The Economy of Workshop Manipulation / A logical method of learning constructive mechanics. Arranged with questions for the use of apprentice engineers and students.

by John Richards

The safety, simplicity, and reliable action of hydraulic machinery has already led to its extensive employment for moving and lifting weights, and it is fair to assume that the importance and success of this invention fully entitle it to be classed as one of the most important that has been made in mechanical engineering during fifty years past. The application of hydraulic force in operating the machinery used in the processes for steel Bessemer manufacture, is one of the best examples to illustrate the advantages and principles of the hydraulic system. Published drawings and descriptions of Bessemer steel plant explain this hydraulic machinery.

There is, however, a principle in hydraulic machinery that must be taken into account, in comparing it with positively geared mechanism, which often leads to loss of power that in many cases will overbalance any gain derived from the peculiar action of hydraulic apparatus. I allude to the loss of power incident to dealing with an inelastic medium, where the amount of force expended is constant, regardless of the resistance offered. A hydraulic crane, for instance, consumes power in proportion to its movements, and not as the amount of duty performed; it takes the same quantity of water to fill the cylinders of such cranes, whether the water exert much or little force in moving the pistons. The difference between employing elastic mediums like air and steam, and an inelastic medium like water, for transmitting force in performing irregular duty, has been already alluded to, and forms a very interesting study for a student in mechanics, leading, as it does, to the solution of many problems concerning the use and effect of power.

The steam cranes of Mr Morrison, which resemble hydraulic cranes, except that steam instead of water is employed as a medium for transmitting force, combine all the advantages of hydraulic apparatus, except positive movement, and evade the loss of power that occurs in the use of water. The elasticity of the steam is found in practice to offer no obstacle to steady and accurate movement of a load, provided the mechanism is well constructed, while the loss of heat by radiation is but trifling.

To return to shop processes in manufacturing. Material operated upon has to be often, sometimes continually, moved from one place to another to receive successive operations, and this movement may be either vertically or horizontally as determined, first, by the relative facility with which the material may be raised vertically, or moved horizontally, and secondly, by the value of the ground and the amount of room that may be available, and thirdly by local conditions of arrangement. In large cities, where a great share of manufacturing is carried on, the value of ground is so great that its cost becomes a valid reason for constructing high buildings of several storeys, and moving material vertically by hoists, thus gaining surface by floors, instead of spreading the work over the ground; nor is there any disadvantage in high buildings for most kinds of manufacture, including machine fitting even, a proposition that will hardly be accepted in Europe, where fitting operations, except for small pieces, are rarely performed on upper floors.

Vertical handling, although it consumes more power, as a rule costs less, is more convenient, and requires less room than horizontal handling, which is sure to interfere more or less with the constructive operations of a workshop. In machine fitting there is generally a wrong estimate placed upon the value of ground floors, which are no doubt indispensable for the heaviest class of work, and for the heaviest tools; but with an ordinary class of work, where the pieces do not exceed two tons in weight, upper floors if strong are quite as convenient, if there is proper machinery for handling material; in fact, the records of any establishment, where cost accounts are carefully made up, will show that the expense of fitting on upper floors is less than on ground floors. This is to be accounted for by better light, and a removal of the fitting from the influences and interference of other operations that must necessarily be carried on upon ground floors.

For loading and unloading carts and waggons, the convenience of the old outside sling is well known; it is also a well-attested fact that accidents rarely happen with sling hoists, although they appear to be less safe than running platforms or lifts. As a general rule, the most dangerous machinery for handling or raising material is that which pretends to dispense with the care and vigilance of attendants, and the safest machinery that which enforces such attention. The condition which leads to danger in hoisting machinery is, that the power employed is opposed to the force of gravity, and as the force of gravity is acting continually, it is always ready to take advantage of the least cessation in the opposing force employed, and thus drag away the weight for which the two forces are contending; as a weight when under the influence of gravity is moved at an accelerated velocity, if gravity becomes the master, the result is generally a serious accident. Lifting may be considered a case wherein the contrivances of man are brought to bear in overcoming or opposing a natural force; the imperfect force of the machinery is liable to accident or interruption, but gravity never fails to act. Acting on every piece of matter in proportion to its weight must be some force opposing and equal to that of gravity; for example, a piece of iron lying on a bench is opposed by the bench and held in resistance to gravity, and to move this piece of iron we have to substitute some opposing force, like that of the hands or lifting mechanism, to overcome gravity.

As molecular adhesion keeps the particles of matter together so as to form solids, so the force of gravity keeps objects in their place; and to attain a proper conception of forces, especially in handling and moving material, it is necessary to familiarise the mind with this thought.

The force of gravity acts only in one direction—vertically, so that the main force of hoisting and handling machinery which opposes gravity must also act vertically, while the horizontal movement of objects may be accomplished by simply overcoming the friction between them and the surfaces on which they move. This is seen in practice. A force of a hundred pounds may move a loaded truck, which it would require tons to lift; hence the horizontal movements of material may be easily accomplished by hand with the aid of trucks and rollers, so long as it is moved on level planes; but if a weight has to be raised even a single inch by reason of irregularity in floors, the difference between overcoming frictional contact and opposing gravity is at once apparent.

One of the problems connected with the handling of material is to determine where hand-power should stop and motive-power begin—what conditions will justify the erection of cranes, hoists, or tramways, and what conditions will not. Frequent mistakes are made in the application of power when it is not required, especially for handling material; the too common tendency of the present day being to apply power to every purpose where it is possible, without estimating the actual saving that, may be effected. A common impression is that motive power, wherever applied to supplant hand labour in handling material, produces a gain; but in many cases the fallacy of this will be apparent, when all the conditions are taken into account.