab- oratory completed. 36—THE IRON AGE, March 1938 This non-luminous flame would em- ployed until after the addition hot metal, then the furnace shifted back again luminous flame. Possibly this method getting non-luminous flame will not produce just the results desired. The gas checkers may cool too rapidly, the air checkers may become overheated. There still remain other ways get- ting this non-luminous flame, and would seem efficient flame too. For example, auxiliary high pressure Ib. per sq. in.) gas line could placed the gas port and made discharge along the center line the port. This gas would not, because its high velocity, remain long enough the gas port cracked. would get some turbulence from the air coming through the gas passage. And would, because the differ- ential velocities, induce rapid mix- ing with overhead air, and passing through the venturi throat the com- bustion chamber would given characteristics quite like those the McKune furnace flame. The writer has warrant for stating that this resultant flame, having flame tem perature possibly 3150 deg. F., will much useful work flame with temperature 3450 deg. which would luminous flame, but believed that some work will done finishing the melting -of the cold charge, and much useful work will done stepping regenera- tor temperatures which cooled the charging the furnace. After the hot metal added, can assumed that return luminous- flame conditions will desirable until the bath thickens with lime. this Radiators give off heat primarily two ways, direct radiation and convection, the transfer heat particles circulating the air. Since radiation accounts for between and per cent the heat transmitted, any factor which decreases lowers the efficiency the radiator. The use highly reflecting paint, such bright aluminum bronze, the sur- face radiator, may reduce the heat output much per cent, Rubert found. Flat paints, particular- flat black, allow high degree radiation. Rubert also discovered that the use reflecting surfaces behind radiators will considerably increase the amount heat emitted. point possible enter the field interesting conjecture. Would blow- torch-like, highly oxidizing flame for balance heat cycle, transferring much oxygen the slag, optimum? Would soft, luminous, reducing flame more Which would found best for particular plant from metallurgical viewpoint and from that economy? Which would give least brick expenditure? One company has structed luminous-flame furnace and has apparently placed all reliance luminous for instead sending air into the gas system heated before mixing with the natural gas, this company putting blast fur- nace gas through the chamber. This furnace should have very luminous flame and must depend variations overhead air pro- duce oxidizing reducing conditions the melting chamber. However, will most surely never capable producing non-luminous flame unless provision made admit the nat- ural gas some point nearer the point ultimate discharge when re- This provision would not en- tail great expense. Natural gas lb. pressure often available the shop. 4-in. line this piped the gas port bulkhead and sent into the furnace along the longitudinal cen- ter line would give non-luminous flame, even conjunction with pre- heated blast furnace gas. The possible and feasible combina- tions and permutations fuels, flames and melting conditions obtainable with this type furnace certainly should make important factor present day metallurgical fuel contemplation. Correction Jan. 20, 1938, article en- titled “Highlights the Year Metal Finishing,” Handy Harman, manu- facturers precious metals Fulton Street, New York City, were solders which give high joints metal parts temperatures low 170 deg. This tempera- ture figure was typographical error, the correct figure being 1175 deg. for the lowest flow point any braz- ing alloy made the company and giving high strength. | “Without Sit Down? prophet who would predict what labor relations America will like year from now. But whether unionization industry continues, unions become discredited, the ab- surdities human nature will re- main the same and the new era cry for baloney will not abated. unionization labor com- pleted there will fierce battles with- the unions, and industry, smart, will have adopted such progres- sive labor relations policies will then cause labor react harmonious- ° ° ° JOHN RICHELSEN Personnel Director, Vanadium Corp. America ° ° ° and sentimentally toward their job makers. unionization meets defeats, indus- try will have been well advised have read what follows, here, and have governed itself accordingly. For renewed efforts induce labor follow after strange gods will sure- have come and our proposals, accepted, will have had great influence neutralizing those efforts. alloys plant, which the next thing boiler factory, enthusiasm has been aroused several suggestions which have recently read, in- troduce music into all our industrial workshops. If, what follows, the reader detects few queer notes ecstasy otherwise matter-of-fact presentation, begged bear THE IRON AGE, March 1938—37 ig ig Id 3 n- a a ns ss e- 1S 2S j | b 5 : the skies labor relations repress hallelujah when new star swims into his ken. submitted that what this coun- try needs Amendment the Constitution, prohibiting any work done anywhere, anyone, with- out song. Since the morning stars first sang together and there was the music the spheres, until now when last medical authority and labor leadership have industry has resisted the introduction sweet melodies soothe toiling have. But new morning dawning. Only details remain worked out. The best procedure, and the selections the proper songs for every job, may yet stumping us. But let not industry trifle. Soon, now, without song there’ll hell pay. clear with his magnetic voice over the radio, that life altogether punk “Without And quote the president the American Federation Labor, the authority Dr. Garner, chief surgeon the Atlanta and West Point Railroad lightens the task nerves and spirit.” eminent medical publication re- cently stated that “efforts chang- 38—THE IRON AGE, March 1938 ing supplanting the character sound have met with remarkable suc- means loud speakers in- stalled throughout many factories Germany the rhythm been used overcome the hum industry. The idea music during working hours was vogue ancient Greece where special work songs were used during the performance cer- tain labors.” cess. handwriting the wall. It’s going addition all the wet-nursing fabor which already our job, also run the musical programs and select the appropriate songs for every industrial work operation. not our thought berate any- thing which promises ameliorate the burdens toil. Coming think it, have known before this that hath charms soothe the savage But are perplexed. are adapt this innovation the Drazdowskis and our tappers, mixmen, castmen, and chargers? This problem causing some burn the midnight bulbs. create worthy and appropriate work songs for all our industries cannot depend tin pan shall Mellon Research Bureau. help the Institute and the General Until can make labor happy folly proceed further with snooping. Chemurgic and metallurgy must the human element de- mands. ridiculous suppose our furnace room men can sing “She Was Only Bird Gilded Cage” while tapping. And our cranemen get shouting “She May Have Seen Better Days,” they are liable smash things their enthusiasm. New uses for new tunes and America’s musi- cians are about challenged save our standards living pro- ducing efficient industrial work songs which may put handy cans. Can capitalism conform the cur- rent challenge? surmise that soon Bruce Barton has cleared few obsolete statutes from the legis- lative books, Senator Norris will paged for the amendment the Con- stitution. Perhaps the reform bad, after all, when once operation. may like the millennium hear Tony, Pasquale, Mike and Manuel, the beginning and end each shift, holding hands, singing “America, the Beautiful Let industry set its house order. The day close hand when with- out song there may sit-down! ALF mill mechanization and technique for- cibly visualized this picture taken 1892. the prized pos- pensioner the Gary Sheet Tin Mills, now Carnegie- Corp. Photographers may wonder the unusu- ally good lighting this picture. was due the fact that the mill roof had blown off the day before the picture was taken. s Chapter Series the Eco- nomics Industrial Power Transmis- sion Methods and Equipment. various problems varia- ble speed control industrial mechanisms may roughly classified mechanically heads; (1) those having with the adjustment the speed rotat- ing shaft, (2) those having with the adjustment speed recipro- cating mechanism, and (3) those hav- ing with the adjustment the speed conveyor. The first two are usually concerned the third with the problems bringing goods materials and taking them away machines. Again, the first two are problems revolving around the desire improve the production machines which make goods, secure better utilization factor, secure lower production cost, secure better quality product, meet more suc- cessfully the varying conditions the characteristics the materials worked upon external conditions affect- ing work upon them, any combi- nation these factors; while the third problem revolving around the better timing work delivered and taken from the production ma- chines, secure more perfect co- ordination processes. will interest touch very briefly upon the salient points few these problems, show general way the range usefulness variable speed transmission equip- ment. These illustrations are far from complete, particularly since the field use such equipment being ex- tended further every day. They will, however, indicate some the broader Rotating Shafts Machine tools—lathes, milling ma- chines, boring mills, honing machines, drill presses, screw machines and grinders. accommodate varying characteristics the materials being worked upon, changes depths cut, changes the nature the cutting tool grinding wheel used. Fans and blowers—to accommodate requirements draft suc- tion, depending upon atmospheric con- ditions changes the nature the work done. Centrifugal and rotary pumps—to accommodate variations the volume pplication Control ariable Spee Transmissions FRANCIS JURASCHEK Consulting Editor, The Age pressure the liquid required. Rotary cutters and slitters—to ac- commodate variations size and physical characteristics the mate- rials handled, well meet the skill the machine attendant handling the work. Winding rolls—strip metal, paper, cloth and wire winding machines re- quire automatic variable speed con- trol maintain constant tension the diameters the rolls increase decrease. Wire stranding and cable laying requirements tensile strength the twist “lay” wire rope, well varying characteristics the wire itself. the insulating electrical wires and cables, close regulation the speed the machinery neces- sary secure uniform quality product. Chemical engineering equipment— speed regulation great importance many chemically controlled indus- tries accommodate varying char- acteristics materials, varying den- ° sities viscosities materials are mixed, varying atmospheric conditions and production schedules. Only few applications may named here the field extremely large. cement and lime manufacturing and clay products work, may mention rotary kilns and kiln feeders, concrete pipe spin- ning machines, mills and granulators and filter pumps; foodstuffs manu- facturing, traveling baking ovens, fill- ing and bottling machinery, wrapping and cartoning machinery, mixers and beaters, macaroni machines, enrobing machines, can-making and soldering machines, pasteurizers and freezers; the glass industry, glass grinding, polishing and cutting equipment; the metal trades, metal washing, clean- ing and polishing equipment; the paper industry, macerators, cylinder and Fourdrinier machines, sectional paper machines, dryers, coaters, wax- ers, pasters and facers, feed rolls and spiral tube machines, and rotary print- ing presses; the rubber industry, washers, shredders, mixers and rolls; the soap industry, agitators, flakers, pulverizers, plodders THE IRON AGE, March 1938—39 on ral fic gy c le- ile ar ° ° ° ft, J is, u- Miscellaneous chemical equipment will include agitators, centrifuges, drum- dryers and sewage screens. Reciprocating Mechanisms slotters, shapers, broaches and die sinkers. accommodate varying characteristics the materials handled, changes depths cuts, character cut- ting tool used. Presses—punching, notching presses may often regulated se- cure maximum operation consistent with the skill the attendant. Form- ing and molding presses require close regulation accommodate varying characteristics the material and process. closely deliver coiled stock punch presses the best speed which the presses can operated; this regula- tion depending upon the quality and thickness the stock well the temper the material and the size and shape the blank desired. extrusion presses accommodates variations tempera- ture and composition the material handled. Stokers—to accommodate varying firing demands the furnace and varying calorific values the fuel, maintain uniform steam pressure even 40—THE IRON AGE, March 1938 when steam use demands fluctuate. (Likewise applies chain grate conveyor type stokers and powdered coal screw type feeders.) Chemical engineering equipment— the cement, lime and clay products machines, dry presses and the food- stuffs industries, bread-slicing chines, bottle capping machines, candy molding and cutting machines, vegetable graders and wash- the paper industry, slotters, creasers, folders, paper bag machines, stayers, envelope machines, flat bed presses, paper ruling machines. Mis- filter presses. Conveyors Speed regulation conveyors essentially concerned with the process coordination handling materials and from production equipment, but may also involve variations the treatment materials when the con- veyor part the production process itself, heat treatment work. few types conveyors only are here named. assembly lines. Foundry mold con- veyors. Straight-line machining through number machine tools. Power plant—coal delivery and ash removal conveyors. Heat treatment—continuous process ovens and furnaces. Chemical engineering equipment— the cement, lime and clay industries, screw type kiln feeders, powdered coal feeders, auger machines, tunnel kiln car pushers, continuous kiln convey- ors; the food products industries, dough dividers, cracker-cooling conveyors, icing trol- leys, dough sheeters, dough depositors, candy cooling tunnels, continuous cookers, blanchers, sorting ° ° ° INK-BELT gear with Link- Belt chain drives, driving lathe worm shaft in. diam- eter roll-machining job. scalders, disk feeders, feed mixers, molasses pumps, grain cleaners and wheat washers; the glass industry, lehrs, batch loaders, glaziers and auto- matic batch weight regulators; the soap industry, screw-type pumps, soap dryers. Miscellaneous; traveling water screens. Many important industries are not touched upon the above list- ings. Numerous special cases, how- ever, call for the widespread use variable speed control practically every phase the operations the textile, wood-working and meat-pack- ing industries which the limitations this article not permit adequate discussion, Ratios and Horsepowers Selection the proper size and range speeds variable speed | 7 EEVES variable speed units with James worm gear re- ducers pull-out roll and take-up reel, handling strip metal bath. transmission device determined (1) the horsepower transmitted and, (2) the full range speed varia- tion desired. For most applications the unit will required operate constant torque; that is, the horse- power required drive the driven ma- chine increases decreases propor- tion the speed revolutions per minute that machine. all such cases the maximum horsepower capac- ity the transmission unit the highest speed the output shaft will governing factor. other cases, constant horsepower required throughout the whole range opera- tion all speeds; and these cases, the minimum horsepower capacity the transmission unit must equal the maximum drive requirements. Lewellen va- riable speed units coupled directly paper-board cutting machine. variable speed transmission unit should not selected less horse- power capacity than the motor which connected, since, should the driven mechanism stall and the motor continue running, the transmis- sion unit becomes the weakest link the chain operations, and apt suffer damage. Reeves and Lewellen type variable speed transmissions are made open and inclosed types for horizontal and vertical applications. the various sizes the capacities range from frac- tional .100 hp. all capacities speed variations are available capacities the ranges are available the inclosed type only, the mechanism runs constant bath oil; and for horizontal vertical applications. five sizes the capaci- ties range from one hp., with speed variation ratios ranging each unit made one size only, with maximum capacity hp. and maximum ratio speed varia- The fluid power variable speed transmission units have con- stant torque motor, with maximum torque available all speeds. the integral units, four sizes are now available with capacities ranging from hp. and range speed varia- tions from r.p.m. minimum, depending upon the nature the load THE IRON AGE, March 7 cess ink- | and the type the machine driven, 1090 maximum, either di- rection. Where separate pump and motor units may used, the motor unit may either the constant dis- placement variable displacement type, and the capacities range from 100 hp., with range speed variations similar the integral units. Reeves and Link-Belt transmissions may had with integral-built electric motors Reeves, Link-Belt and Oilgear transmissions may had with inte- gral-built gear-reducer units; and all types may, course, direct-coupled to, drive chain belt-coupled sepa- rate gear-reducer units. (In later chapter, under the head- ing “Pulleys,” there will in- cluded descriptions various single pulley type variable speed devices, such the Reeves Vari-Speed motor pulley, the Allis-Chalmers Vari-pitch sheaves, the Equipment Engineering Hi-lo pulley, etc.) Controls The control variable speed trans- missions may either manual automatic. Manual control general- located the case the transmis- sion unit, with pointer indicate either the speed the output shaft the ratio speed variation between the input and output shafts. The hand wheel shaft movement multiplied through worm-and-screw, gear action, that large movement the wheel results small variation speed ratio, thus providing for close regulation speed. Automatic control may mechani- cal, electrical, hydraulic. The three methods differ, application; large- virtue the sensitivity the response required the demand for speed variation the driven mecha- nism, and virtue the power and range travel the speed variation indicator the driven machine. the driven machine embodies some speed indicating movement sufficient pow- and range travel operate substantial lever, the automatic control may mechanically actuated. The hand wheel and its multiplying move- ment replaced lever other similar mechanical movement which directly connected moving function the driven machine. series conveyors may thus linked secure uniform speed for each, having the variable speed transmis- sion drive one controlled the speed travel the just preceding line; the tension 42—THE IRON AGE, March 1938 held uniform the material fed winding reel connection which regulates the speed the reel ac- cordance with its enlarging diameter. Electrical Control—Should the pow- exerted the indicating mecha- nism the driven machine not sufficient, the range travel too small actuate mechanical de- vice control the speed the trans- phenomenon which may described pendulum-like swing both sides the required speed point the ef- fort attain the actual desired speed. Hydraulic Control—In this method oil pump driven small electric pilot motor maintains pressure oil line which governed two- way valve. Movement this valve actuated mechanically lever electric automatic control device, mounted the transmission case the work altering the speed ratio, and automatic electric trol switch employing rheostats, mag- netic contactors relays, driven machine, actuated lever mechanically connected with speed indicator the driven equip- ment. Thus, the rate feed stoker may controlled the steam pressure indicator the boiler. advisable make sure that the nections to, and the automatic control switch itself, are such design that, when contacts are formed switch increase decrease the speed operation the drive equip- ment, the first effect bring the contacts neutral position, and the second effect make the proper contacts for definite required speed. Thus. the phenomenon known cam connection the driven machine indicator, and admits oil one side the other fluid motor, the out- put shaft which connected direct- the speed variation mechanism the transmission unit. This control very sensitive, that change pressure the oil line but two three ounces sufficient cause change the speed ratio the trans- mission unit. Since the control oil pressure positive, all “hunting” eliminated, and any desired change speed gained both rapidly and surely. Actuating trol actuating device the driven machine will, course, vary the character type machine. the many mechanisms available lowing are among those most gen- erally used: floating rolls, follower rolls, cam controls, diaphragm regula- tors, governor controls, differential controls, photo-electric tubes, dancer rolls, knife carriages, steam pressure - reg pos flu | | Va regulators, ratchet controls, levers, and scale-beams. Desirable Qualifications the selection variable speed transmission unit, tions play important economic parts. important are the advantages pro- vided complete speed adjustability that the equipment used for that pur- pose should carefully checked against all the qualifications which in- fluence the utmost efficiency power transmission variable speeds. tabulating the following points, there- fore, adapted large part from the Reeves Pulley Co. “Speed Control Handbook,” has been considered that economy derives free, low maintenance-cost power ap- plications high efficiency and gen- eral utility. transmission the ap- plied power. all speeds and under varying loads, the transmission LEFT TEPHENS-ADAM- type variable speed used control the operating speeds power plant RIGHT INK-BELT motor- ized gear driving, through Link- Belt roller chain, the feeder roll tin- ning machine tin mill plant. power should definite, dependa- ble value. Fluctuation invalidates the essential principles variable speed control. speed adjustability. Be- tween the high and low limits the transmission unit, any and all speeds should instantly available, smooth gradation and without steps, while the driven machine operation. 3—Proportionate power consump- tion. The consumption power for all normal installations should di- rectly proportional the speed the output shaft; maximum speed taking the maximum power consumption. 4—Wide ratios variation. For utmost all-around usefulness, few limited speed ratios are not sufficient. The range available ratios any single unit should wide pos- sible meet any normal service requirement. 5—High efficiency operation. Since variable equipment one more mechanism in- terposed between the source and the final application the power, power losses that equipment negligible. much the power in- put reasonably possible should delivered the driven machine. 6—Simple design and construction. insure trouble-free performance and low maintenance costs, the design and construction the unit should simple, durable, and easy maintain. 7—Compact and adaptable. Since auxiliary equipment only, the varia- ble speed transmission unit should take the minimum amount space, and should adapted mounting the floor, ceiling, wall platform, upon the driven machine, any necessary position. should rotate either direction, and adapted receive and transmit power from and either side the driven machine. 8—Reasonable range sizes and coatrols. Various applications require different sizes variable speed trans- mission units. limited range sizes, therefore, will not serve many requirements. Controls should pri- marily manual, but fully adapted any degree automatic operation. The more nearly these qualifications are met, and the more carefully the unit under consideration adapted pre- cisely the work hand, the more economical will its operation be. With the increasing use variable speed transmissions every industry are gradually approaching the ideal ap- plication; that is, speed control which automatically actuated any variation operating conditions de- manding change speed for most operation, such variations the density, toughness, molecular structure temperature the mate- rial worked, variations the tem- perature, humidity gaseous content the surrounding atmosphere, variations the speed production machine operation affecting the speed piece materials handling equip- ment leading toward away from it. THE IRON AGE, March : 7 F res. | | | | Recent Developments Metal plating both zinc and nickel gaining wide acceptance and two leading companies are pushing proprie- tary processes, described this review. Other developments mentioned include fully auto- matic time-cycle method for anodic treatment aluminum, plating rectifier, acid bucket, rubber and enamel compounds for plating tanks and racks, metal spray gun universal ap- plication, three-dip degreaser, new type sandblast gun, static-proof sandblast hose, sev- eral new types shotblast cleaners, magnetic separator for enameling frits, color mixer and number new finishes, including acid-proof paints and perspiration proof lacquers. Next week's review will cover machine tool announcements the past month. ITHIN the last there has been decided swing bright zinc coatings place cadmium the price that metal rose due the demand the auto- motive industry for its use bear- ing alloying element. One the most recent developments apparatus for bright zinc plating mechanical cylinder barrel now being supplied the Co., Matawan, J., for use with the Mazic process. this plating proc- ess, the necessity for subsequent bright dipping practically eliminated. The solution recommended for use with Mazic similar the solutions generally used for barrel zinc plating, follows: Zine cyanide Sodium cyanide oz. per gal. water oz. per gal. water Sodium hydroxide oz. per gal. water Mazic Brightener No. per 100 gal. solution This solution will found anal- after all the salts are dissolved consist of: oz. per gal. Total sodium cyanide...... oz. per gal. Sodium hydroxide oz. per gal. The ratio the metal content total sodium cyanide should main- tained Should the total sodium cyanide concentration decrease below this ratio, the brightness dimin- ishes. Sodium carbonate content should kept below oz. per 44—THE IRON AGE, March 1938 gal. there will decrease so- lution efficiency. high tempera- ture the carbonate formation accel- erated, the solution should never allowed become warmer than 100 deg. The optimum amount Mazic brightener No. oz. per gal. When the plating solution operat- ing its best, the brightener con- sumption very slow, about oz. per 100 gal. per 8-hr. day, but this varies according local conditions. Brightener should dissolved thor- oughly hot water before being added the plating bath. The solu- tion can analyzed easily the method used for regular cyanide so- lutions. deposit zinc, 23.3 amp.- hr. needed. deposit 0.001 in. zinc, 13/7 amp.-hr. are required. Ap- paratus must supplied with current from 10- 12-volt source. least 200 amperes should drawn the average size barrel. Ball anodes spiral wire containers mended. operation, the solution tempera- ture will rise because the large amount current going through, and when bath being operated contin- uously, provision should made for cooling. economical circulate the solution, since this saves the so- dium cyanide required maintain the bath proper concentration. After the work plated the cylin- der should taken from the tank and rinsed thoroughly clean cold water avoid staining. After rinsing cold and hot water, the work trans- ferred baskets, centrifuged and dried. the parts are small and light, they should tumbled heated hardwood sawdust. all bright plating operations, the brightness barrel plated zinc depends somewhat the lustre the surface being plated. good grade cold rolled steel will give better fin- ish than, for example, pickled hot rolled stock. Gray and malleable iron castings have always been difficult plate any cyanide solution. Freshly sand blasted rolled castings requir- ing only weak acid dip usually plate satisfactorily, but prolonged strong- acid dip may necessary re- move oxide and rust, and they change the surface the work that zinc will not deposit. Any impurities any bright zinc plating solution have highly detri- mental effect. The material recom- mended for the barrels cylinders either Mercilite hard rubber. Bright Nickel Plating With bright nickel plating, the cessity copper buffing before nickel plating eliminated are most not all, buffing, tumbling and “color- ing” operations needed give the nickel coating the proper lustre for the final chromium plated finish. Bright nickel deposits are now being secured deep recesses, making the process applicable die castings. brass and steel parts irregular shape, and hence expensive buff. Because the saving subsequent operations and the fact that nickel lost and that rejections through cutting through the plate buffing are eliminated, savings between and per cent costs over dull nickel plating are estimated. There addi- tional saving parts plated sim- ple racks wire that may taken directly from the nickel bath the q q ch rai all we its ity th TO su | | SC cc m al el | Finishing Processes chromium plating bath racking. recent weeks, the Udylite Co., Detroit, has announced new process bright nickel plating that fulfills above. process said produce smooth and ductile film well bright surface. The solution itself stable, easily controlled bath having good throwing power abil- ity deposit into recesses. The oper- ating efficiency said around 98-99 per cent. Lustrous nickel de- posits are obtained over wide range plating conditions. Materials for the Udylite process are furnished competitive prices and special royalties fees are connected with the process, but Udylite engineering feature. Anodic Treatment Aluminum The Hanson-Van Winkle-Munning Co., Matawan, has built for use the anodic treatment aluminum some motor-generator sets large size that are equipped with automatic control devices designed vary the generator voltage through termined cycle required for the specified treatment batch alu- minum For normal operation, parts anodized are cleaned and hung an- odizing bath and button pressed set the automatic control. motor driven field rheostat increases gen- period min. the completion the &-min. treatment, nous motor driven timer starts op- erate. The generator voltage held volts until the timer completes its operation (normally min.) which time the generator field circuit opened and warning signal an- nounces that the cycle completed. The control automatically resets. During the treatment cycle the volt- age and current are recorded graphic meters strip charts, dated and numbered correspond with the batch number. These charts plus similar temperature chart and rec- ord the solution analysis constitute complete record the treatment. The generator control cludes the regular indicating instru- ments and equipment for visual and manual control. The automatic con- trol includes the motor driven field rheostat and timer manufactured the Ward-Leonard Electric Co. and graphic recording ammeter meter manufactured Roller Smith Co. Auxiliary overload and reverse current relay and indicating and signalling devices. The normal rating the generators RIGHT HIS Hanson-Van Winkle-Mun- ning mechanical plating barrel was especially designed for bright plating the Mazic process, completely described the text. LEFT example the throwing power the new Udylite bright nickel plating process this 8-in. saucepan, which has been flashed with copper, then bright nickel plated. Base metal cold rolled steel finished with No. 200 emery grease prior plating. ° ° ° FRANK OLIVER Associate Editor, The Iron Age 1500 amp. volts, continuous operation. They are driven 125- hp. synchronous motors mounted di- rectly the generator shaft and have 125-volt exciters. The common sub- base, motor and generator rings, etc., are built heavy steel shapes and plates fabricated arc