The Corning Ribbon Machine For Incandescent Light Bulb Blanks

The Corning Ribbon Machine
For Incandescent Light Bulb Blanks
International Historic Mechanical Engineering Landmark
1983
American Society of Mechanical Engineers
Will Woods And His
Fabulous Machine When William J. Woods first came to work at Corning Glass Works in
1898, there was little — except for his shock of auburn hair — that would have
indicated he was anything out of the ordinary.
Of medium height and weight, 19-year-old Woods — everyone called him Will —
was a newcomer to Corning, N.Y., from the Pittsburgh area where he had been
born in the town of Martinsburg to an Irish mother and a Scottish father. As a
boy, he had learned to blow glass in the Westinghouse Glass Works, one of
many such enterprises which flourished off the abundant coal that underlay the
wooded ridges of western Pennsylvania.
Will Woods had come to Corning to pursue his calling as a glassblower. And
despite his appearance, Will Woods was anything but ordinary.
He was a man with an instinctive fascination for the inner workings of
machinery. Although Woods had little formal education and no training
whatsoever in the mechanical arts, his “open and independent mind,” in the
words of one Corning Glass historian, enabled him to see possibilities hidden to
others of his trade.
It was a time for invention, one of those rare periods in human history when the
activity of man’s mind resulted in technological achievement that forever
changed the face of the earth and man’s outlook upon it.
One of these triumphs was the invention, in 1879 (the year of Will Woods’
birth), of a successful incandescent electric light bulb by Thomas Alva Edison,
the “Wizard of Menlo Park” whose keen intellect and driving spirit also
produced the phonograph, the motion picture and countless other inventions
and improvements.
A BOYISH WILL WOODS DEMONSTRATES
THE GLASSBLOWING
TECHNIQUE THAT
BROUGHT HIM SUCCESS.
1
‘Let There Be
Light Bulbs’
A CORNING INVOICE DATED
1880 SHOWS THE PURCHASE
OF VARIOUS KINDS OF GLASS
TUBING BY THOMAS EDISON
“FOR ELECTRIC LIGHT.”
Aware of the company’s dedication to science and engineering,
Edison had chosen Corning Glass to manufacture the glass envelope for his first
bulbs. The carbon filament that first glowed brightly in his New Jersey
laboratories was enclosed by a bulb produced by Corning glassblowers to
Edison’s specifications.
That first bulb sparked a dream in the minds of many: a world where the sunset
would no longer limit man’s activities, a world where inexpensive electricity
could illuminate even the darkest and most farflung of regions.
Electric light certainly was no myth, but in the years following Edison’s
invention, it proved more difficult to achieve than had been at first anticipated.
Although its possibilities were immediately foreseen, production was difficult
and expensive.
While filaments and bases could be manufactured, glass bulb envelopes could
be made only by hand, or by mouth as it were, by glassblowers skilled in an
ancient trade. These master craftsmen, called gaffers, learned their trade during
a long apprenticeship and were few in number.
2
Towards Automation
AT THE TURN OF THE CENTURY,
A TEAM OF TWO MEN
COULD PRODUCE THREE
GLASS BULBS PER MINUTE.
Working at top speed in the red-orange radiance of a glass-melting tank, a team
of two men, gaffer and assistant, could produce two bulbs per minute in the
glass works of the 1890s. It was clear that, at this speed, Edison’s Age of
Universal Light would be a long time dawning. To complicate matters further,
the hand-blown bulbs were expensive by the standards of the time, so that,
even if large enough quantities could be produced, they would be beyond the
means of most people even in nations that were rapidly developing their
industrial base.
Nevertheless, the concept of the electric light fired the imagination, and people
embraced it eagerly. News of Edison’s remarkable success spread over the globe
with only slightly less speed than that of light itself.
Into this climate stepped young Will Woods, glassblower. In 1907,
eight years after Woods had come to Corning Glass, the company began work
on what was to become known as the “E” Machine, the world’s first automated
process for glass light bulb envelope production.
Automated, but hardly automatic, the Empire “E” Machine (Empire was a
Corning Glass subsidiary founded to design and produce automated glass-making
and finishing machinery) still required workers to “gather” the molten glass by
hand for blowing into bulbs.
By 1913, the “E” Machine was producing glass bulbs at the then- rapid rate of
seven per minute. Corning installed numbers of these machines at its newly
purchased plant in nearby Wellsboro, Pa. — where Will Woods had been
transferred — and the race for automatic light bulb envelope production began
in earnest.
It had indeed become a race. In 1912, even before the “E” Machine began
producing bulbs, Empire engineers had in 1912 begun work on its successor,
appropriately named the “F” Machine. And even earlier, General Electric had
3
A Shovel, A Gob
And A Brainstorm
AN EARLY ATTEMPT AT AUTOMATING
THE BULB-BLOWING
PROCESS RESULTED IN
THIS ODD-LOOKING MACHINE.
THE AIR WAS STILL
SUPPLIED BY LUNG POWER
begun work on its “Westlake” machine, which promised to eclipse the hardworking
“E” types.
The “Westlake” and “F” machines were rotary-type machines, capable of
producing 12, 24 or 48 bulb envelopes during each revolution. Glass was
delivered to the machines as they operated, eliminating the cumbersome and
time-consuming hand-gather system that slowed the operation of the “E”
Machine to a relative crawl. Corning began installing the “F” Machines in its
Wellsboro plant in 1923.
Will Woods was not idle during these years of machine development.
First in Corning and then in Wellsboro, he actively studied the crafthe had
chosen until he had become a master gaffer himself.
Greatly intrigued by the possibilities of electric light and the application of
mechanical technology to the production of light bulbs, Woods had become
instrumental to the success of the slow but effective “E” Machine at Wellsboro.
rising to the post of production superintendent by 1917.
Woods’s production efforts quickly became the stuff of legend. Corning Glass
historian George Buell Hollister records that “With the help of a few bulb
gatherers brought from the Corning plant he manned his battery of machines
with boys from the neighboring farms, taught them to handle the equipment
and in a surprisingly short time transformed them into a body of efficient
workmen.”
Then, in the spring of 1921, Woods conceived the idea that would, if not bring
him fame, at least secure him the enviable reputation of a man of mechanical
genius.
Otto Hilbert, a companion of Woods, wrote in 1979 that Woods saw a shovel
which had been used to collect glass. On that shovel was a still-molten gob of
4
THE “E” MACHINE WAS A
DIRECT ANCESTOR OF THE
RIBBON MACHINE. WILLIAM J
WOODS APPEARS (IN BOW TIE)
IN RIGHT CENTER BACKGROUND.
glass which looked like a light bulb blank.
Another account has it that the shovel had a hole in it, a hole through which the
semi-molten glass had sagged in the shape of a bulb blank.
Whatever the truth, in the spring of 1921, Will Woods suddenly conceived the
revolutionary idea of automatically blowing light bulb blanks through a hole in a
metal plate.
It was a simple idea; simple, but elgant in its simplicity. Woods had gone to
the heart of the matter, and his idea was to change radically the way in which
bulb blanks were – and are – manufactured.
And like all ideas which promise radical change, it was greeted with skepticism
on the part of Woods’s fellow glassblowers, who preferred traditional methods of
making bulb blanks to the newfangled machines that already were taking their
places in the nation’s glass plants. (In Europe, nearly all bulbs still were being
blown by hand.)
5
From Brainstorm To
Bulb Blanks
Nevertheless, an undaunted Woods persevered with his conception and won
the minds of Corning’s engineering staff; the company authorized construction
of a prototype – if indeed one could be constructed – to test Woods’s theory.
That theory, basically, was this: If a gather of molten glass were flattened and
then placed on a plate with a hole of the proper size, the glass might sag through
the hole to form a globular bag. If air were then forced into this bag, it might be
expanded to form the basic shape of a bulb blank. To perfect this shape, a mold
could be closed around it and the air pressure continued.
Then carne the piece de resistance: If a series of such plates were hinged
together to form an “endless chain” or belt, and a flat stream of molten glass
were to be laid on the belt while in motion, perfect blanks might be made in
continuous succession.
Historian Hollister continues: “With this basic idea in mind, Woods started to
experiment with a single plate and a plunger or blowhead by which he could
introduce air into the bag formed by the molten glass sagging through the hole
or orifice in the plate, and after many attempts succeeded in forming bags which
had all the earmarks of the beginnings of good bulb blanks . . .
“The full solution of the problem then resolved itself into the designing of a
mechanism which would first form the desired blanks and, second, conduct
them with properly maintained temperatures and predetermined speed through
the elongating and blowing operations and, finally, to the finished bulb.”
Will Woods had conceived the fabulous Ribbon Machine. The problem of
building one remained.
The building known as Building 9 on Corning’s Pine Street already was
old when Will Woods moved in with his development crew of one person,
6
IN LATER YEARS, WOODS ENJOYED
AN OFFICE – AND A
STRAW BOATER – OF HIS OWN.
David E. Gray. But Gray was no ordinary developer, just as Woods was no
ordinary inventor.
Gray had been trained in mechanical engineering at the Massachusetts Institute
of Technology. Experienced and competent, Gray was in 1922 Corning Glass
Works’ chief engineer and a man with a special interest in the development of
machines to manufacture glass products.
It was Gray who, intrigued with Woods’ idea for a bulb blank machine, had
studied the possibilities and concluded such a machine was practical. Astonished
at the results of his own study, Gray decided to produce the prototype and
found the funds to proceed.
Woods and Gray didn’t know they were working on the Ribbon Machine. On
the origina1 books for the project, the machine was called, in code, the “399
Machine.” Later, it became known, as if there were no other machine in the
world, as “The Corning Machine.”
7
The Ribbon Machine:
A Runaway Success
Indeed, there was no other machine in the world like the one Woods and Gray
were constructing in Building 9.
Woods’s conception proved remarkably adaptable to design and construction,
and the older machines had provided a wealth of experience that guided the
Ribbon Machine’s developers to a successful conclusion.
By 1925, it had become clear to Woods and Gray – and to others at Corning –
that the Ribbon Machine had become a reality. By 1926 the ungainly creature
began to produce bulb blanks, slowly at first, but with increasing rapidity. The
derisive hoots which had greeted Woods’s idea gave way to awe.
As it emerged from its creative metamorphosis in the cocoon of
Building 9, the first Ribbon Machine presented an awesome sight.
A glass melting tank sat above one end of the machine, feeding a stream of
molten glass from its forehearth down between two metal drums, which
flattened the glass into a thick, glowing ribbon. This yellow-orange ribbon was
laid onto a series of square plates, each with a small hole in its center, which
were linked together in the manner of a bicycle chain and driven by sprockets at
either end of the oval.
As soon as the glass ribbon was laid on the chain, the glass began to sink through
the holes, giving nascent form to the future bulb blanks. A chained series of
moving plungers above the chain descended on the hot ribbon, pushing
compressed air into the sagging glass. And a third chain, below and inside the
first, thrust up a series of split molds which snapped together around the
forming glass to give final shape to the bulb blanks before unsnapping just as
quickly to revea1 the familiar light bulb configuration.
For each bulb blank, the entire forming operation lasted but a few seconds,
resulting in what one observer termed “a veritable shower” of finished bulbs as
8
Bulbs For The Lamps
Of The World
THE CORNING RIBBON MACHINE:
DELIVERS FINISHED
BULBS AT DIZZYING RATES UP
TO 2000 PER MINITE.
the blanks were tapped off a fraction of a second apart.
The first production runs of the prototype Ribbon Machine were astonishing,
especially to those used to the slower “E” and “F” machines. Actual records
show runs of around 400,000 blanks in 24 hours, almost five times the output of
the earlier machines.
In the 1890s only 20 to 30 years before the advent of the Ribbon
Machine, the slogan of American merchants seeking to participate in the
Chinese market had been “Oil for the lamps of China.”
By 1926, when the first Ribbon Machines were installed in Corning’s Wellsboro
plant, that slogan was irrevocably dated. The new machine would provide bulbs
for the lamps of the world. And it was becoming more and more apparent that it
wouldn’t take very many Ribbon Machines to provide those bulbs, either.
The Ribbon Machine was a marvel of efficiency. The astonishing figures of the
early production runs were, by 1930, almost ancient history as the Ribbon
Machine reached, and then surpassed, 1 million bulb blanks in 24 hours. This
figure, in turn, receded as the Ribbon Machine was fine-tuned to its capacity of
some 2,000 bulb blanks per minute, or nearly 3 million blanks in 24 hours, for
smaller-sized bulbs.
With few mechanical changes, the Corning Ribbon Machine remains the
highest state of the technology today, more than 50 years after its conception
and construction in the old building, long since vanished, on Corning’s Pine
Street. Fewer than 15 Ribbon Machines now supply the entire world’s
consumption of glass blanks for incandescent light bulbs, with the exception of
some small blanks that are hand-made for specialty lamps.
9
Ribbon Machines Today
ROLLERS SQUEEZE HOT
GLASS FROM MELTING ‘IANK
INTO THE CHARACTERISTIC
“RIBBON” OF ‘IHE CORNING
RIBBON MACHINE.
HOT GLASS RIBBON SAGS
‘IHROUGH HOLES IN PLATES
BEFORE COMPRESSED AIR
JETS COMPLETE THE BLOWING
PROCESS.
Ribbon Machines are flourishing in England, Belgium, Hungary, the Soviet
Union, Japan and Iraq, providing inexpensive light bulb components for the
light which now illuminates homes from the grandest of manors to the meanest
of hovels.
Today, there are two different types of Ribbon Machine, the lowervolume
Model 100 and the faster Model 400. Both have chain pitches of three
inches and manufacture bulb envelopes in weights from eight to 45 grams, with
maximum and minimum outer diameters of 67 and 19 millimeters respectively
and maximum and minimum bulb lengths of 171.5 millimeters and 50
millimeters.
Both machines have the ability to produce irregular shapes, and, by using a
process known as the nonrotating-mold hot-iron process, both may manufacture
nonsymmetrical shapes.
The 25foot-long Model 100 Ribbon Machine, operating at a standard speed of
275-300 pieces per minute (ED 60/A-type bulb blanks) can produce 100 million
perfect bulb envelopes per year. Operating at a standard speed of 1000-1100
pieces per minute (ED 60/A blanks), the Model 400 can manufacture 400
million bulb envelopes per year.
These Ribbon Machines are little changed from the prototype model built by
Woods and Gray. On the original, the holed plates were split, but on the
modern versions, these plates are in one piece.
The single problem encountered by Woods and Gray – breakage of the blanks
as they were separated from the plates – was solved before 1930 with a tap-off
system that delivers a quick blow to the blank at the point where it joins the
orifice plate, allowing a clean break with minimum breakage.
10
MOLDS CLOSE AROUND SAGGING
GLASS TO GIVE FINAL
FORM TO BULB BLANKS.
Coda
Today’s Ribbon Machines manufacture not only light bulb blanks, but a wide
variety of other glass components, including such seemingly divergent items as
vacuum bottles and clock domes.
After 1930, it quickly was recognized that the Ribbon Machine would become
the standard manufacturing technology for light bulb blanks. Corning retired its
almost-new “F” Machines in favor of the quicker technology. General Electric
did the same with its once-formidable “Westlake” machines, licensing the
Ribbon Machine technology in its stead. By the decade’s end, the Ribbon
Machine had assumed its rightful place as the sole machine for production of
incandescent light bulb blanks.
Even though Corning kept its “E” Machines in use into the 1940s for the
production of items unrelated to lighting, an era that had begun with Edison had
ended in the ultimate triumph of Will Woods and his marvelous machine.
Will Woods wasn’t quite finished, however. Before his death on
Christmas Eve, 1937, he also perfected what became known as the Woods
Updraw Tubing Machine for the fully automatic production of thermometer
tubing. But that’s another story.
Corning Glass Works slowly is leaving the once-profitable business of
manufacturing glass light bulb blanks. The famed specialty glass firm continues
to license the Ribbon Machine technology worldwide, however, through its
subsidiary company, Corning Engineering. And Corning has not forgotten its
involvement with light – among its newer products are optical waveguides, hairthin
strands of glass that permit the long-distance transmittance of thousands of
simultaneous telephone calls using pulsed light.
11
The company was proud to learn that the American Society of Mechanical
Engineers had designated the Ribbon Machine as the tenth International
Historic Mechanical Engineering Landmark, a ranking which places it on a scale
with the first operational steam engine in considering mechanical devices that
have changed the face of history.
Will Woods, the unassuming and unsung hero of the Age of Universal Light,
would surely have been gratified.
SCHEMATIC RENDERING
SHOWS AN ENGINEERING IMPROVEMENT.
PLATES NOW
MOVE ON CHAIN AROUND RIBBON
MACHINE.
12
International Historic Mechanical Engineering Landmark
1983
American Society of Mechanical Engineers
H081
CORNING