Q. David Bowers
Making Planchets
Just turn around and we shall sec the next process the strip undergoes, after being washed free from grease or wax in warm water. Round pieces, called planchets, a little larger than the coins they are to make, are being cut from them. Four cutting presses of one kind are in a row; but more being required, Mr. Peale constructed two on about the same principle, but much more compact and handsome. They are not, however, quite so conveniently adjusted as the old ones; and as these show the mode of operating more plainly, we will examine them.
The press consists of a vertical steel punch, which works in a round hole or matrix, cut in a solid steel plate. The action of the punch is obtained by an eccentric wheel. For instance, in an ordinary carriage wheel the axis is in the centre, and the wheel revolves evenly around it. But if the axis is placed, say four inches from the centre, then it would revolve with a kind of hobble. From this peculiar motion is its name derived. Suppose the tire of the wheel is arranged, not to revolve with, but to slip easily around the wheel, and a rod is fastened to one side of the tire which prevents its turning. Now as the wheel revolves and brings the long side nearest the rod, it will push forward the rod, and when the long side of the wheel is away from the rod, it draws the rod with it.
The upper shaft, on which are seen the three large wheels, has also fastened to it, over each press, an eccentric wheel. In the first press will be seen three upright rods running from near the table to the top. The middle one is connected with a tire around the eccentric wheel, and rises and falls with each revolution. The eccentric power is very popular among machinists, as it gives great rapidity of motion with but little jerking.
The operator places one end of the strip under the punch and cuts out a couple of planchets, which are a fraction larger than the coin to be struck. As the strips are of uniform thickness, if these two are of the right weight, all cut from the strip will be. They are therefore weighed accurately. If right, or a little too heavy, they are allowed to pass, as the extra weight can- be filed off. If too light, the whole strip has to be remelted. The strips that are correct are quickly cut up, the press striking 220 double eagle planchets, or 250 smaller pieces, in a minute. A man has cut over a million dollars in double eagles [planchets] in a single day.
As fast as cut the planchets fall into a box below, and the perforated strips are folded into convenient lengths to be remelted. From a strip valued at about eleven hundred dollars, eight hundred dollars of planchets will be cut. They are still in a very rough, ragged state, and look but little like coin. The second press, rather smaller than the rest, is the first introduced, and has been in constant 'Use for about 40 years; has never been broken, or had 50 cents' worth of repairs done to it.
We will leave this room, and go into a much more cheerful one for a moment, to see the sorting of the planchets. They are thrown upon a table with two holes in it, and a woman picks out all the imperfect pieces or chips, which are slipped into one hole, and the perfect ones into the other, where they fall into different boxes.
It is not much to see; so come into the entry, up the marble stairs to the second story, past the Director's room, out upon a.gallery looking down upon the courtyard below. At the further end of the gallery we pass through a small entry, and enter a room. What a peculiar noise, like a young ladies' school at recess, only a strange filing sound withal! Nearly 60 females, some young and pretty, some middle-aged and fine-looking. Jessie will have to do the examination: we can not stand the 120 eyes brought to a focus on us.
She tells us it is the Adjusting Room. Each operator has on the table before her a pair of assay scales. Seated close to the table, a leather apron, one end tacked to the table, is fastened under her arms to catch any gold that may fall. In short sleeves, to avoid sweeping away the dust, and armed with a fine flat file, she is at work, chatting and laughing merrily. She catches a double eagle planchet from a pile by her side and puts it into the scale. It is too heavy. She files around the edge, and weighs it. Still too heavy. Files it again, and weighs it. Almost right. Just touches it with the file. Right; the index is in the centre. She tosses it into the box, and picks up another to undergo the same operation.
The proper weight of the double eagle is 516 grains, and the smaller gold coins are in the same proportion. Absolute perfection is impossible in the weight of a coin, as in other matters, and the law therefore allows a variation of one half of a grain in the double eagles; therefore, between a heavy and a light piece, there may be a difference of one grain. This is so slight, however, not two cents in value, as to be deemed sufficiently correct. The weight of the silver half dollar is 192 grains, and smaller pieces in proportion, with the exception of the cent, which, being composed of 88 per cent copper and 12 per cent nickel, the weight is 72 grains. The weight of the silver coin was reduced in April 1853. Prior to that date the half dollar was 206-1/4 grains.
To adjust a coin so accurately requires great delicacy and skill, as a too free use of the file would quickly make it too light. Yet by long practice, so accustomed do the operators become, that they work with apparently recklessness, scarcely glancing at planchet or scales, but seemingly guided by their touch. Our artist attempted to obtain a photograph of the room while they were at work, but it was found impossible for 55 out of the 60 to remain quiet long enough for the camera to operate. It was necessary to take the room after they had left, supplying the figures in the drawing.
The exceedingly delicate scales were made under the direction of Mr. Peale, who greatly improved on the old ones in use. So delicate are they that the slightest breath of air affects their accuracy, rendering it necessary to exclude every draft from the room, which, being poorly ventilated, in a hot day is an uncomfortable and probably an unhealthy place. Colonel Childs, the late chief coiner, exercised great care to counteract this difficulty by occasionally stopping work, and opening the windows. The whole process, however, is behind the times. Hand-work can not compete with machinery. Sixty adjusters can not keep the coining presses supplied, and genius must find a quicker way of performing the work. It is here that the delay occurs, keeping depositors waiting from 20 to 30 days for the coin they should receive in a week. It is astonishing that our Mint has not made the advancement here that it has in every other department.
Only the gold pieces are adjusted in this manner. The silver has merely the adjustment of the two planchets weighed at the cutting press. A greater allowance is made in the weight of the silver coin, as it is less valuable, and it would be almost impossible to have such a vast number of small pieces separately examined. Mr. Peale ordered from Paris a beautiful and delicate coin-separator, which he intended to apply to silver (although the one received is adapted to the half eagle only), but owing to its not arriving until he had been removed it has never been put into operation. It is so arranged that the planchets, being placed in at one end, are carried through the hopper and dropped singly on a balance. If too light it is tipped into a box at one side; if too heavy, into another box; if exactly right, into a third box. The instrument does not adjust the weight, but merely separates the heavy and light planchets. For silver, however, this would be desirable, as a more uniform weight could be preserved. Why it has never been put into use we are unable to learn.
The females in the adjusting room are paid $1.10 a day for 10 hours work. They look happy and contented. Behind the screens, at each end of the room, are dining halls, where they eat the dinners they bring with them. On the whole, it is the pleasantest workshop for women we have yet seen, and the pay, in comparison with that ordinarily given to women, is good.