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Narrator:
Today, on "How it's made"...
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...Putty knives...
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...Garage doors...
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...Electric motors...
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...And wool.
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Rummage through
A do-it-yourselfer's toolbox,
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00:00:56,034 --> 00:00:59,862
And chances are, you'll come
Across a putty knife or two.
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They come in several widths.
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So whether you're
Scraping off paint,
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Old wallpaper,
Or installing drywall,
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There's a putty knife
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That's the right size and shape
For the job.
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These putty-knife blades
Are made of steel
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That's flexible and durable,
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Due in part
To its high carbon content.
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Production begins with workers
Feeding steel sheets
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Into a press one by one.
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The press's cutting guy
Punches out a blade
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For the type of putty knife
They're producing.
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The next press
Punches three rivet holes
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In the handle portion
Of the blade.
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These are for attaching
A hard plastic handle.
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For models
That'll have a handle
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Made of a softer,
Rubberlike plastic,
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They fishbone the handle portion
Of the blade,
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So that it'll grip the plastic.
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Steel has to be heat-treated
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To gain its full flexibility
And strength.
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First, they submerge the blades
In a bath of molten salt.
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The heat is intense --
1,400 degrees fahrenheit.
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The blades soak
For about a minute --
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The time it takes
For the metal temperature
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To rise to that of the tank.
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As it does,
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The steel's molecular structure
Begins to change.
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From here,
They transfer the blades
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To two successively cooler
Salt baths.
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That quenching, as it's called,
Further hardens the steel.
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The blades are then tempered
In an oven for eight hours
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At 400 degrees fahrenheit.
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This gives the steel memory,
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Meaning the blade will revert
To its original shape when bent.
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After heat treatment,
Lukewarm water jets
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Rinse off the salt residue
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And cool the metal
To room temperature.
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Now that the metal
Has the required properties,
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The blades
Need the right profile.
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A worker lays them on a magnetic
Plate that angles them downward.
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The plate spins, running the
Blades against a grinding wheel.
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00:03:06,137 --> 00:03:09,241
It takes about 30 seconds
Of grinding
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To profile each blade
And form the flex point --
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The thinnest
And most flexible part
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That's 1 1/2 inches
From the end of the blade.
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Blade profiles vary,
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Because some jobs require a more
Flexible tool than others.
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Now they clean the blades
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In a revolving drum
Filled with absorbent sand.
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This removes oil
And other residues
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Left by the production process,
And it preps the surface
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For the protective layer
Of lacquer that's applied next.
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After coating the blades
In lacquer,
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They dry them in an oven.
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This seals the metal,
Preventing rust.
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Assembly
Is completely automated.
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The first machine
Slips on the plastic handle.
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The next machine rivets it on.
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The following machine
Slaps on a label,
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Which identifies the size
And type of putty knife.
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Professional-quality
Putty knives
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Have a thicker, stiffer blade.
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The handle
Is made up of two halves.
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The machine positions them onto
The handle portion of the blade,
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Then attaches them
With a hollow ribbon.
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This enables the knife
To be hung up.
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This factory also produces
Retractable utility knives.
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00:05:04,793 --> 00:05:08,655
It puts the cast aluminum
Handles through a machine
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That uses polishing stones
To remove any shards of metal.
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Workers assemble
The utility knives manually,
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First installing the push button
That moves the blade in and out.
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After putting in a spare blade,
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They close up the handle
With one screw.
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This factory produces
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150 different
Paint-preparation tools
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For a wide range of uses,
From scraping to filling
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To smoothing out tape
On wall joints.
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Narrator:
Garage doors come in many
Styles, colors, and materials.
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They can be made of steel,
Aluminum, wood, or vinyl.
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Whether you choose a style
That's plain, paneled, smooth,
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Or textured, quality
Garage doors are lightweight,
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Well-insulated, and airtight.
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The typical residential garage
Door is made up of four panels.
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Each one begins as a sheet
Of either aluminum or steel --
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Two metals that can tolerate
Harsh climates.
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The side that will show
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Has a baked-on coat
Of polyester paint.
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Depending on the model,
The sheet passes through rollers
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That imprint a texture,
Such as a simulated wood grain.
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Then it goes through a press
That imprints a design.
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This model
Will have raised rectangles.
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Others have horizontal stripes
Or no design at all.
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After an automated machine
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Cuts the continuous sheet
To garage-door widths,
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Another machine
Folds over the edges.
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This creates half-inch joints
For attaching the panels.
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The polyester paint is elastic,
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So it simply stretches
With the bending.
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00:07:12,620 --> 00:07:15,689
Now on the back side
Of the sheets,
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They hot-glue metal plates
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To reinforce
The various components
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They'll later screw
Into the garage door,
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Parts such as the lift handles,
The hinge,
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00:07:25,275 --> 00:07:28,000
And the bracket for
The electric opener mechanism.
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They also drill a hole
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Through which
They'll later inject insulation.
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Now they slide two sheets
Together to form a panel.
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They close off the ends
With blocks of pine.
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This will prevent cold air
From penetrating inside.
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They apply various stickers
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With installation, maintenance,
And safety information.
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Orange stick-on dots mark
The location of the metal plates
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Into which the installer
Will screw the hinges
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And lift handles.
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00:07:59,827 --> 00:08:03,931
They attach an aluminum bar
To the long ends of each panel.
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00:08:03,931 --> 00:08:07,827
This holds the panel steady
During the injection process.
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00:08:07,827 --> 00:08:11,000
After injection,
The bars come off.
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00:08:11,000 --> 00:08:14,793
They load the panels onto
A carousel and begin the process
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Of filling the hollow
Interior cavity with insulation.
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Through the hole
They drilled earlier,
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00:08:21,103 --> 00:08:24,068
They inject polyurethane foam,
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An expanding,
Plastic insulation material
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That's specially designed to
Penetrate hard-to-access spaces.
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As we see in this demonstration,
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The polyurethane expands
And becomes rigid.
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This creates a solid core
Inside the garage door.
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Polyurethane is one of the
Lightest types of insulation,
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So it doesn't make
The garage door heavy.
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Here's what the inside
Of a panel looks like
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Once the foam hardens.
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Now workers install
Various components,
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00:09:13,310 --> 00:09:16,793
Such as the rubber weather seal
On the bottom panel.
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This seal prevents cold air
And water
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From entering the garage
Under the door.
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Some garage-door models
Have windows
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To allow in natural light.
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00:09:33,413 --> 00:09:35,896
Workers first use
A high-speed router
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00:09:35,896 --> 00:09:39,655
To remove the rectangles where
These windows will be installed.
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Then they insert one of
Several window styles available.
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These are
Double-sealed windows --
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Two thermal panes with
An aluminum spacer in between.
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The framing around the glass
Comes in different colors.
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It's made of pvc -- a synthetic
Resin that doesn't discolor.
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00:09:58,931 --> 00:10:01,482
The frame prevents
Water and cold air
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00:10:01,482 --> 00:10:03,896
From penetrating
Through the window.
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00:10:03,896 --> 00:10:06,931
Workers pack
The installation hardware.
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00:10:06,931 --> 00:10:11,172
Then they weigh the box
To ensure no part was left out.
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00:10:15,517 --> 00:10:16,931
At installation time,
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00:10:16,931 --> 00:10:20,275
They attach the door panels
At the joints with hinges.
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A system of springs
Ensures the garage door
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00:10:23,827 --> 00:10:27,172
Is perfectly balanced
And moves smoothly.
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00:10:28,862 --> 00:10:32,379
If properly installed,
You should be able
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00:10:32,379 --> 00:10:36,620
To lift or lower the garage door
Using two fingers.
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00:10:46,965 --> 00:10:50,310
Narrator: electric motors are
Made of two main components --
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One stationary,
Called the stator,
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The other a rotor
That moves inside the stator.
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The stator
Has multiple wire coils.
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Running electricity through them
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00:11:00,689 --> 00:11:03,137
Creates a concentrated
Magnetic field
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00:11:03,137 --> 00:11:06,965
That turns the rotor,
Creating mechanical power.
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00:11:10,310 --> 00:11:12,689
The stator is lined with slots,
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00:11:12,689 --> 00:11:15,137
Each of which
Holds a copper coil.
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00:11:15,137 --> 00:11:17,034
The more powerful the motor,
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00:11:17,034 --> 00:11:19,931
The bigger the stator
And the larger the slots.
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00:11:24,103 --> 00:11:28,068
The first step is to line
The slots with insulation.
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00:11:28,068 --> 00:11:31,620
This insulation will keep the
Voltage confined to the coils.
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00:11:41,275 --> 00:11:44,413
The coils are made
From several copper wires
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Wound together
By programmable machines.
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00:11:47,275 --> 00:11:51,862
The bigger the motor,
The more wires per coil.
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00:11:51,862 --> 00:11:53,896
In this motor,
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00:11:53,896 --> 00:11:56,620
Each coil consists
Of 13 strands of copper wire.
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00:12:07,206 --> 00:12:10,344
Now workers tie the coils.
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00:12:10,344 --> 00:12:12,758
This prevents the wires
From unraveling
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00:12:12,758 --> 00:12:15,551
While being inserted
Into the stator slots.
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00:12:22,655 --> 00:12:27,068
Workers cap each coil
With fiberglass insulation.
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00:12:28,827 --> 00:12:31,448
Then they insulate
The portion of the coil
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00:12:31,448 --> 00:12:34,206
Left outside the slots
With fiberglass sheets.
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00:12:36,724 --> 00:12:39,448
Fiberglass wedges are inserted,
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00:12:39,448 --> 00:12:42,000
Locking the coils
Inside the slots.
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00:12:45,241 --> 00:12:48,206
Once all the coils
Are inserted and insulated,
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00:12:48,206 --> 00:12:51,034
Workers begin preparing
The connection.
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00:12:51,034 --> 00:12:52,965
They slip
An acrylic insulation sleeve
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00:12:52,965 --> 00:12:59,689
Over both ends of each coil --
13 coils, 26 ends.
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00:12:59,689 --> 00:13:04,931
Then they group these insulated
Wires into large power cables.
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00:13:04,931 --> 00:13:07,275
The number of wires
Per cable varies
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00:13:07,275 --> 00:13:10,206
According to the speed
And voltage of the motor.
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00:13:16,793 --> 00:13:19,103
They solder
The grouped wires together,
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00:13:19,103 --> 00:13:21,931
Then insulate the cables.
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00:13:21,931 --> 00:13:25,862
They tuck some inside the stator
And leave others accessible
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00:13:25,862 --> 00:13:31,103
To be attached to a power source
When the motor is installed.
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00:13:31,103 --> 00:13:33,137
Now, using a cord
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00:13:33,137 --> 00:13:35,758
Made of heat- and
Chemical-resistant polyester,
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00:13:35,758 --> 00:13:37,689
They bind the coils tightly
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00:13:37,689 --> 00:13:41,068
To ensure they won't move
When the motor spins.
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This unit of bound coils
Is known as the stator coil.
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00:13:45,758 --> 00:13:49,793
They now submerge the stator
In a polyester-based varnish
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00:13:49,793 --> 00:13:52,103
And vacuum it right through.
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00:13:52,103 --> 00:13:53,655
This thorough penetration
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00:13:53,655 --> 00:13:56,137
Makes the stator coil
Moisture-resistant.
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00:14:00,965 --> 00:14:03,827
The stator is put into an oven
For six hours
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00:14:03,827 --> 00:14:07,586
At 280 degrees fahrenheit.
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00:14:07,586 --> 00:14:12,758
The varnish hardens,
Making the stator coil rigid.
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00:14:12,758 --> 00:14:16,172
Now they have
To balance the rotor.
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00:14:16,172 --> 00:14:19,275
If it's off-kilter,
The motor will vibrate,
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00:14:19,275 --> 00:14:21,000
Hampering performance.
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00:14:21,000 --> 00:14:24,275
They balance it the same way
A mechanic balances car tires,
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00:14:24,275 --> 00:14:27,758
Only with 100 times
Greater precision.
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00:14:27,758 --> 00:14:32,034
Now they slowly slide the rotor
Into the stator,
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00:14:32,034 --> 00:14:35,137
Careful not to damage
The stator coil.
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00:14:35,137 --> 00:14:37,965
The rotor will turn
On steel bearings.
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00:14:37,965 --> 00:14:41,172
They heat these bearings
To expand them,
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00:14:41,172 --> 00:14:43,413
So they'll install easily.
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00:14:43,413 --> 00:14:47,172
Then they blow on cold air
To shrink them to a tight fit.
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00:14:47,172 --> 00:14:50,413
It's the same process
With the motor's back cover.
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00:14:56,689 --> 00:15:00,551
Now they heat the fan and
Install it over the back cover.
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00:15:00,551 --> 00:15:04,068
The fan's job is to cool
The running motor
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00:15:04,068 --> 00:15:06,517
So that it doesn't overheat
And break down.
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00:15:08,551 --> 00:15:11,241
They cover the fan
With a safety guard,
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00:15:11,241 --> 00:15:15,000
Then install a cover on
The front of the motor as well.
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00:15:17,103 --> 00:15:20,103
They run the finished motor
Through various tests to assess,
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00:15:20,103 --> 00:15:24,413
Among other things, insulation
Strength and performance.
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00:15:24,413 --> 00:15:27,862
These industrial motors are
Designed for use in factories,
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00:15:27,862 --> 00:15:30,655
For running machinery,
Such as conveyer belts,
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00:15:30,655 --> 00:15:33,172
Pumps, fans, and compressors.
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00:15:44,793 --> 00:15:48,137
Narrator: what do wool
And hand cream have in common?
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00:15:48,137 --> 00:15:51,034
Well, a sheep's fleece
Has an oily protective coating
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00:15:51,034 --> 00:15:53,931
Which contains a substance
Called wool grease.
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00:15:53,931 --> 00:15:55,517
When factories make yarn,
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00:15:55,517 --> 00:15:58,206
They first clean the wool
With detergents.
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00:15:58,206 --> 00:16:00,758
The grease is processed
Into lanolin --
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00:16:00,758 --> 00:16:03,931
A common ingredient
In hand creams.
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00:16:09,275 --> 00:16:13,241
Historians believe
That people began raising sheep
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00:16:13,241 --> 00:16:16,862
For food and clothing
About 10,000 years ago.
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00:16:16,862 --> 00:16:19,448
And around 4,000 b.C.,
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00:16:19,448 --> 00:16:23,379
They started spinning the wool
Into yarn for weaving fabric.
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00:16:23,379 --> 00:16:26,793
The romans brought
Wool production to england
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00:16:26,793 --> 00:16:28,655
In about 50 a.D.
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00:16:28,655 --> 00:16:30,758
Woolen fabrics would become
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00:16:30,758 --> 00:16:34,034
The country's chief export
For centuries.
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In 1797, britain shipped
13 sheep to australia,
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Starting what would become
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00:16:39,724 --> 00:16:44,206
The largest wool industry
In the world today.
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Wool fabric is durable,
Wrinkle-proof,
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And holds its shape well.
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00:16:57,620 --> 00:17:01,413
It absorbs moisture and
Insulates against heat and cold.
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That's why wool is ideal
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00:17:03,068 --> 00:17:05,689
For clothing
Like sweaters and coats.
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Sheep shearers use power shears,
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00:17:10,655 --> 00:17:13,000
Removing the fleece
In one piece.
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00:17:17,000 --> 00:17:20,241
They discard any stained
Or inferior wool
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And then sort the rest according
To the quality of the fibers.
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This grading is based on length,
Color, waviness, and fineness.
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00:17:31,517 --> 00:17:34,827
The wool is cleaned with
Detergents before processing.
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00:17:38,310 --> 00:17:42,206
The wool arrives at the factory
In compressed bales.
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Workers untie them and feed the
Wool into the opening equipment,
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00:17:45,689 --> 00:17:51,448
Whose metal tooth rollers comb
Out and separate the fibers.
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00:17:51,448 --> 00:17:54,310
From there, the fibers
Go into the blending room,
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Where air currents
Mix different grades of wool
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To get the desired texture.
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00:17:59,896 --> 00:18:02,034
If they'll be weaving
A wool blend,
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00:18:02,034 --> 00:18:03,965
They mix the wool fibers
With other material,
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00:18:03,965 --> 00:18:06,241
Such as polyester fibers.
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00:18:06,241 --> 00:18:09,862
A thorough blending
Takes about an hour.
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00:18:12,103 --> 00:18:14,827
An air pipe transports
The blended fibers
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00:18:14,827 --> 00:18:16,931
To the next station.
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00:18:16,931 --> 00:18:20,206
On the way, sprayers lubricate
Them with a mineral-oil mixture
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00:18:20,206 --> 00:18:22,413
To make processing easier.
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00:18:24,034 --> 00:18:26,310
The fibers arrive
At the carding machine,
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00:18:26,310 --> 00:18:30,068
Where they pass through a series
Of rollers with thin wire teeth.
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00:18:30,068 --> 00:18:32,620
This untangles the fibers
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00:18:32,620 --> 00:18:35,379
And lines them up parallel
To each other.
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00:18:35,379 --> 00:18:38,000
This process also removes
Any pieces of debris
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00:18:38,000 --> 00:18:40,310
Caught in the fibers.
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00:18:43,965 --> 00:18:48,689
The carding process produces a
Smooth, flat sheet called a web.
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00:19:15,068 --> 00:19:20,000
The equipment divides this web
Into thin, flat strips.
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00:19:25,517 --> 00:19:27,793
These strips
Go through rub aprons --
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00:19:27,793 --> 00:19:29,413
Two rollers that twirl them
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00:19:29,413 --> 00:19:32,482
Into thinner, rounded strips,
Called rovings.
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00:19:40,862 --> 00:19:43,448
The rovings wind onto a spool.
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00:19:45,689 --> 00:19:47,137
Rovings look like yarn.
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00:19:47,137 --> 00:19:50,000
But if you pull on them,
They simply tear.
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00:19:50,000 --> 00:19:53,241
They haven't been spun,
So they have no strength.
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00:19:53,241 --> 00:19:58,241
Each roving goes into a device
Called a spinning frame.
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00:19:58,241 --> 00:20:00,827
It stretches the roving
And spins it tightly,
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00:20:00,827 --> 00:20:03,034
Producing wool yarn.
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00:20:05,448 --> 00:20:08,758
The yarn winds onto a bobbin.
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00:20:12,034 --> 00:20:14,724
Spinning gives
The yarn strength.
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00:20:14,724 --> 00:20:18,103
Now they can weave it
Into wool fabric.
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00:20:18,103 --> 00:20:21,379
A fully automated loom
Does it all.
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00:20:25,068 --> 00:20:28,344
Watch in slow motion as
It inserts one strand at a time
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00:20:28,344 --> 00:20:32,551
Crosswise through stationary
Lengthwise strands.
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00:20:32,551 --> 00:20:35,241
It's computer-programmed
To thread
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00:20:35,241 --> 00:20:37,379
In a specific
Under/over configuration,
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00:20:37,379 --> 00:20:41,034
According to the type of weave.
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00:20:47,310 --> 00:20:50,137
The loom inserts
400 strands per minute.
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00:20:50,137 --> 00:20:53,931
After weaving,
They burn off vegetal matter,
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00:20:53,931 --> 00:20:55,655
Such as straw fragments,
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00:20:55,655 --> 00:20:58,068
Then they dye
And dry the fabric.
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00:20:58,068 --> 00:21:01,448
All wool fabrics
Undergo finishing
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00:21:01,448 --> 00:21:04,517
To give them a particular
Appearance and feel.
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00:21:04,517 --> 00:21:08,827
These spiked rollers
Created a plush finish.
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00:21:08,827 --> 00:21:14,068
Wool fabrics can also have
A sheered or flat finish.
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00:21:14,068 --> 00:21:17,068
--captions by vitac--
Www.Vitac.Com
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00:21:17,068 --> 00:21:20,034
Captions paid for by
Discovery communications, inc.
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00:21:22,379 --> 00:21:24,448
If you have any comments
About the show,
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00:21:24,448 --> 00:21:27,103
Or if you'd like to suggest
Topics for future shows,
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00:21:27,103 --> 00:21:29,689
Drop us a line at...
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