The next chassis is brought in and placed with its front axle opposite the first one. In this way the chassis alternate until the car is full. The space in the center of the car contains the fenders, and other removable parts of the equipment.
Just beyond the loading docks is the foundry.
The foundry is one of the most interesting divisions of the entire plant, and ranks, perhaps, as one of the most unique in the country, as far as practice and equipment are concerned. As a general rule, foundry practice has not shown the changes in an increase of production that machine departments have, but in this foundry, due to standardization of parts and specialization on the one car, it has been possible to devise and install the unique equipment now used, which brings this department down to the plane of expense and up in the labor-saving efficiency prevailing throughout the entire plant.
Craneway, Showing Loading Platforms
This department works twenty-four hours a day, in three shifts of eight hours each; iron is being melted and poured continuously during the day and first night shifts. An average of over 400 tons of iron is poured daily, and 426 tons of gray iron have been poured in a single day. This tonnage is especially interesting, as it is produced on a floor space of only 36,324 square feet.
Continuous Core-Oven
All this iron is poured on overhead power-driven mold carriers, which travel about twelve feet per minute. These mold carriers have suspended from them pendulum-like arms, on the lower end of which is a shelf. The molders who make the molds for the castings are stationed alongside of these conveyors; the molding sand with which they fill the flasks is stored overhead in a hopper, the gate of which discharges directly onto the molding machine. There are two molders for each part, one making the “drag,” or lower part of the mold, the other making the “cope,” or the upper half. When these two halves of the mold are finished they are put together, or “closed” on the shelf of the conveyor, which carries the finished mold to the man who pours the molten metal. The molten metal is brought to this man’s station by means of large ladles, suspended on a trolley on an I-beam track, running from the cupola through the entire length of the foundry. This does away with the necessity of carrying the ladle of iron a long distance, thus saving much time and lessening the liability to accidents.