Part 6

In the bucket elevator, an endless belt or chain runs over terminal pulleys which are fixed at different levels, the distance from centre to centre of these pulleys beings known as the length of the elevator. The design and construction of the elevator will be varied to suit its purpose. Grain elevators are invariably cased in wooden or iron trunks, and the head and foot are also of wood or iron, iron trunks being particularly used in so-called fire-proof buildings. The trunk of the grain elevator (fig. 14) is almost always vertical whilst the band to which the buckets are attached may consist of leather, cotton, hemp, webbing or other suitable substances. When an elevator is intended for lifting heavy materials, such as coal, coke or cement, it is usually set at a slant (figs. 15 and 16), and the endless belt is replaced by one or two strands of endless chain which support the buckets and run over the terminal sprocket wheels. The buckets are attached to the links of the chains, and to prevent these heavy buckets and chains from sagging in their inclined position, rollers or more often short skidder bars are fixed to each bucket, sliding on well-oiled angle bars on each side of the elevator frame.

Both grain and mineral elevators are usually fitted with tightening gears to keep the belt or chain taut; these are generally placed at the lower or well end so as not to interfere with the position of the upper terminal, which is almost invariably the driven one. The tightening of the band at the bottom terminal in the elevator well necessarily alters the space between the terminal pulley and the bottom of the well. This is of little consequence in grain elevators, but for elevators intended to handle coal or any material of varying size the ordinary tightening gear is unsuitable. In such a case the best plan is to attach the elevator-well to the terminal in such a way as to go up or down with the sprocket wheel when the chain is loosened or tightened, while the foot bracket which supports the well and terminal spindle remains a fixture. In order to tighten elevator chains without interfering with either of the terminals, adjustable jockey pulleys at some suitable point may be used, and the desired effect can thus be attained by pressing against the chains and thereby taking up the slack without any interference with either the feed or delivery end.

Elevator buckets must be proportioned to the size and nature of the material they are intended to carry, and care must be taken to maintain a uniform feed. This may readily be effected by adjustable outlets and spouts for grain and the like, and by certain feeding devices for handling minerals of uneven size. For instance, an oscillating feed shoot making from 30 to 60 oscillations per minute can be installed in such a case, and adjusted to deposit at each backward and forward stroke the exact amount of material adapted to the capacity of the elevator. The speed of the shoot will naturally vary with the size of material to be fed. For small coal 60 oscillations would be about the correct speed; for large coal the speed might be reduced to 30 or less. Speaking generally, care should always be taken to prevent an undue rush of feed, that is, more than the elevator can take up, and if tenacious materials are handled, feeding devices should be employed provided with stirrers or agitators that will effectually keep the material moving and prevent any larger lumps from arching over the feed spout, and thus producing chokes. Elevators should always be fed from that side on which the buckets ascend, that the stream of material may meet the elevator buckets on their upward journey. This will prevent the material from filling up the elevator well and spare the buckets from dredging through an accumulation of feed. Elevators erected at an incline are best fed at a point several feet above the well into the chain of ascending buckets, as under such conditions little will miss the buckets and drop into the well.

The reason why grain elevators are set vertically, whereas elevators intended to carry heavy bodies such as coal and ore are generally inclined at an angle, is that the former can be run at a much greater velocity than the latter. Grain, for instance, would be uninjured by a velocity at the delivery end which would fracture coal and seriously reduce its value, to say nothing of the dust production and the damage which would be done to the receiving spouts and shoots. Elevators carrying a light material can be run at a circumferential velocity of 250 to 350 ft. per minute, and if vertically set, will throw the grain, &c., clear of the elevator into the shoot for its reception. On the other hand, elevators handling heavy material must be set at an angle in order to give a clear delivery at a much lower speed of 50 to 60 ft. per minute; in other words, the elevator is so inclined that the shoot for the reception of the material can be put underneath the delivering buckets which slowly disgorge their load. To obtain good results, without taking up too much space, an elevator carrying heavy material should be set at 40° to 60° to the horizontal. The same results can be obtained if the main portion of the elevator is vertical and only the upper portion inclined, or so curved as to bring the delivery over the shoot. The speed at which vertical elevators should be run will depend on the diameter of the terminal pulley, that is, the pulley over which the buckets and bands pass. The centrifugal force of pulleys revolving at the same speed is in direct proportion to their diameters, and this is twice as much in a 2 ft. as in a 1 ft. pulley. It may be taken that the centrifugal force of a pulley will increase in proportion to the square of its velocity; hence the centrifugal force of a pulley 2 ft. in diameter running at 50 revolutions per minute will be four times the centrifugal force of a pulley of the same diameter making only 25 revolutions per minute. It must not be forgotten that to effect a clean discharge of the buckets of a vertical elevator, the centrifugal force must be sufficient to overcome the gravity of the material, because the material thrown off the delivery pulley in a horizontal direction will be more rapidly deflected into a parabolic curve the higher its specific gravity. It follows that for a specifically heavy material a greater centrifugal force will be required; that is to say, the elevator will have to be higher speeded than in dealing with a lighter material.

Elevator buckets must be varied according to the nature of the material; for instance, shallow buckets will be found best for a soft and clinging material such as flour, moist sugar, sand, small coal, &c., while for a hard or semi-hard body such as wheat, coal, &c., deeper buckets are preferable. On account of their lower speed, elevators for specifically heavy material require much larger buckets and chains than grain elevators of the same bulk capacity. The most economical form of elevator is fitted with a continuous chain of buckets. Such elevators may be constructed to carry either grain or minerals. The advantages are greater capacity than an ordinary elevator of the same dimensions and a more uniform delivery; moreover, smoother running is secured, since the buckets being close together need not plunge intermittently through the contents of the elevator-well.

_Intermittent Conveyors._--The elevators we have been considering, whether used for carrying and distributing coal or grain, have this in common, that they raise material from a lower to a higher level, so to speak, in a continuous stream, the continuity being broken only by the short spaces between the buckets. In the continuous bucket type indeed the stream of material is practically, if not absolutely, continuous. In all these cases the elevator is fed with the material in a continuous stream, and by some mechanical means; whether by band, worm or shoot, is immaterial. Elevators of a somewhat different and more substantial construction may be and are often used for handling filled sacks, barrels, carcases of animals and other bulky objects, which cannot be delivered in a uniform stream, but may have to be conveyed by the elevator intermittently. The ordinary buckets used for grain or coal are replaced by other appliances for gripping and holding the object to be raised from a lower to a higher level, but in principle these appliances are essentially elevators.

Another kind of elevator, known as a _lift_ or _hoist_, is used in mines and quarries and in serving blast furnaces. This is an elevator with one or two buckets. Essentially a heavy load lifter, it is intended for material of too large a bulk to be handled economically by ordinary elevators, and is employed for lifting in either a vertical or, more often, an inclined direction.

For elevating materials, such as large coal, iron ore, limestone, &c., which are too large to be fed into ordinary elevators, and must therefore be handled intermittently, the single bucket elevator or hoist may be used with advantage. But as the essential use of mechanical appliances for handling material is to save human labour as far as possible, that hoist will prove the most economical the operation of which is as automatic as possible. The Americans seem to have been pioneers in the construction of _furnace hoists_, which form the principal elevators of this class, but some excellent examples of the modern furnace hoist are now to be found in Great Britain and elsewhere in Europe. Generally speaking, a furnace hoist consists of an inclined iron bridge girder set at an angle to the upright shaft of the furnace. On this incline are laid rails for the ascent and descent of the bucket, which in this case is known as a skip and is provided with suitable wheels, while the hoisting gear manipulating the skips by a steel rope is erected on or near the ground level. The rails when they approach the upper terminus are usually bent in a more or less horizontal position so as automatically to tilt and thereby unload the skip. To attain the same end, the rails supporting the back wheels of the skips may be bent at the terminus, or the back wheels may have additional wheels of a larger diameter on the other side of their flanges, so that during the ascent and descent the skip runs on its four normal wheels, while at the upper terminus the outer and larger back wheels engage with short lengths of extra rails and thus tilt and effect the automatic clearance of the skip. The dead weight of the skip may be balanced by a counter weight, or double tracks may be laid, so that the empty skip descends on one track whilst the loaded skip is being raised on the other. In this case the distributing hopper at the top of the furnace has an elongated shape so as to take the charges alternately from buckets on either track. Again, the two tracks may be laid one above the other, so that one skip runs on the upper rails and the other on the lower. The two buckets will pass each other at about the centre of the framing, where there will be plenty of room for clearance.

The capacity of the skip will of course depend to some extent on the capacity of the furnace, but an average charge may be put down at 2 tons of ore and lime, or 1 ton of coke. To raise such a charge to a furnace 80 ft. high would require, assuming no counter weight were used, a motor of about 100 h.p. On account of the great speed at which the hoist works, the time taken in raising the charged skip, discharging it, and returning it empty would be only 30 to 40 seconds. The hoist cable runs over guide pulleys placed at the top of the furnace, and the cable is often manipulated by an electrically driven winch in a cabin below. The descent of the empty skip in more modern installations is utilized to effect an even distribution of the feed from the hopper to the furnace by causing the hopper to revolve. To this end the latter is provided with an ingenious mechanism which only comes into operation as the car descends. After every charge shot into the hopper the latter is revolved a few degrees, and this has the effect of giving the delivery of the next load in another direction, so that the charges of the skip are in turn distributed over the whole area of the surface. This is deemed a most essential point in furnace-charging, and it is not one of the least recommendations of this mechanical system of furnace-charging that it can give an even feed without any hand labour whatever. A double hoist has been designed which has the advantage that if one elevator breaks down the work of the furnace is not interrupted. In this system two furnaces are connected at the top by a gantry or bridge, against which, between the furnaces, two inclined elevators are set, so that each can serve either furnace. The skips are on wheels and detachable from the elevator, and are loaded from the ore pockets at the lower terminal and drawn up on a cradle; as this reaches the top where the rails on the gantry correspond with the gauge of the skip or car, the latter is carried by its own weight down a slight incline to either furnace, discharging its contents as it passes over the conical mouth. Another advantage claimed for this system is that the rails of the cradle, when in its lowest position, correspond with the rails which lie parallel to the furnaces and run right under the store bins from which the skip is loaded. The economy to be realized from a furnace hoist will be in direct proportion to the use made of mechanical means of feed conveyance. For instance, the store bins in connexion with such elevators might be economically fed by suitable conveyors, or the material might be brought in self-unloading hoppered trucks into conveniently placed bins, ready to be drawn into the skips.

_Ropeways._--A ropeway has been defined as that method of handling material which consists of drawing buckets on ropes, and by means of ropes, such buckets being filled with the material to be handled and being automatically or otherwise discharged. At what period of history ropeways were first used it is impossible to say, but the fact that pulley blocks, and even wire ropes, were known to the ancients, renders a pedigree of 2000 years at least possible. In more modern days, an old engraving shows a single ropeway in working order in 1644 in the city of Danzig. This, the work of Adam Wybe, a Dutch engineer, was a single ropeway in its simplest form, consisting of an endless rope passing over pulleys suspended on posts; to the rope were attached a number of small buckets, which evidently carried earth from a hill outside the city to the rampart inside the moat. The rope was probably of hemp. Modern ropeways worked with wire ropes date from about 1860, when a ropeway was erected in the Harz Mountains. Since then several systems have been evolved, but in the main ropeways may be divided into the single and double rope class.

The ropeway is essentially an intermittent conveyor, the material being carried in buckets or skips, and practice has proved it an economical means of handling heavy material. The prime cost of a ropeway is usually moderate, though of course it varies with the ground and other local conditions. Working expenses should be low, because under the supervision of one competent engineer unskilled labour is quite sufficient. A ropeway may be carried over ground over which rails could only be laid at enormous cost. To a certain extent ropeways are independent of weather conditions, because their working need not be interrupted even by heavy snowfalls. Their construction is very simple, and there is little gear to get out of order. Sound workmanship and good material will ensure a relatively long life. As an instance, a certain rope in a Spanish ropeway tested new to a breaking strain of 29½ tons was shown after carrying 160,000 tons (in two years' incessant work) still to possess a breaking strain of 27½ tons. The power absorbed by a ropeway is relatively moderate, and under special conditions may be nil. The only demand it makes on the superficial area of the ground traversed is the small emplacements of the standards, which in modern ropeways are few and far between. Wayleaves, or the permission to erect standards and run the line over private land, may of course mean an item in the capital outlay. This circumstance may have checked ropeway construction in Great Britain, but it must also be borne in mind that a large portion of that country is comparatively level and well provided with railways. In building a ropeway it is essential to take as straight a line as possible, because curves generally necessitate angle stations, which mean extra capital and working cost. On the other hand, ground that would be difficult for the railway engineer, such as steep hills, deep valleys and turbulent streams, has no terror for the ropeway erector. There is a case of a ropeway of a total length of 5400 ft. with a total difference in altitude of 2000 ft.; it is claimed this ground could not be covered by a railway with less than 15 m. of line graded at 1 in 40.

Perhaps the simplest type of a single rope system is an endless running rope from which the carriers are suspended, and with which they move by frictional contact. Or the carriers may be fixed to this rope and move with it. The ropeway itself would consist of an endless rope running between two drums, one, known as the driving drum, being provided with power receiving and transmitting gear, while the drum at the opposite terminal would be fitted with tightening gear. The endless rope is carried on suitable pulleys which themselves are supported on standards or trestles spaced at intervals varying with the nature of the ground. The rope runs at an average speed of 4 m. per hour, a speed at which the bucket or skip can automatically unload itself. In the double ropeway the carrier runs on a fixed rope, which takes the place of the rails of a railway. The carrier is fitted with running heads furnished with grooved steel wheels. The load is borne by a hanger pivoted from the carrier, and is conveyed along the rail rope by an endless hauling rope at an average speed of 4 to 6 m. per hour. The hauling is operated by driving gear at one end, and controlled by tightening gear at the other end just as in the single rope system. Double ropeways have been carried in one section over 18 to 20 m., and will transport single loads of 6 cwt. to a ton or more.

Broadly speaking, the single ropeway is not so suitable for heavy loads and long distances as the double, but in this connexion the work of Ropeways Limited should be noted, which favours a single rope system. Their engineer, J. Pearce Roe, introduced multiple sheaves for supporting the rope at each standard. Thus the rope may pass over one, two or four sheaves, which are provided with balance beams that have the advantage of adjusting themselves to the angle caused by the rope passing over the sheaves, thus equalizing the pressure over a number of sheaves. A ropeway erected on this system in Japan spans 4000 yds. of very broken ground; yet only 17 trestles are used, and as each support is placed as high as possible, no one is of great height. An altitude of 1130 ft. is reached in a distance of 1200 yds. The ropeway has a daily carrying capacity of 60 tons in one direction and of 30 tons in the other. Another installation on this system, which serves an iron mine in Spain, spans 6500 yds. of very rough country, so steep that in many places the sure-footed mule cannot keep on the track. This ropeway can deal with 85 tons per hour. The greatest distance covered by this system, on one section, is 7100 yds., or about 4 m., and the carrying capacity is 45 tons per hour.

The motive power required for a ropeway will vary with the conditions. In cases of descending loads the power generated is sometimes so considerable as to render it available for driving other machinery, or it may have to be absorbed by some special brake device. In a ropeway in Japan of 1800 yds., which runs mostly at an incline of 1 in 1½, the force generated is absorbed by a hydraulic brake the revolving fan of which drives the water against fixed vanes which repel and heat it. In this way, 50 h.p. is absorbed and the speed brought under the control of a hand brake.

_Aerial Cableways._--The aerial cableway is a development of the ropeway, and is a conveyor capable of hoisting and dumping at any desired point. The load is carried along a trackway consisting of a single span of suspended cable, which covers a comparatively short distance. The trackway may either run in a more or less horizontal direction, i.e. the terminals may be on the same level, or it may be inclined at such an angle that the load will descend by gravity. The trackway or rail rope rests upon saddles of iron or hard wood on the tops of terminal supports, usually known as towers. These towers may be constructed either of wood or iron, and if the exigencies of the work render it desirable, they may be mounted on trolleys and rails, in which case the cableway is rendered portable, and can be moved about, sometimes a great advantage in excavating work. The motive power may be either steam, gas, or electricity. The motor is situated in what is termed the head tower, which is sometimes a little higher than the other or tail tower. Sometimes, but not frequently, the latter is also fitted with a motor. The span between the two towers sometimes extends to 2000 ft., but this is exceptional. Very heavy loads are dealt with, sometimes as much as 8 tons in a single load. The load, which may be carried in a skip or a tray, is borne by an apparatus called the carrier, which is a modification of a running head, consisting of pulleys and blocks and running along the main cable or trackway. The carrier is also fitted with pulleys or guides for the dump line. The carrier is drawn along the main cable by an endless or hauling rope which passes from the carrier over the head tower and is wound several times round the drum of the winding engine to secure frictional hold, then back over the head tower, to the tail tower, returning to the rear end of the carrier. The hoisting rope passes from the engine to the fall block for raising the load. The dump line comes from the other side of the winding engine drum and passes to a smaller block attached to the rear end of the skip or tray. The whole weight of the skip is borne by the hoisting rope, while the dump line comes in slack, but at the same rate of speed. Whenever it is desired to dump the load, the dump line is shifted to a section of the drum having a slightly larger diameter, and being thus drawn in at a higher rate of speed the load is discharged. The engine is then reversed, and the carriage brought back for the next load.

This is in outline the mode of operating all cableways. This appliance has rendered great service as a labour saver in navvying, quarrying and mining work; in placer-mining, for instance, cableways have been found very useful when fitted with a self-filling drag bucket, which will take the place of a great number of hands. Cableways can be worked at a great speed, but a good mean speed would be 500 to 750 ft. for conveying and 200 to 300 ft. for hoisting. A cableway used in excavating work in Chicago was credited with a capacity of 400 to 600 cub. yds. per day at a total cost of 2d. per yard, including labour, coal, oil, waste, &c.