Thecurseofthisworkandofallthatsucceededitforascoreofyearswasthenecessityofdependinguponchemicalbatteriesforcurrent,themachineusuallybeingself-containedandhaulingthebatteriesalongwithitself,asinthecaseofthefamousPageexperimentsinApril,1851,whenaspeedofnineteenmilesanhourwasattainedonthelineoftheWashington&Baltimoreroad。Tothisunfruitfulperiodbelonged,however,thecrudeideaoftakingthecurrentfromastationarysourceofpowerbymeansofanoverheadcontact,whichhasfounditspracticalevolutioninthemodernubiquitoustrolley;
althoughthepatentforthis,basedonhiscaveatof1879,wasgrantedseveralyearslaterthanthattoStephenD。Field,forthecombinationofanelectricmotoroperatedbymeansofacurrentfromastationarydynamoorsourceofelectricityconductedthroughtherails。Asamatteroffact,in1856andagainin1875,GeorgeF。Green,ajobbingmachinist,ofKalamazoo,Michigan,builtsmallcarsandtrackstowhichcurrentwasfedfromadistantbattery,enoughenergybeingutilizedtohaulonehundredpoundsoffreightoronepassengerupanddowna“road“twohundredfeetlong。Alltheworkpriortothedevelopmentofthedynamoasasourceofcurrentwassporadicandspasmodic,andcannotbesaidtohaveleftanytraceontheart,thoughitofferedmanysuggestionsastooperativemethods。
Thecloseofthesamedecadeofthenineteenthcenturythatsawtheelectriclightbroughttoperfection,sawalsotherealizationinpracticeofallthehopesoffiftyyearsastoelectrictraction。Bothutilizationsdependeduponthesupplyofcurrentnowcheaplyobtainablefromthedynamo。Theseartswereindeedtwins,feedingatinexhaustiblebreasts。
In1879,attheBerlinExhibition,thedistinguishedfirmofSiemens,towhoseingenuityandenterpriseelectricaldevelopmentowessomuch,installedaroadaboutone-thirdofamileinlength,overwhichthelocomotivehauledatrainofthreesmallcarsataspeedofabouteightmilesanhour,carryingsometwentypersonseverytrip。Currentwasfedfromadynamotothemotorthroughacentralthirdrail,thetwoouterrailsbeingjoinedtogetherasthenegativeorreturncircuit。Primitivebutessentiallysuccessful,thislittleroadmadeaprofoundimpressiononthemindsofmanyinventorsandengineers,andmarkedtherealbeginningofthegreatnewera,whichhasalreadyseenelectricityappliedtotheoperationofmainlinesoftrunkrailways。Butitisnottobesupposedthatonthepartofthepublictherewasanygreatamountoffaiththendiscernible;andforsomeyearsthepioneershadgreatdifficulty,especiallyinthiscountry,inraisingmoneyfortheirearlymodestexperiments。OfthegeneralconditionsatthismomentFrankJ。SpraguesaysinanarticleintheCenturyMagazineofJuly,1905,onthecreationofthenewart:“Edisonwasperhapsnearerthevergeofgreatelectric-railwaypossibilitiesthananyotherAmerican。Inthefaceofmuchadversecriticismhehaddevelopedtheessentialsofthelow-internal-
resistancedynamowithhigh-resistancefield,andmanyoftheessentialfeaturesofmultiple-arcdistribution,andin1880hebuiltasmallroadathislaboratoryatMenloPark。“
OnMay13thoftheyearnamedthisinterestingroadwentintooperationastheresultofhardandhurriedworkofpreparationduringthespringmonths。
Thefirsttrackwasaboutathirdofamileinlength,startingfromtheshops,followingacountryroad,passingaroundahillattherearandcurvinghome,inthegeneralformoftheletter“U。“Therailswereverylight。CharlesT。Hughes,whowentwithEdisonin1879,andwasinchargeofmuchofthework,statesthattheywere“second“street-carrails,insulatedwithtarcanvaspaperandthingsofthatsort——
“asphalt。“Theywerespikeddownonordinarysleeperslaiduponthenaturalgrade,andthegaugewasaboutthreefeetsixinches。Atonepointthegradedroppedsomesixtyfeetinadistanceofthreehundred,andthecurveswereofrecklesslyshortradius。Thedynamossupplyingcurrenttotheroadwereoriginallytwoofthestandardsize“Z“machinesthenbeingmadeatthelaboratory,popularlyknownthroughouttheEdisonranksas“LongwaistedMaryAnns,“andthecircuitsfromthesewerecarriedouttotherailsbyundergroundconductors。Theywerenotlarge——abouttwelvehorse-powereach——generatingseventy-fiveamperesofcurrentatonehundredandtenvolts,sothatnotquitetwenty-fivehorse-powerofelectricalenergywasavailableforpropulsion。
Thelocomotivebuiltwhiletheroadbedwasgettingreadywasafour-wheeledirontruck,anordinaryflatdump-caraboutsixfeetlongandfourfeetwide,uponwhichwasmounteda“Z“dynamousedasamotor,sothatithadacapacityofabouttwelvehorsepower。Thismachinewaslaidonitsside,withthearmatureendcomingoutatthefrontofthelocomotive,andthemotivepowerwasappliedtothedriving-axlebyacumbersomeseriesoffrictionpulleys。
Eachwheelofthelocomotivehadametalrimandacentrewebofwoodorpapier-mache,andthecurrentpickedupbyonesetofwheelswascarriedthroughcontactbrushesandabrasshubtothemotor;thecircuitbacktothetrack,orotherrail,beingclosedthroughtheotherwheelsinasimilarmanner。Themotorhaditsfield-magnetcircuitinpermanentconnectionasashuntacrosstherails,protectedbyacrudebarecopper-wiresafety-catch。
Aswitchinthearmaturecircuitenabledthemotormantoreversethedirectionoftravelbyreversingthecurrentflowthroughthearmaturecoils。
ThingswentfairlywellforatimeonthatmemorableThursdayafternoon,whenallthelaboratoryforcemadehighholidayandscrambledforfootholdonthelocomotiveforatrip;butthefrictiongearingwasnotequaltothesuddenstrainputuponitduringonerunandwenttopieces。Someyearslater,also,DaftagaintriedfrictiongearinhishistoricalexperimentsontheManhattanElevatedroad,buttheresultswereattendedwithnogreatersuccess。ThenextresortofEdisonwastobelts,thearmatureshaftingbeltedtoacountershaftonthelocomotiveframe,andthecountershaftbeltedtoapulleyonthecar-
axle。Theleverwhichthrewtheformerfrictiongearintoadjustmentwasmadetooperateanidlerpulleyfortighteningtheaxle-belt。Whenthemotorwasstarted,thearmaturewasbroughtuptofullrevolutionandthenthebeltwastightenedonthecar-
axle,compellingmotionofthelocomotive。Butthebeltswereliabletoslipagreatdealintheprocess,andthechafingofthebeltscharredthembadly。Ifthatdidnothappen,andifthebeltwasmadetautsuddenly,thearmatureburnedout——whichitdidwithdisconcertingfrequency。Thenextstepwastouseanumberofresistance-boxesinserieswiththearmature,sothatthelocomotivecouldstartwiththoseincircuit,andthenthemotormancouldbringituptospeedgraduallybycuttingoneboxoutaftertheother。Tostopthelocomotive,thearmaturecircuitwasopenedbythemainswitch,stoppingtheflowofcurrent,andthenbrakeswereappliedbylonglevers。
Mattersgenerallyandthemotorsinparticularwentmuchbetter,evenifthelocomotivewassofreelyfestoonedwithresistance-boxesallofperceptibleweightandoccupyingmuchofthelimitedspace。
Thesedetailsshowforciblyandtypicallythepainfulstepsofadvancethateveryinventorinthisnewfieldhadtomakeintheefforttoreachnotalonecommercialpracticability,butmechanicalfeasibility。
Itwasallempiricalenough;butthatwastheonlywayopeneventothehighesttalent。
Smugglerslandinglacesandsilkshavebeenknowntowindthemaroundtheirbodies,asbeinglessostentatiousthancarryingtheminatrunk。Edisonthoughthisresistance-boxesanequallysuperfluousdisplay,andthereforeingeniouslywoundsomecopperresistancewirearoundoneofthelegsofthemotorfieldmagnet,whereitwasoutoftheway,servedasausefulextrafieldcoilinstartingupthemotor,anddismissedmostoftheboxesbacktothelaboratory;
afewbeingretainedundertheseatforchanceemergencies。
Liketheboxes,thiscoilwasinserieswiththearmature,andsubjecttoplugginginandoutatwillbythemotorman。Thusequipped,thelocomotivewasfoundquitesatisfactory,andlongdidyeomanservice。Itwasgiventhreecarstopull,oneanopenawning-carwithtwoparkbenchesplacedbacktoback;oneaflatfreight-car,andonebox-cardubbedthe“Pullman,“withwhichEdisonillustratedasystemofelectricbraking。Althoughworkhadbeenbegunsoearlyintheyear,andtheroadhadbeenoperatingsinceMay,itwasnotuntilJulythatEdisonexecutedanyapplicationforpatentsonhis“electromagneticrailwayengine,“orhisingeniousbrakingsystem。Everyinventorknowshowlargelyhisfateliesinthehandsofacompetentandalertpatentattorney,inboththepreparationandtheprosecutionofhiscase;andMr。SpragueisjustifiedinobservinginhisCenturyarticle:““Thepaucityofcontrollingclaimsobtainedintheseearlypatentsisremarkable。“
ItisnotoriousthatEdisondidnotthenenjoytheskilfulaidinsafeguardinghisideasthathecommandedlater。
Thedailynewspapersandtechnicaljournalslostnotimeinbringingtheroadtopublicattention,andtheNewYorkHeraldofJune25thwasswifttosuggestthatherewasthelocomotivethatwouldbe“mostpleasingtotheaverageNewYorker,whoseheadhasachedwithnoise,whoseeyeshavebeenfilledwithdust,orwhoseclotheshavebeenruinedwithoil。“Acoupleofdayslater,theDailyGraphicillustratedanddescribedtheroadandpublishedasketchofaone-hundred-horse-powerelectriclocomotivefortheuseofthePennsylvaniaRailroadbetweenPerthAmboyandRahway。Visitors,ofcourse,werenumerous,includingmanycurious,scepticalrailroadmanagers,fewifanyofwhomexceptVillardcouldseetheslightestuseforthenewmotivepower。Thereis,perhaps,someexcuseforsuchindifference。Nomenintheworldhavemorenewinventionsbroughttothemthanrailroadmanagers,andthiswastherankestkindofnovelty。Itwasnot,indeed,untilayearlater,inMay,1881,thatthefirstregularroadcollectingfareswasputinoperation——alittlestretchofoneandahalfmilesfromBerlintoLichterfelde,withoneminiaturemotorcar。
Edisonwasinrealitydoingsomeheavyelectric-
railwayengineering,hisapparatusfullofideas,suggestions,prophecies;buttotheoperatorsoflongtrunklinesitmusthaveseemedutterlyinsignificantand“excellentfooling。“
Speakingofthissituation,Mr。Edisonsays:“OnedayFrankThomson,thePresidentofthePennsylvaniaRailroad,cameouttoseetheelectriclightandtheelectricrailwayinoperation。Thelatterwasthenaboutamilelong。Herodeonit。AtthattimeI
wasgettingoutplanstomakeanelectriclocomotiveofthreehundredhorse-powerwithsix-footdrivers,withtheideaofshowingpeoplethattheycoulddispensewiththeirsteamlocomotives。Mr。Thomsonmadetheobjectionthatitwasimpracticable,andthatitwouldbeimpossibletosupplantsteam。Hisgreatexperienceandstandingthrewawetblanketonmyhopes。ButIthoughthemightperhapsbemistaken,astherehadbeenmanysuchinstancesonrecord。Icontinuedtoworkontheplans,andaboutthreeyearslaterIstartedtobuildthelocomotiveattheworksatGoerckStreet,andhaditaboutfinishedwhenIwasswitchedoffonsomeotherwork。
OneofthereasonswhyIfelttheelectricrailwaytobeeminentlypracticalwasthatHenryVillard,thePresidentoftheNorthernPacific,saidthatoneofthegreatestthingsthatcouldbedonewouldbetobuildright-anglefeedersintothewheat-fieldsofDakotaandbringinthewheattothemainlines,asthefarmersthenhadtodrawitfromfortytoeightymiles。Therewasapointwhereitwouldnotpaytoraiseitatall;andlargeareasofthecountrywerethusofnovalue。Iconceivedtheideaofbuildingaverylightrailroadofnarrowgauge,andhadgotallthedataastothewindsontheplains,andfoundthatitwouldbepossiblewithverylargewindmillstosupplyenoughpowertodrivethosewheattrains。“
AmongotherswhovisitedthelittleroadatthisjuncturewerepersonsinterestedintheManhattanElevatedsystemofNewYork,onwhichexperimentswererepeatedlytriedlater,butwhichwasnotdestinedtoadoptamethodsoobviouslywellsuitedtoalltheconditionsuntilaftermanysuccessfuldemonstrationshadbeenmadeonelevatedroadselsewhere。
ItmustbeadmittedthatMr。Edisonwasnotveryprofoundlyimpressedwiththedesireentertainedinthatquartertoutilizeanyimprovement,forheremarks:“WhentheElevatedRailroadinNewYork,upSixthAvenue,wasstartedtherewasagreatclamoraboutthenoise,andinjunctionswerethreatened。
Themanagementengagedmetomakeareportonthecauseofthenoise。Iconstructedaninstrumentthatwouldrecordthesound,andsetouttomakeapreliminaryreport,butIfoundthattheyneverintendedtodoanythingbutletthepeoplecomplain。“
Itwasupontheco-operationofVillardthatEdisonfellback,andanagreementwasenteredintobetweenthemonSeptember14,1881,whichprovidedthatthelatterwould“buildtwoandahalfmilesofelectricrailwayatMenloPark,equippedwiththreecars,twolocomotives,oneforfreight,andoneforpassengers,capacityoflattersixtymilesanhour。
Capacityfreightengine,tentonsnetfreight;costofhandlingatonoffreightpermileperhorse-powertobelessthanordinarylocomotive……Ifexperimentsaresuccessful,Villardtopayactualoutlayinexperiments,andtotreatwiththeLightCompanyfortheinstallationofatleastfiftymilesofelectricrailroadinthewheatregions。“Mr。EdisonisauthorityforthestatementthatMr。Villardadvancedbetween$35,000and$40,000,andthattheworkdonewasverysatisfactory;butitdidnotendatthattimeinanypracticalresults,astheNorthernPacificwentintothehandsofareceiver,andMr。Villard'sabilitytohelpwashopelesslycrippled。ThedirectorsoftheEdisonElectricLightCompanycouldnotbeinducedtohaveanythingtodowiththeelectricrailway,andMr。InsullstatesthatthemoneyadvancedwastreatedbyMr。EdisonasapersonalloanandrepaidtoMr。Villard,forwhomhehadahighadmirationandastrongfeelingofattachment。Mr。Insullsays:
“AmongthefinancialmenwhoseclosepersonalfriendshipEdisonenjoyed,IwouldmentionHenryVillard,who,Ithink,hadahigherappreciationofthepossibilitiesoftheEdisonsystemthanprobablyanyothermanofhistimeinWallStreet。HedroppedoutofthebusinessatthetimeoftheconsolidationoftheThomson-HoustonCompanywiththeEdisonGeneralElectricCompany;butfromtheearliestdaysofthebusiness,whenitwasinitsexperimentalperiod,whentheEdisonlightandpowersystemwasbutanidea,downtothedayofhisdeath,HenryVillardcontinuedastrongsupporternotonlywithhisinfluence,butwithhismoney。HewasthefirstcapitalisttobackindividuallyEdison'sexperimentsinelectricrailways。“
InspeakingofhisrelationshipswithMr。Villardatthistime,Edisonsays:“WhenVillardwasallbrokendown,andinastuporcausedbyhisdisastersinconnectionwiththeNorthernPacific,Mrs。Villardsentformetocomeandcheerhimup。Itwasverydifficulttorousehimfromhisdespairandapathy,butItalkedabouttheelectriclighttohim,anditsdevelopment,andtoldhimthatitwouldhelphimwinitallbackandputhiminhisformerposition。Villardmadehisgreatrally;hemademoneyoutoftheelectriclight;andhegotbackcontroloftheNorthernPacific。Undernocircumstancescanahustlerbekeptdown。Ifheisonlysquare,heisboundtogetbackonhisfeet。Villardhasoftenbeenblamedandseverelycriticised,buthewasnottheonlyonetoblame。Hisengineershadspent$20,000,000toomuchinbuildingtheroad,anditwasnothisfaultifhefoundhimselfshortofmoney,andatthattimeunabletoraiseanymore。“
Villardmaintainedhisintelligentinterestinelectric-
railwaydevelopment,withregardtowhichEdisonremarks:“AtonetimeMr。VillardgottheideathathewouldrunthemountaindivisionoftheNorthernPacificRailroadbyelectricity。Heaskedmeifitcouldbedone。Isaid:`Certainly,itistooeasyformetoundertake;letsomeoneelsedoit。'Hesaid:
`Iwantyoutotackletheproblem,'andheinsistedonit。SoIgotupaschemeofathirdrailandshoeanderecteditinmyyardhereinOrange。WhenI
gotitallready,hehadallhisdivisionengineerscomeontoNewYork,andtheycameoverhere。Ishowedthemmyplans,andtheunanimousdecisionoftheengineerswasthatitwasabsolutelyandutterlyimpracticable。ThatsystemisontheNewYorkCentralnow,andwasalsousedontheNewHavenroadinitsfirstworkwithelectricity。“
AtthispointitmaybewelltocitesomeotherstatementsofEdisonastokindredwork,withwhichhehasnotusuallybeenassociatedinthepublicmind。
“InthesamemannerIhadworkedoutfortheManhattanElevatedRailroadasystemofelectrictrains,andhadthecontrolofeachcarcentredatoneplace——multiplecontrol。ThiswasafterwardworkedoutandmadepracticalbyFrankSprague。Igotupaslotcontactforstreetrailways,andhaveapatentonit——aslidingcontactinaslot。EdwardLauterbachwasconnectedwiththeThirdAvenueRailroadinNewYork——ascounsel——andItoldhimhewasmak-
ingahorriblemistakeputtinginthecable。Itoldhimtoletthecablestandstillandsendelectricitythroughit,andhewouldnothavetomovehundredsoftonsofmetalallthetime。Hewouldruethedaywhenheputthecablein。“Itcannotbedeniedthattheprophecywasfulfilled,forthecablewasthebeginningofthefrightfulfinancialcollapseofthesystem,andwastornoutinafewyearstomakewayforthetriumphant“trolleyintheslot。“
Incidentalglimpsesofthisworkarebothamusingandinteresting。Hughes,whowasworkingontheexperimentalroadwithMr。Edison,tellsthefollowingstory:“VillardsentJ。C。Henderson,oneofhismechanicalengineers,toseetheroadwhenitwasinoperation,andwewentdownoneday——Edison,Henderson,andI——andwentonthelocomotive。Edisonranit,andjustafterwestartedtherewasatrestlesixtyfeetlongandsevenfeetdeep,andEdisonputonallthepower。Whenwewentoveritwemusthavebeengoingfortymilesanhour,andIcouldseetheperspirationcomeoutonHenderson。Afterwegotoverthetrestleandstartedondownthetrack,Hendersonsaid:`WhenwegobackIwillwalk。IfthereisanymoreofthatkindofrunningIwon'tbeinitmyself。'“TothecorrespondenceofGrosvenorP。Lowreyweareindebtedforasimilarreminiscence,underdateofJune5,1880:“GoddardandIhavespentapartofthedayatMenlo,andallisglorious。
IhaveriddenatfortymilesanhouronMr。Edison'selectricrailway——andweranoffthetrack。Iprotestedattherateofspeedoverthesharpcurves,designedtoshowthepoweroftheengine,butEdisonsaidtheyhaddoneitoften。Finally,whenthelasttripwastobetaken,IsaidIdidnotlikeit,butwouldgoalong。Thetrainjumpedthetrackonashortcurve,throwingKruesi,whowasdrivingtheengine,withhisfacedowninthedirt,andanothermaninacomicalsomersaultthroughsomeunderbrush。Edisonwasoffinaminute,jumpingandlaughing,anddeclaringitamostbeautifulaccident。Kruesigotup,hisfacebleedingandagooddealshaken;andI
shallneverforgettheexpressionofvoiceandfaceinwhichhesaid,withsomeforeignaccent:`Oh!
yes,pairfecklysafe。'Fortunatelynootherhurtsweresuffered,andinafewminuteswehadthetrainonthetrackandrunningagain。“
Allthisrough-and-readydealingwithgradesandcurveswasnotmerehorse-play,buthadaseriouspurposeunderlyingit,everytriphavingitsrecordastosomefeatureofdefectorimprovement。OneparticularsetofexperimentsrelatingtosuchworkwasmadeonbehalfofvisitorsfromSouthAmerica,andweredoubtlessthefirsttestsofthekindmadeforthatcontinent,wherenowmanyfineelectricstreetandinterurbanrailwaysystemsareinoperation。
Mr。Edisonhimselfsuppliesthefollowingdata:
“Duringtheelectric-railwayexperimentsatMenloPark,wehadashortspuroftrackuponeofthesteepgullies。Theexperimentcameaboutinthisway。Bogota,thecapitalofColumbia,isreachedonmuleback——orwas——fromHondaontheheadwatersoftheMagdalenaRiver。Therewerepartieswhowantedtoknowiftransportationoverthemuleroutecouldnotbedonebyelectricity。Theysaidthegradeswereexcessive,anditwouldcosttoomuchtodoitwithsteamlocomotives,eveniftheycouldclimbthegrades。Isaid:`Well,itcan'tbemuchmorethan45percent。;wewilltrythatfirst。Ifitwilldothatitwilldoanythingelse。'Istartedat45percent。Igotupanelectriclocomotivewithagripontherailbywhichitwentupthe45percent。
grade。Thentheysaidthecurveswereveryshort。
Iputthecurvesin。Westartedthelocomotivewithnobodyonit,andgotuptotwentymilesanhour,takingthosecurvesofveryshortradius;butitwasweeksbeforewecouldpreventitfromrunningoff。
Wehadtobankthetracksuptoanangleofthirtydegreesbeforewecouldturnthecurveandstayon。
TheseSpanishpartieswereperfectlysatisfiedwecouldputinanelectricrailwayfromHondatoBogotasuccessfully,andthentheydisappeared。Ihaveneverseenthemsince。Asusual,Ipaidfortheexperiment。“
Inthespringof1883theElectricRailwayCompanyofAmericawasincorporatedintheStateofNewYorkwithacapitalof$2,000,000todevelopthepatentsandinventionsofEdisonandStephenD。Field,tothelatterofwhomthepracticalworkofactivedevelopmentwasconfided,andinJuneofthesameyearanexhibitwasmadeattheChicagoRailwayExposition,whichattractedattentionthroughoutthecountry,anddidmuchtostimulatethegrowinginterestinelectric-railwaywork。WiththeaidofMessrs。F。B。Rae,C。L。Healy,andC。O。MaillouxatrackandlocomotivewereconstructedforthecompanybyMr。Fieldandputinserviceinthegalleryofthemainexhibitionbuilding。Thetrackcurvedsharplyateitherendonaradiusoffifty-sixfeet,andthelengthwasaboutone-thirdofamile。Thelocomotivenamed“TheJudge,“afterJusticeField,anuncleofStephenD。Field,tookcurrentfromacentralrailbetweenthetwoouterrails,thatwerethereturncircuit,thecontactbeingarubbingwirebrushoneachsideofthe“thirdrail,“answeringthesamepurposeasthecontactshoeoflaterdate。Thelocomotiveweighedthreetons,wastwelvefeetlong,fivefeetwide,andmadeaspeedofninemilesanhourwithatrailercarforpassengers。StartingonJune5th,whentheexhibitionclosedonJune23dthistinybuttypicalroadhadoperatedforover118hours,hadmadeover446miles,andhadcarried26,805passengers。
AftertheexpositionclosedtheoutfitwastakenduringthesameyeartotheexpositionatLouisville,Kentucky,whereitwasalsosuccessful,carryingalargenumberofpassengers。ItdeservesnotethatatChicagoregularrailwayticketswereissuedtopayingpassengers,thefirsteveremployedonAmericanelectricrailways。
Withthismodestbutbrilliantdemonstration,towhichtheillustriousnamesofEdisonandFieldwereattached,begantheoutburstofexcitementoverelectricrailways,verymuchliketheerasofspeculationandexploitationthatattendedonlyafewyearsearliertheintroductionofthetelephoneandtheelectriclight,butwithsuchsignificantresultsthatthecapitalizationofelectricroadsinAmericaisnowover$4,000,000,000,ortwiceasmuchasthatoftheothertwoartscombined。Therewasatremendousrushintotheelectric-railwayfieldafter1883,andanoutburstofinventiveactivitythathasrarely,ifever,beenequalled。Itisremarkablethat,exceptSiemens,noEuropeanachievedfameinthisearlywork,whilefromAmericatheideasandappliancesofEdison,VanDepoele,Sprague,Field,Daft,andShorthavebeencarriedandadoptedallovertheworld。
Mr。EdisonwasconsultingelectricianfortheElectricRailwayCompany,butneitheradirectornoranexecutiveofficer。Justwhatthetroublewasastotheinternalmanagementofthecorporationitishardtodetermineaquarterofacenturylater;butitwasequippedwithallessentialelementstodominateanartinwhichafteritsfirsteffortsitremainedpracticallysupineanduseless,whileotherinterestsforgedaheadandreapedboththeprofitandtheglory。
DissensionsarosebetweentherepresentativesoftheFieldandEdisoninterests,andinApril,1890,theRailwayCompanyassigneditsrightstotheEdisonpatentstotheEdisonGeneralElectricCompany,recentlyformedbytheconsolidationofallthebranchesoftheEdisonlight,power,andmanufacturingindustryunderonemanagement。TheonlypatentrightsremainingtotheRailwayCompanywerethoseunderthreeFieldpatents,oneofwhich,withcontrollingclaims,wasputinsuitJune,1890,againsttheJamaica&BrooklynRoadCompany,acustomeroftheEdisonGeneralElectricCompany。
Thiswas,tosaytheleast,acuriousandanomaloussituation。Voluminousrecordsweremadebybothpartiestothesuit,andinthespringof1894thecasewasarguedbeforethelateJudgeTownsend,whowrotealongopiniondismissingthebillofcomplaint。[15]Thestudentwillfindthereinaverycompleteandcarefulstudyoftheearlyelectric-railwayart。Afterthisdecisionwasrendered,theElectricRailwayCompanyremainedforseveralyearsinamoribundcondition,andonthelastdayof1896itspropertywasplacedinthehandsofareceiver。InFebruaryof1897thereceiversoldthethreeFieldpatentstotheiroriginalowner,andheinturnsoldthemtotheWestinghouseElectricandManufacturingCompany。TheRailwayCompanythenwentintovoluntarydissolution,asadexampleoffailuretoseizetheopportunityatthepsychologicalmoment,andonthepartoftheinventortosecureanyadequatereturnforyearsofeffortandstruggleinfoundingoneofthegreatarts。
Neitherofthesemenwassquelchedbysuchacalamitousresult,butiftherewerenotsomethingofbitternessintheirfeelingsastheysurveywhathascomeoftheirwork,theywouldnotbehuman。
Asamatteroffact,Edisonretainedaverylivelyinterestinelectric-railwayprogresslongafterthepregnantdaysatMenloPark,oneofthebestevidencesofwhichisanarticleintheNewYorkElectricalEngineerofNovember18,1891,whichdescribessomeimportantandoriginalexperimentsinthedirectionofadaptingelectricalconditionstothelargercities。Theoverheadtrolleyhadbythattimebegunitsvictoriouscareer,buttherewasintensehostilitydisplayedtowarditinmanyplacesbecauseoftheinevitableincreaseinthenumberofoverheadwires,which,carrying,astheydid,acurrentofhighvoltageandlargequantity,wereregardedasamenacetolifeandproperty。Edisonhasalwaysmanifestedastrongobjectiontooverheadwiresincities,andurgedplacingthemunderground;andtheoutcryagainsttheoverhead“deadly“trolleymetwithhisinstantsympathy。Hisstudyoftheproblembroughthimtothedevelopmentofthemodern“substation,“
althoughthetwiststhatlaterevolutionshavegiventheideahaveleftitscarcelyrecognizable。
[15]See61Fed。Rep。655。
Mr。Villard,asPresidentoftheEdisonGeneralElectricCompany,requestedMr。Edison,aselectricianofthecompany,todeviseastreet-railwaysystemwhichshouldbeapplicabletothelargestcitieswheretheuseofthetrolleywouldnotbepermitted,wheretheslotconduitsystemwouldnotbeused,andwhere,ingeneral,thedetailsofconstructionshouldbereducedtothesimplestform。Thelimitsimposedpracticallyweresuchastorequirethatthesystemshouldnotcostmorethanacableroadtoinstall。Edisonrevertedtohisingeniouslightingplanofyearsearlier,andthussettledonamethodbywhichcurrentshouldbeconveyedfromthepowerplantathighpotentialtomotor-generatorsplacedbelowthegroundincloseproximitytotherails。
Thesesubstationswouldconvertthecurrentreceivedatapressureof,say,onethousandvoltstooneoftwentyvoltsavailablebetweenrailandrail,withacorrespondingincreaseinthevolumeofthecurrent。
Withtheutilizationofheavycurrentsatlowvoltageitbecamenecessary,ofcourse,todeviseapparatuswhichshouldbeabletopickupwithabsolutecertaintyonethousandamperesofcurrentatthispress-
urethroughtwoinchesofmud,ifnecessary。WithhiswontedactivityandfertilityEdisonsetaboutdevisingsuchacontact,andexperimentedwithmetalwheelsunderallconditionsofspeedandtrackconditions。
Itwasseveralmonthsbeforehecouldconveyonehundredamperesbymeansofsuchcontacts,butheworkedoutatlastasatisfactorydevicewhichwasequaltothetask。Thenextpointwastosecureajointbetweencontiguousrailssuchaswouldpermitofthepassageofseveralthousandampereswithoutintroducingundueresistance。Thiswasalsoaccomplished。
Objectionswerenaturallymadetorailsoutintheopenonthestreetsurfacecarryinglargecurrentsatapotentialoftwentyvolts。Itwassaidthatvehicleswithironwheelspassingoverthetracksandspanningthetworailswouldshort-circuitthecurrent,“chew“themselvesup,anddestroythedynamosgeneratingthecurrentbychokingallthattremendousamountofenergybackintothem。Edisontackledtheobjectionsquarelyandshort-circuitedhistrackwithsuchavehicle,butsucceededingettingonlyabouttwohundredamperesthroughthewheels,thelowvoltageandtheinsulatingpropertiesoftheaxle-
greasebeingsufficienttoaccountforsucharesult。
Anironbarwasalsoused,polished,andwithamanstandingonittoinsuresolidcontact;butonlyonethousandamperespassedthroughit——i。e。,theamountrequiredbyasinglecar,and,ofcourse,muchlessthanthecapacityofthegeneratorsabletooperateasystemofseveralhundredcars。
Furtherinterestingexperimentsshowedthattheexpectedlargeleakageofcurrentfromtherailsinwetweatherdidnotmaterialize。Edisonfoundthatundertheworstconditionswithawetandsaltedtrack,atapotentialdifferenceoftwentyvoltsbetweenthetworails,theextremelosswasonlytwoandone-halfhorse-power。Inthisrespectthephenomenonfollowedthesameruleasthattowhichtelegraphwiresaresubject——namely,thatthelossofinsulationisgreaterindamp,murkyweatherwhentheinsulatorsarecoveredwithwetdustthanduringheavyrainswhentheinsulatorsarethoroughlywashedbytheactionofthewater。Inlikemanneraheavyrain-stormcleanedthetracksfromtheaccumulationsduechieflytothedroppingsofthehorses,whichotherwiseservedlargelytoincreasetheconductivity。
Ofcourse,indryweatherthelossofcurrentwaspracticallynothing,and,underordinaryconditions,Edisonheld,hissystemwasinrespecttoleakageandtheproblemsofelectrolyticattackofthecurrentonadjacentpipes,etc。,asfullyinsulatedasthestandardtrolleynetworkoftheday。ThecostofhissystemMr。Edisonplacedatfrom$30,000to$100,000permileofdoubletrack,inaccordancewithlocalconditions,andinthisrespectcomparingveryfavorablywiththecablesystemsthensomuchinfavorforheavytraffic。Alltheargumentsthatcouldbeurgedinsupportofthisingenioussystemaretenableandlogicalatthepresentmoment;butthetrolleyhaditswayexceptonafewlineswheretheconduit-and-shoemethodwasadopted;andintheinterveningyearsthevolumeoftrafficcreatedandhandledbyelectricityincentresofdensepopulationhasbroughtintoexistencethemodernsubway。
Butdowntothemomentofthepreparationofthisbiography,Edisonhasretainedanactiveinterestintransportationproblems,andhislatestworkhasbeenthatofrevivingtheuseofthestoragebatteryforstreet-carpurposes。Atonetimetherewereanumberofstorage-batterylinesandcarsinoperationinsuchcitiesasWashington,NewYork,Chicago,andBoston;butthecostsofoperationandmaintenancewerefoundtobeinordinatelyhighascomparedwiththoseofthedirect-supplymethods,andthebatterycarsalldisappeared。Theneedforthemundermanyconditionsremained,as,forexample,inplacesinGreaterNewYorkwheretheoverheadtrolleywiresareforbiddenasobjectionable,andwherethegroundistoowetortoooftensubmergedtopermitoftheconduitwiththeslot。SomeoftheroadsinGreaterNewYorkhavebeenanxioustosecuresuchcars,and,asusual,themostresourcefulelectricalengineerandinventorofhistimeshasmadetheeffort。AspecialexperimentaltrackhasbeenlaidattheOrangelaboratory,andacarequippedwiththeEdisonstoragebatteryandotherdeviceshasbeenputundersevereandextendedtrialthereandinNewYork。
MenloPark,inruinanddecay,affordsnotracesoftheearlyEdisonelectric-railwaywork,butthecrudelittlelocomotivebuiltbyCharlesT。Hugheswasrescuedfromdestruction,andhasbecomethepropertyofthePrattInstitute,ofBrooklyn,towhosethousandsoftechnicalstudentsitisaconstantexampleandincentive。
Itwasloanedin1904totheAssociationofEdisonIlluminatingCompanies,andbyitexhibitedaspartofthehistoricalEdisoncollectionattheSt。LouisExposition。
EDISON
HISLIFEANDINVENTIONS
CHAPTERXIX
MAGNETICOREMILLINGWORK
DURINGtheHudson-FultoncelebrationofOctober,1909,BurgomasterVanLeeuwen,ofAmsterdam,memberofthedelegationsentofficiallyfromHollandtoescorttheHalfMoonandparticipateinthefunctionsoftheanniversary,paidavisittotheEdisonlaboratoryatOrangetoseetheinventor,whomayberegardedaspre-eminentamongthoseofDutchdescentinthiscountry。Found,asusual,hardatwork——thistimeonhiscementhouse,ofwhichheshowedtheironmolds——Edisontookoccasiontoremarkthatifhehadachievedanythingworthwhile,itwasduetotheobstinacyandpertinacityhehadinheritedfromhisforefathers。Towhichitmaybeaddedthatnotlessequallyhavethenatureofinheritanceandthequalityofatavismbeenexhibitedinhisextraordinarypredilectionforthemiller'sart。
WhilethoseBatavianancestorsonthelowshoresoftheZuyderZeedevotedtheirenergiestogrindinggrain,hehasbeennotlessassiduousthantheyinreducingtherocksoftheearthitselftoflour。
AlthoughthisphaseofMr。Edison'sdiverseactivitiesisnotasgenerallyknowntotheworldasmanyothersofamorepopularcharacter,themillingoflow-gradeauriferousoresandthemagneticseparationofironoreshavebeensubjectsofengrossinginterestandstudytohimformanyyears。Indeed,hiscomparativelyunknownenterpriseofseparatingmagneticallyandputtingintocommercialformlow-
gradeironore,ascarriedonatEdison,NewJersey,provedtobethemostcolossalexperimentthathehasevermade。
Ifapersonqualifiedtojudgewereaskedtoanswercategoricallyastowhetherornotthatenterprisewasafailure,hecouldtruthfullyanswerbothyesandno。Yes,inthatcircumstancesoverwhichMr。
Edisonhadnocontrolcompelledtheshuttingdownoftheplantattheverymomentofsuccess;andno,inthatthemechanicallysuccessfulandcommerciallypracticalresultsobtained,aftertheexerciseofstupendouseffortsandtheexpenditureofafortune,aresoconclusivethattheymustinevitablybetherelianceofmanyfutureiron-masters。Inotherwords,Mr。
Edisonwasatleastaquarterofacenturyaheadofthetimesintheworknowtobeconsidered。
Beforeproceedingtoaspecificdescriptionofthisremarkableenterprise,however,letusglanceatanearlyexperimentinseparatingmagneticironsandsontheAtlanticsea-shore:“SomeyearsagoIheardonedaythatdownatQuogue,LongIsland,therewereimmensedepositsofblackmagneticsand。Thiswouldbeveryvaluableiftheironcouldbeseparatedfromthesand。SoIwentdowntoQuoguewithoneofmyassistantsandsawthereformileslargebedsofblacksandonthebeachinlayersfromonetosixinchesthick——hundredsofthousandsoftons。Myfirstthoughtwasthatitwouldbeaveryeasymattertoconcentratethis,andIfoundIcouldsellthestuffatagoodprice。Iputupasmallplant,butjustasIgotitstartedatremendousstormcameup,andeverybitofthatblacksandwentouttosea。Duringthetwenty-eightyearsthathaveintervenedithasnevercomeback。“Thisincidentwasreallythepreludetothedevelopmentsetforthinthischapter。
IntheearlyeightiesEdisonbecamefamiliarwiththefactthattheEasternsteeltradewassufferingadisastrouschange,andthatbusinesswasslowlydriftingwestward,chieflybyreasonofthediscoveryandopeningupofenormousdepositsofhigh-gradeironoreintheupperpeninsulaofMichigan。Thisorecouldbeexcavatedverycheaplybymeansofimprovedminingfacilities,andtransportedatlowcosttolakeports。HencetheironandsteelmillseastoftheAlleghanies——compelledtorelyonlimitedlocaldepositsofBessemerore,anduponforeignoreswhichwereconstantlyrisinginvalue——begantosustainaseriouscompetitionwithWesternmills,eveninEasternmarkets。
Longbeforethissituationarose,ithadbeenrecognizedbyEasterniron-mastersthatsoonerorlaterthedepositsofhigh-gradeorewouldbeexhausted,and,inconsequence,therewouldensueacompellingnecessitytofallbackonthelow-grademagneticores。
Formanyyearsithadbeenamuch-discussedquestionhowtomaketheseoresavailablefortransporta-
tiontodistantfurnaces。Topayrailroadchargesonorescarryingperhaps80to90percent。ofuselessmaterialwouldbeprohibitive。Hencetheeliminationoftheworthless“gangue“byconcentrationoftheironparticlesassociatedwithit,seemedtobetheonlysolutionoftheproblem。
Manyattemptshadbeenmadeinby-gonedaystoconcentratetheironinsuchoresbywaterprocesses,butwithonlyapartialdegreeofsuccess。Theimpossibilityofobtainingauniformconcentratewasamostseriousobjection,hadtherenotindeedbeenotherdifficultieswhichrenderedthismethodcommerciallyimpracticable。Itisquitenatural,therefore,thattheideaofmagneticseparationshouldhaveoccurredtomanyinventors。Thuswefindnumerousinstancesthroughoutthelastcenturyofexperimentsalongthisline;andparticularlyinthelastfortyorfiftyyears,duringwhichvariousattemptshavebeenmadebyothersthanEdisontoperfectmagneticseparationandbringituptosomethinglikecommercialpractice。Atthetimehetookupthematter,however,nooneseemstohaverealizedthefullmeaningofthetremendousproblemsinvolved。
From1880to1885,whilestillverybusyinthedevelopmentofhiselectric-lightsystem,Edisonfoundopportunitytoplancrushingandseparatingmachinery。
Hisfirstpatentonthesubjectwasappliedforandissuedearlyin1880。Hedecided,aftermaturedeliberation,thatthemagneticseparationoflow-gradeoresonacolossalscaleatalowcostwastheonlypracticalwayofsupplyingthefurnacemanwithahighqualityofironore。Itwashisopinionthatitwascheapertoquarryandconcentrateleanoreinabigwaythantoattempttomine,underadversecircumstances,limitedbodiesofhigh-gradeore。
Heappreciatedfullytheseriousnatureofthegiganticquestionsinvolved;andhisplanswerelaidwithaviewtoexercisingtheutmosteconomyinthedesignandoperationoftheplantinwhichhecontemplatedtheautomatichandlingofmanythousandsoftonsofmaterialdaily。ItmaybestatedasbroadlytruethatEdisonengineeredtohandleimmensemassesofstuffautomatically,whilehispredecessorsaimedchieflyatcloseseparation。
Reducedtoitsbarest,crudestterms,thepropositionofmagneticseparationissimplicityitself。A
pieceoftheoremagnetitemaybereducedtopowderandtheoreparticlesseparatedtherefrombythehelpofasimplehandmagnet。ToelucidatethebasicprincipleofEdison'smethod,letthecrushedorefallinathinstreampastsuchamagnet。Themagneticparticlesareattractedoutofthestraightlineofthefallingstream,andbeingheavy,gravitateinwardlyandfalltoonesideofapartitionplacedbelow。Thenon-magneticganguedescendsinastraightlinetotheothersideofthepartition。Thusacompleteseparationiseffected。
Simplethoughtheprincipleappears,itwasinitsapplicationtovastmassesofmaterialandinthesolvingofgreatengineeringproblemsconnectedtherewiththatEdison'soriginalitymadeitselfmanifestintheconcentratingworksthatheestablishedinNewJersey,earlyinthenineties。Notonlydidhedevelopthoroughlytherefiningofthecrushedore,sothatafterithadpassedthefourhundredandeightymagnetsinthemill,theconcentratescameoutfinallycontaining91to93percent。ofironoxide,buthealsodevisedcollateralmachinery,methodsandprocessesallfundamentalintheirnature。Thesearetoonumeroustospecifyindetail,astheyextendedthroughoutthevariousramificationsoftheplant,buttheprincipalonesareworthyofmention,suchas:
Thegiantrollsforcrushing。
Intermediaterolls。
Three-highrolls。
Giantcranes215feetlongspan。
Verticaldryer。
Beltconveyors。
Airseparation。
Mechanicalseparationofphosphorus。
Briquetting。
ThatMr。Edison'sworkwasappreciatedatthetimeismadeevidentbythefollowingextractfromanarticledescribingtheEdisonplant,publishedinTheIronAgeofOctober28,1897;inwhich,aftermentioninghisstrugglewithadverseconditions,itsays:“Thereisverylittlethatisshowy,fromthepopularpointofview,inthegiganticworkwhichMr。Edisonhasdoneduringtheseyears,buttothosewhoarecapableofgraspingthedifficultiesencountered,Mr。Edisonappearsinthenewlightofabrilliantconstructingengineergrapplingwithtechnicalandcommercialproblemsofthehighestorder。Hisgeniusasaninventorisrevealedinmanydetailsofthegreatconcentratingplant……Buttoourmind,originalityofthehighesttypeasaconstructoranddesignerappearsintheboldwayinwhichhesweepsasideacceptedpracticeinthisparticularfieldandattainsresultsnothithertoapproached。Hepursuesmethodsinore-dressingatwhichthosewhoaretrainedintheusualpracticemaywellstandaghast。
Butconsideringthespecialfeaturesoftheproblemstobesolved,hismethodswillbeacceptedasthoseeconomicallywiseandexpedient。“
Acursoryglanceattheseproblemswillrevealtheirimport。Mountainsmustbereducedtodust;allthisdustmustbehandledindetail,sotospeak,andfromitmustbeseparatedthefineparticlesofironconstitutingonlyone-fourthorone-fifthofitsmass;
andthenthisiron-oredustmustbeputintosuchshapethatitcouldbecommerciallyshippedandused。
OneofthemostinterestingandstrikinginvestigationsmadebyEdisoninthisconnectionisworthyofnote,andmayberelatedinhisownwords:“I
feltcertainthattheremustbelargebodiesofmagnetiteintheEast,whichifcrushedandconcentratedwouldsatisfythewantsoftheEasternfurnacesforsteel-making。HavingdeterminedtoinvestigatethemountainregionsofNewJersey,Iconstructedaverysensitivemagneticneedle,whichwoulddiptowardtheearthifbroughtoveranyconsiderablebodyofmagneticironore。OneofmylaboratoryassistantswentoutwithmeandwevisitedmanyoftheminesofNewJersey,butdidnotfinddepositsofanymagnitude。
Oneday,however,aswedroveoveramountainrange,notknownasiron-bearingland,Iwasastonishedtofindthattheneedlewasstronglyattractedandremainedso;thusindicatingthatthewholemountainwasunderlaidwithvastbodiesofmagneticore。
“Iknewitwasacommercialproblemtoproducehigh-gradeBessemerorefromthesedeposits,andtookstepstoacquirealargeamountoftheproperty。
IalsoplannedagreatmagneticsurveyoftheEast,andIbelieveitremainsthemostcomprehensiveofitskindyetperformed。IhadanumberofmensurveyastripreachingfromLowerCanadatoNorthCarolina。Theonlyinstrumentweusedwasthespecialmagneticneedle。WestartedinLowerCanadaandtravelledacrossthelineofmarchtwenty-fivemiles;thenadvancedsouthonethousandfeet;thenbackacrossthelineofmarchagaintwenty-fivemiles;
thensouthanotherthousandfeet,acrossagain,andsoon。ThusweadvancedallthewaytoNorthCarolina,varyingourcross-countrymarchfromtwototwenty-fivemiles,accordingtogeologicalformation。
Ourmagneticneedleindicatedthepresenceandrichnessoftheinvisibledepositsofmagneticore。
Wekeptminuterecordsoftheseindications,andwhenthesurveywasfinishedwehadexactinformationofthedepositsineverypartofeachStatewehadpassedthrough。Wealsoknewthewidth,length,andapproximatedepthofeveryoneofthesedeposits,whichwereenormous。
“Theamountoforedisclosedbythissurveywassimplyfabulous。HowmuchsomaybejudgedfromthefactthatinthethreethousandacresimmediatelysurroundingthemillsthatIafterwardestablishedatEdisontherewereover200,000,000tonsoflow-
gradeore。Ialsosecuredsixteenthousandacresinwhichthedepositwasproportionatelyaslarge。
ThesefewacresalonecontainedsufficientoretosupplythewholeUnitedStatesirontrade,includingexports,forseventyyears。“
Givenamountainofrockcontainingonlyone-fifthtoone-fourthmagneticiron,thebroadproblemconfrontingEdisonresolveditselfintothreedistinctparts——first,toteardownthemountainbodilyandgrindittopowder;second,toextractfromthispowdertheparticlesofironmingledinitsmass;
and,third,toaccomplishtheseresultsatacostsufficientlylowtogivetheproductacommercialvalue。
Edisonrealizedfromthestartthatthetruesolutionofthisproblemlayinthecontinuoustreatmentofthematerial,withthemaximumemploymentofnaturalforcesandtheminimumofmanuallaborandgeneratedpower。Hence,allhisconceptionsfollowedthisgeneralprinciplesofaithfullyandcompletelythatwefindintheplantembodyinghisideastheforcesofmomentumandgravitysteadilyinharnessandkeepingthetracestaut;whiletherewasnotouchofthehumanhanduponthematerialfromthebeginningofthetreatmenttoitsfinish——thestaffbeingemployedmainlytokeepwatchonthecorrectworkingofthevariousprocesses。
Itishardlynecessarytodevotespacetothebeginningsoftheenterprise,althoughtheyarefullofinterest。Theyserved,however,toconvinceEdisonthatifheeverexpectedtocarryouthisschemeontheextensivescaleplanned,hecouldnotdependuponthemarkettosupplysuitablemachineryforimportantoperations,butwouldbeobligedtodeviseandbuildithimself。Thus,outsidethesteam-
shovelandsuchstapleitemsasengines,boilers,dynamos,andmotors,allofthediverseandcomplexmachineryoftheentireconcentratingplant,assubsequentlycompleted,wasdevisedbyhimespeciallyforthepurpose。Thenecessityforthiswasduetothemanyradicalvariationsmadefromacceptedmethods。
Nosuchdeparturewasasradicalasthatofthemethodofcrushingtheore。Existingmachineryforthispurposehadbeendesignedonthebasisofminingmethodstheninvogue,bywhichtherockwasthoroughlyshatteredbymeansofhighexplosivesandreducedtopiecesofonehundredpoundsorless。Thesepieceswerethencrushedbypowerdirectlyapplied。Ifaconcentratingmill,plannedtotreatfiveorsixthousandtonsperday,weretobeoperatedonthisbasistheinvestmentincrushersandthesupplyofpowerwouldbeenormous,tosaynothingoftheriskoffrequentbreakdownsbyreasonofmultiplicityofmachineryandparts。Fromaconsiderationofthesefacts,andwithhisusualtendencytoupsettraditionalobservances,Edisonconceivedtheboldideaofconstructinggiganticrollswhich,bytheforceofmomentum,wouldbecapableofcrushingindividualrocksofvastlygreatersizethaneverbeforeattempted。
Hereasonedthattheadvantagesthusobtainedwouldbefourfold:aminimumofmachineryandparts;
greatercompactness;asavingofpower;andgreatereconomyinmining。Asthislast-namedoperationprecedesthecrushing,letusfirstconsideritasitwasprojectedandcarriedonbyhim。
Perhapsquarryingwouldbeabettertermthanmininginthiscase,asEdison'splanwastoapproachtherockandtearitdownbodily。Thefaiththat“movesmountains“hadanewopportunity。Inworkofthisnatureithadbeencustomary,asabovestated,todependuponahighexplosive,suchasdynamite,toshatterandbreaktheoretolumpsofonehundredpoundsorless。This,however,hedeemedtobeamostuneconomicalprocess,forenergystoredasheatunitsindynamiteat$260pertonwasmuchmoreexpensivethanthatofcaloriesinatonofcoalat$3perton。Hence,hebelievedthatonlytheminimumofworkshouldbedonewiththecostlyexplosive;and,therefore,plannedtousedynamitemerelytodislodgegreatmassesofrock,anddependeduponthesteam-shovel,operatedbycoalundertheboiler,todisplace,handle,andremovetherockindetail。ThiswastheplanthatwassubsequentlyputintopracticeinthegreatworksatEdison,NewJersey。
Aseriesofthree-inchholestwentyfeetdeepweredrilledeightfeetapart,abouttwelvefeetbackoftheore-bank,andintothesewereinserteddynamitecartridges。Theblastwoulddislodgethirtytothirty-
fivethousandtonsofrock,whichwasscoopedupbygreatsteam-shovelsandloadedontoskipscarriedbyalineofcarsonanarrow-gaugerailroadrunningtoandfromthecrushingmill。Herethematerialwasautomaticallydeliveredtothegiantrolls。Theproblemincludedhandlingandcrushingthe“runofthemine,“withoutselection。Thesteam-shoveldidnotdiscriminate,butpickeduphandilysinglepiecesweighingfiveorsixtonsandloadedthemontheskipswithquantitiesofsmallerlumps。Whentheskipsarrivedatthegiantrolls,theircontentsweredumpedautomaticallyintoasuperimposedhopper。Therollswerewellnamed,forwithear-
splittingnoisetheybrokeupinafewsecondsthegreatpiecesofrocktossedinfromtheskips。
Itisnoteasytoappreciatetothefullthedaringexemplifiedinthesegreatcrushingrolls,orrather“rock-crackers,“withouthavingwatchedtheminoperationdeliveringtheir“solar-plexus“blows。Itwasonlyasonemightstandintheirvicinityandhearthethunderousroaraccompanyingthesmashingandrendingofthemassiverocksastheydisappearedfromviewthatthemindwasoverwhelmedwithasenseofthemagnificentproportionsofthisoperation。Theenormousforceexertedduringthisprocessmaybeillustratedfromthefactthatduringitsdevelopment,inrunningoneoftheearlyformsofrolls,piecesofrockweighingmorethanhalfatonwouldbeshotupintheairtoaheightoftwentyortwenty-
fivefeet。
Thegiantrollsweretwosolidcylinders,sixfeetindiameterandfivefeetlong,madeofcastiron。Tothefacesoftheserollswereboltedaseriesofheavy,chilled-ironplatescontaininganumberofprojectingknobstwoincheshigh。Eachrollhadalsotworowsoffour-inchknobs,intendedtostrikeaseriesofhammer-likeblows。Therollsweresetfacetofacefourteeninchesapart,inaheavyframe,andthetotalweightwasonehundredandthirtytons,ofwhichseventytonswereinmovingparts。Thespacebetweenthesetworollsallowedpiecesofrockmeasuringlessthanfourteeninchestodescendtoothersmallerrollsplacedbelow。Thegiantrollswerebelt-driven,inoppositedirections,throughfrictionclutches,althoughthebeltwasnotdependeduponfortheactualcrushing。
Previoustothedumpingofaskip,therollswerespeededuptoacircumferentialvelocityofnearlyamileaminute,thusimpartingtothemtheterrificmomentumthatwouldbreakupeasilyinafewsecondsbouldersweighingfiveorsixtonseach。Itwasasthougharockofthissizehadgotinthewayoftwoexpresstrainstravellinginoppositedirectionsatnearlysixtymilesanhour。Inotherwords,itwasthekineticenergyoftherollsthatcrumbleduptherockswithpile-drivereffect。Thissuddenstrainmighthavetendedtostoptheenginedrivingtherolls;butbyaningeniousclutcharrangementthebeltwasreleasedatthemomentofresistanceintherollsbyreasonoftherocksfallingbetweenthem。
Theactofbreakingandcrushingwouldnaturallydecreasethetremendousmomentum,butaftertherockwasreducedandthepieceshadpassedthrough,thebeltwouldagaincomeintoplay,andoncemorespeeduptherollsforarepetitionoftheirregularprize-fighterduty。
Onleavingthegiantrollstherocks,havingbeenreducedtopiecesnotlargerthanfourteeninches,passedintotheseriesof“IntermediateRolls“ofsimilarconstructionandoperation,bywhichtheywerestillfurtherreduced,andagainpassedontothreeothersetsofrollsofsmallerdimensions。Theselatterrollswerealsoface-linedwithchilled-ironplates;but,unlikethelargerones,werepositivelydriven,reducingtherocktopiecesofaboutone-half-inchsize,orsmaller。Thewholecrushingoperationofreductionfrommassiveboulderstosmallpebblypieceshavingbeendoneinlesstimethanthetellinghasoccupied,theproductwasconveyedtothe“Dryer,“atowerninefeetsquareandfiftyfeethigh,heatedfrombelowbygreatopenfurnacefires。Alldowntheinsidewallsofthistowerwereplacedcast-ironplates,ninefeetlongandsevenincheswide,arrangedalternatelyin“fish-ladder“fashion。Thecrushedrock,beingdeliveredatthetop,wouldfalldownfromplatetoplate,constantlyexposingdifferentsurfacestotheheat,untilitlandedcompletelydriedinthelowerportionofthetower,whereitfellintoconveyorswhichtookituptothestock-house。
ThismethodofdryingwasoriginalwithEdison。
Atthetimethisadjuncttotheplantwasrequired,thebestdryeronthemarketwasofarotarytype,whichhadacapacityofonlytwentytonsperhour,withtheexpenditureofconsiderablepower。AsEdisonhaddeterminedupontreatingtwohundredandfiftytonsormoreperhour,hedecidedtodeviseanentirelynewtypeofgreatcapacity,requiringaminimumofpowerforelevatingthematerial,anddependingupontheforceofgravityforhandlingitduringthedryingprocess。Alongseriesofexperimentsresultedintheinventionofthetowerdryerwithacapacityofthreehundredtonsperhour。
Therock,brokenupintopiecesaboutthesizeofmarbles,havingbeendriedandconveyedtothestock-house,thesurplusagewasautomaticallycarriedoutfromtheotherendofthestock-housebycon-
veyors,topassthroughthenextprocess,bywhichitwasreducedtoapowder。ThemachineryforaccomplishingthisresultrepresentsanotherinterestingandradicaldepartureofEdisonfromacceptedusage。Hehadinvestigatedallthecrushing-machinesonthemarket,andtriedallhecouldget。Hefoundthemallgreatlylackingineconomyofoperation;indeed,thehighestresultsobtainablefromthebestwere18
percent。ofactualwork,involvingalossof82percent。
byfriction。Hisnaturerevoltedatsuchanimmenselossofpower,especiallyasheproposedthecrushingofvastquantitiesofore。Thus,hewasobligedtobeginagainatthefoundation,andhedevisedacrushing-machinewhichwassubsequentlynamedthe“Three-HighRolls,“andwhichpracticallyreversedtheabovefigures,asitdeveloped84percent。ofworkdonewithonly16percent。lossinfriction。
Abriefdescriptionofthisremarkablemachinewillprobablyinterestthereader。Inthetwoendpiecesofaheavyironframeweresetthreerolls,orcylinders——oneinthecentre,anotherbelow,andtheotherabove——allthreebeinginaverticalline。Theserollswereofcastironthreefeetindiameter,havingchilled-ironsmoothface-platesofconsiderablethickness。
Thelowestrollwassetinafixedbearingatthebottomoftheframe,and,therefore,couldonlyturnaroundonitsaxis。Themiddleandtoprollswerefreetomoveupordownfromandtowardthelowerroll,andtheshaftsofthemiddleandupperrollsweresetinaloosebearingwhichcouldslipupanddownintheironframe。Itwillbeapparent,therefore,thatanymaterialwhichpassedinbetweenthetopandthemiddlerolls,andthemiddleandbottomrolls,couldbegroundasfineasmightbedesired,dependingentirelyupontheamountofpressureappliedtothelooserolls。Inoperationthematerialpassedfirstthroughtheupperandmiddlerolls,andthenbetweenthemiddleandlowestrolls。
Thispressurewasappliedinamostingeniousmanner。
Ontheendsoftheshaftsofthebottomandtoprollstherewerecylindricalsleeves,orbearings,havingsevensheaves,inwhichwasrunahalf-inchendlesswirerope。Thisropewaswoundseventimesoverthesheavesasabove,andledupwardandoverasingle-
groovesheavewhichwasoperatedbythepistonofanaircylinder,andinthismannerthepressurewasappliedtotherolls。Itwillbeseen,therefore,thatthesystemconsistedinasingleropepassedoversheavesandsoarrangedthatitcouldbevariedinlength,thusprovidingforelasticityinexertingpressureandregulatingitasdesired。Theefficiencyofthissystemwasincomparablygreaterthanthatofanyotherknowncrusherorgrinder,forwhileapressureofonehundredandtwenty-fivethousandpoundscouldbeexertedbytheserolls,frictionwasalmostentirelyeliminatedbecausetheupperandlowerrollbearingsturnedwiththerollsandrevolvedinthewirerope,whichconstitutedthebearingproper。
ThesamecautiousforesightexercisedbyEdisoninprovidingasafetydevice——thefuse——topreventfiresinhiselectric-lightsystem,wasagaindisplayedinthisconcentratingplant,where,tosavepossibleinjurytoitsexpensiveoperatingparts,hedevisedananalogousfactor,providingallthecrush-
ingmachinerywithcloselycalculated“safetypins,“
which,onbeingoverloaded,wouldshearoffandthusstopthemachineatonce。
Therockshavingthusbeenreducedtofinepowder,themasswasreadyforscreeningonitswaytothemagneticseparators。HereagainEdisonreversedpriorpracticebydiscardingrotaryscreensanddevisingaformoftowerscreen,which,besideshavingaverylargeworkingcapacitybygravity,eliminatedallpowerexceptthatrequiredtoelevatethematerial。
Thescreeningprocessallowedthefinestpartofthecrushedrocktopasson,byconveyorbelts,tothemagneticseparators,whilethecoarserparticleswereinlikemannerautomaticallyreturnedtotherollsforfurtherreduction。
Inanarrativenotintendedtobestrictlytechnical,itwouldprobablytirethereadertofollowthismaterialindetailthroughthenumerousstepsattendingthemagneticseparation。Thesemaybeseeninadiagramreproducedfromtheabove-namedarticleintheIronAge,andsupplementedbythefollowingextractfromtheElectricalEngineer,NewYork,October28,1897:“Atthestarttheweakestmagnetatthetopfreesthepurestparticles,andthesecondtakescareofothers;butthethirdcatchesthosetowhichrockadheres,andwillextractparticlesofwhichonlyone-eighthisiron。Thisbatchofmaterialgoesbackforanothercrushing,sothateverythingissubjectedtoanequalityofrefining。Wearenowinsightofthereal`concentrates,'whichareconveyedtodryerNo。2fordryingagain,andarethendeliveredtothefifty-meshscreens。Whateverisfineenoughgoesthroughtotheeight-inchmagnets,andtheremaindergoesbackforrecrushing。Belowtheeight-
inchmagnetsthedustisblownoutoftheparticlesmechanically,andtheythengotothefour-inchmagnetsforfinalcleansingandseparation……Obviously,ateachstepthepercentageoffelsparandphosphorusislessandlessuntilinthefinalconcentratesthepercentageofironoxideis91to93percent。
Asintimatedattheoutset,thetailingswillbe75percent。oftherocktakenfromtheveinsofore,sothateveryfourtonsofcrude,raw,low-gradeorewillhaveyieldedroughlyonetonofhigh-gradeconcentrateandthreetonsofsand,thelatteralsohavingitsvalueinvariousways。“
Thissandwastransportedautomaticallybybeltconveyorstotherearoftheworkstobestoredandsold。Beingsharp,crystalline,andeveninquality,itwasavaluableby-product,findingareadysaleforbuildingpurposes,railwaysand-boxes,andvariousindustrialuses。Theconcentrate,infinepowderyform,wasdeliveredinsimilarmannertoastock-
house。
Astothenextstepintheprocess,wemaynowquoteagainfromthearticleintheIronAge:“WhileMr。Edisonandhisassociateswereworkingontheproblemofcheapconcentrationofironore,anaddeddifficultyfacedtheminthepreparationoftheconcentratesforthemarket。Furnacemenobjecttomorethanaverysmallproportionoffineoreintheirmixtures,particularlywhentheoreismagnetic,noteasilyreduced。Theproblemtobesolvedwastomarketanagglomeratedmaterialsoastoavoidthedrawbacksoffineore。Theagglomeratedproductmustbeporoussoastoaffordaccessofthefurnace-
reducinggasestotheore。Itmustbehardenoughtobeartransportation,andtocarrythefurnaceburdenwithoutcrumblingtopieces。Itmustbewaterproof,toacertainextent,becauseconsiderationsconnectedwithsecuringlowratesoffreightmakeitnecessarytobeabletoshiptheconcentratestomarketinopencoalcars,exposedtosnowandrain。InmanyrespectstheattainmentofthesesomewhatconflictingendswasthemostperplexingoftheproblemswhichconfrontedMr。Edison。Theagglomerationoftheconcentrateshavingbeendecidedupon,twootherconsiderations,notmentionedabove,wereofprimaryimportance——first,tofindasuitablecheapbindingmaterial;and,second,itsnaturemustbesuchthatverylittlewouldbenecessarypertonofconcentrates。
Thesesevererequirementswerestaggering,butMr。Edison'scouragedidnotfalter。Althoughitseemedawell-nighhopelesstask,heenteredupontheinvestigationwithhisusualoptimismandvim。
Aftermanymonthsofunremittingtoilandresearch,andthetrialofthousandsofexperiments,thegoalwasreachedinthecompletionofasuccessfulformulaforagglomeratingthefineoreandpressingitintobriquettesbyspecialmachinery。“
Thiswasthefinalprocessrequisiteforthemakingofacompletedcommercialproduct。Itspractice,ofcourse,necessitatedtheadditionofanentirelynewdepartmentoftheworks,whichwascarriedintoeffectbytheconstructionandinstallationofthenovelmixingandbriquettingmachinery,togetherwithex-
tensionsoftheconveyors,withwhichtheplanthadalreadybeenliberallyprovided。
Brieflydescribed,theprocessconsistedinmixingtheconcentrateswiththespecialbindingmaterialinmachinesofanentirelynewtype,andinpassingtheresultantpastymassintothebriquettingmachines,whereitwaspressedintocylindricalcakesthreeinchesindiameterandoneandahalfinchesthick,undersuccessivepressuresof7800,14,000,and60,000
pounds。Eachmachinemadethesebriquettesattherateofsixtyperminute,anddroppedthemintobucketconveyorsbywhichtheywerecarriedintodryingfurnaces,throughwhichtheymadefiveloops,andwerethendeliveredtocross-conveyorswhichcarriedthemintothestock-house。Attheendofthisprocessthebriquettesweresohardthattheywouldnotbreakorcrumbleinloadingonthecarsorintransportationbyrail,whiletheyweresoporousastobecapableofabsorbing26percent。oftheirownvolumeinalcohol,butrepellingwaterabsolutely——
perfect“oldsoaks。“
Thus,withnever-failingpersistenceandpatience,coupledwithintensethoughtandhardwork,Edisonmetandconquered,onebyone,thecomplexdifficultiesthatconfrontedhim。Hesucceededinwhathehadsetouttodo,anditisnowtobenotedthattheproducthehadstrivensosedulouslytoobtainwasahighlycommercialone,fornotonlydidthebriquettesofconcentratedorefulfilthepurposeoftheircreation,butinuseactuallytendedtoincreasetheworkingcapacityofthefurnace,asthefollowingtest,quotedfromtheIronAge,October28,1897,willattest:“Theonlytrialofanymagnitudeofthebriquettesintheblast-furnacewascarriedthroughearlythisyearattheCraneIronWorks,Catasauqua,Pennsylvania,byLeonardPeckitt。
“Thefurnaceatwhichthetestwasmadeproducesfromonehundredtoonehundredandtentonsperdaywhenrunningontheordinarymixture。Thechargingofbriquetteswasbegunwithapercentageof25percent。,andwascarriedupto100percent。
Thefollowingistherecordoftheresults:
RESULTSOFWORKINGBRIQUETTESATTHECRANEFURNACE
QuantityofPhos-Man-
DateBriquetteTonsSilicaphorusSulphurganeseWorkingPerCent。
January5th251042。7700。8300。0180。500
January6th371/241/22。62007400。0180。350
January7th501381/22。5720。5800。0150。200
January8th751191。8440。2640。0220。200
January9th1001381/21。7120。1470。0380。185
“Onthe9th,at5P。M。,thebriquetteshavingbeennearlyexhausted,thepercentagewasdroppedto25percent。,andonthe10ththeoutputdroppedto120tons,andonthe11ththefurnacehadresumedtheusualworkontheregularstandardores。
“Thesefiguresprovethattheyieldofthefurnaceisconsiderablyincreased。TheCranetrialwastooshorttosettlethequestiontowhatextenttheincreaseinproductmaybecarried。Thisincreaseinoutput,ofcourse,meansareductioninthecostoflaborandofgeneralexpenses。
“Therichnessoftheoreanditspurityofcourseaffectthelimestoneconsumption。InthecaseoftheCranetrialtherewasareductionfrom30percent。to12percent。oftheorecharge。
“Finally,thefuelconsumptionisreduced,whichinthecaseoftheEasternplants,withtheirrelativelycostlycoke,isaveryimportantconsideration。ItisregardedaspossiblethatEasternfurnaceswillbeabletouseasmallerproportionofthecostliercokeandcorrespondinglyincreaseinanthracitecoal,whichisacheaperfuelinthatsection。Sofarasfoundryironisconcerned,theexperienceatCatasauqua,Pennsylvania,briefasithasbeen,showsthatastrongerandtoughermetalismade。“
Edisonhimselftellsaninterestinglittlestoryinthisconnection,whenheenjoyedtheactivehelpofthatnoblecharacter,JohnFritz,thedistinguishedinventorandpioneerofthemodernsteelindustryinAmerica。Hesays:“WhenIwasstrugglingalongwiththeiron-oreconcentration,Iwenttoseeseveralblast-furnacementoselltheoreatthemarketprice。