The Iron Age 1938-07-28: Vol 142 Iss 4

| Managing Editor F. J. OLIVER LEROY W. ALLISON Publication Office Chestnut and 56th Sts., Philadelphia, Pa. FRITZ J. FRANK President J. H. VAN DEVENTER Editor News Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors T. C. CAMPBELL Editor Emeritus Vachineru Editor Editor Editar BINGHAM Pittsburgh Chicago Cleveland Detroit Correspondents London, England Cincinnati FRAZAR Ropert G. MCINTOSH Boston Hambura, Germany CHARLES Pos San Francisco MEYER Milwaukee ASA ROUNTREE, Birmingham SANDERSON Toronto, Ontario Newark, N. J. St. Louis TURNER, Buffalo Owned and Published by CHILTON COMPANY (Incorporated) 239 West 30th New York, N OFFICERS AND DIRECTORS C. A. MUSSELMAN, President WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Seeretary JOHN H. VAN DEVENTER JULIAN CHASE THOMAS L, KANE CHARLES 8. BAUR G. CARROLL BUZBY P. M. FAHRENDORE DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index Published every Thursday. Subscerip tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, 25 cents. Cable Address ‘“*Ironage, N. Y."’ ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago Wf. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh D. C. Warren, P. ©. Box 81, Hartford, Corn toy EDMONDS Editorial and Executive Offices st FRITZ J. FRANK, Executive Vice-President FREDERIC STEVENS, JOSEPH S. HILDRETH, GEORGE H. GRIFFITHS, EVERIT TERHUNE, Vice-President BAUR, General Advertising 28, 1938 How Much $40 Billion? Molding Sand for Non-Ferrous Metals Industrial Plant Mobilization for War Progress Industrial Building Design Economics the Pivoted Motor Base Recent Advance Welding and Cutting Equipment Lengthening Life Lathe Bed Ways Automotive Industry Opening New Pipe Mill Washington News THE NEWS BRIEF Rate Activity Capital Goods Weekly Ingot Operating Rate Plant Expansion and Equipment Buying New Industrial Literature Products Advertised Index Advertisers Copyright 1938 Chilton Company (Inc.) 114 | 3 2 r it t. 5 as A 1 re ct i t- od il- st d- ds : a- ip- jas x unique feature bethanizing that it’s just natural and inevitable for bethanized coating uniform thickness for the surface water ina pan level. The electricity flows into all parts the surface the same rate and deposits the same amount zinc everywhere the wire. impossible put eccentric coating the bethanizing process. Uniform thickness vital protective coating 20—THE IRON AGE, July 28, 1938 This uniform thickness the bethanized coating, the 99.99-per-cent purity the zinc and the tight bond- ing that enables the coating stand the most severe fabricating operations are steadily increasing the utility zinc-coated wire. Bethanized wire even serv- ing satisfactorily many applications where expensive alloys have heretofore been used. Whatever the total weight zinc wire may be, the coating tive than the thin part, shown exaggerated form the lett. a STEEL ESTABLISHED THE IRON AGE... JULY 28, 1938 How Much $40 this time next year, the national debt the United States will more than $40 billion. Does that mean anything you? Probably not, because billions are diffi- cult visualize for practical people who have earn living meet payroll. Let's try visualize $40 billion. $40 ton, would buy one billion tons structural steel. all the ingot produc- ing capacity the United States were kept busy per cent capacity and all our steel finishing capacity could applied structurals, would take about years produce this amount steel. One billion tons structural steel would amount 7!/ tons each and every lineal foot the earth's 25,000-mile circumference the equator. That would enough steel, solid ground were available, build elevated highway around the world six times wide six times heavy per mile either the great Pulaski Skyway over the Jersey meadows the West Side Highway New York. Nobody every going build such highway, produce the steel that would necessary for it. But our national debt ever paid, we, our children and our grandchildren will have work for Uncle Sam—at pay—sufficiently long produce that equivalent. take this illustration example: There are 420,000 miles railroad track the United States. Assuming that track ties are ft. centers, Uncle Sam has written sufficient put $40 each rail- road tie the United States. Since political ledgerdemain Uncle Sam's automatically become future Americans will have to, figuratively speak- ing, dig and slap down $40 for each railway tie the United States take themselves out hock. man were given the job walking the tracks and could pick these the rate one every four seconds, $36,000 worth per hour, starting the age and working hr. per week, would 599 years old the time picked the last one. According Biblical history, Adam was created 5942 years ago. Adam and Eve had been thrifty enough save six and one half million dollars per year, starting with the year creation, and their descendants had followed suit, year after year 1938, the total sum, without interest, would now enough pay the national debt the United States. Now you begin realize how much $40 billion. It's lot when you have pay it. Vol. 142, No. | 7 4 F 4 fs > - d : } Molding Sands for UCH has been written the subject molding sands for foundry work. Detailed methods analysis, tests and classifi- cation molding sands have been worked out the Sand Research Committee the American Foundry- Association. Various classifica- number, clay content, have also been worked And there are numerous proposals systems designating grain size distribution. general these various publications deal TABLE Grain Size Distribution for Various Albany No. Sands (Per Cent) No. 100 140 200 270 270 Clay 0.04 0.06 0.04 0.54 1.60 6.34 8.98 19.58 39.62 24.08 203 0.04 0.08 1.30 3.16 7.58 10.86 27.50 207 0.30 0.38 2.12 4.92 8.50 12.42 23.64 12.76 238 0.12 0.62 2.20 7.80 12.04 26.42 32.74 18.24 244 0.02 0.02 0.02 2.48 13.30 18.60 19.34 259 0.04 0.08 0.12 0.50 6.74 29.34 21.44 22.18 15.28 4.46 0.12 0.04 1.04 10.24 6.10 5.40 TABLE Grain Size Distribution for Various Albany No. Sands (Per Cent) No. 100 140 200 270 270 Clay 206 0.10 0.42 3.50 3.04 3.54 4.38 18.92 240 0.10 0.34 1.02 15.82 12.26 241 0.04 0.32 1.06 4.16 15.04 21.64 28.64 20.76 7.88 255 0.04 0.12 0.50 2.70 3.08 5.50 12.10 28.68 33.92 13.52 228 0.10 0.14 0.44 15.06 16.16 14.98 18.86 17.68 9.96 250 0.16 0.16 0.30 4.76 8.08 17.10 23.98 24.00 260 0.10 0.40 1.88 10.24 27.12 19.46 16.16 364 0.06 0.10 1.22 10.22 9.92 15.78 369 0.20 0.16 0.36 20.34 14.64 19.04 22.04 9.70 TABLE III Proposed Specifications for Non-Ferrous Foundry Sands (Per Cent) Fine Medium Heavy Core Fineness 180 200 150 180 120 150 50to Grain Strength 22—THE IRON AGE, July 28, 1938 Non- with foundry sand whole and not specifically with foundry non-ferrous foundries. not proposed here review the published work foundry sands, nor outline the various cedures for testing foundry simply proposed describe some the essential prob- lems the non-ferrous foundries connection with foundry sands and propose set specifications which general will properly select sands for the non-ferrous foundries. many years, the foundry supply houses have supplied sands designations, common designation being “Albany Albany Sands further divided into grades such 00, ete. tunately, however, these are not tive designations grain size grain distribution, even furnished one supplier. The situation addi- tionally complicated the fact that various suppliers classify their sands differently. non-ferrous foundry- man purchasing Albany No. from one supplier may using consider- ably different sand than another non- ferrous foundry Albany No. from the same supplier. non-ferrous foundrymen general result this situation, not talk the same language when they refer the specific type sand which they are using which they recommend for use for given job. June, 1925, study “Albany Molding Sands the Hudson was made Charles Nevin and published New York State Museum Bulletin No. 263 the University the State New York. This bulletin described the method used the ous suppliers determining the des- lar load sand. The publication also contained the results fineness tests and clay determinations some samples Albany Sand furnished some five different tests, Mr. Nevin found necessary disregard the grade designation the supplier and plot the fineness tests | | j | he 7 7 Ferrous Metals under modified grade designation arrived him. The results these fineness tests grade designa- tions, modified Nevin, still show wide variation the essential grain size distribution the various sands. How great the confusion really can ° ° ° Different Albany No. sands will often show such grain size dis- tributions are plotted here. Per cent weight only shown replotting the data reported Nevin the basis the classifications used the suppliers the samples. This has been done only for two grades sand, namely Albany No. and Albany No. which are Figs. and The detailed figures ° ° SAM TOUR Lucius Pitkin, New York are also tabulated Tables and Considering Albany No. Fig. and Table once evident that sand represented samples 211 and 259 are way comparable sand represented samples 251 and 203. Similarly, considering Albany No. Clay 200 140 100 Sieve mesh ° ° ° IG. Wide grain bution various Albany No. sands. this variation which casting difficul- ties. Per cent weight Through 210 200 140 100 Sieve mesh THE IRON AGE, July 28, 1938—23 tor sand, Fig. and Table II, becomes immediately evident that the coarse sand represented sample 364 way comparable the fine quite evident that something more needed than the present method classifying sands terms Albany grade designations, are referred these two charts. has been amply demonstrated that simple grain fineness designation showing the average grain fineness accordance with the American Foun- drymen’s Association method insuf- ficient properly designate foundry sands. This obvious when consid- ered that the A.F.A. number purely average number obtained from general sieve analysis and may arrived having quantity fine silt present counter- quantity coarse particles. combination very coarse with very fine sand obviously not suit- able for foundry sand. Another dif- ficulty encountered the non-ferrous foundrymen making use the A.F.A. classification grain fine- ness the rather broad range covered given class designation the class designa- tion No. covers the entire range foundry sands with average fineness within this range that majority non-ferrous foundry should come. within this range that some differentiation made between sands for light weight fine finish castings against sands for medium weight castings and sands for fairly heavy castings the non- ferrous metals. There hardly any question, how- ever, but that sieve analysis fineness test plus clay content determination are tests upon which foundry sands should chased. The important thing then that seems necessary set various minimum and maximum the percentages grain retained various sieves the carrying out the standard sieve analysis. Table III shows proposed classi- fication for three different grades molding sands for use non-ferrous foundries and one grade core sand for use non-ferrous foundries. believed that these four sands will cover majority the work done non-ferrous foundries the United States the copper-base alloys and the aluminum-base alloys fields. not expected that these sands will adequate for some the special requirements connection with very heavy massive castings occasional- made, nor connection with the high melting alloys the nickel and Monel type. For want better des- ignations, the sands have been desig- nated “Fine,” “Medium,” “Heavy” and “Core.” Letter designations have not been used order avoid con- fusion connection with the letter designations adopted the American Foundrymen’s Association for clay content molding sand. Number des- ignations have not been used order avoid confusion with the number designations adopted the American Foundrymen’s Association connec- tion with the classification sands according grain fineness. Dump Car Weight Reduced Welding EDUCTION weight some 12,000 compared with previous design has been ac- complished the Western-Austin Co., Aurora, the yd. rail- road dump car pictured accompany- ing illustrations. The actual weight the old car 69,000 and that the new 57,000 rated capacity the lightweight car 100,000 Ib. the accompanying table general dimensions, will seen TABLE I—DIMENSIONS DUMP CAR NEW AND OLD DESIGN Length body, inside, bottom Length body, inside, top Width body, inside, top............ Width body, inside, bottom... Depth body, inside... Height, top rails top body.. Height, top rails center couplers.... Length, face face striking castings Length, knuckle knuckle couplers... Length, center center trucks... Angle dump, from horizontal...... type dump car welded steel construction weighs 12,000 less than previous equal capacity. The frame constructed entirely standard structural steel shapes and plates arc welded. 24—THE IRON AGE, July 28, 1938 New Old 34% in. in. deg. deg. that the new car has the same capac- ity overall body length ft. the car previously built, which was ft. 634 in. dong. Are welded steel used through- out constructing cars the new design. The frame built standard structural members high- channels and plates cut size, assem- bled fit the design, and fused to- gether electric arc welding. The pneumatic cylinder the dumping mechanism also welded steel. superseding iron castings. The shield- arc welding process, with equip- (CONTINUED PAGE 45) Gun, Model mounted disap- pearing carriage, Model 1907. action. (Photos Courtesy 8. Army Signal Corps.) Industrial Plant Mobilization for the Next PLANTS" will acquaint our man- ufacturers, particularly the metal working industry, with munition case war. These plants which small educational or- ders are financed Govern- ment appropriations will emerge from shadow into definite realities case national conflict which shall involved. These shadow plants are scattered throughout the length and breadth our metal working look for minute beyond the procurement Which each branch the Army the country for administration just what conditions must met producing modern ordnance. Take the case the automatic rifle, which can deliver much fire five ° ° ° COL. TOULMIN, Jr., D.S.M. ° ° industry. them, the educa- tional orders financed special Government appro- priations will provide famil- iarity with war requirement and also the jigs, features, tools and special facilities re- quired such production. This policy, inaugurated our War Department repre- sents what might called the last word non-militarist preparedness. The first ar- this subject appeared The Age, July page 26. ° seven men can get out ordinary Springfield rifle the World War type. This automatic quires 2345 gages, 1766 fixtures, 1388 special tools, and punches and dies for its parts. Congress appro- priating $1,800,000 for these rifles and $6,000,000 $8,000,000 for machine bucket. will need least six million these automatic rifles adequately equip our four field armies. The Springfield rifle alone has parts and requires 103 dies, 463 jigs and fixtures, 506 special cutting tools, 1320 working gages and 1339 inspec- tion gages. wonder the Government ginning its educational orders through bill Congress for two million dollars acquaint manufacturers with the art making munitions through these “shadow plants.” problems munitions are relatively simple compared the problems gages, jigs, fixtures and tools. this neck the bottle that the Gov- ernment trying remedy indus- trial mobilization preparing for the more difficult specialized munitions production getting the gages, jigs, fixtures and tools ready now and teaching factories how produce the special educational orders. are going try learn walk before try learn run. That idea Colonel Johnson some day may THE IRON AGE, July 28, 1938—25 ll 4 ‘ (pn n — — an in. in. in. in. in. in. in. in. in, in. ft. es, ng the .50 caliber anti-aircraft machine gun. March 18, 1938. mean the difference between failure and success this age when wars may start unexpectedly and run for six months before they are even declared. Munitions Contracts \Ve have even made study the contract each type muni- tions, facility purchased, will have. some cases, have Negotiated Price Contract, which the work will bought agreed upon price. other cases, will have Ad- justed Compensation Contract, which modification the old cost plus contract which caused much profit, caused much loss and created much scandal the World War days. have Evaluated Fee Con- tract also which the contractor will paid set fee for certain facilities. War time contracts either spelled vast fortunes industrial ruin during the last war. Under the present setup, the purchase supplies where prices are generally established the commer- cial market will effected through the Negotiated Price doubtedly there will reasonable regulations prevent runaway prices not only for the protection the Government, but for the protection industry engaged non-war work. Then the adjusted compensation 26—THE IRON AGE, 28, 1938 contract will give the contractor his costs and profit reasonable per- centage the capital invested, and anything over the contracted -price will share with the that every inducement cut costs which was true the old war time cost-plus contract. The evaluated fee contract will probably used mainly for contract work will provide for paying facilities plus the cost the construction. good deal discussion has been going about taking the profits out war. You can more get effec- tive production time war without profits than you can get business times peace. The true answer the prevention excessive profits, while leaving the profit motive function normally possible for the benefit war time production. nation ever succeeded war that nationalized its munitions production. Our Government armories and arse- nals could not produce fraction our war time requirements. Industrial Coordination industrial management and team work that will win the day. the poem runs: “It the guns armaments Nor the tunes the bands can play, But the close cooperaton That makes win the day.” you may expect some morning when mobilize our war time production have laid down already been negotiated its terms with the Government, except the spe- figures. Out the plant you will have gained experience with the “pilot and the educational orders you will know how correctly late costs and other data order put the right figures the contract. You will dust off the plan for ex- panding the plant take the bottle necks out munitions production. You will put that additional power line, and you will know house the added men and women step production. You will sure that your ordinary customers will taken care of, rea- sonably well, because you will only have turn over from twenty per cent the productive capac- ity your plant munitions work. The jigs, gages, fixtures tools will already available, ready put into production uses. Anyone who lived through the last war and the industrial mobilization problems will realize how sharply all this contrasts with the hectic confu- sion those memorable days. Decentralization for War Better the Ordnance Depart- ment, the Quartermaster Department, the Air Corps, the Signal Corps, and other similar Bureaus have divided the United States into industrial dis- tricts with organizations each trict, which have been decentralized from Washington, that they can work directly with the plants and the di 0 > q | al ] district allocated them. close. friendly and understanding working relationship, thoroughly decentralized from central control Washington, makes industrial mobilization our great country entirely each district the district office, with suitable military and staff that has already made the survey the facilities your factory, has agreed with you upon the allocation these facilities and has worked out exactly what you can do, how you can it, and what more you need see These district offices are good deal like the sales engineering offices large with your plant about the same that you have with such sales engineering offices those who sell putting the plan such well-known commercial basis, will organized for the complicated business mechanized war, based upon the art fabricating and working metals. The way save the dol- ABOVE ARCH the Ist Cavalry, Mech- anized, from Ft. Knox, Ft. Riley, Kansas. RIGHT ANTONIO held San Antonio, Texas, Fall 1937. Side view mm. Howitzer. Army Maneuvers, Pine Camp, Y., August, 1935. Rapid fire with new auto- matic lars make preparations like this prevent wasting them. are still paying for the horrible expense from the gross waste due lack organization during the World War. \Ve only spend one and one-half cents per day, per capita, for our Army, Navy and Air Corps. This $5.60 per year per person very small com pared England’s $30, $21, Not rifle. and Russia’s Our economy comes from careful planning, minute and detailed preparation, and vigi- lant organization ready mobilize industrially upon the first danger. can continue such tain, are now efficient organization, and economic, timely industrial mobil- ization. The cost money and lives due the neglect these principles the reader this article paying taxes for those past mistakes. The great cost war not preparation for it, nor the conduct it. but making for the lack preparation after have once entered it, when must pay for the mistakes that result from such lack foresight prepare for the inevitable day. And the thing that the greater the preparation make make the less likelihood that will ever have use it. THE IRON AGE, July 28, 1938—27 ) unusual opportunity observe progress made during the last few years the design indus- trial buildings presented the Ham- ilton plant, recently erected East Hartford, Conn., the United Corp. The plant, which for the manufacture controllable-pitch propellers, adjoins two other United factories, the Pratt Whit- ney plant and the Chance Vought plant, both built compari- 28—THE IRON AGE, July 28, 1938 son the new plant with the two earlier ones offers salient proof the forward steps that have occurred industrial architecture period years that tween the times construction. Such comparison especially significant since all three plants were designed the same firm architects and en- gineers, Albert Kahn, Inc., Detroit. Both the Pratt Whitney and the Chance Vought buildings were con- J | sidered modern and effective buildings the time they were built. many respects they are still up-to-date. But the Hamilton plant there are em- bodied many features which were un- attainable 1929 and which result greatly improved efficiency. fact that the floor factory build- ing should free from obstructions which tend cramp production which hamper the placing ma- intensity daylight this plant the same the intensity the Pratt Whitney plant, but the Hamilton plant the glass the roof placed that the natural light the building uniformly distributed. The ma- chines stand out with equal color values and shadows are prac- tically eliminated. a l 4 ( ~ — and view the desirabil- ity unimpeded floor columns are usually spaced apart possible, taking into consider- the nature the product and With this consideration mind, the interior columns the Pratt Whit- ney plant were spaced ft. apart one direction and ft. the other. unobstructed floor area that re- sulted was 1280 sq. ft. per bay. These dimensions were considered large, the time, and represented improvement structed buildings. However, the Hamilton plant new design for roof trusses permitted the spacing interior columns ft. apart both directions, thus obtain- ing unobstructed floor area each approximately 225 per cent. novel application cantilever roof improvement without construction cost. trusses over alternate bays are continuous over the type roof the weight the tural steel, per sq. ft. floor area, more for the 4096 sq. ft. bay than the 1280 sq. ft. bay. over the intermediate bays. Projecting the roof trusses beyond the column supports produce the the width the roof moni- the distance the LTHOUGH the interior the building flooded with day- light penetrating through the glass the roof monitors, nevertheless the light not uniformly distribut- ed, evidenced the many shadows cast the floor and the machine tools. monitor sash, the daylight which pene- trates through the sash more uni- formly distributed than the case the earlier factories. And uniformity mechanic has stand between the source light and his work, will cast shadow his work; the machine placed that its frame stands between the work source light, production will similarly impaired. And this true matter how bright the light itself may be. The desired intensity natural lighting building always ob- tainable, because governed the area the glass the monitors. all three plants the area the monitor sash equals per cent the floor area. But uniformity lighting governed the proper location the sash, and this factor depends upon design. Experiments conducted during the period between the erection the Hamilton and the Pratt Whitney plants demonstrated the advantages obtainable increasing the width the monitors. the Hamilton plan the monitors are one-third wider than the Pratt Whitney. The effectiveness the monitor lighting the Hamilton plant clear- ans shown the accompanying interior views. For purposes comparison interior view the Pratt Whit- ney plant shown above. this case there ample intensity light, though not uniformly distributed. spite the bright interior, there are many pronounced shadows. Photo- graph opposite page the in- terior the Hamilton plant, shows the light much more evenly distributed shadows are practically eliminated and the various machine tools stand out with nearly equal color values. result this uniform lighting there necessity for using local light- ing any the machine tools the Hamilton plant, even where the most intricate work being performed. achieved the Hamilton plant; such improved artificial lighting, more effective heating and ventilating sys- tems, more flexible means power distribution, better wearing floor sur- faces, and more conveniently located locker and toilet rooms. interesting note that these improve- ments did not increase construction costs. Since the progress industrial construction generally coincides with industrial developments the Hamilton propeller plant has par- ticular interest. The many improve- ments this plant have been necessi- tated and are significant the forward steps that have occurred dur- ing the past few years the airplane THE IRON AGE, July 28, 1938—29 ° | ENSION the bugbear all belting drives. The efficiency the drive depends primarily the maintenance proper belt tension, but all things seem conspire make that tension vary from instant in- stant throughout the entire life the drive. First, the starting load may several times the normal running load due the inertia which must over- come get any rotative shaft and its attendent mechanism motion; then most industrial loads vary from mo- ment moment, from much less than many times more than the normal running load. High speeds multiply the effect centrifugal tension, and helts stretch operation, destroying the initial values the tension which the drive has been adjusted. not sufficient, therefore, make sure that the initial tension correct; means should provided insure correct tension during opera- tion and throughout the life the belt. general, the three ways doing this are: adjust the length the belt the drive. ley the belt. adjust the length the drive the belt, automatically. The first method somewhat “hit-or-miss” proposition, one waits until the belt slips unduly during op- eration, then stops the drive and either shortens the belt, or, increases the pulley center distance means shaft take-up mechanism. either case, only part the dif- met; that caused the stretching the belt. Nothing can done about the variations tension caused variations the load while operating. costly method; wasting time and labor, stopping pro- duction while the adjustment made, and between with constantly decreasing efficiency. The second method has the advantage being automatic, but has the disad- vantage consuming more power and causing more rapid belt wear. The third method completely automatic, and actually saves power and increases belt accomplished generally means the use pivoted mo- tor base, and therefore not univer- sally applicable all industrial drives, will shown this discussion. Where the pivoted motor base can used logically, important fac- tor economy the transmission system, and therefore quite properly subject for careful consideration. IRON AGE, July 28, 1938 grasp the theory the pivoted motor base, and apply that theory particular drive problem, will necessary glance briefly the subject belt tension general. The usual approach hedged about with lot terrifying mathematics, but possible simplify that approach and still not depart unduly from strict scientific fact. Most ing men will agree with the following exposition, Belt Tension Variation Fig. driving pulley turning clockwise, causes driven pulley turn clockwise direction likewise means the travel the belt which connects the two pulleys. When there load imposed the driven pulley shaft, that this pulley turns freely, the pull, tension the lower side the belt (running from to- wards may taken equal the pull, tension, the upper side the belt (running from towards B). This expressed the engineer the mathematical form 7, ~« belt operating under load. conomics the trial Power Transmission (or the initial tension the belt, rest freely running load. This tension must great enough cause the belt grip the pulleys over the respective contact sufficiently keep the driven pulley turning when the load ap- plied its the moment application this load the tension the tight pulling side the belt will more than the normal running load the full load applied instantly. This the case when there clutch the driven pulley shaft and the driving pulley directly connected the motor shaft. workable rule take this starting tension 1.5 times the normal run- ning tension for compensator-started motor, 2.5 times the normal run- ning tension for started motor. The point un- derstood here that the initial tension (or tightness the belt around the pulleys) must sufficient come slippage under load-starting con- ditions. Whenever the driving pulley pull- ing the driven pulley, tight side the belt, the tension 2—Full line indicates belt running position under normal tension; dotted line indicates position due influence centrifugal tension. ‘ ‘ 1 1 3 3-1 = \ A < Pivoted Motor Base the Economics Indus- Methods and Equipment. FRANCIS JURASCHEK Consulting Editor, The Age greater than the tension slack side the belt; for then the only function the slack side return from the driving the driven pulley whereas the tight side transmits the full power the drive. The ten- sion always has positive value be- cause the combined influences the weight the belt and the centri- force caused the speed the belt travel. The difference between the values and any moment equal the transmitted load multi- plied factor which takes into ac- count the belt speed feet per min- ute, the diameter the driving pulley inches, and the number revolu- tions the driving pulley per minute. (For highly accurate results, the angle are contact between belt and driving pulley and the friction should considered here IG. 3—Rockwood type piv- oted motor base drive. Motor pivots below the plane the motor feet. Adjustable movable base Simply, this factor may taken equivalent belt speed ft. per min. Mathematically, the differ- ence belt tensions under normal pressed horsepower. Practical considerations belting operation have shown that the ratio between the tight and slack side tensions should lie between the range 2.5 and that is, the tight side ten- sion should not less than 2.5 nor more than times the slack side tension. This ratio part ent upon the angle “wrap” con tact the belt the driving being low for small contact angles and high for large contact angles. very low value this ratio indicates large amount total tension the belt, accompanied good frictional grip the belt the pulleys, but with the danger, carried too far, shortened belt life and worn bearings. very high value the ratio in- small amount total tension movable base base 4—American Pulley type pivoted motor base drive. Motor pivots above the plane the motor feet. the belt, which, carried too far, will result excessive belt slippage, undue power losses, loss production and shortened belt always safest, whenever possible, take figure approximately midway between these extremes, Say between and for the tension ratio. call this ratio tensions between the tight and slack sides another mathematical expression available which will useful application problems. Now, whenever the actual load transmitted known, and the tension ratio can either determined as- sumed, have from the foregoing equations means calculating the respective tight side and slack side tensions for any belt actual opera- tion: and starting loads running over- loads, the load actually trans- mitted will higher than during nor- mal load operation, but the equations still hold provided the value suitably increased. high belt speeds the centrifugal tension must alse considered, this tension in- creases value the square the speed. is, the speed doubled, centrifugal tension quadrupled, the speed tripled, centrifugal ten- sion increases nine times.) The for- mula for the centrifugal tension pounds 116,000 where the weight the belt pounds per foot and the square the speed the belt ft. per min. this value low compared the more than per cent, should added. The practical effects cen- trifugal tension are two; tends 5—Special Rockwood base adapted for vertical drives, with tension controlled heavy coiled springs counter- acting the motor weight. THE IRON AGE, July 28, af ; ' ad pull the belt away contact with the pulleys, and thus cause slippage, and pulling the belt outwards from the normal position all around the drive (see Fig. adds the total tension. If, heavy belting run extremely high speed, the centrifugal tension should equal the total initial tension the belt, the drive 6—American Pulley pivoted motor base, adapted equally for floor, wall ceiling mounting, with counter-weighted arms, for down drives. would impractical, since the belt would not grip the pulleys. The Effects Tension Variation Since the efficiency belting drive depends upon the maintenance uniform belt tension, clear that such tension maintenance about the most important factor belting drive operation. the tension too low, grip will fail and excessive slippage will occur. the tension too high, excessive belt wear will result, shaft bearings will run hot, and the belt will stretch, break. Starting loads and overloads encountered operation should not increase normal running tension beyond the elastic limit the belt material, for when this happens the belt stretches, and all previous values tension are altered. The belt must taken (or shaft center distances increased) regain proper tension values. And, stretches continually, tension values must kept abnormally high with the result not only that power wasted, but that more stretch occurs, well excessive belt wear. good belting use can kept tension ratio (or be- tween and with total tension well 32—THE IRON AGE, July 28, 1938 within the normal elastic limits the belt material, has been found that the most economical results will obtained. For heavy, load, horizontal, long center distance drives, this not difficult thing do, pro- vided the belt correctly proportioned and excellent quality. But for very large number industrial drives other than these difficult prob- lem, unless some means the drive hold the tension ratio automatically, under the various con- ditions variable loading, short centers, and high-inclination, vertical drives. One the most popular and throw the weight the motor, pivoted outside the lines belt travel, into the loop formed the belt passes around the driving pulley. The first type relies for its tension adjusting effect wholly the weight the motor; the second partly the weight the motor and partly torque the motor. construction difference two is, that the first type mounts the motor rocking base pivoted be- low the plane the motor feet, while the second mounts the motor rocking base pivoted above the plane the motor feet. (See Figs. and 4.) The first form typified the 7—Two 2700 hydraulic pumps driven and 20-hp. motor ft. centers from Rockwood vertical pivoted bases. fective means accomplishing this automatic tension adjustment the pivoted motor base, which operates the basic principle synchronizing the load variation with counterbal- ancing tension adjustments auto- matically altering pulley center distance with limited range. The Pivoted Motor Base Drive There are two generally recognized types pivoted motor bases. Both Rockwood base. The motor secured adjustably arms which curve down- ward pivot below the feet the motor. The whole weight the motor thus utilized force, flexibly disposed, tending maintain form adjustment the tension the belt; free lift when momentary overloads impose added stress the tension drop when the the motor the movable arms may the drive, that proper value initial tension obtained. Thereafter, the motor weight depended upon counterbalance variations the load, stretch the belt. The second form typified the American Pulley base. The motor secured here cradle pivoted above the feet the motor. The weight the motor utilized secure the minimum required value initial ten- sion; thereafter the reaction torque the motor used force coun- stresses. This reaction torque simply physics: every action there equal and opposite reaction. When push with our hand against wall, the wall resists the push with equal force. rotor spinning clockwise motor frame produces opposite rotational force the stator. Normal- ly, since the motor fixed the floor, this reaction absorbed the mount- ing. But the motor were freely suspended the air and the rotor continued spin clockwise direc- tion, the reaction torque produced the stator would tend turn the whole motor counter clockwise around the point suspension. the reaction torque base this fact taken ad- vantage suspending the cradle which the motor rests from pivot above the motor feet, that the motor will tend push away from the line the belt pull with force equal that pull. The greater the load the belt the greater this reaction torque. Thus, when the whole drive cor- rectly designed and installed, the ef- fect one securing maximum belt pull with minimum belt tensions, auto- matically. How Does This Equipment Act? The theory the pivoted motor base simple. The system permits the weight the motor partly supported the pivoted base and partly utilized means applying minimum effective tensions the belt altering the pulley center distance stresses increase decrease. therefore, the operat- ing tension the drive, instead being variable function fixed center distance between the two pulley variable center distance. This the whole secret the proposition. The advantages maintaining uni- form tension are apparent from con- sideration the disadvantages tension. Too much tension, has been said, causes excessive wear the belt and the bearings, and tends cause undue belt stretch. Too little tension reduces the power-trans- mitting capacity the drive, promotes slippage, and restricts the output the driven machine. Since load varia- tion the driving and driven ma- chines cannot overcome completely, and since load variation under fixed center distance conditions always pro- duces tension variation, system which automatically compensates for load variation the drive (as well for small amounts belt stretch) will avoid the economic evils ten- sion variation and produce smooth, 8—Large fan driven motor weighing 3,000 cradled American Pulley pivoted base; center distance, 43.3 in. that maximum values this power may utilized every instant operation. Staniar says, this sys- tem “synchronizes belt tension with belt load, absorbs centrifugal tension and stretch, and sustains its maximum efficiency peak loads.” The pivoted motor base principle cannot applied universally all belting drives. Manifestly limited, first such drives employ motor the driving pulley end. Secondly, limited those motor drives which the weight the motor sufficient furnish the necessary working tension. fortunate that motor weights are proportioned speed and horsepower make the use the pivoted motor base prac- ticable. general reduction the weight electric motors per cent would put out commission most the successful pivoted motor drives now use, says Robert Tatnall, who has made extensive study the subject. This same investigator suggests three important points borne mind when designing and pivoted motor drives: Low belt speeds should avoided, proper specification motor speeds and pulley diameters, order get away from the necessity high tension ratios. short center distances and high ratios avoided, since small pulley contact angles produce low tension ratios. 3—Belts “high capacity” should used, since the belt tension de- manded the drive varies decidedly with the coefficient friction. Pivoted motor drives are, however, particularly suited for compressors, pumps, blowers, exhausters and equip- ment like load types, for many ma- chine tools, and for the driving in- dustrial head and line shafting. Cen- ters close twice the diameter the larger pulley are quite some cases even shorter center distances work successfully. Pulley dinarily, fixed center belting drives are not practical for ratios over 1); thus the use high speed motors, costing less than low speed motors and yielding higher efficiencies, made even more practical. (The next chapter this series will include discussion the problems application pivoted motor drives.) THE IRON AGE, July 28, 1938—33 pe he : le 1e le n “ Recent Advances sheet steel with accurate po- sitioning and warping the assembly are features new high production spot welding troduced the Roth Welding Engi- Avenue, Detroit. Federal Machine Co., Warren, Ohio, has been licensed manufacture similar equip- ment under Roth patents. With the Roth Ultraspeed welder, any number electrodes from several hundred are put sure simultaneously, but only one elec- transformer requirements low. Each electrode spring supported and un- derneath each row rows cop- per conductor resting table which raised hydraulically produce the pressure. The current distributing unit mounted behind the The secondary circuit established the roller through its track. Con- trol the primary circuit con- tact bar which has make-and-break action notched distributor bar. This design differs from the 34—THE IRON AGE, July 28, 1938 FRANK OLIVER Editor, The lron Age practice making the electrodes contact separately rapid succession. said avoid metal “pick-up,” and increase electrode life through the absence shock. Other advan- tages claimed for this type welder are: clean welds improved strength and uniformity and maintenance shape and position the work be- LEFT PEEDS five times faster than other spot welding methods are claimed for the Roth speed spot welder. The model shown one designed for weld- ing straight seam flat sheets. ABOVE Eisler No. 210-VN kva. spot welder with plunger action the upper electrode. Spot, and cause the individual electrodes act hold-down clamps. Power Driven Spot Welder ERIES spot welders made the Thomson-Gibb Electric been designed specifically for power drive. Pressure supplied cam driven worm reduction unit and acting the rocker arm into which the upper welding arm Pressure can regulated from about five point regulator. Control the current dwell magnetic con- tactor, limit switch and adjustable fan type cam operating conjunction with the pressure cam. Drive three-step V-belt pulleys, from 127 spots per min. can obtained. The frame made Tabricated steel base with cast iron head bolted BELOW series Thomson spot weider has designed for power operation the upper electrode. ° ° a : ‘ Gas Welding and Cutting Equipment it. Both arms are hard rolled cop- veloping the design, welding tip nose LEFT per, The lower new types spot forms, water hole depths and wall arm has in. welders have recently thickness were tested determine arm can been placed the market, the best proportions for maximum side. Throat also standardized spot weld- ciency. aresult, the nose the tip 12, in. may had ing tips and welding timers. sturdier and together with better uni- capacity Improvements have been formity the metal makes for longer 20, 30, 40, kva. made life. length has also been pro- arc welders give more welds Plunger Type Welders company give more welds with eretofore producer d.c. proper cooling. Selection round precision spot welding machines has brought out bottomed water hole provides stream- small parts, the Eisler Engineer- a.c. transformer type. line cooling, with corners trap ing Co., 754 South 13th Street, New- large number welding steam, and permits proper hole depth ark, has developed line rods for special purposes without decreasing wall thickness vertical type welding have been announced re- reducing the current carrying capacity which the upper electrode actuated cent weeks. Gas cutting the section the tip the bottom plunger action. These machines equipment running pop- the hole. especially adaptable where studs ular priced models light new tips may had Elkaloy and lugs are accurately welded weight for portability. and Mallory metal. Water-cooled holders have also been standardized. holes. standard single-phase trans- All types and sizes are available from former supplies the welding current. stock. Sizes range from kva., and six Standardized Welding Tip points heat control are obtained. NEW type spot-welding tip A.C. Are Welders can had foot, air power complete range standard NEW atomic-hydrogen are weld- operated models and either bench sizes has been introduced ing equipment, pedestal types. Mallory Co., Indianapolis. de- able for the fusion ABOVE ALLORY tips for spot welders, gun welders and hydromatics have been standardized after much cooperative research with the users re- sistance welding. ODEL No. 210-JMS, made Engi- neering Co., 754 South 13th Street, Newark, J., designed for welding the binder asbestos core gaskets. this overhead spot welding unit, both electrodes contact the top the work. Rais- ing lowering the electrodes provided handwheel. This particular machine rated kva. and intended for welding stainless steel gasket binders. RIGHT ESTINGHOUSE type ignitron spot welding timer mounts two sizes tubes. low duty cycles, the WL-652 tube will carry 1500 amp. 220 550 volts, whereas the will carry 2800 amp. 440 and 550 volts 4300 amp. 220 volts. The current rating reduced higher duty cycles. These timers are adjustable pass current for any exact number cycles from 15. For longer times, the SP-11-A adjustable THE IRON AGE, July 28, 1938—35 ; welder improved model made General Electric 35, and 150-amp. capacities. special alloys, like stainless steel, and thin sections any metal difficult impossible weld other methods, has been announced Elec- tric Co. The unit said produce uniformly strong weld, free from porosity and with smooth appearance. atomic-hydrogen are welding, a.c. arc maintained between two ad- justable tungsten electrodes, and hydrogen fed the are. The hydrogen molecules when subjected the intense heat the are are broken into atoms, the majority which recombine outside the arc zone, liberating heat far excess that obtainable from gas flame from electric alone. The re- maining atomic-hydrogen provides extremely active reducing atmosphere which effectively prevents oxidation the weld and protects and cools the tungsten electrodes, thereby minimiz- ing electrode consumption. suitable filler rod fed into the weld needed. The new G-E equipment combines into compact, portable unit, all the electric devices used with the process. Convenient terminals and pipe fittings allow ready connection the electrode holder, power supply, and hydrogen source. convenient handwheel the top the set controls continu- ously variable reactor which gives stepless current adjustment. am- meter indicates the amount current being used. The drip-proof enclosure 36—THE IRON AGE, July 28, 1938 protects the equipment and the opera- tor. Ventilation provided louv- ers the ends. Lifting eyes facili- bearing wheels can added make the unit even more easily portable. For hand welding, the familiar rod- type electrode holder together with supply tungsten electrodes. For automatic welding, equipment with either head can supplied, to- gether with the necessary control, TOUT handles and large casters make portable this 190-lb. USL transformer type electric a.c. arc welder 150-amp. rating. means for holding the work, and traveling mechanism. power-control unit that for hand welding applicable auto- matic installations. Owen-Dyneto Corp., Syracuse, Y., which has made welding units for years, now offering a.c. der the trade name, USL Protected Are Welder. The machine which can attached any standard power line, rated 150 amp., and has range 280 amp. output, with volts across the arc. Size rod used ranges from 1/16 in. steady are secured means reactor the secondary winding the transfomer that creates power influx when the phase cycle passes the zero