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--Captions by VITAC--
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
TODAY ON "HOW IT'S MADE"...
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WITNESS SAMPLES.
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PRESSURE WASHERS.
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BEE HIVES.
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AND CAST IRON COOKERS.
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SPECIAL COATINGS APPLIED
TO OPTICAL GLASS
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CHANGE THE WAY
IT TRANSMITS LIGHT,
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00:00:58,310 --> 00:01:00,862
SO THAT IT BECOMES MORE
OR LESS REFLECTIVE
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00:01:00,862 --> 00:01:03,344
OR EVEN ELECTRICALLY CONDUCTIVE.
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00:01:03,344 --> 00:01:06,172
TESTING BEFOREHAND ON LITTLE
GLASS DISCS
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KNOWN AS WITNESS SAMPLES
BEARS WITNESS
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00:01:08,689 --> 00:01:10,793
TO THE QUALITY OF THE COATINGS.
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00:01:14,551 --> 00:01:17,620
WITH WITNESS SAMPLES,
IT'S ALL ABOUT THE OPTICS.
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THEY MUST BE FLAWLESS
ON THE SURFACE
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IN ORDER FOR OPTICAL COATINGS
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TO BE APPLIED
AND PROPERLY EVALUATED.
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A DIAMOND DRILL CUTS
SOLID CYLINDERS
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OUT OF A BLOCK OF OPTICAL GLASS.
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EACH ONE IS AN INCH IN DIAMETER.
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A WORKER GLUES THE CYLINDERS
TOGETHER TO A GLASS PLATE.
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THIS KEEPS THEM IN A TIGHT PACK
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SO THAT THEY CAN BE
CUT INTO DISCS.
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THE WORKER SUSPENDS THE CYLINDER
PACK ABOVE A GRID OF PIANO WIRE.
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THE WIRE MOVES BACK AND FORTH
TO GRIND A SILICON CARBIDE
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SLURRY INTO THE GLASS CYLINDERS,
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TO CUT THEM AT INTERVALS
ABOUT A TENTH OF AN INCH.
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THE SLICED CYLINDERS THEN GO
INTO A HOT BATH FOR 15 MINUTES.
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THIS DISSOLVES THE GLUE.
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THE GLASS DISCS SEPARATE,
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AND ARE RELEASED
FROM THE BASE PLATE.
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THE WORKER RINSES EACH DISC
INDIVIDUALLY TO REMOVE
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ANY REMAINING GLUE.
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SHE SETS THE DISCS
ON A CARDBOARD SURFACE TO DRY.
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ONCE LOADED INTO SLOTS,
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A ROBOT COLLECTS THE DISC
USING SUCTIONING FINGERS.
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THE ROBOT INSERTS A DISC
INTO A SUCTIONING CLAMP,
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AND NUDGES IT TO FURTHER
ESTABLISH IT THERE.
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A DIAMOND CUTTING WHEEL MEETS UP
WITH THE DISC HELD IN THE CLAMP,
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AND MACHINES A BEVEL
INTO THE DISC.
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A TECHNICIAN PLACES PLASTIC
CARRIERS WITH DISC-SIZE SLOTS
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ON A PAD IN A POLISHING MACHINE.
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THE CARRIER'S GEAR-STYLE TEETH
INTERMESH WITH TEETH
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ON THE MACHINE'S
HUB AND OUTER FRAME.
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SHE TRANSFERS THE GLASS DISCS
TO THE SLOTS IN THE CARRIERS.
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THE UPPER POLISHING PAD
DESCENDS,
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AND THE CARRIERS ROTATE
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AS THE PADS
BUFF THE DISCS ON BOTH SIDES.
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THE GLASS GOES FROM FROSTY
TO TRANSPARENT.
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SHE RINSES OFF
THE POLISHING COMPOUND.
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THEN, FOR AN INTENSIVE CLEANING,
AN AUTOMATED RACK SYSTEM
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LOWERS THE DISCS
INTO A SERIES OF TUBS.
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IN THE FIRST ONE,
THEY UNDERGO ANOTHER RINSE.
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IN THE NEXT TUB,
A SPECIAL CLEANING SOLUTION
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HAS BEEN ADDED TO WATER --
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ONE THAT WON'T LEAVE
A SOAPY RESIDUE.
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SOUND WAVES BUBBLE
THROUGH THIS WASHTUB
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TO GENTLY SCRUB THE DISC.
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AFTER ANOTHER RINSE,
IT'S INTO A DRYER.
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IT BLOWS HOT AIR ONTO THE GLASS
SAMPLES TO DRY THEM
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WITHOUT LEAVING STREAKS.
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A WORKER TESTS
ONE WITNESS SAMPLE
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00:04:01,413 --> 00:04:03,724
FROM EVERY PRODUCTION RUN.
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BOTH A CAMERA AND A LASER SCAN
THE SAMPLE,
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00:04:06,620 --> 00:04:09,448
AND A COMPUTER ANALYZES
THE INFORMATION.
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THE WITNESS SAMPLES ARE NOW
READY FOR COATING.
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THE TECHNICIAN LOADS THE SAMPLE
INTO FIXTURES
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IN THE COATING MACHINE.
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USING A LIFT,
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HE ELEVATES THE FIXTURES TO
THE TOP OF THE COATING CHAMBER.
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HE INSERTS SMALL CRUCIBLES
OF COATING MATERIAL
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00:04:28,931 --> 00:04:31,241
IN THE BASE
OF THE COATING MACHINE.
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THE MATERIALS ARE METAL
OXIDE COMPOUNDS
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THAT MAKE GLASS LESS REFLECTIVE.
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FOR DEMONSTRATION PURPOSES,
THE CHAMBER REMAINS OPEN,
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AND HE SETS THE FIXTURES
IN MOTION.
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AS THEY SPIN, THE COATING
MATERIALS WILL BE HEATED
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TO THE POINT OF EVAPORATION,
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00:04:48,310 --> 00:04:51,034
FORMING A CLOUD THAT
WILL CONDENSE ON THE SAMPLES
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AT A CERTAIN THICKNESS.
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THE TECHNICIAN CLOSES THE
CHAMBER, AND THE PROCESS BEGINS.
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AN INTENSE ELECTRON BEAM HEATS
THE COATING MATERIALS.
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ONCE THE COATINGS HAVE CURED
TO THE GLASS,
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THEY CAN BE EVALUATED.
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A COMPUTERIZED MACHINE
TAKES MEASUREMENTS TO CONFIRM
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THAT THE REFLECTIVE PROPERTIES
ARE CORRECT.
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THE WITNESS SAMPLE
HAS DONE ITS JOB,
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AND THE COATINGS ARE READY
FOR PRODUCTION.
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Narrator:
ARMED WITH A PRESSURE WASHER,
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IT'S EASY TO GET CARRIED AWAY
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00:05:37,379 --> 00:05:39,379
AND GO ON AN OUTDOOR
CLEANING SPREE.
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IT CAN BE USED TO WASH DOWN
THE DRIVEWAY,
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00:05:43,517 --> 00:05:45,482
CLEAN THE SIDING ON THE HOUSE,
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REMOVE DIRT FROM THE DECK,
WASH THE CAR, AND MUCH MORE.
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A PRESSURE WASHER CONTAINS
AN ELECTRIC MOTOR,
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WHICH DRIVES A PUMP
THAT PROPELS WATER
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AT HIGH PRESSURE DOWN A HOSE,
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AND OUT
A TRIGGER-OPERATED NOZZLE.
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00:06:04,965 --> 00:06:07,000
THE MACHINE'S MECHANICS
AND ELECTRONICS
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ARE HIDDEN FROM VIEW
BY A TWO-PART PLASTIC COVER.
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THE TWO MAIN PARTS
OF THE ELECTRIC MOTOR
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ARE THE ROTOR AND THE STATOR.
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TO MAKE THE STATOR,
THIS AUTOMATED STATION
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WINDS 1,640 FEET
OF COPPER WIRE --
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OR, FOR CERTAIN MODELS,
ALUMINUM WIRE --
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00:06:26,689 --> 00:06:28,758
THEN INSERTS THE WINDING
INTO THE SLOTS
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OF A STEEL CYLINDRICAL FRAME.
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THE ROTOR IS ALSO
A STEEL CYLINDER.
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IT WILL SIT INSIDE THE STATOR,
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ATTACHED AT ONE END
TO THE MOTOR SHAFT.
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WHEN THE POWER WASHER
IS TURNED ON,
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THE A/C CURRENT PASSING
THROUGH THE STATOR WINDING
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CREATES
A ROTATING MAGNETIC FIELD.
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THIS TURNS THE ROTOR,
DRIVING THE MOTOR SHAFT,
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WHICH DRIVES THE PUMP.
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AT THE NEXT STATION, A WORKER
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PREPARES THE STATOR'S
ELECTRICAL CONNECTIONS,
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SECURING THEM WITH A CABLE TIE.
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SHE CONTAINS AND PROTECTS
THE COPPER WINDING WITH TAPE.
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THEN, THE STATOR MOVES ON
TO RECEIVE THE ROTOR.
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ON ANOTHER ASSEMBLY LINE,
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A WORKER MATES THE GUIDE
FOR THE MOTOR'S THREE PISTONS
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WITH THE ALUMINUM CYLINDER HEAD
AND THE MOTOR,
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NOW IN AN OIL-FILLED
ALUMINUM HOUSING.
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THE MOTOR DRIVES A RUBBER PLATE
WHICH MOVES THE PISTONS,
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WHICH MOVE VARIOUS
INTERNAL COMPONENTS
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THAT PRESSURIZE THE WATER.
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A WORKER PLACES A NEW STATOR
ON THE CARRIER
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TO PREPARE IT
FOR MOTOR ASSEMBLY.
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THEN ON THE PUMPSET, HE INSTALLS
A PLASTIC WATER INLET PIPE.
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HE PLACES THE BOTTOM SECTION
OF THE MOTOR HOUSING
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AROUND THE NEW STATOR
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THAT'S HEADING
TO THE MOTOR ASSEMBLY.
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00:07:48,689 --> 00:07:52,448
THE AUTOMATED HANDLING SYSTEM
REMOVES THE COMPLETED PUMPSET
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00:07:52,448 --> 00:07:54,620
AND TRANSFERS IT
TO ANOTHER CARRIER,
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WHICH TRANSPORTS IT
TO THE FINAL ASSEMBLY LINE.
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A WORKER INSTALLS A RUBBER TUBE,
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WHICH KEEPS WATER
OUT OF THE MOTOR.
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HE PULLS THE STATOR ELECTRICAL
CONNECTIONS THROUGH IT,
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00:08:07,551 --> 00:08:10,241
THEN INSTALLS A WATERTIGHT
PLASTIC BOX
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00:08:10,241 --> 00:08:14,206
CONTAINING ALL THE ELECTRONICS
AND THE POWER SWITCH.
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HE PLUGS THE POWER CORD
INTO THE CIRCUIT BOARD
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INSIDE THE BOX,
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00:08:18,310 --> 00:08:21,034
THEN SCREWS DOWN
THE STATOR'S GROUND WIRE.
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00:08:22,827 --> 00:08:26,241
A WORKER CONNECTS BOTH
POWER AND WATER.
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THEN A TEST MACHINE
AUTOMATICALLY RUNS THE UNIT
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00:08:28,896 --> 00:08:30,517
THROUGH ALL THE FUNCTIONS.
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REMEMBER THAT TWO-PART
PLASTIC COVER?
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00:08:36,448 --> 00:08:38,724
AN INJECTION-MOLDING MACHINE
MAKES THE PARTS
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IN SEPARATE OPERATIONS --
A YELLOW TOP AND A BLACK BOTTOM.
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THE AUTOMATED HANDLING SYSTEM
EXTRACTS THE PART
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AND PLACES THEM ON A CARRIER
HEADED TO THE PAD PRINTER.
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THE PRINTER STAMPS
THE MODEL NAME IN QUICK-DRY INK
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ON THE TOP COVER.
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WORKERS WILL LATER ATTACH
THE COMPANY NAME
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00:09:01,758 --> 00:09:03,448
TO THE FRONT OF THE MACHINE.
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THE NEXT STATION TAKES THE TOP
TO THE FINAL ASSEMBLY LINE,
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WHERE THE HANDLING SYSTEM
TURNS IT UPSIDE DOWN
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00:09:12,344 --> 00:09:15,068
AND PLACES THE PUMPSET INSIDE.
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00:09:17,758 --> 00:09:20,413
AT THE NEXT STOP,
A WORKER INSTALLS A GUIDE
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00:09:20,413 --> 00:09:24,827
FOR THE MACHINE'S WATER HOSE,
THEN POSITIONS THE BOTTOM COVER.
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00:09:26,310 --> 00:09:29,517
AN AUTOMATED MACHINE SCREWS
THE COVERS TOGETHER.
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00:09:32,827 --> 00:09:35,862
ANOTHER WORKER INSTALLS
A GALVANIZED-STEEL AXLE
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00:09:35,862 --> 00:09:37,896
AND TWO RUGGED PLASTIC WHEELS.
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00:09:41,275 --> 00:09:44,000
HE APPLIES A DECAL
WITH SAFETY INSTRUCTIONS,
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00:09:44,000 --> 00:09:45,655
PLASTIC WHEEL COVERS,
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00:09:45,655 --> 00:09:51,310
AND A 33-FOOT-LONG RUBBER WATER
HOSE WOUND ON A PLASTIC REEL.
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00:09:51,310 --> 00:09:54,413
THE PRESSURE WASHER THEN
GOES OFF TO THE PACKAGING AREA,
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00:09:54,413 --> 00:09:57,000
WHERE IT'S BOXED WITH
THE HANDLE, ACCESSORIES,
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00:09:57,000 --> 00:09:58,655
AND DETERGENTS.
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00:10:00,586 --> 00:10:02,482
IN THE PRODUCT-DEVELOPMENT
STAGE,
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00:10:02,482 --> 00:10:05,862
A SOUND ENGINEER TESTS
THE PROTOTYPE AT A SOUND LAB
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00:10:05,862 --> 00:10:08,551
TO MAKE SURE THE NOISE
THE PRESSURE WASHER EMITS
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00:10:08,551 --> 00:10:10,758
ISN'T TOO LOUD AND SHRILL.
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00:10:10,758 --> 00:10:14,586
HE RUNS THE MACHINE
AMID NINE MICROPHONES,
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00:10:14,586 --> 00:10:18,517
EACH POSITIONED THREE FEET AWAY
IN A DIFFERENT DIRECTION.
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00:10:18,517 --> 00:10:22,586
TO PASS THE TEST, THE NOISE
MUST BE A LOW BASS-RANGE HUM.
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00:10:25,379 --> 00:10:27,310
TO OPERATE THE PRESSURE WASHER,
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00:10:27,310 --> 00:10:30,827
THE USER CONNECTS A GARDEN HOSE
TO THE WATER-INLET PIPE,
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00:10:30,827 --> 00:10:33,344
CONNECTS THE HANDLE
TO THE MACHINE'S HOSE,
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00:10:33,344 --> 00:10:38,000
TURNS ON THE WATER AND POWER,
THEN PULLS THE TRIGGER TO SPRAY.
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00:10:48,000 --> 00:10:51,241
Narrator: FOR CENTURIES,
BEEKEEPERS USED DOME BASKETS
184
00:10:51,241 --> 00:10:53,241
CALLED SKEPS AS HIVES.
185
00:10:53,241 --> 00:10:56,482
BUT TO HARVEST THE HONEY,
THE SKEPS HAD TO BE DESTROYED.
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00:10:56,482 --> 00:10:59,655
IN THE MID-19th CENTURY,
THEY CAME UP WITH A BOX HIVE
187
00:10:59,655 --> 00:11:01,379
WITH REMOVABLE FRAMES.
188
00:11:01,379 --> 00:11:03,758
BEES BUILT THEIR HONEYCOMBS
ON THE FRAMES,
189
00:11:03,758 --> 00:11:07,344
WHICH BEEKEEPERS COULD REMOVE
WITHOUT DESTROYING THEM.
190
00:11:09,586 --> 00:11:12,482
A HIVE IS HOME
FOR THOUSANDS OF BEES.
191
00:11:12,482 --> 00:11:14,896
THE QUEEN RESIDES
ON THE BOTTOM LEVEL.
192
00:11:14,896 --> 00:11:16,793
WORKER BEES HAVE THE RUN
OF THE HOUSE
193
00:11:16,793 --> 00:11:18,655
AND MOVE AROUND
MAKING HONEY.
194
00:11:20,862 --> 00:11:22,344
CONSTRUCTION OF THIS BEEHIVE
195
00:11:22,344 --> 00:11:25,137
STARTS WITH THE INNER
COVER OF THE HIVE.
196
00:11:25,137 --> 00:11:27,620
A WORKER CUTS A PIECE
OF PINE PLYWOOD
197
00:11:27,620 --> 00:11:29,827
TO THE CORRECT DIMENSIONS.
198
00:11:29,827 --> 00:11:34,172
HE PLACES THE PLYWOOD IN A JIG,
AND CARVES AN OBLONG-SHAPED HOLE
199
00:11:34,172 --> 00:11:37,275
INTO IT
USING A HAND-HELD ROUTER.
200
00:11:37,275 --> 00:11:40,103
THIS HOLE WILL PROVIDE
BOTH VENTILATION
201
00:11:40,103 --> 00:11:42,413
AND AN UPPER EXIT POINT
FOR THE BEES.
202
00:11:45,000 --> 00:11:48,034
FOR THE BODY OF THE HIVE,
HE USES CYPRESS WOOD
203
00:11:48,034 --> 00:11:52,310
BECAUSE IT'S RESISTANT
TO INSECT DAMAGE AND ROT.
204
00:11:52,310 --> 00:11:53,655
WITH A TABLE SAW,
205
00:11:53,655 --> 00:11:56,137
THE WORKER TRIMS
ONE EDGE OF THE WALL PANEL,
206
00:11:56,137 --> 00:11:58,310
TAKING IT FROM ROUGH TO SMOOTH.
207
00:12:00,379 --> 00:12:03,103
HE CUTS A LITTLE MORE OFF
THE OTHER SIDE OF THE PANEL
208
00:12:03,103 --> 00:12:05,275
TO MAKE IT THE CORRECT WIDTH.
209
00:12:05,275 --> 00:12:08,517
THIS GIVES THIS SIDE
A CLEAN EDGE, TOO.
210
00:12:12,586 --> 00:12:15,655
A CIRCULAR SAW AUTOMATICALLY
CARVES A DRAWER PULL
211
00:12:15,655 --> 00:12:17,137
INTO THE PANEL.
212
00:12:17,137 --> 00:12:20,172
THIS PULL IS KNOWN
AS A HANDHOLD.
213
00:12:20,172 --> 00:12:22,931
THERE WILL BE HANDHOLDS
ON ALL SIDES OF THE HIVE BOX
214
00:12:22,931 --> 00:12:24,413
FOR EASY ACCESS.
215
00:12:28,827 --> 00:12:31,137
THE PANEL, FRONT-SIDE DOWN NOW,
216
00:12:31,137 --> 00:12:34,827
RIDES A CONVEYER
TO THE NEXT OPERATION.
217
00:12:34,827 --> 00:12:37,965
NUMEROUS SAWS CUT LONG GROOVES
ALONG THE BOTTOM
218
00:12:37,965 --> 00:12:40,137
AND THE SIDES OF THE PANEL.
219
00:12:40,137 --> 00:12:42,517
THIS CREATES JOINTS
THAT WILL FIT THE HIVE PANELS
220
00:12:42,517 --> 00:12:44,068
TIGHTLY TOGETHER.
221
00:12:47,586 --> 00:12:49,517
A WORKER STACKS THE PANELS
TO AWAIT
222
00:12:49,517 --> 00:12:51,413
THE NEXT STAGE OF ASSEMBLY.
223
00:12:54,586 --> 00:12:56,241
MEANWHILE,
AT ANOTHER STATION,
224
00:12:56,241 --> 00:12:58,551
THE NEXT WORKER NOTCHES
PIECES OF WOOD
225
00:12:58,551 --> 00:13:01,344
TO MAKE A PART
CALLED THE ENTRANCE REDUCER.
226
00:13:02,620 --> 00:13:04,827
IT'S THE DOORWAY TO THE HIVE.
227
00:13:04,827 --> 00:13:06,724
IT WILL ALLOW THE BEES TO ENTER,
228
00:13:06,724 --> 00:13:09,310
BUT KEEP INTRUDERS
LIKE MICE OUT.
229
00:13:11,000 --> 00:13:13,551
HE MAKES A WIDE ENTRANCEWAY
ON ONE SIDE
230
00:13:13,551 --> 00:13:15,620
AND A NARROWER ONE ON THE OTHER.
231
00:13:18,172 --> 00:13:21,172
A WORKER THEN CUTS
TONGUE-AND-GROOVE JOINTS IN WOOD
232
00:13:21,172 --> 00:13:24,689
THAT WILL BE USED FOR THE BOTTOM
AND THE COVER OF THE BEEHIVE.
233
00:13:28,310 --> 00:13:32,206
MOVING TO THE BEEHIVE STAND,
HE CUTS A 45-DEGREE ANGLE
234
00:13:32,206 --> 00:13:34,793
ON BOTH SIDES
OF A PIECE OF WOOD.
235
00:13:34,793 --> 00:13:39,448
THIS PART WILL SERVE
AS A LANDING STRIP FOR THE BEES.
236
00:13:39,448 --> 00:13:42,068
A TEAM SLICES A SHEET
OF GALVANIZED STEEL
237
00:13:42,068 --> 00:13:43,689
TO THE DESIRED LENGTH.
238
00:13:47,344 --> 00:13:48,689
USING A PRESS BRAKE,
239
00:13:48,689 --> 00:13:52,793
A WORKER BENDS THE EDGES
OF THE SHEET AGAINST A DIE.
240
00:13:52,793 --> 00:13:56,103
THIS FORMS A COVER THAT WILL FIT
OVER THE ROOF OF THE HIVE.
241
00:14:00,448 --> 00:14:01,965
AT ANOTHER STATION,
242
00:14:01,965 --> 00:14:05,517
A WORKER PIPES GLUE ALONG THE
INSIDE GROOVE OF THE ROOF FRAME.
243
00:14:08,310 --> 00:14:10,413
HE ARRANGES
THE TONGUE-AND-GROOVE BOARDS
244
00:14:10,413 --> 00:14:11,793
IN A TIGHT INTERLOCK
245
00:14:11,793 --> 00:14:14,793
AND INSERTS THEM IN
THE GLUED GROOVE OF THE FRAME.
246
00:14:17,724 --> 00:14:20,413
HE APPLIES PRESSURE TO FURTHER
ENTRENCH THEM,
247
00:14:20,413 --> 00:14:25,551
AND DRIVES NAILS INTO THE WOOD
FRAME TO SECURE THE BOARDS.
248
00:14:25,551 --> 00:14:29,275
HE FITS THE METAL
CLADDING OVER THE WOOD ROOF.
249
00:14:29,275 --> 00:14:31,344
IT'S BEEN MADE
TO FIT LIKE A GLOVE,
250
00:14:31,344 --> 00:14:33,413
SO IT TAKES A BIT
OF MANEUVERING.
251
00:14:36,448 --> 00:14:39,448
HE NOW JOINS FOUR OF THE PANELS
TO MAKE A BOX.
252
00:14:39,448 --> 00:14:41,758
AND THANKS TO
THE GROOVED JOINTS,
253
00:14:41,758 --> 00:14:44,586
THE CORNERS FIT TOGETHER NEATLY.
254
00:14:44,586 --> 00:14:49,000
HE GLUES THEM, AND THEN SECURES
THE JOINTS WITH NAILS.
255
00:14:49,000 --> 00:14:51,068
THIS ASSEMBLY WILL BE
THE BROOD BOX
256
00:14:51,068 --> 00:14:53,000
THAT HOUSES THE QUEEN BEE.
257
00:14:55,448 --> 00:14:58,965
HE NOW BUILDS THE FRAME FOR THE
INNER COVER OF THE HIVE CEILING.
258
00:15:01,241 --> 00:15:03,379
HE APPLIES GLUE TO THE FRAME.
259
00:15:05,862 --> 00:15:07,862
HE INSERTS THE COVER
AND POUNDS IT
260
00:15:07,862 --> 00:15:09,827
TO DRIVE IT FURTHER INTO PLACE.
261
00:15:12,413 --> 00:15:15,241
IT'S NOW TIME
FOR THE FINAL ASSEMBLY.
262
00:15:15,241 --> 00:15:18,034
THEY INSTALL THE FLOOR
ON THE STAND AND POSITION
263
00:15:18,034 --> 00:15:20,586
THE ENTRANCEWAY PIECE
AT THE FRONT.
264
00:15:20,586 --> 00:15:22,586
THE BROOD BOX IS NEXT.
265
00:15:22,586 --> 00:15:25,517
THEY HANG FRAMES WITH STARTER
HONEYCOMB BEESWAX
266
00:15:25,517 --> 00:15:27,137
ON THE INNER LEDGES.
267
00:15:30,827 --> 00:15:34,000
THEY PLACE A WIRE MESH EXCLUDER
OVER THE BROOD BOX
268
00:15:34,000 --> 00:15:37,137
TO KEEP THE QUEEN BEE
OUT OF THE UPPER CHAMBER.
269
00:15:37,137 --> 00:15:40,000
THE SMALLER WORKER BEES
WILL BE ABLE TO MOVE THROUGH IT
270
00:15:40,000 --> 00:15:44,241
TO DEPOSIT HONEY
ON MORE HONEYCOMB FRAMES.
271
00:15:44,241 --> 00:15:46,344
THEY STACK THE INNER COVER
ON TOP,
272
00:15:46,344 --> 00:15:48,896
FOLLOWED BY THE METAL-CLAD ROOF.
273
00:15:48,896 --> 00:15:53,448
THIS EMPTY HIVE WILL SOON BE
A-BUZZ WITH ACTIVITY AND HONEY.
274
00:16:03,241 --> 00:16:05,206
Narrator: HUMANS HAVE BEEN
COOKING OVER FIRE
275
00:16:05,206 --> 00:16:08,586
WITH IRON IMPLEMENTS
SINCE, WELL, THE IRON AGE.
276
00:16:08,586 --> 00:16:13,137
TODAY, MOST OUTDOOR COOKING
REQUIRES SOME TYPE OF APPLIANCE.
277
00:16:13,137 --> 00:16:16,068
AND BECAUSE OF IRON'S
SUPERIOR ABILITY TO RETAIN
278
00:16:16,068 --> 00:16:17,862
AND DIFFUSE HEAT EVENLY,
279
00:16:17,862 --> 00:16:21,586
A CAST-IRON COOKER IS SURE
TO GET EVERYONE FIRED UP.
280
00:16:23,620 --> 00:16:27,275
THIS CAST-IRON COOKER MAY LOOK
LIKE AN ORDINARY BARBECUE,
281
00:16:27,275 --> 00:16:29,827
BUT IT DOES SO MUCH
MORE THAN GRILL.
282
00:16:29,827 --> 00:16:33,275
IT ALSO SLOW-SMOKES,
CARAMELIZES, SEARS,
283
00:16:33,275 --> 00:16:35,586
AND EVEN BAKES.
284
00:16:35,586 --> 00:16:37,379
TO PRODUCE THE CAST IRON,
285
00:16:37,379 --> 00:16:41,517
THE COMPANY BUYS SCRAP PIECES
OF NEW STEEL FROM STEEL MILLS
286
00:16:41,517 --> 00:16:45,689
AND FROM FACTORIES THAT USE
STEEL TO MAKE THEIR PRODUCTS.
287
00:16:45,689 --> 00:16:49,379
MANUFACTURERS HEAT THE STEEL
IN A PRE-HEAT FURNACE.
288
00:16:49,379 --> 00:16:52,206
THIS EVAPORATES ANY
RESIDUAL MOISTURE
289
00:16:52,206 --> 00:16:55,275
AND SPEEDS UP MELTING
IN THE MAIN FURNACE.
290
00:16:55,275 --> 00:16:58,241
THE MAIN FURNACE OPERATOR
ADDS A POWDERED CHEMICAL
291
00:16:58,241 --> 00:17:02,827
THAT SOLIDIFIES THE IMPURITIES
SO THAT HE CAN SCOOP THEM OUT.
292
00:17:02,827 --> 00:17:05,241
HE ALSO ADDS CARBON, SILICON,
293
00:17:05,241 --> 00:17:09,827
AND OTHER ALLOYS TO TRANSFORM
THE STEEL INTO IRON.
294
00:17:09,827 --> 00:17:14,344
THE MOLDS ARE MADE OF A SAND,
CLAY, FINELY GROUND COAL,
295
00:17:14,344 --> 00:17:17,758
AND WATER MIX COMPRESSED
AT HIGH PRESSURE.
296
00:17:17,758 --> 00:17:19,758
THE MOLTEN IRON
CAUSES THE MOISTURE
297
00:17:19,758 --> 00:17:22,000
IN THE MOLD TO EVAPORATE.
298
00:17:22,000 --> 00:17:26,137
THE RESULTING STEAM ESCAPES
THROUGH VENT HOLES AT THE TOP.
299
00:17:26,137 --> 00:17:28,482
THIS MACHINE LOWERS THE TOP
HALF OF THE MOLD
300
00:17:28,482 --> 00:17:30,413
OVER THE BOTTOM HALF.
301
00:17:30,413 --> 00:17:33,275
THE FURNACE EMPTIES
THE MOLTEN IRON INTO A LADLE,
302
00:17:33,275 --> 00:17:36,551
WHICH CONTAINS
ADDITIONAL ALLOYS.
303
00:17:36,551 --> 00:17:38,965
A WORKER POSITIONS THE LADLE
OVER AN OPENING
304
00:17:38,965 --> 00:17:43,068
AT THE TOP OF THE MOLD
AND POURS IN THE MOLTEN IRON.
305
00:17:43,068 --> 00:17:44,793
AFTER ABOUT TWO HOURS,
306
00:17:44,793 --> 00:17:47,931
HE BREAKS THE SAND MOLD
AND EXTRACTS THE CASTING.
307
00:17:49,517 --> 00:17:52,758
WORKERS USE A SLEDGEHAMMER
TO BREAK OFF EXCESS METAL.
308
00:17:55,482 --> 00:17:58,896
THE CAST-IRON PARTS ARE STILL
ENCRUSTED IN SAND,
309
00:17:58,896 --> 00:18:02,724
SO WORKERS LOAD THEM
INTO A SHOT-BLASTING MACHINE.
310
00:18:02,724 --> 00:18:05,172
SHOT BLASTING IS LIKE
SANDBLASTING,
311
00:18:05,172 --> 00:18:07,965
EXCEPT INSTEAD OF SAND,
THE MACHINE PUMMELS
312
00:18:07,965 --> 00:18:11,103
THE SURFACE
WITH TINY STEEL BALLS.
313
00:18:11,103 --> 00:18:14,586
THE SHOT-BLASTING CYCLE
THOROUGHLY CLEANS THE SURFACE.
314
00:18:16,586 --> 00:18:19,172
THE SURFACE IS STILL
QUITE ROUGH, HOWEVER.
315
00:18:19,172 --> 00:18:21,862
SO WORKERS REFINE IT
WITH HAND TOOLS,
316
00:18:21,862 --> 00:18:24,655
HAMMERING OFF ANY REMAINING
EXCESS METAL
317
00:18:24,655 --> 00:18:27,275
AND GRINDING THE SURFACE SMOOTH.
318
00:18:32,517 --> 00:18:35,275
THE TOP HALF OF THE COOKER
HAS A HANDLE ON THE FRONT
319
00:18:35,275 --> 00:18:37,517
AND HALF A HINGE ON THE BACK.
320
00:18:37,517 --> 00:18:40,724
THE BOTTOM HALF HAS THE OTHER
HALF OF THE HINGE.
321
00:18:42,344 --> 00:18:45,482
A WORKER DRILLS A HOLE
THROUGH EACH HINGE HALF
322
00:18:45,482 --> 00:18:48,275
FOR THE SHAFT
THAT WILL CONNECT THEM.
323
00:18:48,275 --> 00:18:50,448
HE DRILLS HOLES IN THE FIRE BOX
324
00:18:50,448 --> 00:18:52,896
THAT WILL LET IN AIR
TO FEED THE FIRE.
325
00:18:55,586 --> 00:18:57,758
USING A TEMPLATE
AND LASER CUTTER,
326
00:18:57,758 --> 00:19:01,517
HE CUTS AN OPENING IN THE BOTTOM
FOR THE VENTILATION-DRAFT DOOR.
327
00:19:03,586 --> 00:19:06,000
HE DRILLS MOUNTING HOLES
AROUND THE VENT,
328
00:19:06,000 --> 00:19:09,241
AND INSTALLS THE DRAFT DOOR.
329
00:19:09,241 --> 00:19:12,034
ITS PERFORATED HOLE COVER
LETS AIR IN.
330
00:19:12,034 --> 00:19:14,793
ITS SOLID SLIDING DOOR
SHUTS IT OUT.
331
00:19:14,793 --> 00:19:18,137
THE AIR INTAKE FEEDING THE FIRE
REGULATES COOKING TEMPERATURE.
332
00:19:20,379 --> 00:19:24,551
THE COOKER SITS
IN A HAND-CRAFTED STEEL CART.
333
00:19:24,551 --> 00:19:27,275
A WELDER PLACES THE PARTS
FOR THE CART'S FRAME
334
00:19:27,275 --> 00:19:31,551
IN AN ASSEMBLY FIXTURE,
WHICH POSITIONS THEM CORRECTLY.
335
00:19:31,551 --> 00:19:34,827
AFTER WELDING THE FRAME,
HE FILES DOWN THE WELDS
336
00:19:34,827 --> 00:19:36,655
SO THAT THEY'LL BE
VIRTUALLY INVISIBLE
337
00:19:36,655 --> 00:19:38,413
ONCE THE FRAME IS PAINTED.
338
00:19:41,793 --> 00:19:44,103
THIS COMPUTER-GUIDED
LATHE MACHINES
339
00:19:44,103 --> 00:19:48,551
THE CART'S CAST-IRON WHEELS
TO THE FINAL DIMENSIONS.
340
00:19:48,551 --> 00:19:51,551
THE SAND MOLDS USED TO CAST
THE WHEELS WERE DESIGNED
341
00:19:51,551 --> 00:19:56,275
USING CENTURY-OLD
PATTERNS FOR CAST-IRON PULLEYS.
342
00:19:56,275 --> 00:19:58,517
ONCE WORKERS HAVE MOUNTED
THE TWO WHEELS,
343
00:19:58,517 --> 00:20:01,827
THE CART GOES OFF TO BE PAINTED.
344
00:20:01,827 --> 00:20:05,620
THEN, A WORKER INSTALLS SHELVES
MADE OF EITHER STAINLESS STEEL,
345
00:20:05,620 --> 00:20:08,482
HARDWOOD,
OR COMPOSITE DECKING PLANKS.
346
00:20:10,103 --> 00:20:13,551
WORKERS BOLT THE BOTTOM HALF
OF THE COOKER TO THE CART.
347
00:20:13,551 --> 00:20:15,482
THEN THEY LOWER IN THE FIRE BOX,
348
00:20:15,482 --> 00:20:17,655
WHICH HOLDS THE FUEL
FOR COOKING.
349
00:20:17,655 --> 00:20:21,034
THE RECOMMENDED FUEL
IS HARDWOOD LUMP CHARCOAL.
350
00:20:23,482 --> 00:20:26,724
NEXT, A WORKER MOUNTS
THE COOKER'S TEMPERATURE GAUGE.
351
00:20:28,586 --> 00:20:30,862
THEN HE INSTALLS THE TOP VENT.
352
00:20:30,862 --> 00:20:33,413
IT CONSISTS OF TWO
CAST-IRON DISCS
353
00:20:33,413 --> 00:20:37,241
WHICH ROTATE TO LET IN MORE AIR
OR LESS AIR.
354
00:20:37,241 --> 00:20:38,724
HAVING ADJUSTABLE VENTILATION
355
00:20:38,724 --> 00:20:41,034
AT BOTH THE TOP
AND BOTTOM OF THE COOKER
356
00:20:41,034 --> 00:20:45,655
ENABLES MORE PRECISE
TEMPERATURE CONTROL.
357
00:20:45,655 --> 00:20:48,586
THEY POSITION THE TOP OF THE
COOKER OVER THE BOTTOM,
358
00:20:48,586 --> 00:20:51,586
AND MATE THE TWO HINGE HALVES
WITH THE STEEL SHAFT
359
00:20:51,586 --> 00:20:54,724
AND TWO STAINLESS-STEEL SPRINGS.
360
00:20:54,724 --> 00:20:57,413
FIBER GASKETS ENSURE GOOD SEAL
WHEN THE COOKER
361
00:20:57,413 --> 00:21:00,965
IS CLOSED
OVER THE CAST-IRON GRATES.
362
00:21:00,965 --> 00:21:02,655
THOSE GRATES ARE REVERSIBLE,
363
00:21:02,655 --> 00:21:05,206
WITH ONE SIDE HIGHER
THAN THE OTHER,
364
00:21:05,206 --> 00:21:08,344
PROVIDING A CHOICE OF COOKING
HEIGHTS ABOVE THE FIRE.
29360
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