All language subtitles for S09E09 - Bumpers; Lighting Gels and Camera Filters; Steam-Powered Models; Candy Canes (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, llc
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Narrator:
Today on "How it's made"...
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Bumpers...
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...Lighting gels
And camera filters...
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...Steam-powered models...
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...And candy canes.
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With all the attention we pay
To our car's high-tech parts,
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It's easy
To overlook the importance
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Of a vehicle's bumpers.
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About 80% of car accidents
Are front or rear collisions.
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The bumper is designed to absorb
The force of the impact,
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Minimizing damage
In low-speed collisions.
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Bumpers can be made of plastic,
Fiberglass, aluminum, or steel.
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This company
Makes steel bumpers.
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They start out as blanks,
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Steel sheets
Just 8/100 of an inch thick.
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These are en route
To becoming truck bumpers.
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A robot feeds each blank through
A series of seven to nine dies,
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Depending on the bumper model.
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Each die stamps the blank
Into a particular shape,
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Using some 2,000 tons of force.
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This progressively
Forms the blank
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Into the final bumper shape.
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Both the front and rear bumpers
Go through the same process,
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Only with different dies.
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The bumpers now travel
To the next production area,
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Where a worker clamps each one
Onto a specially designed cart.
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At this point, the factory
Paints certain models.
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These bumpers
Will get chrome plating.
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But first they travel through
A series of buffing wheels.
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The bumper surface
Must be impeccably smooth
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Because the chrome finish
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Magnifies even
The tiniest flaws.
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A computer-guided crane
Stacks the bumpers
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And maneuvers them through
The chrome-plating process.
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First it submerges the bumpers
In several cleaning tanks
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To remove any residue
Left on the surface
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From previous operations.
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The company won't divulge
What chemicals it uses
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To clean the steel
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Because this surface preparation
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Is the secret
To first-rate metal plating.
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The first plating tank
Applies a coat of nickel
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To protect the steel
From corrosion.
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The next tank
Applies the chrome layer.
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The factory uses the standard
Electroplating process.
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In a water-and-chemical-filled
Tank,
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The plating metal particles
Get a positive charge
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While a negative charge
Runs through the bumpers.
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This magnetically draws
The particles onto the bumpers
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In an even layer.
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After a thorough rinse,
The bumpers are inspected.
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Workers scrutinize
The chrome-mirror finish
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Under high-intensity light.
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Meanwhile, this machine
Pressure injects molten plastic
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Into various molds.
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A built-in cooling system
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Hardens the plastic
Within seconds.
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Then out comes
The plastic components
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That attach to the bumpers.
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One of those plastic parts
Is this step pad
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That covers the top
Of the rear bumper.
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Once the pad's in place,
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A worker attaches
A built-in trailer hitch.
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Steel mounting brackets
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Help structurally reinforce
The bumper.
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The front bumper goes down
A different assembly line.
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A worker attaches a plastic trim
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That hangs down
Just below the bumper.
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Its aerodynamic shape
Helps direct air flow
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To the engine compartment.
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Next, four steel
Reinforcing brackets
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That will attach the bumper
To the truck's frame.
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And, finally,
The license-plate holder...
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And fog lamps.
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Workers tighten all the bolts
To a specified tightness.
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This ensures that the bumper
And its mounting brackets
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Will adequately absorb
The force of the collision.
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Whenever a new model
Goes into production,
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The first few bumpers
Off the line
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Go through a battery of tests
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To prove they can withstand
Stress, vibration,
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And a certain degree of what
Engineers call crash energy.
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Other types of bumper systems
Use a combination of springs
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And energy-absorbing material,
Such as plastic foam.
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With either method,
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The goal is for the bumper
To absorb the impact.
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In a low-impact crash,
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This should ideally confine
The damage to the bumper itself,
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Leaving the headlights,
The engine,
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And the driver unscathed.
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Up next, some colorful products
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That set the stage
In a whole new light.
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Narrator: gels and filters
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Can turn a bad scene
Into a beautiful one.
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They're used
In theater productions
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To enhance the mood on stage.
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They're also used
In film and photography
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To adjust color temperatures
From different light sources.
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These lighting gels can make any
Scene take on a different mood.
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They're called gels because they
Used to be made of gelatin film,
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But today they are made
Out of transparent polyester.
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The process begins
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With a mix of solvent, dye,
And flame-retardant chemicals.
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This produces a colored lacquer.
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A worker tests
The lacquer's thickness
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By pouring it into a brass cup
With a hole in the bottom.
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As the lacquer drains out
Of the hole, it's timed.
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If it flows too quickly,
The lacquer is too thin,
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00:07:03,827 --> 00:07:06,758
And if it drains too slowly,
It's too thick.
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A steady flow
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Means the lacquer mix
Is the perfect consistency --
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About as thick as engine oil.
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A sample of every batch
Undergoes this test
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Because the lacquer's
Consistency is critical.
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If the factory
Doesn't get it right,
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It won't bond
To the clear polyester.
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With the lacquer prepared,
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Workers load the polyester film
Into the coating machine.
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A big roller soaks up lacquer
From a tray below
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00:07:42,482 --> 00:07:44,241
And spreads it on the film.
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A thin bar
On the roller evens the spread
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And scrapes off the excess.
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The lacquer dries in seconds.
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Every production run
Of the same color
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Has to precisely match the last,
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So inspectors regularly test
The lacquer's hue
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On swatches of clear polyester.
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00:08:11,724 --> 00:08:14,275
If gel colors
Are even slightly mismatched,
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Using them together will make
For a patchy-looking job.
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Differently colored gels
Create different effects.
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This orangey red one
Will warm up daylight
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00:08:33,827 --> 00:08:36,241
To look more like
Indoor lighting.
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Now, in a test, a gel swatch
Is held over a flame.
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The gel burns
But never catches fire --
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Proving that this batch is ready
For the hot lights
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Of a movie set.
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Over at another station,
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00:09:07,275 --> 00:09:10,275
They're working on a different
Sort of color-changer --
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00:09:10,379 --> 00:09:12,517
A filter that
Goes on a camera lens.
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00:09:13,241 --> 00:09:15,448
A special sheet
Of optical plastic
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Is dipped in hot water and dye.
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The hot water
Opens the plastic's pores,
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Allowing the dye to penetrate.
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When the plastic cools,
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00:09:23,827 --> 00:09:26,172
The color
Will be trapped inside.
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00:09:26,275 --> 00:09:28,724
The longer the plastic
Stays in the dye bath,
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00:09:28,827 --> 00:09:31,586
The deeper the color.
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Some sheets
Only get partially dyed.
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00:09:34,068 --> 00:09:35,862
They'll be turned into filters
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That affect only half
An image's exposure.
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Filters made
From a range of colors
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Will help the camera's eye
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Do what the human eye
Does effortlessly --
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Adjust to different
Lighting conditions.
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The colored sheets are sheathed
In thin plastic.
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00:09:57,827 --> 00:10:01,137
This prevents scratching
As they're cut to size.
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00:10:09,793 --> 00:10:13,241
These camera filters
Are nearly done.
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00:10:13,344 --> 00:10:16,344
All that's left is for the
Ink-jet printer to brand them.
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A similar type of printer
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Gives the lighting gels
Their trademark stamp.
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And now it's time
To wrap things up.
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A cardboard core slides
Into a machine
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That winds the finished
Gel sheets onto it.
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00:10:41,103 --> 00:10:43,931
Then a pneumatic ram pushes
The roll of lighting gel
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Into a plastic bag.
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Now these filters and gels
Are ready to show life
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In the best light possible.
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When we return,
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Making tiny models
That are a blast from the past.
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Narrator: when factories
Build live steam models,
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They're reconstructing history.
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00:11:15,137 --> 00:11:20,103
These working steam models
Take us on a nostalgic journey,
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00:11:20,206 --> 00:11:23,103
And they're fun
For hobbyists of all ages.
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Add a little water...
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Light some fuel
For the boiler...
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00:11:37,862 --> 00:11:39,275
And it's full steam ahead
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00:11:39,379 --> 00:11:42,620
For this mini replica of
A 19th-century road locomotive.
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00:11:50,620 --> 00:11:53,344
Production starts
With the boiler.
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A hydraulic press repeatedly
Punches a piece of brass,
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00:11:56,862 --> 00:11:59,620
Stretching the brass cap
Into a cylinder.
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It's a process called drawing,
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And it also strengthens
The metal.
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A flat piece of brass
Is transformed into a cylinder
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In only a few minutes.
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00:12:17,931 --> 00:12:21,172
Next the ends of the cylinder
Are trimmed.
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Solder paste
Is brushed onto a brass cap
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00:12:23,758 --> 00:12:26,620
And slotted
Into a holding device.
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00:12:32,034 --> 00:12:36,034
Paste goes onto attachments
Inside the cylindrical boiler.
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00:12:36,137 --> 00:12:39,793
Then the boiler and cap
Are press-fitted together.
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The cap boilers travel
Through a furnace,
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00:12:47,793 --> 00:12:51,379
Which melts the solder paste,
Fusing the caps to the cylinder.
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00:12:54,310 --> 00:12:57,137
Workers polish the brass
To give it a nice sheen.
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00:13:02,724 --> 00:13:05,310
Then they solder copper pipes
To the boiler.
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00:13:05,413 --> 00:13:07,310
These pipes will expel the steam
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00:13:07,413 --> 00:13:09,827
As it powers
This little locomotive.
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00:13:18,586 --> 00:13:20,689
Next up --
Trimming the flywheel,
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00:13:20,793 --> 00:13:22,275
Which has been precast.
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00:13:26,206 --> 00:13:29,482
The flywheel will smooth out
The engine's firing impulses
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00:13:29,586 --> 00:13:31,241
So that it runs more evenly.
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00:13:35,310 --> 00:13:38,310
The flywheel is tightly screwed
To the crank shaft.
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00:13:42,241 --> 00:13:46,241
Workers check the sliding action
Of the piston and its cylinder.
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00:13:46,344 --> 00:13:48,793
Then they attach the assembly
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00:13:48,896 --> 00:13:51,758
To the engine frame
And the crank shaft.
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00:13:53,931 --> 00:13:58,103
Lubricating the piston assembly
Enhances its sliding action.
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00:14:03,206 --> 00:14:05,137
Using compressed air,
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00:14:05,241 --> 00:14:09,103
Workers make sure the engine
Functions and has no leaks.
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00:14:12,206 --> 00:14:14,413
Once the model passes the test,
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00:14:14,517 --> 00:14:16,620
It gets its front
Steering mechanism.
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00:14:16,724 --> 00:14:18,827
This will control
The model's front wheels
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00:14:18,931 --> 00:14:21,000
While the back wheels
Power it forward.
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00:14:23,034 --> 00:14:26,137
Steam machines
Are usually rear-wheel drive.
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00:14:31,103 --> 00:14:33,931
A wire called the drive band
Transfers the energy
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00:14:34,034 --> 00:14:36,379
From the flywheel
To the rear wheel.
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00:14:43,172 --> 00:14:44,758
The steam model
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00:14:44,862 --> 00:14:47,206
Is hooked up to the compressed
Air tank once again
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00:14:47,310 --> 00:14:49,068
For a final test run.
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00:14:49,172 --> 00:14:53,448
And it looks like this model
Is ready for some action.
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00:14:55,103 --> 00:14:58,034
All it needs is a canopy
To provide a little shade.
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00:14:59,034 --> 00:15:02,655
A ribbed design is punched
Into a little steel roof.
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00:15:05,310 --> 00:15:09,172
After it gets a nice paint job,
It's attached to the model.
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00:15:11,137 --> 00:15:15,448
Production on this tiny treasure
Is now complete.
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00:15:18,758 --> 00:15:20,965
This model will also
Take you back in time,
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00:15:21,068 --> 00:15:22,379
But in high style.
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00:15:22,482 --> 00:15:24,344
It's a luxury touring car.
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00:15:39,655 --> 00:15:42,310
Workers install
The piston cylinder assembly
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00:15:42,413 --> 00:15:45,758
A little lower on this roadster
And fire it up.
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00:15:52,034 --> 00:15:56,034
Each of these mini steam models
Is a tribute to the original
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00:15:56,137 --> 00:15:57,862
And give us all a glimpse
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00:15:57,965 --> 00:16:00,379
Into the colorful history
Of transportation.
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00:16:07,103 --> 00:16:08,655
Coming up...
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Turning sugar into one
Of our favorite holiday treats.
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00:16:16,758 --> 00:16:18,448
Narrator:
In the 17th century,
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00:16:18,551 --> 00:16:19,758
A german choirmaster
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00:16:19,862 --> 00:16:22,241
Had some sugar sticks
Bent into shepherd's crooks
237
00:16:22,344 --> 00:16:25,344
As a special treat
For his choir.
238
00:16:25,448 --> 00:16:29,655
And that's how the candy cane is
Believed to have been invented.
239
00:16:29,758 --> 00:16:32,241
But it wasn't until more
Than a century later
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00:16:32,344 --> 00:16:34,034
That they earned their stripes.
241
00:16:41,172 --> 00:16:44,827
Today candy canes come in
All different colors and sizes.
242
00:16:44,931 --> 00:16:47,758
Candymakers start
By cooking up a big batch
243
00:16:47,862 --> 00:16:50,620
Of sugar, water, and corn syrup.
244
00:16:54,482 --> 00:16:57,689
Next, they prepare a mix
Of starch and flavoring,
245
00:16:57,793 --> 00:17:01,034
Like peppermint or strawberry.
246
00:17:01,137 --> 00:17:03,068
As they blend together,
247
00:17:03,172 --> 00:17:06,137
The flavoring binds
To the starch.
248
00:17:06,241 --> 00:17:07,758
The flavoring mix
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Is emptied into the middle
Of a syrupy slab.
250
00:17:10,517 --> 00:17:13,000
Then the whole thing
Is fed into a machine
251
00:17:13,103 --> 00:17:16,448
That folds the batch repeatedly
Using shovels and a plunger.
252
00:17:16,551 --> 00:17:20,620
This distributes
The flavoring evenly.
253
00:17:32,620 --> 00:17:35,689
Cold water is piped into the
Shovels and the kneading table
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00:17:35,793 --> 00:17:37,172
To cool the candy-cane mix
255
00:17:37,275 --> 00:17:39,413
So it takes on
The stiffer consistency
256
00:17:39,517 --> 00:17:42,310
That's necessary
For the next step.
257
00:17:44,034 --> 00:17:47,310
Now it's over
To the automated pullers.
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00:17:47,413 --> 00:17:51,034
These pullers stretch
The mixture around a metal post.
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00:17:51,137 --> 00:17:54,448
This action aerates the candy,
Turning it white.
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00:17:54,551 --> 00:17:57,310
This batch
Will make 3,200 candy canes,
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00:17:57,413 --> 00:18:00,655
But there's still
A lot more work to be done.
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The candy is rolled
Into a fat log,
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00:18:12,103 --> 00:18:15,379
While heaters warm it until
Its pliable enough to shape.
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00:18:22,172 --> 00:18:26,241
Next, strips of red-colored
Candy are rolled out.
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00:18:29,724 --> 00:18:32,103
A worker stretches and folds it
To widen the strip.
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00:18:39,137 --> 00:18:40,931
Two of the red strips
Are arranged
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00:18:41,034 --> 00:18:42,896
On either side
Of the white candy.
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00:18:47,068 --> 00:18:48,655
It weighs 100 pounds,
269
00:18:48,758 --> 00:18:52,000
So it takes two workers to
Transfer it to the next machine.
270
00:18:54,379 --> 00:18:56,034
It's called a batch roller,
271
00:18:56,137 --> 00:18:59,103
And its cylinders roll the candy
Thinner and thinner,
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00:18:59,206 --> 00:19:01,689
Dramatically reducing
The log's diameter
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00:19:01,793 --> 00:19:04,586
Until it reaches
Candy-cane dimensions.
274
00:19:04,689 --> 00:19:07,655
A torch moves across the candy
To keep it pliable.
275
00:19:07,758 --> 00:19:10,379
Then the sugary batch
Travels between wheels
276
00:19:10,482 --> 00:19:12,137
That slim it down even more.
277
00:19:14,172 --> 00:19:17,206
The rope of candy moves forward
In a wave-like fashion.
278
00:19:17,310 --> 00:19:19,862
This gives it some slack
So it doesn't stretch
279
00:19:19,965 --> 00:19:22,862
As it moves through
The next set of wheels.
280
00:19:29,655 --> 00:19:33,620
The candy rope moves through
Two angled belts that twist it,
281
00:19:33,724 --> 00:19:38,137
And a chain of knives cut the
Twisted rope to candy-cane size.
282
00:19:42,448 --> 00:19:44,482
This production has been
Perfectly choreographed.
283
00:19:44,586 --> 00:19:48,827
One misstep,
And the job would hit a snarl.
284
00:19:51,517 --> 00:19:53,137
Here, a roll
Of cellophane unwinds,
285
00:19:53,241 --> 00:19:56,068
And a device wraps it
Around the candy sticks.
286
00:19:57,896 --> 00:19:59,482
A blast of hot air
Shrinks the cellophane
287
00:19:59,586 --> 00:20:00,551
On the ends of the canes.
288
00:20:05,793 --> 00:20:07,689
Now it's time
For these candy sticks
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00:20:07,793 --> 00:20:09,586
To get their signature crooks.
290
00:20:12,034 --> 00:20:15,413
This machine, called
A crooker deck, bends the ends.
291
00:20:18,724 --> 00:20:21,965
An overhead bracket brush
Gently secures the canes
292
00:20:22,068 --> 00:20:24,379
Because though
They're pliable enough to bend,
293
00:20:24,482 --> 00:20:26,000
They're still fragile.
294
00:20:34,000 --> 00:20:36,172
There's a camera
Inside this robotic arm,
295
00:20:36,275 --> 00:20:39,206
Which allows it to spot the
Candy canes on the conveyer belt
296
00:20:39,310 --> 00:20:41,068
And pick them up
Two at a time.
297
00:20:44,448 --> 00:20:48,551
It places them in cardboard
Packages by the dozen.
298
00:20:56,275 --> 00:20:59,724
It takes about half an hour
To make a box of candy canes.
299
00:20:59,827 --> 00:21:03,413
And they're sure to come
To a very sticky end
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00:21:03,517 --> 00:21:04,862
In even less time.
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00:21:13,448 --> 00:21:15,620
If you have any comments
About the show,
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00:21:15,724 --> 00:21:18,413
Or if you'd like to suggest
Topics for future shows,
303
00:21:18,517 --> 00:21:20,241
Drop us a line at...
24404
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