Advances in Manufacturing, Production

Management and Process Control:

Proceedings of the AHFE 2019
International Conference on Human
Aspects of Advanced Manufacturing,
and the AHFE International Conference
on Advanced Production Management
and Process Con Waldemar Karwowski
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Advances in Intelligent Systems and Computing 971

Waldemar Karwowski
Stefan Trzcielinski
Beata Mrugalska Editors

Advances in Manufacturing,
Production Management
and Process Control
Proceedings of the AHFE 2019
International Conference on Human
Aspects of Advanced Manufacturing,
and the AHFE International Conference
on Advanced Production Management
and Process Control, July 24–28, 2019,
Washington D.C., USA
Advances in Intelligent Systems and Computing

Volume 971

Series Editor
Janusz Kacprzyk, Systems Research Institute, Polish Academy of Sciences,
Warsaw, Poland

Advisory Editors
Nikhil R. Pal, Indian Statistical Institute, Kolkata, India
Rafael Bello Perez, Faculty of Mathematics, Physics and Computing,
Universidad Central de Las Villas, Santa Clara, Cuba
Emilio S. Corchado, University of Salamanca, Salamanca, Spain
Hani Hagras, School of Computer Science & Electronic Engineering,
University of Essex, Colchester, UK
László T. Kóczy, Department of Automation, Széchenyi István University,
Gyor, Hungary
Vladik Kreinovich, Department of Computer Science, University of Texas
at El Paso, El Paso, TX, USA
Chin-Teng Lin, Department of Electrical Engineering, National Chiao
Tung University, Hsinchu, Taiwan
Jie Lu, Faculty of Engineering and Information Technology,
University of Technology Sydney, Sydney, NSW, Australia
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of Technology, Tijuana, Mexico
Nadia Nedjah, Department of Electronics Engineering, University of Rio de Janeiro,
Rio de Janeiro, Brazil
Ngoc Thanh Nguyen, Faculty of Computer Science and Management,
Wrocław University of Technology, Wrocław, Poland
Jun Wang, Department of Mechanical and Automation Engineering,
The Chinese University of Hong Kong, Shatin, Hong Kong
The series “Advances in Intelligent Systems and Computing” contains publications
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Waldemar Karwowski •

Stefan Trzcielinski Beata Mrugalska

•

Editors

Advances in Manufacturing,
Production Management
and Process Control
Proceedings of the AHFE 2019 International
Conference on Human Aspects of Advanced
Manufacturing, and the AHFE International
Conference on Advanced Production
Management and Process Control,
July 24–28, 2019, Washington D.C., USA

123
Editors
Waldemar Karwowski Stefan Trzcielinski
Department of Industrial Engineering Poznan University of Technology
and Management System Poznan, Poland
University of Central Florida
Orlando, FL, USA

Beata Mrugalska
Poznan University of Technology
Poznan, Poland

ISSN 2194-5357 ISSN 2194-5365 (electronic)

Advances in Intelligent Systems and Computing
ISBN 978-3-030-20493-8 ISBN 978-3-030-20494-5 (eBook)
https://doi.org/10.1007/978-3-030-20494-5
© Springer Nature Switzerland AG 2020
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Advances in Human Factors
and Ergonomics 2019

AHFE 2019 Series Editors

Tareq Ahram, Florida, USA
Waldemar Karwowski, Florida, USA

10th International Conference on Applied Human Factors and Ergonomics and the
Affiliated Conferences

Proceedings of the AHFE 2019 International Conference on Human Aspects of

Advanced Manufacturing, and the AHFE International Conference on Advanced
Production Management and Process Control, held on July 24–28, 2019, in
Washington D.C., USA

Advances in Affective and Pleasurable Design Shuichi Fukuda

Advances in Neuroergonomics Hasan Ayaz
and Cognitive Engineering
Advances in Design for Inclusion Giuseppe Di Bucchianico
Advances in Ergonomics in Design Francisco Rebelo and Marcelo M. Soares
Advances in Human Error, Reliability, Resilience, Ronald L. Boring
and Performance
Advances in Human Factors and Ergonomics in Nancy J. Lightner and Jay Kalra
Healthcare and Medical Devices
Advances in Human Factors and Simulation Daniel N. Cassenti
Advances in Human Factors and Systems Isabel L. Nunes
Interaction
Advances in Human Factors in Cybersecurity Tareq Ahram and Waldemar Karwowski
Advances in Human Factors, Business Jussi Ilari Kantola and Salman Nazir
Management and Leadership
Advances in Human Factors in Robots Jessie Chen
and Unmanned Systems
Advances in Human Factors in Training, Waldemar Karwowski, Tareq Ahram
Education, and Learning Sciences and Salman Nazir
Advances in Human Factors of Transportation Neville Stanton
(continued)

v
vi Advances in Human Factors and Ergonomics 2019

(continued)
Advances in Artificial Intelligence, Software Tareq Ahram
and Systems Engineering
Advances in Human Factors in Architecture, Jerzy Charytonowicz and Christianne
Sustainable Urban Planning and Infrastructure Falcão
Advances in Physical Ergonomics and Human Ravindra S. Goonetilleke and Waldemar
Factors Karwowski
Advances in Interdisciplinary Practice in Industrial Cliff Sungsoo Shin
Design
Advances in Safety Management and Human Pedro M. Arezes
Factors
Advances in Social and Occupational Ergonomics Richard H. M. Goossens and Atsuo
Murata
Advances in Manufacturing, Production Waldemar Karwowski, Stefan
Management and Process Control Trzcielinski and Beata Mrugalska
Advances in Usability and User Experience Tareq Ahram and Christianne Falcão
Advances in Human Factors in Wearable Tareq Ahram
Technologies and Game Design
Advances in Human Factors in Communication Amic G. Ho
of Design
Advances in Additive Manufacturing, Modeling Massimo Di Nicolantonio, Emilio Rossi
Systems and 3D Prototyping and Thomas Alexander
Preface

Contemporary manufacturing enterprises aim to deliver a great number of consumer

products and systems through friendly and satisfying working environments for
people who are involved in manufacturing services. Human-centered design factors,
which strongly affect manufacturing processes, as well as the potential end-users,
are crucial for achieving continuous progress in this respect. Researchers around the
world attempt to improve the quality of consumer products and working environ-
ments. The AHFE International Conference on Advanced Production Management
and Process Control (APMPC) promotes the exchange of ideas and developments
in production, sustainability, life cycle, innovation, development, fault diagnostics,
and control systems. It addresses a spectrum of theoretical and practical topics. It
provides an excellent forum of exploring frontiers between researchers and prac-
titioners from academia and industry. It offers the possibility of discussing research
results, innovative applications, and future directions.
We believe that such findings can either inspire or support others in the field of
manufacturing and process control to advance their designs and implement them
into practice. Therefore, this book is addressed to both researchers and practitioners.
The papers presented in this book have been arranged into nine sections. The
first three sections focus mainly on topics in advanced manufacturing, while the
remaining six sections focus on topics related to advanced production management
and process control.
Section 1 Ergonomics in Manufacturing
Section 2 Agile Manufacturing
Section 3 Competencies in Work Environment
Section 4 Human Aspects in Industrial and Work Environment
Section 5 Strategic Decision-Making Models in Manufacturing
and Service Systems
Section 6 Manufacturing Aspects of Work Improvement

vii
viii Preface

Section 7 Production Management and Process Control

Section 8 Management Approaches in Contemporary Enterprise
Section 9 Production, Quality, and Maintenance Management.

The contents of this book required the dedicated effort of many people. We
would like to thank the authors, whose research and development efforts are pub-
lished here. Finally, we also wish to thank the following editorial board members
for their diligence and expertise in selecting and reviewing the presented papers:

Advanced Manufacturing

Madalena Araujo, Portugal

Dominique Besson, France
Lucia Botti, Italy
Alan Chan, China
Keyur Darji, India
Enda Fallon, Ireland
Sarah Fletcher, UK
Weimin Ge, China
H. Hamada, Japan
Irena Hejduk, Poland
Joanna Kalkowska, Poland
Aleksandr Kozlov, Russia
Guangwen Luo, China
Preeti Nair, India
Edmund Pawlowski, Poland
Aleksandra Polak-Sopinska, Poland
Vesa Salminen, Finland
Antonio Lucas Soares, Portugal
Lukasz Sulkowski, Poland
Gyula Szabó, Hungary
Yingchun Wang, China
Marc-Andre Weber, Germany
Hanna Wlodarkiewicz-Klimek, Poland
Preface ix

Production Management and Process Control

Salvador Ávila Filho, Brazil

Mihai Dragomir, Romania
Murray Gibson, USA
Akihiko Goto, Japan
Adam Hamrol, Poland
Aidé Aracely Maldonado Macias, Mexico
Jörg Niemann, Germany
Tomoko Ota, Japan
Silvio Simani, Italy
Yusuf Tansel İç, Turkey
Magdalena Wyrwicka, Poland

July 2019 Waldemar Karwowski

Stefan Trzcielinski
Beata Mrugalska
Contents

Ergonomics in Manufacturing
Development of an Intelligent Robotic Additive Manufacturing
Cell for the Nuclear Industry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Richard French, Hector Marin-Reyes, Gabriel Kapellmann-Zafra,
and Samantha Abrego-Hernandez
Manageable and Scalable Manufacturing IT Through
an App Based Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Christian Knecht, Andreas Schuller, and Andrei Miclaus
Ergonomics Principles for the Design of an Assembly Workstation
for Left-Handed and Right-Handed Users . . . . . . . . . . . . . . . . . . . . . . . 27
Lucia Botti, Alice Caporale, Maddalena Coccagna, and Cristina Mora
Impact of Industry 4.0 on Occupational Health and Safety . . . . . . . . . . 40
Aleksandra Polak-Sopinska, Zbigniew Wisniewski,
Anna Walaszczyk, Anna Maczewska, and Piotr Sopinski
Lean Production Management Model for SME Waste
Reduction in the Processed Food Sector in Peru . . . . . . . . . . . . . . . . . . 53
José Chávez, Fernando Osorio, Ernesto Altamirano, Carlos Raymundo,
and Francisco Dominguez
Qualitative Features of Human Capital in the Formation
of Enterprise Agility. Research Results in Polish Enterprises . . . . . . . . . 63
Hanna Wlodarkiewicz-Klimek

xi
xii Contents

Agile Manufacturing
Reflections on Production Working Environments
in Smart Factories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Sebastian Pimminger, Werner Kurschl, Mirjam Augstein,
Thomas Neumayr, Christine Ebner, Josef Altmann,
and Johann Heinzelreiter
The Relation of Proexploitation Attributes with Selected
Criterion of Agility of Public Transport Vehicles Manufacturing . . . . . 86
Joanna Kalkowska
Management System of Intelligent, Autonomous Environment
(IAEMS). The Methodological Approach to Designing
and Developing the Organizational Structure of IAEMS . . . . . . . . . . . . 92
Edmund Pawlowski and Krystian Pawlowski
Lean Manufacturing Model in a Make to Order Environment
in the Printing Sector in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Adriana Becerra, Alessandro Villanueva, Víctor Núñez,
Carlos Raymundo, and Francisco Dominguez
The Influence of Macroenvironment Changes on Agility
of Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Stefan Trzcielinski
Agile Management Methods in an Enterprise Based
on Cloud Computing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Michal Trziszka

Competencies in Work Environment

Competency Model for Logistics Employees in Smart Factories . . . . . . 133
Markus Kohl, Carina Heimeldinger, Michael Brieke,
and Johannes Fottner
Competency Profiles as a Means of Employee Advancement
for a Resource-Efficient Chipping Production . . . . . . . . . . . . . . . . . . . . 146
Leif Goldhahn, Robert Eckardt, Christina Pietschmann,
and Sebastian Roch

Human Aspects in Industrial and Work Environment

Cognitive and Organizational Criteria for Workstation Design . . . . . . . 161
Salvador Ávila, Beata Mrugalska, Magdalena K. Wyrwicka,
Maraisa Souza, Jade Ávila, Érica Cayres, and Júlia Ávila
Contents xiii

Motion Analysis of Manufacturing of Large “Echizen Washi”

Japanese Traditional Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Yuji Kawamori, Hiroyuki Nkagawa, Akihiko Goto, Hiroyuki Hamada,
Kazuaki Yamashiro, Naoki Sugiyama, Mitsunori Suda, Kozo Igarashi,
and Yoshiki Yamada
Cognitive Analyses for the Improvement of Service Orders
in an Information Technology Center: A Case of Study . . . . . . . . . . . . 188
Manuel Alejandro Barajas-Bustillos, Aide Maldonado-Macias,
Margarita Ortiz-Solis, Arturo Realyvazquez-Vargas,
and Juan Luis Hernández-Arellano
Design of a Model of Assignment of Workers and Operations
that Reduces the Biomechanical Danger in a Panela Productive
Unit of Colombia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Y. A. Paredes-Astudillo and Juan P. Caballero-Villalobos
Job Strain Index by Gender Among Middle and High Managers
of the Maquiladora Industry in Ciudad Juarez Mexico . . . . . . . . . . . . . 209
Aidé Aracely Maldonado-Macías, Margarita Ortiz Solís,
Oziely Daniela Armenta Hernández, Karla Janeth Hernández Luna,
and Jorge Luis García Alcaraz
The Difference Between Expert and Non-expert Skill in Beauty
Services Based on Eye Tracking Technology . . . . . . . . . . . . . . . . . . . . . 219
Kohei Okado, Kazuyuki Tanida, Hiroyuki Hamada, Akihiko Goto,
and Yuka Takai
Evaluation of “Jiai” of Large “Echizen Washi” Japanese
Traditional Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Hiroyuki Nakagawa, Yuji Kawamori, Akihiko Goto, Hiroyuki Hamada,
Kazuaki Yamashiro, Naoki Sugiyama, Mitsunori Suda, Kozo Igarashi,
and Yoshiki Yamada
Three-Dimensional Motion Analysis of Mochi Pounding . . . . . . . . . . . . 233
Akihiko Goto, Naoki Sugiyama, Daigo Goto, Tomoko Ota,
and Hiroyuki Hamada
Organizational Culture Requirements for the Achievement
of World Class Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Zbigniew Wisniewski, Michal Paszkowski, and Malgorzata Wisniewska
Research on Thermal Comfort Equation of Comfort Temperature
Range Based on Chinese Thermal Sensation Characteristics . . . . . . . . . 254
Rui Wang, Chaoyi Zhao, Wei Li, and Yun Qi
Study on the Perception Characteristics of Different
Populations to Thermal Comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Rui Wang, Wei Li, Chaoyi Zhao, and Yun Qi
xiv Contents

Strategic Decision Making Models in Manufacturing

and Service Systems
A Component Based Model Developed for Machine
Tool Selection Decisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Yusuf Tansel İç and Mustafa Yurdakul
Multiple Service Home Health Care Routing and Scheduling
Problem: A Mathematical Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Asiye Ozge Dengiz, Kumru Didem Atalay, and Fulya Altiparmak
Management Model Logistic for the Use of Planning
and Inventory Tools in a Selling Company of the Automotive
Sector in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Luis Carazas, Manuel Barrios, Victor Nuñez, Carlos Raymundo,
and Francisco Dominguez
Order Acceptance and Scheduling Problem: A Proposed
Formulation and the Comparison with the Literature . . . . . . . . . . . . . . 310
Papatya S. Bıçakcı and İmdat Kara

Manufacturing Aspects of Work Improvement

Use of Quality Management Tools to Identify Ergonomic
Non-conformities in Human Activities . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Adam Górny
The Method of Ergonomic Design of Technological Devices . . . . . . . . . 330
Małgorzata Sławińska
Cognitive and Emotional-Motivational Aspects of Communication
to Improve Work Safety in Production Processes: Case Study . . . . . . . . 340
Joanna Sadłowska-Wrzesińska
Benefits on the Field of Ergonomics and Work Safety from
Development of the Information System in the Enterprise . . . . . . . . . . . 350
Krzysztof Hankiewicz and Andrzej Marek Lasota

Production Management and Process Control

Six Sigma-Based Optimization Model in Hauling Cut
and Fill Exploitation Activities to Reduce Downtime
in Underground Mines in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Kevin Rojas, Vidal Aramburú, Edgar Ramos, Carlos Raymundo,
and Javier M. Moguerza
Contents xv

Analysis of the Technological Capability of Linking SMEs

in the Electronic Sector to Integrate into the Maquiladora
Industry Electronic Sector in Tijuana, Baja California, Mexico . . . . . . . 376
Maria Marcela Solis-Quinteros, Luis Alfredo Avila-Lopez,
Carolina Zayas-Márquez, Teresa Carrillo-Gutierrez,
and Karina Cecilia Arredondo-Soto
Discussion on the Iterative Process in Robust Algorithm A . . . . . . . . . . 388
Yue Zhang, Fan Zhang, Jing Zhao, Chao Zhao, Gang Wu, Xinyu Cao,
and Haitao Wang
Model for Monitoring Socioenvironmental Conflicts in Relation
to the Emission of Particulate Matter in the Prehauling Phase
of a Surface Mine in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Marcio Filomeno, Josemaria Heracles, Vidal Aramburu,
Carlos Raymundo, and Javier M. Moguerza
Research on Sampling Inspection Procedures for Bank Service
Time Based on Bayes Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Jingjing Wang, Haitao Wang, Fan Zhang, Chao Zhao, Gang Wu,
and Jing Zhao
Remaining Useful Life Prediction for Components of Automated
Guided Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Beata Mrugalska and Ralf Stetter
Discussion on the Range of Cut-Off Values in Robust Algorithm A . . . . 430
Fan Zhang, Yue Zhang, Jing Zhao, Chao Zhao, Gang Wu, Xinyu Cao,
and Haitao Wang
Model for Dilution Control Applying Empirical Methods in Narrow
Vein Mine Deposits in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Luis Salgado-Medina, Diego Núñez-Ramírez, Humberto Pehovaz-Alvarez,
Carlos Raymundo, and Javier M. Moguerza

Management Approaches in Contemporary Enterprise

Management of Anthropopression Factors in Poland in the Context
of the European Union Waste Economy . . . . . . . . . . . . . . . . . . . . . . . . . 449
Jozef Fras, Ilona Olsztynska, and Sebastian Scholz
Human Factors/Ergonomics in eWorld: Methodology, Techniques
and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Oleksandr Burov
xvi Contents

Production, Quality and Maintenance Management

Production Management Model Based on Lean Manufacturing
for Cost Reduction in the Timber Sector in Peru . . . . . . . . . . . . . . . . . . 467
Fiorella Lastra, Nicolás Meneses, Ernesto Altamirano, Carlos Raymundo,
and Javier M. Moguerza
Production Management Model for Increasing Productivity
in Bakery SMEs in Peru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Junior Huallpa, Tomas Vera, Ernesto Altamirano, Carlos Raymundo,
and Javier M. Moguerza
Conditioning of Computerized Maintenance Management
Systems Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Zbigniew Wisniewski and Artur Blaszczyk
Analysis of Operational Efficiency in Picking Activity
on a Pipes and Fittings Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
Vanina Macowski Durski Silva and Gustavo Henrique Moresco
Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Ergonomics in Manufacturing
 Development of an Intelligent Robotic Additive
Manufacturing Cell for the Nuclear Industry

Richard French(&), Hector Marin-Reyes, Gabriel Kapellmann-Zafra,

and Samantha Abrego-Hernandez

Physics and Astronomy, The University of Sheffield,

Hicks Building, Hounsfield Road, Sheffield S3 7RH, UK
{R.S.French,H.Marin-Reyes,G.Kapellmann,
S.Abrego}@sheffield.ac.uk

Abstract. Applications of Advanced manufacturing methods in the nuclear

industry to ensure quality, security, process codes and standardisation are
increasingly needed to ease adoption of new technologies. Many assemblies and
decommissioning tasks are still heavily dependent on experienced human
engineers and practitioners. Human error in production plays a large part in the
development of standardisation to avoid defects and increase productivity. Risks
to humans, previously considered as “part of the job” are no longer acceptable.
Within European manufacturing, a greater problem exists; a dwindling skilled
workforce capable of delivering high precision manufactured products. To
address these issues this paper describes the motivation, design and imple-
mentation phases of the SERFOW (Smart Enabling Robotics driving Free Form
Welding) project, which is an automated fusion-welding cell, linking future
nuclear industry manufacturing requirements by mimicking human skill and
technical experience combined with academic knowledge and UK based inno-
vation. Development of key machine vision systems combined with novel
robotic grasping technology and experienced welding engineers has made
possible the construction of a potentially disruptive robotic manufacturing
platform.

Keywords: Robot
Grasper
Ergonomic
3D
Vision system
TIG welding

Additive manufacturing

1 Introduction

Advances in novel manufacturing processes demand the application of Advanced

Manufacturing Technologies (AMT), to obtain optimum results regarding quality,
productivity, efficiency and responsiveness to the marketplace changes. This
technology-centred approach is the design vehicle in which the majority of these
manufacturing processes follow. Even though AMT can help to reduce direct labour,
set-up time, inventory and manufacturing lead times [1], humans still playing an
important role in delivering performance, but attributing cost within the organisations
and manufacturing process. The importance of working towards the consideration of a
combined human-design approach will drive improvements in ergonomics and safety

© Springer Nature Switzerland AG 2020

W. Karwowski et al. (Eds.): AHFE 2019, AISC 971, pp. 3–13, 2020.
https://doi.org/10.1007/978-3-030-20494-5_1
4 R. French et al.

whilst reducing security risks. Failure to adopt will affect the performance and future
capabilities of manufacturing companies [2]. Innovation in the nuclear manufacturing
industry is correctly mitigated by risk; therefore, the industry is slow to adopt new
technology capable of supporting the development of components used on-site for low
carbon power generation. Within the UK, investment is steadily ramping up to ensure
an augmented clean energy supply can fill the energy production void that fossil fuels
would otherwise occupy should deployment of renewable energy not meet the antic-
ipated power demand. By 2030 most existing (AGR) Advanced Gas Cooled reactors
within the UK will be retired [3] and subsequently decommissioned until 2097 [4].
Preparations to adapt and develop new technologies for deployment in the next gen-
eration of advanced reactors, which could potentially be operational by 2030, is
underway. However, who is actually going to make them? [5], Fig. 1.

Fig. 1. Top 10 UK manufacturing technical skills shortages extracted from [5].

The backbone of UK manufacturing is supported by small manufacturing com-

panies (SME) who work across all sectors, somewhat similar to Germany’s “Mittle-
stand” SME Sector [6]. However, to be effective, they must invest in technology to
augment and develop human skills to remain competitive against low-wage emerging
economies.
The joining of metallic materials permanently by applying heat (fusion) or pressure
(solid state) [7, 8] is effectively known as welding. Different types of fusion welding
such as spot welding, metal inert gas (MIG), and tungsten inert gas (TIG or GTAW), to
mention a few, are widely used by industry [9]. The welding process can build-up
components through material deposition layer-by-layer which is well known as
Additive Manufacturing, AM [10]. The majority of welding procedures are performed
by highly skilled welding engineers because of the complex geometries of the products
 Development of an Intelligent Robotic Additive 5

as the weld form and layer build up. These manual welding procedures involve risks
such as heavy equipment handling, burns, toxic gas inhalation, ultraviolet and elec-
tromagnetic radiation which adversely affect the health of the human welders [7, 8].
Industrial accidents due to the risks mentioned above could represent costs related to
indemnification, medical cost, re-staffing and damage to the equipment [9]. Critical
human factors such as, the ageing workforce seeing retirement of these highly skilled
welders when combined with the length of recruitment and the long term learning
timescale required to produce new, skilled welding engineers within a declining
workforce must be taking into account as part of the reason for the development of
automated processes [10]. The ambition and vision of future high value manufacturing
industries, such as nuclear, involves the implementation of Industry 4.0 technologies
which ensures short development periods, producing customisable components on
demand. In this case it requires adaptation to human needs, security, sustainability and
resource-efficiency [11]. To mimic and automate the welding and AM process, robotic
and computerised vision systems must be integrated to generate data and provide
feedback to control the welding or AM platform.
This project aims to produce a low-cost prototype that is capable of providing
welding and AM. The Smart Enabling Robotics driving Free Form Welding (SER-
FOW) concept is an automated welding cell which takes into account industrial
requirements and the human-centred approach design to eliminate risks and improve
the ergonomics of the process. This collaborative research project has been carried out
by i3D Robotics LTD (UK), the Shadow Robot Company Limited (UK) and The
University of Sheffield (UK) associating the nuclear industry demand with academic
knowledge and innovation. Development of new autonomous AM technologies, as
depicted here, adds flexibility with the rapid dynamic adaption of production tasks,
reducing the high financial penalties of more complex traditional systems.

2 Methodology

The work presented in this paper was focused on the development of automated
welding and AM cell designed from a technology-human perspective to improve
quality, efficiency, ergonomics, safety and security in the nuclear industry. This pro-
totype aims to mimic highly skilled fusion welding engineers by the integration of a 3D
vision system and a robotic manipulator, which can perform layer-by-layer AM by
means of automated fusion welding. The SERFOW cell is comprised of the following
components: the main structure, the robot arm and smart gripper, the welding power
source, 3D stereo vision and security system.
The main structure was made adaptable through the use of extruded aluminium
profile sections with T-slot channels to allow the flexible attachment of cameras,
sensors and other devices. Essential design points under consideration were to mini-
mum size, reduce floor space, providing flexibility for design adaptation in future use,
ergonomics and security. The Universal Robots UR-10 robot [12] arm and the Shadow
Robot Smart Grasping System SGS [13] were used to pick and place the work pieces
from the loading tray to the automated turn-table.
6 R. French et al.

The TIG welding system (wire feeder and torch) was automated by two linear
positioners in the X and Z axis. The safety system of the cell was designed according to
ISO 10218-2 required for industrial collaborative robots. It consisted of two start
buttons outside the welding and robot movements to ensure the security of the oper-
ators. Additionally, two of emergency or E-Stop buttons were installed.
Integration and assembly of the above-mentioned components with the innovative
3D stereo vision system developed by I3D robotics [14] is illustrated in Fig. 2.

Fig. 2. SERFOW 3D CAD rendering: (1) aluminium structure, (2) robotic arm, (3) smart
grasper, (4) wire feeder, (5) torch, (6) turn-table, (7) “Z” and (8) “X” linear motor drives, (9) left-
hand, and (10) right-hand safety buttons.

The assembly, fusion welding, and AM layer build-up trials of this prototype were
performed in the Enabling Sciences for Intelligent Manufacturing Laboratory at the
University of Sheffield. The samples used for the welding and AM were made of 316L
Stainless Steel which represent elements found in the design of nuclear heat exchanger
manifolds, Fig. 3. A detailed explanation of the robotic, 3D stereo vision, welding and
security system are presented in the following sections of this paper.
 Development of an Intelligent Robotic Additive 7

Fig. 3. 3D CAD rendering of the representative heat exchanger manifold components.

3 Smart Robot Arm and Grasper System

The six degrees-of-freedom UR10 robotic arm and the Shadow Robotics Smart
Grasper, SGS, were required to pick and place the representative work pieces from the
jig in the loading tray and deliver accurately to the automated rotary table.
The UR10 robotic arm is a collaborative robot that can withstand a payload mass of
10 kg; it can reach up to 1.3 m with a repeatable accuracy of 0.1 mm.
The Shadow Robotics Smart Grasper [15] system is a nine degrees-of-freedom
gripper that is modular, flexible, robust, cost-effective and can tolerate working in
radioactive environments [16, 17]. Its flexibility allows for the grasping of small and
large complex shapes and objects up to 2 kg weight. The modularity of the SGS system
offers a variety of configurations from two to three fingertips. In this development, a
two-fingertip configuration was used to grab the working piece with good dexterity as
Fig. 4 shows. The third fingertip was later used to stabilise the components during AM
operations. The UR10 robot arm and Shadow’s Smart Grasper are interfaced and
controlled by ROS-Industrial software [18]. The use of ROS-Industrial has allowed the
customisation of the inverse kinematics for manipulators. The coordinates acquired by
the I3D robotics 3D stereo vision system when scanning robot position, dictate the
location and movements meaning that manual programming was no longer needed.

4 Automatic Welding System

The welding system used is comprised of what could be considered an industry

standard Miller Dynasty 350 TIG power source. This is effectively a reliable and
proven generic power unit that can provide GTAW (gas tungsten arc welding) capa-
bilities to the AM cell. Conducting the arc from the power source was via an umbilical
cable to a machine type TIG Torch and the additive wire was delivered by means of a
TIGFEED 40 automatic wire feeder. In this application a stainless steel filler wire with
a high silicon content was selected for its weldability, wetting effect in the weld pool
and ability to deliver layered weld build up or AM. For later production applications
this filler wire would not be suitable due to having poorer metallurgical performance
when compared with more advanced filler wires or additive materials.
8 R. French et al.

Fig. 4. Shadow Robotics Smart Grasper system holding a work piece with three fingers.

4.1 Linear Motor Driver System and Automatic Turn-Table

Control and automation of the welding torch were by means of an adapted mounting
onto two linear stages produced by Parker Hannifin. Motorisation of these linear stages
was by means of advanced servo motors from Kollmorgan enabling accurate, auto-
mated movements in the X and Z axis of the cell. This linear positioning system was
covered with aluminium sheet to protect from internal contamination and trapping of
fingers or clothing and electrical limit switches were added to avoid physical collisions
in fault conditions.
The rotary turntable was a modified, low-cost automatic unit with a modified
Maxon DC motor coupled to a simple speed controller with on/off switches. Com-
municating via the RS-485 asynchronous serial protocol, the system can either run at a
set speed and then measure and match the absolute encoder, or the motor control
systems may be changed to have better control of the speed. Isolation of the electronics
components and motor were implemented to avoid short-circuiting, back EMF and HF
conductance risks associated with welding.

5 Smart 3D Stereo Vision System for Welding Process

Vision systems for industrial inspection and assembly are widely used in automated
manufacturing processes by identifying and processing images with a similar mecha-
nism as to what a human eye would use. The vision systems obtain the images and then
conduct both the processing and analysis of the image in order to provide accurate
feedback to the robotic system. This feedback will allow control over the required AM
and robotic path planning and trajectory parameters in order to improve the quality or
 Development of an Intelligent Robotic Additive 9

security of the process. Additionally, the stereo vision obtains the 3D information from
the acquired images and matches the features between these images. Algorithms such
as [19] have been developed to overcome the commonly found “correspondence
problem” [20] by making a correlation between points in the image pairs.
Stereo images are usually rectified, such that corresponding features lie on the same
pixel line in each image [21]. Stereo vision utilises the fact that 3D points in space
project to distinct 2D pixel locations in images of the scene when acquired from two
different locations. The differences in pixel coordinates in the images allow recon-
struction of the 3D coordinates from the images. I3D Robotics (I3DR) proposed and
implemented an advanced 3D stereo vision camera system with auto-focus capabilities
to be used in this prototype. This system was focused on identification of the stainless
steel work-pieces for grasping, confirmation of grasp and part/torch location prior to
weld and welding feedback. This vision system was controlled by the Phobos and
PosCam systems [14].

5.1 Phobos Camera System

Phobos is a high-resolution stereo camera developed by I3D Robotics that recognises
and obtains objects dimensional characteristics such as profile, shape and depth, shown
in Fig. 5 using sub-routines constructed in HALCON software [22] as previously
developed in iView project [23].

Fig. 5. Image of blocks with different shapes, sizes and orientations obtained by the Phobos
camera, where the colour gradient indicates different height variations of the blocks.
10 R. French et al.

To obtain the positional coordinates of the components either to be joined by fusion

welding or to undergo the AM process, the SERFOW cell’s Phobos camera was
positioned above the loading area as illustrated in Fig. 6a. This task was essential for
the UR-10 robot arm and SGS to record the exact location of the pieces allowing them
to transport the components accurately to, and install in the automated rotary turntable.

Fig. 6. (a) Phobos camera position within the SERFOW cell, (b) PosCam system comprised of
cameras A, B and C.

White form board walls enclose the component loading area and backlighting in
different angles was added to effectively control the highly reflective nature of the
metallic work-pieces or components.
Following the successful implementation of the lightbox for the loading area, the
Phobos system could reliably acquire the work-piece positional coordinate data.
A considerable amount of refinement to achieve the appropriate set-up and accurate
calibration was required.

5.2 PosCam System

The PosCam system consists of three cameras model DMK23UM021 located in the
welding area as shown in Fig. 6b. The horizontal camera A was attached and centrally
aligned to the welding torch tip. This allowed the precise positioning of the welding
torch tip to the work piece using the linear motor drives X and Z. This position was
absolutely critical to the success of fusion welding and AM. The precision is deter-
mined by the lens choice providing a field of view and a working distance of 150 mm.
The vertical camera B and horizontal camera C were mounted on the welding structures
chassis. Both cameras were needed to monitor the work piece position. The main
purpose of these cameras was to inspect and monitor the welding or AM process from
different angles. 3D models of the conducted weld were produced by camera A as
shown in Fig. 7 in order to give feedback and control the voltage, linear welding speed,
distance between arc tip and AM filler wire delivery speed.
 Development of an Intelligent Robotic Additive 11

Fig. 7. (a) 2D actual welding image, (b) 2D processed welding image and (c) 3D representation
of the welding image of the weld.

6 Implementation and Welding Trials

The integration and assembly of the subsystems described previously was successfully
performed. Welding trials on a 316L Stainless Steel samples were conducted as shown
in Fig. 8. This was to establish the correct fusion of additive filler with the work piece
and then later AM layering of material.

Fig. 8. Fusion AM trials performed in a 20 mm 316L Stainless Steel tube.

7 Conclusions

The welding process in high-value manufacturing industries such as those who produce
components for nuclear power plants, is largely dependent on human, manual welding
engineers because of the complexity of the components and design standardisation.
12 R. French et al.

Current barriers of adoption for automation are attributed to both the material cost, but
also the high labour cost of the human skilled workforce. The human–robot partici-
patory design approach to adopt technology capable of automation and minimising
human exposure to risks within the welding process has been fully accomplished in this
project.
During the build-up of weld filler layers or additive manufacturing, constant
monitoring by skilled welding engineers is needed to inspect the multiple arrays of
changing parameters during the AM and welding processes. The SERFOW design and
integration of the SGS end effector and six degrees of freedom collaborative robot with
the automatic welding and AM system, required the smart 3D stereo positional data to
function correctly. System performance evaluation and further analysis of the repli-
cation of highly skilled human welding engineers required a series of welding trials to
be conducted. The results of the welding trials have provided an accurate initial
assessment to demonstrate initial implementation and function of the SERFOW cell.
The data captured during the later trials have proved that the cell performed the
automatic welding and AM processes successfully, however subsequent improvement
of metallurgical performance in the added layers is required. The project has responded
partially to the desire for a lights out, Industry 4.0 factory of the future for high value
manufacturing, but has shown an easy to adopt methodology to include human input
without detriment to product output via collaborative automation and robotics.

Acknowledgments. The authors would like to thank Ben Crutchley from Industrial 3D
Robotics, Fotios Papadopoulos from Shadow Robotics company, Ben Kitchener, Kieren
Howarth and Samuel Edwards from the Enabling Sciences for Intelligent Manufacturing Lab-
oratory at the University of Sheffield for their help and their invaluable support.

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 Manageable and Scalable Manufacturing IT
Through an App Based Approach

Christian Knecht1(&), Andreas Schuller1, and Andrei Miclaus2

1
Fraunhofer Institute for Industrial Engineering IAO,
Nobelstraße 12, Stuttgart 70569, Germany
{christian.knecht,andreas.schuller}@iao.fraunhofer.de
2
Karlsruhe Institute for Technology KIT,
Vincenz-Prießnitz-Str. 1, Karlsruhe 76131, Germany
[email protected]

Abstract. Software is playing an ever-increasing role in providing the flexi-

bility and efficiency required for handling complex processes. However, the IT
capabilities of manufacturers are mostly limited to legacy systems or expensive,
slow and inflexible development of new software. Therefore, new paradigms are
needed for managing and scaling modern manufacturing processes with the help
of software systems. This paper presents the organizational concepts of a soft-
ware eco-system for the shop floor based on independent software modules
called Apps. Additionally, we present the methodology used in the creation of
industrial Apps. These concepts were successfully implemented in real world
manufacturing scenarios. We focus on describing the specific challenges and
requirements for industrial Apps, the technical architecture of the ScaleIT
platform and a step by step process model to identify App ideas. An evaluation
in the form of a questionnaire describes the assessment of the App-based
approach by an industrial consortium.

Keywords: Industry 4.0
IIoT-Platform
Micro Services, Micro Frontends

Edge Computing
Digitization
Shadow IT

1 Introduction

Staying competitive in today’s globalized industrial markets is a complex cross-

functional endeavor. Manufacturing enterprises need to find the right balance between
optimum quality standards, quickly delivering products, customer orientation, and on-
demand flexibility through customization of products, systems, and services [1, 2].
Continuously optimizing the production process is imperative for reaching these
goals. Digitization and a flexible and agile IT are key factors in this regard [3]. The IT
capabilities of manufacturing enterprises must become faster, highly scalable, and
easily manageable for efficient accomplishment of the workers’ tasks. Value creating
software on the shop floor needs efficient and effective requirements engineering,
implementation and deployment in order to adapt to the fast pace and changing
business needs. Additionally, the costs for maintaining the production IT are a sig-
nificant factor and must be continuously lowered to maintain acceptable margins [4].

© Springer Nature Switzerland AG 2020

W. Karwowski et al. (Eds.): AHFE 2019, AISC 971, pp. 14–26, 2020.
https://doi.org/10.1007/978-3-030-20494-5_2
Another random document with
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improvement of the place, so that it was admitted by the few sober
thinking people who remained there, that St. Michaels was an
unsaintly, as well as unsightly place.
I went to St. Michaels to live in March, 1833. I know the year,
because it was the one succeeding the first cholera in Baltimore, and
was also the year of that strange phenomenon when the heavens
seemed about to part with its starry train. I witnessed this gorgeous
spectacle, and was awestruck. The air seemed filled with bright
descending messengers from the sky. It was about daybreak when I
saw this sublime scene. I was not without the suggestion, at the
moment, that it might be the harbinger of the coming of the Son of
man; and in my then state of mind I was prepared to hail Him as my
friend and deliverer. I had read that the “stars shall fall from heaven,”
and they were now falling. I was suffering very much in my mind. It
did seem that every time the young tendrils of my affection became
attached they were rudely broken by some unnatural outside power;
and I was looking away to heaven for the rest denied me on earth.
But to my story. It was now more than seven years since I had
lived with Master Thomas Auld, in the family of my old master, Capt.
Anthony, on the home plantation of Col. Lloyd. As I knew him then it
was as the husband of old master’s daughter; I had now to know him
as my master. All my lessons concerning his temper and disposition,
and the best methods of pleasing him, were yet to be learned.
Slaveholders, however, were not very ceremonious in approaching a
slave, and my ignorance of the new material in the shape of a
master was but transient. Nor was my new mistress long in making
known her animus. Unlike Miss Lucretia, whom I remembered with
the tenderness which departed blessings leave, Mrs. Rowena Auld
was cold and cruel, as her husband was stingy, and possessed the
power to make him as cruel as herself, while she could easily
descend to the level of his meanness.
As long as I had lived in Mr. Hugh Auld’s family, whatever
changes had come over them there had been always a bountiful
supply of food; and now, for the first time in seven years, I realized
the pitiless pinchings of hunger. So wretchedly starved were we that
we were compelled to live at the expense of our neighbors, or to
steal from the home larder. This was a hard thing to do; but after
much reflection I reasoned myself into the conviction that there was
no other way to do, and that after all there was no wrong in it.
Considering that my labor and person were the property of Master
Thomas, and that I was deprived of the necessaries of life—
necessaries obtained by my own labor, it was easy to deduce the
right to supply myself with what was my own. It was simply
appropriating what was my own to the use of my master, since the
health and strength derived from such food were exerted in his
service. To be sure, this was stealing, according to the law and
gospel I heard from the pulpit; but I had begun to attach less
importance to what dropped from that quarter on such points. It was
not always convenient to steal from Master, and the same reason
why I might innocently steal from him did not seem to justify me in
stealing from others. In the case of my master it was a question of
removal—the taking his meat out of one tub and putting it in another;
the ownership of the meat was not affected by the transaction. At
first he owned it in the tub, and last he owned it in me. His meat-
house was not always open. There was a strict watch kept in that
point, and the key was carried in Mrs. Auld’s pocket. We were
oftentimes severely pinched with hunger, when meat and bread were
mouldering under the lock and key. This was so, when she knew we
were nearly half-starved; and yet with saintly air would she kneel
with her husband and pray each morning that a merciful God would
“bless them in basket and store, and save them at last in His
kingdom.” But I proceed with my argument.
It was necessary that the right to steal from others should be
established; and this could only rest upon a wider range of
generalization than that which supposed the right to steal from my
master. It was some time before I arrived at this clear right. To give
some idea of my train of reasoning, I will state the case as I laid it out
in my mind. “I am,” I thought, “not only the slave of Master Thomas,
but I am the slave of society at large. Society at large has bound
itself, in form and in fact, to assist Master Thomas in robbing me of
my rightful liberty, and of the just reward of my labor; therefore,
whatever rights I have against Master Thomas I have equally against
those confederated with him in robbing me of liberty. As society has
marked me out as privileged plunder, on the principle of self-
preservation, I am justified in plundering in turn. Since each slave
belongs to all, all must therefore belong to each.” I reasoned further,
that within the bounds of his just earnings the slave was fully justified
in helping himself to the gold and silver, and the best apparel of his
master, or that of any other slaveholder; and that such taking was
not stealing, in any just sense of the word.
The morality of free society could have no application to slave
society. Slaveholders made it almost impossible for the slave to
commit any crime, known either to the laws of God or to the laws of
man. If he stole he but took his own; if he killed his master, he only
imitated the heroes of the revolution. Slaveholders I held to be
individually and collectively responsible for all the evils which grew
out of the horrid relation, and I believed they would be so held in the
sight of God. To make a man a slave was to rob him of moral
responsibility. Freedom of choice is the essence of all accountability;
but my kind readers are probably less concerned about what were
my opinions than about that which more nearly touched my personal
experience, albeit my opinions have, in some sort, been the
outgrowth of my experience.
When I lived with Capt. Auld I thought him incapable of a noble
action. His leading characteristic was intense selfishness. I think he
was fully aware of this fact himself, and often tried to conceal it.
Capt. Auld was not a born slaveholder—not a birthright member of
the slaveholding oligarchy. He was only a slaveholder by marriage-
right; and of all slaveholders these were by far the most exacting.
There was in him all the love of domination, the pride of mastery, and
the swagger of authority; but his rule lacked the vital element of
consistency. He could be cruel; but his methods of showing it were
cowardly, and evinced his meanness, rather than his spirit. His
commands were strong, his enforcements weak.
Slaves were not insensible to the whole-souled qualities of a
generous, dashing slaveholder, who was fearless of consequences,
and they preferred a master of this bold and daring kind, even with
the risk of being shot down for impudence, to the fretful little soul
who never used the lash but at the suggestion of a love of gain.
 Slaves too, readily distinguished between the birthright bearing
of the original slaveholder, and the assumed attitudes of the
accidental slaveholder; and while they could have no respect for
either, they despised the latter more than the former.
The luxury of having slaves to wait upon him was new to Master
Thomas, and for it he was wholly unprepared. He was a slaveholder,
without the ability to hold or manage his slaves. Failing to command
their respect, both himself and wife were ever on the alert lest some
indignity should be offered him by the slaves.
It was in the month of August, 1833, when I had become almost
desperate under the treatment of Master Thomas, and entertained
more strongly than ever the oft-repeated determination to run away,
—a circumstance occurred which seemed to promise brighter and
better days for us all. At a Methodist camp-meeting, held in the Bay
side (a famous place for camp-meetings) about eight miles from St.
Michaels, Master Thomas came out with a profession of religion. He
had long been an object of interest to the church, and to the
ministers, as I had seen by the repeated visits and lengthy
exhortations of the latter. He was a fish quite worth catching, for he
had money and standing. In the community of St. Michaels, he was
equal to the best citizen. He was strictly-temperate, and there was
little to do for him, to give him the appearance of piety, and to make
him a pillar of the church. Well, the camp-meeting continued a week;
people gathered from all parts of the country, and two steamboats
came loaded from Baltimore. The ground was happily chosen; seats
were arranged; a stand erected; a rude altar fenced in, fronting the
preacher’s stand, with straw in it, making a soft kneeling-place for
the accommodation of mourners. This place would have held at least
one hundred persons. In front and on the sides of the preacher’s
stand, and outside the long rows of seats, rose the first class of
stately tents, each vieing with the other in strength, neatness, and
capacity for accommodation. Behind this first circle of tents, was
another less imposing, which reached round the camp-ground to the
speaker’s stand. Outside this second class of tents were covered
wagons, ox-carts, and vehicles of every shape and size. These
served as tents to their owners. Outside of these, huge fires were
burning in all directions, where roasting and boiling and frying were
going on, for the benefit of those who were attending to their spiritual
welfare within the circle. Behind the preacher’s stand, a narrow
space was marked out for the use of the colored people. There were
no seats provided for this class of persons, and if the preachers
addressed them at all, it was in an aside. After the preaching was
over, at every service, an invitation was given to mourners to come
forward into the pen; and in some cases, ministers went out to
persuade men and women to come in. By one of these ministers,
Master Thomas was persuaded to go inside the pen. I was deeply
interested in that matter, and followed; and though colored people
were not allowed either in the pen, or in front of the preacher’s stand,
I ventured to take my stand at a sort of half-way place between the
blacks and whites, where I could distinctly see the movements of the
mourners, and especially the progress of Master Thomas. “If he has
got religion,” thought I, “he will emancipate his slaves; or, if he should
not do so much as this, he will at any rate behave towards us more
kindly, and feed us more generously than he has heretofore done.”
Appealing to my own religious experience, and judging my master by
what was true in my own case, I could not regard him as soundly
converted, unless some such good results followed his profession of
religion. But in my expectations I was doubly disappointed: Master
Thomas was Master Thomas still. The fruits of his righteousness
were to show themselves in no such way as I had anticipated. His
conversion was not to change his relation toward men—at any rate
not toward black men—but toward God. My faith, I confess, was not
great. There was something in his appearance that in my mind cast
a doubt over his conversion. Standing where I did, I could see his
every movement. I watched very narrowly while he remained in the
pen; and although I saw that his face was extremely red, and his hair
disheveled, and though I heard him groan, and saw a stray tear
halting on his cheek, as if inquiring, “which way shall I go?”—I could
not wholly confide in the genuineness of the conversion. The
hesitating behavior of that tear-drop, and its loneliness, distressed
me, and cast a doubt upon the whole transaction, of which it was a
part. But people said, “Capt. Auld has come through,” and it was for
me to hope for the best. I was bound to do this in charity, for I, too,
was religious, and had been in the church full three years, although
now I was not more than sixteen years old. Slaveholders might
sometimes have confidence in the piety of some of their slaves, but
the slaves seldom had confidence in the piety of their masters. “He
can’t go to heaven without blood on his skirts,” was a settled point in
the creed of every slave; which rose superior to all teaching to the
contrary, and stood forever as a fixed fact. The highest evidence the
slaveholder could give the slave of his acceptance with God, was the
emancipation of his slaves. This was proof to us that he was willing
to give up all to God, and for the sake of God, and not to do this was,
in our estimation, an evidence of hard-heartedness, and was wholly
inconsistent with the idea of genuine conversion. I had read
somewhere in the Methodist Discipline, the following question and
answer: “Question. What shall be done for the extirpation of
slavery?” “Answer. We declare that we are as much as ever
convinced of the great evil of slavery; therefore, no slaveholder shall
be eligible to any official station in our church.” These words
sounded in my ears for a long time, and encouraged me to hope. But
as I have before said, I was doomed to disappointment. Master
Thomas seemed to be aware of my hopes and expectations
concerning him. I have thought before now that he looked at me in
answer to my glances, as much as to say, “I will teach you, young
man, that though I have parted with my sins, I have not parted with
my sense. I shall hold my slaves, and go to heaven too.”
There was always a scarcity of good nature about the man; but
now his whole countenance was soured all over with the seemings
of piety and he became more rigid and stringent in his exactions. If
religion had any effect at all on him, it made him more cruel and
hateful in all his ways. Do I judge him harshly? God forbid. Capt.
Auld made the greatest professions of piety. His house was literally a
house of prayer. In the morning and in the evening loud prayers and
hymns were heard there, in which both himself and wife joined; yet
no more nor better meal was distributed at the quarters, no more
attention was paid to the moral welfare of the kitchen, and nothing
was done to make us feel that the heart of Master Thomas was one
whit better than it was before he went into the little pen, opposite the
preacher’s stand on the camp-ground. Our hopes, too, founded on
the discipline, soon vanished; for he was taken into the church at
once, and before he was out of his term of probation, he lead in
class. He quite distinguished himself among the brethren as a
fervent exhorter. His progress was almost as rapid as the growth of
the fabled vine of Jack and the bean-stalk. No man was more active
in revivals, or would go more miles to assist in carrying them on, and
in getting outsiders interested in religion. His house, being one of the
holiest in St. Michaels, became the “preachers’ home.” They
evidently liked to share his hospitality; for while he starved us, he
stuffed them—three or four of these “ambassadors” being there not
unfrequently at a time—all living on the fat of the land, while we in
the kitchen were worse than hungry. Not often did we get a smile of
recognition from these holy men. They seemed about as
unconcerned about our getting to heaven, as about our getting out of
slavery. To this general charge, I must make one exception—the
Reverend George Cookman. Unlike Rev. Messrs. Storks, Ewry,
Nicky, Humphrey, and Cooper (all of whom were on the St. Michaels
circuit), he kindly took an interest in our temporal and spiritual
welfare. Our souls and our bodies were alike sacred in his sight, and
he really had a good deal of genuine anti-slavery feeling mingled
with his colonization ideas. There was not a slave in our
neighborhood who did not love and venerate Mr. Cookman. It was
pretty generally believed that he had been instrumental in bringing
one of the largest slaveholders in that neighborhood—Mr. Samuel
Harrison—to emancipate all his slaves, and the general impression
about Mr. Cookman was, that whenever he met slaveholders he
labored faithfully with them, as a religious duty, to induce them to
liberate their bondmen. When this good man was at our house, we
were all sure to be called in to prayers in the morning; and he was
not slow in making inquiries as to the state of our minds, nor in giving
us a word of exhortation and of encouragement. Great was the
sorrow of all the slaves when this faithful preacher of the gospel was
removed from the circuit. He was an eloquent preacher, and
possessed what few ministers, south of Mason and Dixon’s line,
possessed or dared to show; viz., a warm and philanthropic heart.
This Mr. Cookman was an Englishman by birth, and perished on
board the ill-fated steamship “President,” while on his way to
England.
But to my experience with Master Thomas after his conversion.
In Baltimore I could occasionally get into a Sabbath-school, amongst
the free children, and receive lessons with the rest; but having
learned to read and write already, I was more a teacher than a
scholar, even there. When, however, I went back to the eastern
shore and was at the house of Master Thomas, I was not allowed
either to teach or to be taught. The whole community, with but one
single exception, among the whites, frowned upon everything like
imparting instruction, either to slaves or to free colored persons. That
single exception, a pious young man named Wilson, asked me one
day if I would like to assist him in teaching a little Sabbath-school, at
the house of a free colored man named James Mitchell. The idea
was to me a delightful one, and I told him I would gladly devote as
much of my Sabbaths as I could command to that most laudable
work. Mr. Wilson soon mustered up a dozen old spelling-books and a
few testaments, and we commenced operations, with some twenty
scholars in our school. Here, thought I, is something worth living for;
here is a chance for usefulness. The first Sunday passed delightfully,
and I spent the week after very joyously. I could not go to Baltimore,
where I and the little company of young friends who had been so
much to me there, and from whom I felt parted forever, but I could
make a little Baltimore here. At our second meeting I learned there
were some objections to the existence of our school; and sure
enough, we had scarcely got to work—good work, simply teaching a
few colored children how to read the gospel of the Son of God—
when in rushed a mob, headed by two class-leaders, Mr. Wright
Fairbanks and Mr. Garrison West, and with them Master Thomas.
They were armed with sticks and other missiles, and drove us off,
commanding us never to meet for such a purpose again. One of this
pious crew told me that as for me, I wanted to be another Nat.
Turner, and if I did not look out I should get as many balls in me as
Nat. did into him. Thus ended the Sabbath-school; and the reader
will not be surprised that this conduct, on the part of class-leaders
and professedly holy men, did not serve to strengthen my religious
convictions. The cloud over my St. Michaels home grew heavier and
blacker than ever.
It was not merely the agency of Master Thomas in breaking up
our Sabbath-school, that shook my confidence in the power of that
kind of southern religion to make men wiser or better, but I saw in
him all the cruelty and meanness after his conversion which he had
exhibited before time. His cruelty and meanness were especially
displayed in his treatment of my unfortunate cousin Henny, whose
lameness made her a burden to him. I have seen him tie up this
lame and maimed woman and whip her in a manner most brutal and
shocking; and then with blood-chilling blasphemy he would quote the
passage of scripture, “That servant which knew his lord’s will and
prepared not himself, neither did according to his will, shall be
beaten with many stripes.” He would keep this lacerated woman tied
up by her wrists to a bolt in the joist, three, four, and five hours at a
time. He would tie her up early in the morning, whip her with a
cowskin before breakfast, leave her tied up, go to his store, and
returning to dinner repeat the castigation, laying on the rugged lash
on flesh already raw by repeated blows. He seemed desirous to get
the poor girl out of existence, or at any rate off his hands. In proof of
this, he afterwards gave her away to his sister Sarah (Mrs. Cline),
but as in the case of Mr. Hugh, Henny was soon returned on his
hands. Finally, upon a pretense that he could do nothing for her (I
use his own words), he “set her adrift to take care of herself.” Here
was a recently converted man, holding with tight grasp the well-
framed and able-bodied slaves left him by old master—the persons
who in freedom could have taken care of themselves; yet turning
loose the only cripple among them, virtually to starve and die.
No doubt, had Master Thomas been asked by some pious
northern brother, why he held slaves? his reply would have been
precisely that which many another slaveholder has returned to the
same inquiry, viz.: “I hold my slaves for their own good.”
The many differences springing up between Master Thomas and
myself, owing to the clear perception I had of his character, and the
boldness with which I defended myself against his capricious
complaints, led him to declare that I was unsuited to his wants; that
my city life had affected me perniciously; that in fact it had almost
ruined me for every good purpose, and had fitted me for everything
bad. One of my greatest faults, or offences, was that of letting his
horse get away and go down to the farm which belonged to his
father-in-law. The animal had a liking for that farm with which I fully
sympathized. Whenever I let it out it would go dashing down the road
to Mr. Hamilton’s as if going on a grand frolic. My horse gone, of
course I must go after it. The explanation of our mutual attachment
to the place is the same—the horse found good pasturage, and I
found there plenty of bread. Mr. Hamilton had his faults, but starving
his slaves was not one of them. He gave food in abundance, and of
excellent quality. In Mr. Hamilton’s cook—Aunt Mary—I found a
generous and considerate friend. She never allowed me to go there
without giving me bread enough to make good the deficiencies of a
day or two. Master Thomas at last resolved to endure my behavior
no longer; he could keep neither me nor his horse, we liked so well
to be at his father-in-law’s farm. I had now lived with him nearly nine
months, and he had given me a number of severe whippings, without
any visible improvement in my character or conduct, and now he
was resolved to put me out, as he said, “to be broken.”
There was, in the Bay-side, very near the camp-ground where
my master received his religious impressions, a man named Edward
Covey, who enjoyed the reputation of being a first rate hand at
breaking young negroes. This Covey was a poor man, a farm renter;
and his reputation of being a good hand to break in slaves was of
immense pecuniary advantage to him, since it enabled him to get his
farm tilled with very little expense, compared with what it would have
cost him otherwise. Some slaveholders thought it an advantage to let
Mr. Covey have the government of their slaves a year or two, almost
free of charge, for the sake of the excellent training they had under
his management. Like some horse-breakers noted for their skill, who
ride the best horses in the country without expense, Mr. Covey could
have under him the most fiery bloods of the neighborhood, for the
simple reward of returning them to their owners well broken. Added
to the natural fitness of Mr. Covey for the duties of his profession, he
was said “to enjoy religion,” and he was as strict in the cultivation of
piety as he was in the cultivation of his farm. I was made aware of
these traits in his character by some one who had been under his
hand, and while I could not look forward to going to him with any
degree of pleasure, I was glad to get away from St. Michaels. I
believed I should get enough to eat at Covey’s, even if I suffered in
other respects, and this to a hungry man is not a prospect to be
regarded with indifference.
 CHAPTER XV.
COVEY, THE NEGRO BREAKER.

Journey to Covey’s—Meditations by the way—Covey’s house—Family—

Awkwardness as a field hand—A cruel beating—Why given—Description
of Covey—First attempt at driving oxen—Hair-breadth escape—Ox and
man alike property—Hard labor more effective than the whip for breaking
down the spirit—Cunning and trickery of Covey—Family worship—
Shocking and indecent contempt for chastity—Great mental agitation—
Anguish beyond description.

THE morning of January 1, 1834, with its chilling wind and pinching
frost, quite in harmony with the winter in my own mind, found me,
with my little bundle of clothing on the end of a stick swung across
my shoulder, on the main road bending my way towards Covey’s,
whither I had been imperiously ordered by Master Thomas. He had
been as good as his word, and had committed me without reserve to
the mastery of that hard man. Eight or ten years had now passed
since I had been taken from my grandmother’s cabin in Tuckahoe;
and these years, for the most part, I had spent in Baltimore, where,
as the reader has already seen, I was treated with comparative
tenderness. I was now about to sound profounder depths in slave
life. My new master was notorious for his fierce and savage
disposition, and my only consolation in going to live with him was the
certainty of finding him precisely as represented by common fame.
There was neither joy in my heart nor elasticity in my frame as I
started for the tyrant’s home. Starvation made me glad to leave
Thomas Auld’s, and the cruel lash made me dread to go to Covey’s.
Escape, however, was impossible; so, heavy and sad, I paced the
seven miles which lay between his house and St. Michaels, thinking
much by the solitary way of my adverse condition. But thinking was
all I could do. Like a fish in a net, allowed to play for a time, I was
now drawn rapidly to the shore, secured at all points. “I am,” thought
I, “but the sport of a power which makes no account, either of my
welfare or my happiness. By a law which I can comprehend, but
cannot evade or resist, I am ruthlessly snatched from the hearth of a
fond grandmother and hurried away to the home of a mysterious old
master; again I am removed from there to a master in Baltimore;
thence am I snatched away to the eastern shore to be valued with
the beasts of the field, and with them divided and set apart for a
possessor; then I am sent back to Baltimore, and by the time I have
formed new attachments and have begun to hope that no more rude
shocks shall touch me, a difference arises between brothers and I
am again broken up and sent to St. Michaels; and now from the
latter place I am footing my way to the home of another master,
where I am given to understand that like a wild young working animal
I am to be broken to the yoke of a bitter and life-long bondage.” With
thoughts and reflections like these, I came in sight of a small wood-
colored building, about a mile from the main road, which, from the
description I had received at starting I easily recognized as my new
home. The Chesapeake bay, upon the jutting banks of which the little
wood-colored house was standing, white with foam raised by the
heavy northwest wind; Poplar Island, covered with a thick black pine
forest, standing out amid this half ocean; and Keat Point, stretching
its sandy, desert-like shores out into the foam-crested bay, were all in
sight, and served to deepen the wild and desolate scene.
The good clothes I had brought with me from Baltimore were
now worn thin, and had not been replaced; for Master Thomas was
as little careful to provide against cold as hunger. Met here by a
north wind, sweeping through an open space of forty miles, I was
glad to make any port, and, therefore, I speedily pressed on to the
wood-colored house. The family consisted of Mr. and Mrs. Covey;
Mrs. Kemp (a broken-backed woman), sister to Mrs. Covey; William
Hughes, cousin to Mr. Covey; Caroline, the cook; Bill Smith, a hired
man, and myself. Bill Smith, Bill Hughes, and myself were the
working force of the farm, which comprised three or four hundred
acres. I was now for the first time in my life to be a field-hand; and in
my new employment I found myself even more awkward than a
green country boy may be supposed to be upon his first entrance
into the bewildering scenes of city life; and my awkwardness gave
me much trouble. Strange and unnatural as it may seem, I had been
in my new home but three days before Mr. Covey (my brother in the
Methodist church) gave me a bitter foretaste of what was in reserve
for me. I presume he thought that since he had but a single year in
which to complete his work, the sooner he begun, the better.
Perhaps he thought by coming to blows at once we should mutually
understand better our relations to each other. But to whatever
motive, direct or indirect, the cause may be referred, I had not been
in his possession three whole days before he subjected me to a
most brutal chastisement. Under his heavy blows blood flowed
freely, and wales were left on my back as large as my little finger.
The sores from this flogging continued for weeks, for they were kept
open by the rough and coarse cloth which I wore for shirting. The
occasion and details of this first chapter of my experience as a field-
hand, must be told, that the reader may see how unreasonable, as
well as how cruel, my new Master Covey was. The whole thing I
found to be characteristic of the man, and I was probably treated no
worse by him than scores of lads who had previously been
committed to him, for reasons similar to those which induced my
master to place me with him. But here are the facts connected with
the affair, precisely as they occurred.
On one of the coldest mornings of the whole month of January,
1834, I was ordered at daybreak to get a load of wood, from a forest
about two miles from the house. In order to perform this work, Mr.
Covey gave me a pair of unbroken oxen, for it seemed that his
breaking abilities had not been turned in that direction. In due form,
and with all proper ceremony, I was introduced to this huge yoke of
unbroken oxen, and was carefully made to understand which was
“Buck,” and which was “Darby,”—which was the “in hand,” and which
was the “off hand” ox. The master of this important ceremony was no
less a person than Mr. Covey himself; and the introduction was the
first of the kind I had ever had.
My life, hitherto, had been quite away from horned cattle, and I
had no knowledge of the art of managing them. What was meant by
the “in ox,” as against the “off ox,” when both were equally fastened
to one cart, and under one yoke, I could not very easily divine; and
the difference implied by the names, and the peculiar duties of each,
were alike Greek to me. Why was not the “off ox” called the “in ox?”
Where and what is the reason for this distinction in names, when
there is none in the things themselves? After initiating me into the
use of the “whoa,” “back,” “gee,” “hither,”—the entire language
spoken between oxen and driver,—Mr. Covey took a rope about ten
feet long and one inch thick, and placed one end of it around the
horns of the “in hand ox,” and gave the other end to me, telling me
that if the oxen started to run away (as the scamp knew they would),
I must hold on to the rope and stop them. I need not tell any one who
is acquainted with either the strength or the disposition of an
untamed ox, that this order was about as unreasonable as a
command to shoulder a mad bull. I had never driven oxen before,
and I was as awkward, as a driver, as it is possible to conceive. I
could not plead my ignorance to Mr. Covey; there was that in his
manner which forbade any reply. Cold, distant, morose, with a face
wearing all the marks of captious pride and malicious sternness, he
repelled all advances. He was not a large man—not more than five
feet ten inches in height, I should think; short-necked, round-
shouldered, of quick and wiry motion, of thin and wolfish visage, with
a pair of small, greenish-gray eyes, set well back under a forehead
without dignity, and which were constantly in motion, expressing his
passions rather than his thoughts, in sight but denying them
utterance in words. The creature presented an appearance
altogether ferocious and sinister, disagreeable and forbidding, in the
extreme. When he spoke, it was from the corner of his mouth, and in
a sort of light growl, like a dog, when an attempt is made to take a
bone from him. I already believed him a worse fellow than he had
been represented to be. With his directions, and without stopping to
question, I started for the woods, quite anxious to perform my first
exploit in driving in a creditable manner. The distance from the house
to the wood’s gate—a full mile, I should think—was passed over with
little difficulty: for, although the animals ran, I was fleet enough in the
open field to keep pace with them, especially as they pulled me
along at the end of the rope; but on reaching the woods, I was
speedily thrown into a distressing plight. The animals took fright, and
started off ferociously into the woods, carrying the cart full tilt against
trees, over stumps, and dashing from side to side in a manner
altogether frightful. As I held the rope I expected every moment to be
crushed between the cart and the huge trees, among which they
were so furiously dashing. After running thus for several minutes, my
oxen were finally brought to a stand by a tree, against which they
dashed themselves with great violence, upsetting the cart, and
entangling themselves among sundry young saplings. By the shock
the body of the cart was flung in one direction and the wheels and
tongue in another, and all in the greatest confusion. There I was, all
alone in a thick wood to which I was a stranger; my cart upset and
shattered, my oxen entangled, wild, and enraged, and I, poor soul,
but a green hand to set all this disorder right. I knew no more of oxen
than the ox-driver is supposed to know of wisdom.
After standing a few minutes, surveying the damage, and not
without a presentiment that this trouble would draw after it others,
even more distressing, I took one end of the cart body and, by an
extra outlay of strength, I lifted it toward the axle-tree, from which it
had been violently flung; and after much pulling and straining, I
succeeded in getting the body of the cart in its place. This was an
important step out of the difficulty, and its performance increased my
courage for the work which remained to be done. The cart was
provided with an ax, a tool with which I had become pretty well
acquainted in the ship-yard at Baltimore. With this I cut down the
saplings by which my oxen were entangled, and again pursued my
journey, with my heart in my mouth, lest the oxen should again take
it into their senseless heads to cut up a caper. But their spree was
over for the present, and the rascals now moved off as soberly as
though their behavior had been natural and exemplary. On reaching
the part of the forest where I had been the day before chopping
wood, I filled the cart with a heavy load, as a security against another
runaway. But the neck of an ox is equal in strength to iron. It defies
ordinary burdens. Tame and docile to a proverb, when well trained,
the ox is the most sullen and intractable of animals when but half
broken to the yoke. I saw in my own situation several points of
similarity with that of the oxen. They were property; so was I. Covey
was to break me—I was to break them. Break and be broken was
the order.
Half of the day was already gone and I had not yet turned my
face homeward. It required only two days’ experience and
observation to teach me that no such apparent waste of time would
be lightly overlooked by Covey. I therefore hurried toward home; but
in reaching the lane gate I met the crowning disaster of the day. This
gate was a fair specimen of southern handicraft. There were two
huge posts eighteen inches in diameter, rough hewed and square,
and the heavy gate was so hung on one of these that it opened only
about half the proper distance. On arriving here it was necessary for
me to let go the end of the rope on the horns of the “in hand ox;” and
now as soon as the gate was open and I let go of it to get the rope
again, off went my oxen, making nothing of their load, full tilt; and in
so doing they caught the huge gate between the wheel and the cart
body, literally crushing it to splinters, and coming only within a few
inches of subjecting me to a similar crushing, for I was just in
advance of the wheel when it struck the left gate post. With these
two hair-breadth escapes I thought I could successfully explain to Mr.
Covey the delay and avert punishment—I was not without a faint
hope of being commended for the stern resolution which I had
displayed in accomplishing the difficult task—a task which I
afterwards learned even Covey himself would not have undertaken
without first driving the oxen for some time in the open field,
preparatory to their going to the woods. But in this hope I was
disappointed. On coming to him his countenance assumed an
aspect of rigid displeasure, and as I gave him a history of the
casualties of my trip, his wolfish face, with his greenish eyes,
became intensely ferocious. “Go back to the woods again,” he said,
muttering something else about wasting time. I hastily obeyed, but I
had not gone far on my way when I saw him coming after me. My
oxen now behaved themselves with singular propriety, contrasting
their present conduct to my representation of their former antics. I
almost wished, now that Covey was coming, they would do
something in keeping with the character I had given them; but no,
they had already had their spree, and they could afford now to be
extra good, readily obeying orders, and seeming to understand them
quite as well as I did myself. On reaching the woods my tormentor,
who seemed all the time to be remarking to himself upon the good
behavior of the oxen, came up to me and ordered me to stop the
cart, accompanying the same with the threat that he would now
teach me how to break gates and idle away my time when he sent
me to the woods. Suiting the action to the words, Covey paced off, in
his own wiry fashion, to a large black gum tree, the young shoots of
which are generally used for ox goads, they being exceedingly
tough. Three of these goads, from four to six feet long, he cut off and
trimmed up with his large jack-knife. This done, he ordered me to
take off my clothes. To this unreasonable order I made no reply, but
in my apparent unconsciousness and inattention to this command I
indicated very plainly a stern determination to do no such thing. “If
you will beat me,” thought I, “you shall do so over my clothes.” After
many threats, which made no impression upon me, he rushed at me
with something of the savage fierceness of a wolf, tore off the few
and thinly worn clothes I had on, and proceeded to wear out on my
back the heavy goads which he had cut from the gum tree. This
flogging was the first of a series of floggings, and though very
severe, it was less so than many which came after it, and these for
offences far lighter than the gate-breaking.
I remained with Mr. Covey one year (I cannot say I lived with
him), and during the first six months that I was there I was whipped,
either with sticks or cow-skins, every week. Aching bones and a sore
back were my constant companions. Frequent as the lash was used,
Mr. Covey thought less of it as a means of breaking down my spirit
than that of hard and continued labor. He worked me steadily up to
the point of my powers of endurance. From the dawn of day in the
morning till the darkness was complete in the evening I was kept at
hard work in the field or the woods. At certain seasons of the year
we were all kept in the field till eleven and twelve o’clock at night. At
these times Covey would attend us in the field and urge us on with
words or blows, as it seemed best to him. He had, in his life, been an
overseer, and he well understood the business of slave-driving.
There was no deceiving him. He knew just what a man or boy could
do, and he held both to strict account. When he pleased he would
work himself like a very Turk, making everything fly before him. It
was, however, scarcely necessary for Mr. Covey to be really present
in the field to have his work go on industriously. He had the faculty of
making us feel that he was always present. By a series of adroitly
managed surprises which he practiced, I was prepared to expect him
at any moment. His plan was never to approach the spot where his
hands were at work in an open, manly, and direct manner. No thief
was ever more artful in his devices than this man Covey. He would
creep and crawl in ditches and gullies, hide behind stumps and
bushes, and practice so much of the cunning of the serpent, that Bill
Smith and I, between ourselves, never called him by any other name
than “the snake.” We fancied that in his eyes and his gait we could
see a snakish resemblance. One half of his proficiency in the art of
negro-breaking consisted, I should think, in this species of cunning.
We were never secure. He could see or hear us nearly all the time.
He was to us behind every stump, tree, bush, and fence on the
plantation. He carried this kind of trickery so far that he would
sometimes mount his horse and make believe he was going to St.
Michaels, and in thirty minutes afterwards you might find his horse
tied in the woods, and the snake-like Covey lying flat in the ditch with
his head lifted above its edge, or in a fence-corner, watching every
movement of the slaves. I have known him walk up to us and give us
special orders as to our work in advance, as if he were leaving home
with a view to being absent several days, and before he got half way
to the house he would avail himself of our inattention to his
movements to turn short on his heel, conceal himself behind a fence
corner or a tree, and watch us until the going down of the sun. Mean
and contemptible as is all this, it is in keeping with the character
which the life of a slaveholder was calculated to produce. There was
no earthly inducement in the slave’s condition to incite him to labor
faithfully. The fear of punishment was the sole motive of any sort of
industry with him. Knowing this fact as the slaveholder did, and
judging the slave by himself, he naturally concluded that the slave
would be idle whenever the cause for this fear was absent. Hence all
sorts of petty deceptions were practiced to inspire fear.
But with Mr. Covey trickery was natural. Everything in the shape
of learning or religion which he possessed was made to conform to
this semi-lying propensity. He did not seem conscious that the
practice had anything unmanly, base, or contemptible about it. It was
a part of an important system with him, essential to the relation of
master and slave. I thought I saw, in his very religious devotions, this
controlling element of his character. A long prayer at night made up
for a short prayer in the morning, and few men could seem more
devotional than he when he had nothing else to do.
Mr. Covey was not content with the cold style of family worship
adopted in the cold latitudes, which begin and end with a simple
prayer. No! the voice of praise as well as of prayer must be heard in
his house night and morning. At first I was called upon to bear some
part in these exercises; but the repeated floggings given me turned
the whole thing into mockery. He was a poor singer, and mainly
relied on me for raising the hymn for the family, and when I failed to
do so he was thrown into much confusion. I do not think he ever
abused me on account of these vexations. His religion was a thing
altogether apart from his worldly concerns. He knew nothing of it as
a holy principle directing and controlling his daily life, making the
latter conform to the requirements of the gospel. One or two facts will
illustrate his character better than a volume of generalities.
I have already implied that Mr. Edward Covey was a poor man.
He was, in fact, just commencing to lay the foundation of his fortune,
as fortune was regarded in a slave state. The first condition of wealth
and respectability there being the ownership of human property,
every nerve was strained by the poor man to obtain it, with little
regard sometimes as to the means. In pursuit of this object, pious as
Mr. Covey was, he proved himself as unscrupulous and base as the
worst of his neighbors. In the beginning he was only able—as he
said—“to buy one slave;” and scandalous and shocking as is the
fact, he boasted that he bought her simply “as a breeder.” But the
worst of this is not told in this naked statement. This young woman
(Caroline was her name) was virtually compelled by Covey to
abandon herself to the object for which he had purchased her; and
the result was the birth of twins at the end of the year. At this addition
to his human stock Covey and his wife were ecstatic with joy. No one
dreamed of reproaching the woman or of finding fault with the hired