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00:00:01,620 --> 00:00:04,620
--Captions by VITAC--
www.vitac.com
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00:00:04,620 --> 00:00:07,586
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
GUITAR PICKUPS WERE INVENTED
4
00:00:55,206 --> 00:00:57,620
DURING THE TIME
OF THE BIG-BAND ERA.
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00:00:57,620 --> 00:01:02,517
JAZZ MUSIC INCORPORATED BOTH
GUITAR AND LARGE BRASS SECTIONS.
6
00:01:02,517 --> 00:01:05,034
TO OFFSET A GUITAR'S
MELLOW TONES,
7
00:01:05,034 --> 00:01:08,689
A PICKUP DEVICE WAS DEVELOPED
TO AMPLIFY THE VIBRATION
8
00:01:08,689 --> 00:01:12,206
OF THE GUITAR'S STRINGS,
GENERATING A LOUDER SOUND.
9
00:01:14,310 --> 00:01:18,241
THE GUITAR PICKUP WAS INVENTED
IN THE EARLY 20th CENTURY.
10
00:01:18,241 --> 00:01:21,689
THE DEVICE ALLOWED MUSICIANS
TO PLUG INTO A NEW SOUND
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00:01:21,689 --> 00:01:25,793
THAT WOULD LATER
DEFINE ROCK 'N' ROLL.
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00:01:25,793 --> 00:01:29,000
PRODUCTION STARTS WITH
AN EDGED STEEL PART.
13
00:01:31,103 --> 00:01:33,689
A TECHNICIAN APPLIES GLUE
TO THE SPINE
14
00:01:33,689 --> 00:01:35,413
AND ATTACHES PLASTIC STRIPS
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00:01:35,413 --> 00:01:39,034
TO THE GLUED AREAS
FOR FULL ADHESION.
16
00:01:39,034 --> 00:01:42,310
HE GLUES A SECOND EDGED
STEEL PART TO THE FIRST,
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00:01:42,310 --> 00:01:45,068
CREATING A BOBBIN
FOR WIRE WINDINGS.
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00:01:49,655 --> 00:01:51,758
HE APPLIES CLEAR POLYESTER TAPE
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00:01:51,758 --> 00:01:54,206
ALONG THE INNER EDGES
OF THE BOBBIN.
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00:01:54,206 --> 00:01:57,103
THE TAPE WILL SERVE
AS ELECTRICAL INSULATION,
21
00:01:57,103 --> 00:01:59,206
SUPPLEMENTING
AN INSULATING COATING
22
00:01:59,206 --> 00:02:01,172
THAT'S BEEN APPLIED
TO THE METAL.
23
00:02:03,310 --> 00:02:06,275
USING AN ABRASIVE WHEEL,
HE SCUFFS OFF THE FINISH
24
00:02:06,275 --> 00:02:09,482
ON THE END OF THE BOBBIN
TO PREPARE IT FOR SOLDERING.
25
00:02:14,413 --> 00:02:18,275
THE SCUFFED BOBBIN
IS THE ONE ON THE LEFT.
26
00:02:18,275 --> 00:02:21,517
THEN THE BOBBIN IS MOUNTED
TO A WINDING MANDREL.
27
00:02:24,448 --> 00:02:26,931
THE CRAFTSMAN WRAPS
THIN COPPER WIRE
28
00:02:26,931 --> 00:02:28,862
AROUND THE END OF THE BOBBIN
29
00:02:28,862 --> 00:02:31,448
AND ACTIVATES
THE WINDING MANDREL.
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00:02:31,448 --> 00:02:35,034
AS THE MANDREL SPINS, THE BOBBIN
GATHERS THE COPPER WIRE
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00:02:35,034 --> 00:02:39,137
TOGETHER TO PRODUCE A WAD
THAT'S 4,000 WINDINGS THICK.
32
00:02:45,517 --> 00:02:48,965
THE BOBBIN CONTAINING THOUSANDS
OF COPPER-WIRE WINDINGS
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00:02:48,965 --> 00:02:53,172
HAS CREATED A PATH
FOR MAGNETIC ENERGY.
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00:02:53,172 --> 00:02:58,241
NEXT, THE ENDS OF THE COPPER
WIRE ARE SOLDERED TO THE BOBBIN.
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00:02:58,241 --> 00:03:01,310
THE CRAFTSMAN APPLIES A DIRECT
CURRENT THROUGH THE COIL
36
00:03:01,310 --> 00:03:04,275
AND MEASURES
THE ELECTRICAL RESISTANCE.
37
00:03:04,275 --> 00:03:07,310
ONCE THE CURRENT FALLS
WITHIN THE ACCEPTABLE RANGE,
38
00:03:07,310 --> 00:03:10,344
HE SOLDERS CONNECTION CABLES
TO THE WINDINGS.
39
00:03:13,344 --> 00:03:17,000
THEN THE COIL IS SUBMERGED
IN HOT LIQUID WAX.
40
00:03:17,000 --> 00:03:19,413
THE WAX WILL ENCASE
THE WIRE WINDINGS
41
00:03:19,413 --> 00:03:22,793
TO PREVENT
MECHANICAL VIBRATIONS.
42
00:03:22,793 --> 00:03:28,000
NEXT, THE CRAFTSMAN INSERTS
BRASS PINS INTO A PRESS FIXTURE.
43
00:03:28,000 --> 00:03:31,034
HE PLACES A STEEL CHANNEL
ON TOP OF THE PINS,
44
00:03:31,034 --> 00:03:33,931
PIERCING THE PINS
THROUGH THE CHANNEL.
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00:03:33,931 --> 00:03:36,620
HE FLATTENS THE HEADS OF
THE PINS WITH THE PRESS
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00:03:36,620 --> 00:03:40,379
WHILE ALLOWING THE ENDS
TO EXTEND THROUGH THE CHANNEL.
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00:03:40,379 --> 00:03:42,344
TO STABILIZE THE ASSEMBLY,
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00:03:42,344 --> 00:03:44,482
HE PLACES RUBBER
AND STEEL WASHERS
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00:03:44,482 --> 00:03:46,551
OVER THE PROTRUDING PINS.
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00:03:48,689 --> 00:03:52,551
HE MOUNTS A BRASS PLATE TO
THE PINS AND ADDS MORE WASHERS
51
00:03:52,551 --> 00:03:55,000
TO ELECTRICALLY GROUND
THE ASSEMBLY.
52
00:03:58,275 --> 00:04:01,241
THE CRAFTSMAN PRESSES THE PINS
TO FLATTEN THEM,
53
00:04:01,241 --> 00:04:04,068
SECURING THE PLATE
TO THE CHANNEL.
54
00:04:04,068 --> 00:04:06,793
A SECOND STEEL CHANNEL
IS ATTACHED TO THE PLATE
55
00:04:06,793 --> 00:04:09,586
ON TOP OF THE FIRST CHANNEL.
56
00:04:09,586 --> 00:04:13,034
THE DUAL COIL ASSEMBLY CONTAINS
A HIGHER OUTPUT
57
00:04:13,034 --> 00:04:17,827
AND WILL COUNTERACT
ELECTROMAGNETIC INTERFERENCE.
58
00:04:17,827 --> 00:04:21,413
WHILE MOST PICKUPS HAVE MAGNETS
INSIDE THE COILS,
59
00:04:21,413 --> 00:04:25,413
THIS PICKUP CONTAINS MAGNETS
ON THE OUTSIDE OF THE COILS.
60
00:04:25,413 --> 00:04:29,034
THIS DESIGN REDUCES HUM
FROM ELECTRICAL INTERFERENCE.
61
00:04:31,344 --> 00:04:34,310
THE CRAFTSMAN SOLDERS
A GROUND WIRE TO THE UNIT
62
00:04:34,310 --> 00:04:36,689
AND APPLIES MORE SOLDER
TO ONE OF THE PINS
63
00:04:36,689 --> 00:04:40,275
TO CONNECT THE COIL CABLES.
64
00:04:40,275 --> 00:04:43,034
THE COILS ARE INSERTED
IN THE CHANNELS.
65
00:04:45,310 --> 00:04:47,310
A BURNT-CHROME FINISH
CAN BE APPLIED
66
00:04:47,310 --> 00:04:49,379
TO THE PICKUP'S OUTER CASING.
67
00:04:49,379 --> 00:04:52,379
THE BURNT-CHROME CASING PRODUCES
A DISCOLORATION
68
00:04:52,379 --> 00:04:55,206
THAT ADDS VISUAL INTEREST.
69
00:04:55,206 --> 00:04:59,689
HE NOW PIPES A GENEROUS AMOUNT
OF EPOXY INTO THE CASING CAVITY
70
00:04:59,689 --> 00:05:03,137
AND INSERTS THE PICKUP.
71
00:05:03,137 --> 00:05:05,620
HE SOLDERS WIRE FROM THE COVER
TO THE PICKUP
72
00:05:05,620 --> 00:05:07,896
TO GROUND THE UNIT.
73
00:05:07,896 --> 00:05:11,000
THE PICKUP IS PLACED OVER
THE STRINGS OF A GUITAR,
74
00:05:11,000 --> 00:05:13,172
AND HE PLUGS IT
INTO AN AMPLIFIER.
75
00:05:15,517 --> 00:05:18,000
ONCE HE CONFIRMS THE TONE
IS ACCEPTABLE,
76
00:05:18,000 --> 00:05:20,241
HE MEASURES THE RESISTANCE.
77
00:05:21,103 --> 00:05:22,827
THE CRAFTSMAN TESTS
THE DIRECTION
78
00:05:22,827 --> 00:05:25,241
THE CURRENT TRAVELS
THROUGH THE PICKUP.
79
00:05:25,241 --> 00:05:27,310
THIS METHOD IS CALLED PHASE.
80
00:05:27,310 --> 00:05:30,413
HE ALSO ASSESSES THE STRENGTH
OF THE MAGNETIC FIELD
81
00:05:30,413 --> 00:05:34,068
THROUGH A METHOD
KNOWN AS POLARITY.
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00:05:34,068 --> 00:05:36,172
EVEN THOUGH IT'S TAKEN
JUST 15 MINUTES
83
00:05:36,172 --> 00:05:38,034
TO MAKE THIS GUITAR PICKUP,
84
00:05:38,034 --> 00:05:41,793
DUE TO ITS SUSTAINABILITY,
IT SHOULD LAST FOR YEARS,
85
00:05:41,793 --> 00:05:45,172
PROVIDING MUSICIANS
WITH PLENTY OF GOOD VIBES.
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00:05:56,068 --> 00:05:58,103
Narrator:
WHEN YOU'RE SITTING OUTDOORS
87
00:05:58,103 --> 00:05:59,827
AND IT STARTS GETTING CHILLY,
88
00:05:59,827 --> 00:06:02,862
YOU CAN SHIVER,
PUT ON MORE LAYERS OF CLOTHING,
89
00:06:02,862 --> 00:06:04,689
OR PRESS A BUTTON
TO LET THE FURNITURE
90
00:06:04,689 --> 00:06:06,758
YOU'RE SITTING ON WARM YOU UP.
91
00:06:06,758 --> 00:06:10,965
DESIGNED FOR USE IN THE OUTDOORS
AND IN COLDER INDOOR SPACES,
92
00:06:10,965 --> 00:06:13,724
HEATED FURNITURE
IS A HOT NEW TREND.
93
00:06:15,965 --> 00:06:19,241
THIS HEATED LOUNGE IS HIP
AND PRACTICAL.
94
00:06:19,241 --> 00:06:22,448
DISCREET DRAIN HOLES
PREVENT RAINWATER FROM PUDDLING,
95
00:06:22,448 --> 00:06:24,827
AND THE EASY-TO-REACH HEAT
CONTROL KNOB
96
00:06:24,827 --> 00:06:27,379
IS LOCATED UNDERNEATH THE SEAT.
97
00:06:27,379 --> 00:06:29,379
BENCHES, MULTI-SEAT LOUNGES,
98
00:06:29,379 --> 00:06:34,172
AND SINGLE CHAIRS CAN ALL BE
MADE INTO HEATED FURNITURE.
99
00:06:34,172 --> 00:06:36,689
THE FIRST STEP IS TO COAT
A FIBERGLASS MOLD
100
00:06:36,689 --> 00:06:39,000
WITH A RELEASE AGENT.
101
00:06:39,965 --> 00:06:42,965
ONCE A RUBBER INSERT IS GLUED
INTO THE DRAIN HOLE,
102
00:06:42,965 --> 00:06:44,896
A TECHNICIAN MIXES
THE INGREDIENTS
103
00:06:44,896 --> 00:06:47,379
FOR THE CASTING
MATERIAL TOGETHER.
104
00:06:47,379 --> 00:06:50,689
INGREDIENTS INCLUDE PIGMENT
CONTAINING METAL OXIDES,
105
00:06:50,689 --> 00:06:54,000
WHICH PREVENT COLOR FADING,
A CONCRETE MIX CONTAINING
106
00:06:54,000 --> 00:06:57,379
A BLEND OF FIBERS FOR EXTRA
STRENGTH AND RESISTANCE,
107
00:06:57,379 --> 00:07:01,068
AND WATER CONTAINING
PROPRIETARY ADDITIVES.
108
00:07:01,068 --> 00:07:04,551
THE INGREDIENTS ARE MIXED
TOGETHER FOR ABOUT THREE MINUTES
109
00:07:04,551 --> 00:07:09,103
UNTIL THE CONCRETE IS
THE CONSISTENCY OF CAKE BATTER.
110
00:07:09,103 --> 00:07:12,448
A THIN LAYER IS SPRAYED
ON TO THE FIBERGLASS MOLD,
111
00:07:12,448 --> 00:07:16,379
AND ANY RAISED AREAS ARE
FLATTENED TO REMOVE AIR BUBBLES.
112
00:07:19,172 --> 00:07:22,241
THE CHAIR'S COLOR WILL NEVER
RUB OFF OR PEEL
113
00:07:22,241 --> 00:07:26,862
BECAUSE THE PIGMENT IS MIXED
RIGHT INTO THE CONCRETE.
114
00:07:26,862 --> 00:07:29,620
NEXT, TECHNICIANS ADD
THE HEATING ELEMENT,
115
00:07:29,620 --> 00:07:33,172
A CABLE THAT IS WRAPPED AROUND
THE PIECE OF FURNITURE.
116
00:07:33,172 --> 00:07:36,758
THE CABLE IS TACKED IN PLACE
WITH A SEPARATE MIX OF CONCRETE
117
00:07:36,758 --> 00:07:39,620
THAT HAS A HIGHER FIBER CONTENT.
118
00:07:39,620 --> 00:07:42,793
THE ENTIRE HEATING ELEMENT
IS EMBEDDED IN A FULL COAT
119
00:07:42,793 --> 00:07:44,965
OF THE HIGH-FIBER CONCRETE.
120
00:07:44,965 --> 00:07:47,931
THEN A FINISHING COAT
OF THE FIRST MIX IS APPLIED,
121
00:07:47,931 --> 00:07:50,517
AND THE STRUCTURE IS LEFT
TO CURE AT ROOM TEMPERATURE
122
00:07:50,517 --> 00:07:52,896
FOR 24 HOURS.
123
00:07:52,896 --> 00:07:57,103
NOW CURED, THIS WHITE CHAIR
IS READY TO BE EXTRACTED.
124
00:07:57,103 --> 00:07:59,000
A TECHNICIAN PUMPS
COMPRESSED AIR
125
00:07:59,000 --> 00:08:01,103
THROUGH THE DRAIN-HOLE INSERT.
126
00:08:01,103 --> 00:08:03,379
DUE TO THE RELEASE AGENT
APPLICATION,
127
00:08:03,379 --> 00:08:06,931
THE CAST CHAIR EASILY
POPS OFF THE MOLD.
128
00:08:08,034 --> 00:08:11,620
THE ROUGH EDGES ARE SMOOTHED
WITH A DIAMOND FILE.
129
00:08:14,034 --> 00:08:16,551
THEN THE DRAIN-HOLE PLUG
IS REMOVED.
130
00:08:21,620 --> 00:08:25,137
AT ANOTHER STATION, A TECHNICIAN
COATS THE ENTIRE SURFACE
131
00:08:25,137 --> 00:08:28,931
OF ANOTHER CHAIR WITH A SEALANT
THAT BLOCKS MOISTURE.
132
00:08:28,931 --> 00:08:31,586
MOISTURE PENETRATION
WEAKENS CONCRETE
133
00:08:31,586 --> 00:08:35,965
AND DRAWS OUT THE NATURAL SALT,
WHICH LEAVES WHITE STAINS.
134
00:08:35,965 --> 00:08:40,137
MEANWHILE, A WELDER CONSTRUCTS
THE CHAIR'S FRAME WITH PARTS
135
00:08:40,137 --> 00:08:43,551
MADE OUT OF STAINLESS-STEEL
TUBES AND PLATES.
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00:08:43,551 --> 00:08:46,620
THE CHAIR HAS THREE LEGS,
PLUS CROSS MEMBERS
137
00:08:46,620 --> 00:08:49,758
THAT ACT AS CONDUITS
FOR ELECTRICAL WIRES.
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00:08:49,758 --> 00:08:52,896
THE CROSS MEMBERS CONNECT
TO A STAINLESS-STEEL BOX,
139
00:08:52,896 --> 00:08:55,586
WHICH WILL HOUSE
THE TEMPERATURE CONTROL UNIT.
140
00:09:00,724 --> 00:09:03,137
A TECHNICIAN FILLS THE CHANNEL
WITH ADHESIVE
141
00:09:03,137 --> 00:09:04,862
ALONG THE PERIMETER.
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00:09:07,379 --> 00:09:11,172
HE PLACES THE FRAME
INTO THE CHANNEL.
143
00:09:11,172 --> 00:09:14,275
THE ADHESIVE WILL TAKE
A DAY TO CURE.
144
00:09:15,275 --> 00:09:18,000
NEXT, THE ELECTRICAL WIRING
IS ASSEMBLED.
145
00:09:18,000 --> 00:09:20,448
THE TECHNICIAN FISHES
TWO ELECTRICAL WIRES
146
00:09:20,448 --> 00:09:21,758
THROUGH THE FRAME.
147
00:09:21,758 --> 00:09:23,896
ONE WIRE CONNECTS
THE POWER-CORD PLUG
148
00:09:23,896 --> 00:09:25,896
TO THE TEMPERATURE CONTROL UNIT.
149
00:09:25,896 --> 00:09:28,379
THE OTHER RUNS FROM
THE TEMPERATURE CONTROL UNIT
150
00:09:28,379 --> 00:09:30,655
TO THE TEMPERATURE
CONTROL SWITCH.
151
00:09:30,655 --> 00:09:34,931
HE GLUES THE SWITCH INTO A HOLE
IN THE RIGHT FRONT LEG.
152
00:09:34,931 --> 00:09:38,793
ALL THE WIRES ARE EMBEDDED IN
RUBBER, MAKING THEM WATERPROOF.
153
00:09:42,344 --> 00:09:45,206
THE TEMPERATURE CONTROL UNIT
IS INSTALLED IN THE BOX
154
00:09:45,206 --> 00:09:48,172
AT THE CENTER OF THE FRAME.
155
00:09:48,172 --> 00:09:51,827
THEN A TEMPERATURE SENSOR IS
INSTALLED UNDERNEATH THE SEAT.
156
00:09:54,206 --> 00:09:57,586
THE TECHNICIAN HAMMERS PLASTIC
AND STAINLESS-STEEL FEET
157
00:09:57,586 --> 00:09:59,689
INTO THE BOTTOM OF THE LEGS.
158
00:09:59,689 --> 00:10:02,517
THIS PREVENTS THE LEGS FROM
SCRATCHING THE FLOOR
159
00:10:02,517 --> 00:10:06,379
AND LEVELS THE FURNITURE
ON AN UNEVEN SURFACE.
160
00:10:07,275 --> 00:10:12,206
LASTLY, A BRONZE DRAIN
IS INSERTED INTO THE DRAIN HOLE.
161
00:10:12,206 --> 00:10:15,758
A QUALITY CONTROLLED HEAT TEST
MEASURES THE SURFACE TEMPERATURE
162
00:10:15,758 --> 00:10:17,724
WITH AN INFRARED THERMOMETER.
163
00:10:19,931 --> 00:10:23,517
IF ALL IS OPERATING CORRECTLY,
THE SENSOR UNDER THE SEAT
164
00:10:23,517 --> 00:10:26,724
TELLS THE THERMOSTAT
AND THE TEMPERATURE CONTROL UNIT
165
00:10:26,724 --> 00:10:29,724
WHEN TO TURN THE HEAT ON OR OFF.
166
00:10:39,310 --> 00:10:41,689
Narrator: EVER SINCE
THE ANCIENT EGYPTIANS DEVELOPED
167
00:10:41,689 --> 00:10:44,379
THE SHADUF AROUND
4,000 YEARS AGO,
168
00:10:44,379 --> 00:10:47,896
PEOPLE HAVE BEEN CREATING
NEW WAYS TO MOVE WATER.
169
00:10:47,896 --> 00:10:50,137
BEFORE PEOPLE RELIED ON
ELECTRICITY,
170
00:10:50,137 --> 00:10:54,137
WINDMILLS GENERATED POWER
USING WATER-WELL CYLINDERS.
171
00:10:54,137 --> 00:10:56,724
THESE SIMPLE BUT HIGHLY
EFFECTIVE MECHANISMS
172
00:10:56,724 --> 00:10:58,655
ARE STILL IN USE TODAY.
173
00:11:00,896 --> 00:11:02,896
PRODUCTION OF THIS
WATER-WELL CYLINDER
174
00:11:02,896 --> 00:11:05,551
BEGAN IN THE LATE 1800s.
175
00:11:05,551 --> 00:11:09,931
THE DESIGN WAS SO EFFECTIVE,
IT HASN'T CHANGED SINCE.
176
00:11:10,931 --> 00:11:14,413
TO CREATE THE VALVES INTEGRAL
TO WATER-WELL CYLINDERS,
177
00:11:14,413 --> 00:11:17,379
THE PROCESS STARTS
WITH A SPECIALIZED MOLD
178
00:11:17,379 --> 00:11:20,034
MADE OUT OF COMPRESSED SAND.
179
00:11:20,034 --> 00:11:23,413
THESE ORANGE TUBE-SHAPED OBJECTS
ARE CALLED CORES,
180
00:11:23,413 --> 00:11:26,068
ALSO MADE FROM COMPRESSED SAND.
181
00:11:26,068 --> 00:11:28,896
THE CORES ALLOW MOLTEN METAL
TO FLOW AROUND THEM,
182
00:11:28,896 --> 00:11:32,724
ENSURING THAT THE VALVE CAGE
REMAINS HOLLOW.
183
00:11:32,724 --> 00:11:35,379
WITH THE TOP OF THE MOLD CASING
IN PLACE,
184
00:11:35,379 --> 00:11:39,413
THE ASSEMBLY MOVES TO THE NEXT
STATION ON THE PRODUCTION LINE.
185
00:11:40,965 --> 00:11:45,344
A ROBOTIC ARM LOWERS THE JACKET
AND WEIGHT ON TO EACH MOLD
186
00:11:45,344 --> 00:11:48,965
TO PREVENT THE MOLTEN METAL
FROM ESCAPING.
187
00:11:48,965 --> 00:11:52,275
A METAL WORKER DROPS PIECES OF
METAL, CALLED RETURNS,
188
00:11:52,275 --> 00:11:54,000
INTO A CRUCIBLE.
189
00:11:57,931 --> 00:11:59,724
WHEN THE TEMPERATURE
OF THE MOLTEN METAL
190
00:11:59,724 --> 00:12:05,206
REACHES 2,102 DEGREES
FAHRENHEIT, IT'S READY TO POUR.
191
00:12:05,206 --> 00:12:07,379
ANOTHER METAL WORKER
USES A DEVICE
192
00:12:07,379 --> 00:12:11,241
CALLED A CRADLE TO HOIST
AND MOVE THE CRUCIBLE.
193
00:12:11,241 --> 00:12:14,551
HE POURS THE LIQUEFIED METAL
INTO A SPRUE HOLE,
194
00:12:14,551 --> 00:12:18,896
WHICH FLOWS
INTO THE MOLD OPENINGS.
195
00:12:18,896 --> 00:12:23,413
THE MOLDS COOL AS THEY HEAD
TO A VIBRATORY CONVEYOR SYSTEM.
196
00:12:23,413 --> 00:12:25,965
THE VIBRATIONS
BREAK THE SAND APART,
197
00:12:25,965 --> 00:12:30,931
LEAVING IN ITS PLACE
THE NEWLY FORMED METAL PARTS.
198
00:12:30,931 --> 00:12:33,724
A TECHNICIAN REMOVES THE PARTS
WITH A HOOK
199
00:12:33,724 --> 00:12:36,724
AND MOUNTS THEM ON
AN OVERHEAD TRANSPORT SYSTEM.
200
00:12:36,724 --> 00:12:41,310
THE TRANSPORT SYSTEM CARRIES
THEM INTO A BLAST MACHINE.
201
00:12:41,310 --> 00:12:45,172
INSIDE, STEEL SHOT BLASTS
THE METAL CLEAN.
202
00:12:47,965 --> 00:12:50,724
WHEN THE PARTS EMERGE
FROM THE BLAST MACHINE,
203
00:12:50,724 --> 00:12:54,413
THE CASTINGS ARE READY
FOR THE NEXT PHASE.
204
00:12:54,413 --> 00:12:57,482
USING A BAND SAW
WITH A DIAMOND-TIPPED BLADE,
205
00:12:57,482 --> 00:12:59,965
A METAL WORKER CAREFULLY
CUTS THE CASTINGS
206
00:12:59,965 --> 00:13:02,172
INTO THEIR COMPONENT PARTS.
207
00:13:05,931 --> 00:13:09,137
ROUGH CASTINGS HAVE A SEAM
CALLED A PARTING LINE,
208
00:13:09,137 --> 00:13:11,551
WHERE THE TWO HALVES
OF A MOLD MEET.
209
00:13:11,551 --> 00:13:15,103
A METAL WORKER GRINDS OFF
THE EXCESS CASTING.
210
00:13:15,103 --> 00:13:19,413
THE ROUGH CASTING GOES THROUGH
A MACHINING PROCESS.
211
00:13:19,413 --> 00:13:21,172
AS THE VALVES ARE ASSEMBLED,
212
00:13:21,172 --> 00:13:24,379
A SMALL PIECE OF NEWSPAPER
IS PLACED INSIDE
213
00:13:24,379 --> 00:13:28,068
TO PREVENT ANY DAMAGE
TO THE BALLS DURING SHIPMENT.
214
00:13:28,068 --> 00:13:32,034
THESE BRASS, PRECISION-GROUND
BALLS ARE CRUCIAL COMPONENTS
215
00:13:32,034 --> 00:13:34,448
THAT PERMIT
OR PREVENT WATER FLOW
216
00:13:34,448 --> 00:13:39,000
AS THEY MOVE UP
AND DOWN INSIDE THE VALVE CAGE.
217
00:13:39,000 --> 00:13:42,034
THESE COMPONENTS ARE MADE
OF LEATHER THAT'S BEEN PRESSED,
218
00:13:42,034 --> 00:13:45,586
FORMED, AND COATED WITH
GRAPHITE TO LUBRICATE THEM.
219
00:13:46,931 --> 00:13:48,275
WATER-WELL CYLINDERS
220
00:13:48,275 --> 00:13:51,551
HAVE BOTH A CHECK VALVE
AND A PLUNGER VALVE.
221
00:13:51,551 --> 00:13:55,241
A TECHNICIAN TIGHTENS A FOLLOWER
ON A PLUNGER VALVE.
222
00:13:55,241 --> 00:13:57,344
WHILE A CHECK VALVE
REMAINS STATIONARY
223
00:13:57,344 --> 00:13:59,586
AND PREVENTS WATER
FROM ESCAPING,
224
00:13:59,586 --> 00:14:01,758
A PLUNGER VALVE ISN'T FIXED,
225
00:14:01,758 --> 00:14:05,965
SO IT ALLOWS WATER
TO MOVE OUT THE TOP.
226
00:14:05,965 --> 00:14:09,689
A WATER-WELL CYLINDER
REQUIRES CAPS AND CONNECTORS.
227
00:14:09,689 --> 00:14:14,793
A CNC LATHE MACHINES A BRASS CAP
TO THE REQUIRED PARAMETERS.
228
00:14:14,793 --> 00:14:17,896
AS THE COMPONENT SPINS
AT 800 RPM,
229
00:14:17,896 --> 00:14:20,862
CARBIDE-TIPPED
CUTTING TOOLS HONE, BORE,
230
00:14:20,862 --> 00:14:23,655
AND THREAD IT WHERE NEEDED.
231
00:14:23,655 --> 00:14:26,517
THE CYLINDERS ARE MADE
FROM BRASS TUBING.
232
00:14:26,517 --> 00:14:29,068
THE 3-MILLIMETER-THICK
SEAMLESS TUBING
233
00:14:29,068 --> 00:14:32,413
IS MADE FROM A BRASS BILLET
HEATED UNTIL SOFT ENOUGH
234
00:14:32,413 --> 00:14:36,931
TO DRAW THROUGH
AN INNER AND OUTER DIE.
235
00:14:36,931 --> 00:14:40,448
THE RESULT IS A STRONG,
CORROSION-RESISTANT CYLINDER
236
00:14:40,448 --> 00:14:45,206
THAT CAN HANDLE WATER PRESSURE
AND IMMERSION FOR DECADES.
237
00:14:45,206 --> 00:14:48,448
A CNC DEVICE THREADS BOTH ENDS
OF THE CYLINDER
238
00:14:48,448 --> 00:14:51,724
TO RECEIVE THE CAP
AND CONNECTOR.
239
00:14:51,724 --> 00:14:54,551
A TECHNICIAN BRUSHES
A PIPE-COMPOUND SEALANT
240
00:14:54,551 --> 00:14:56,068
ON TO THE THREADS.
241
00:14:56,068 --> 00:14:59,172
THE SEALANT ENSURES
A WATERTIGHT FIT.
242
00:14:59,172 --> 00:15:04,000
THEN HE SCREWS THE CAP TO
THE BOTTOM END OF THE CYLINDER.
243
00:15:04,000 --> 00:15:09,482
HE ADDS THE TOP CONNECTOR AND
INSERTS BOTH ENDS INTO A LATHE.
244
00:15:09,482 --> 00:15:13,068
WITH THE BOTTOM HELD FIRMLY
IN PLACE BY THE LATHE CHUCK,
245
00:15:13,068 --> 00:15:15,275
HE PLACES A WRENCH
ON THE TOP END
246
00:15:15,275 --> 00:15:17,758
AND LETS THE MACHINE
TIGHTEN THE PARTS.
247
00:15:21,000 --> 00:15:23,379
NEXT, THE CHECK VALVE
AND THE PLUNGER VALVE
248
00:15:23,379 --> 00:15:26,965
ARE INSERTED INTO THE CYLINDER.
249
00:15:26,965 --> 00:15:29,137
THIS CLEAR ACRYLIC VERSION
OF THE CYLINDER
250
00:15:29,137 --> 00:15:32,275
DEMONSTRATES
HOW THE PROCESS WORKS.
251
00:15:32,275 --> 00:15:34,862
AS THE PLUNGER VALVE
SLIDES UP AND DOWN,
252
00:15:34,862 --> 00:15:39,034
THE CHECK VALVE
REMAINS STATIONARY.
253
00:15:39,034 --> 00:15:43,862
IT'S HARD NOT TO BE PUMPED ABOUT
AN OLD TECHNOLOGY SO GOOD.
254
00:15:54,344 --> 00:15:56,931
Narrator: NONCONDUCTIVE DIGGING
AND CUTTING TOOLS
255
00:15:56,931 --> 00:15:59,827
PROTECT WORKERS FROM
POTENTIAL HAZARDS SUCH AS
256
00:15:59,827 --> 00:16:01,931
UNDERGROUND POWER LINES.
257
00:16:01,931 --> 00:16:04,724
WHEN A NONCONDUCTIVE TOOL
HITS A LIVE WIRE,
258
00:16:04,724 --> 00:16:06,827
THE RISK IS NEUTRALIZED.
259
00:16:06,827 --> 00:16:09,344
THE HANDLE BLOCKS THE FLOW
OF ELECTRONS
260
00:16:09,344 --> 00:16:13,551
AND REDUCES THE RISK
OF UNEXPECTED SHOCKS.
261
00:16:13,551 --> 00:16:15,931
WORKERS WHO NEED TO DIG
RUN THE RISK
262
00:16:15,931 --> 00:16:18,413
OF HITTING LIVE
ELECTRICAL WIRES.
263
00:16:18,413 --> 00:16:20,965
THE NONCONDUCTIVE HANDLES
OF THESE TOOLS
264
00:16:20,965 --> 00:16:23,000
WILL COUNTERACT
THE FLOW OF ELECTRICITY,
265
00:16:23,000 --> 00:16:26,206
STOPPING DANGER IN ITS PATH.
266
00:16:26,206 --> 00:16:28,655
THE HANDLES ARE MADE
OF FIBERGLASS.
267
00:16:28,655 --> 00:16:32,206
THEY ARE MADE USING A PROCESS
KNOWN AS PULTRUSION.
268
00:16:32,206 --> 00:16:33,965
A MACHINE PULLS GLASS TWINE
269
00:16:33,965 --> 00:16:36,413
THROUGH THE STAGES
OF PRODUCTION.
270
00:16:36,413 --> 00:16:40,655
EACH PIECE OF TWINE IS COMPRISED
OF HUNDREDS OF GLASS STRANDS.
271
00:16:42,000 --> 00:16:45,413
THE TWINE UNWINDS THROUGH
AN ORANGE RESIN BATH,
272
00:16:45,413 --> 00:16:48,655
WHICH PERMEATES
THE GLASS FIBERS.
273
00:16:48,655 --> 00:16:51,275
A DIE COMPRESSES
THE RESIN-SOAKED GLASS
274
00:16:51,275 --> 00:16:53,758
TO A SPECIFIC LENGTH AND WIDTH.
275
00:16:53,758 --> 00:16:58,310
THE RESULT IS SLIGHTLY LARGER
THAN WHAT IS ULTIMATELY NEEDED.
276
00:16:58,310 --> 00:17:00,551
THE COMPRESSED FIBERGLASS
TRAVELS THROUGH
277
00:17:00,551 --> 00:17:04,206
A MICROWAVE OVEN FOR PREHEATING.
278
00:17:04,206 --> 00:17:07,586
THEN THE FIBERGLASS ENTERS
A SECOND HEATED DIE.
279
00:17:07,586 --> 00:17:12,000
THE PROCESS SQUEEZES THE HANDLE
TO ITS FINAL SIZE, SHAPES IT,
280
00:17:12,000 --> 00:17:14,000
AND CURES THE MATERIAL.
281
00:17:14,000 --> 00:17:15,586
AS IT'S PULLED FORWARD,
282
00:17:15,586 --> 00:17:19,793
THE LONG FIBERGLASS FORM COOLS
AND SOLIDIFIES.
283
00:17:19,793 --> 00:17:23,379
THIS MACHINE, CALLED THE
TRACTOR, IS DOING THE PULLING.
284
00:17:23,379 --> 00:17:27,448
THE TRACTOR'S TREADED RUBBER
PADS GRAB THE FIBERGLASS SHAFT
285
00:17:27,448 --> 00:17:30,137
AND DELIVER IT
TO A CIRCULAR SAW.
286
00:17:30,137 --> 00:17:34,586
THE SAW SLICES THE FIBERGLASS
SHAFT TO A SPECIFIED LENGTH.
287
00:17:34,586 --> 00:17:37,620
SINCE THE FIBERGLASS IS ONLY
PARTIALLY CURED,
288
00:17:37,620 --> 00:17:42,137
THE HANDLES ARE COOLED AT
ROOM TEMPERATURE FOR 24 HOURS.
289
00:17:42,137 --> 00:17:45,758
THE HANDLES VARY BASED
ON THE TYPE OF TOOL.
290
00:17:45,758 --> 00:17:49,034
A MACHINIST CUTS ONE END OF
THE HANDLE ON AN ANGLE
291
00:17:49,034 --> 00:17:50,896
TO FIT THE BLADE SHANK.
292
00:17:54,655 --> 00:17:56,344
USING A SHARP DISC,
293
00:17:56,344 --> 00:18:00,275
HE CARVES SPIRAL GROOVES
AT THE BASE OF THE ANGLE CUT.
294
00:18:00,275 --> 00:18:03,034
THESE GROOVES ALLOW
THE SHOVEL SHANK TO FUSE
295
00:18:03,034 --> 00:18:04,758
WITH THE END OF THE HANDLE.
296
00:18:07,793 --> 00:18:11,655
NEXT, THE HANDLE IS PLACED
IN AN INJECTION-MOLDING MACHINE
297
00:18:11,655 --> 00:18:15,206
WITH THE GROOVED END
EXTENDED INTO THE MOLD.
298
00:18:15,206 --> 00:18:18,103
GLASS-FILLED NYLON PELLETS MOVE
THROUGH THE MACHINE'S
299
00:18:18,103 --> 00:18:21,275
HEATED CHAMBER AND MELT.
300
00:18:21,275 --> 00:18:24,862
AN AUGER FORCES THE THICK LIQUID
INTO THE MOLD.
301
00:18:24,862 --> 00:18:28,344
THE SHOVEL SHANK TAKES SHAPE
AROUND THE END OF THE HANDLE,
302
00:18:28,344 --> 00:18:32,551
AND GLASS-FILLED NYLON LIQUID
FLOWS INTO THE GROOVES.
303
00:18:32,551 --> 00:18:35,344
THE SHANK BECOMES INTEGRAL
TO THE HANDLE.
304
00:18:37,862 --> 00:18:41,034
NEXT, A MACHINIST CLIPS
THE EXCESS MATERIAL
305
00:18:41,034 --> 00:18:43,241
FROM THE NEWLY FORMED SHANK.
306
00:18:43,241 --> 00:18:46,827
THE GLASS AND NYLON SHANK
IS ALSO NONCONDUCTIVE.
307
00:18:46,827 --> 00:18:51,758
THE SHANK END IS SUBMERGED
IN A COOLING BATH.
308
00:18:51,758 --> 00:18:55,482
USING A DRILL, THE MACHINIST
REMOVES BOLTS FROM NUTS
309
00:18:55,482 --> 00:18:58,310
INSTALLED IN THE SHANK
DURING MOLDING.
310
00:18:58,310 --> 00:19:01,275
THIS LEAVES THE NUTS EMBEDDED
IN THE SHANK.
311
00:19:01,275 --> 00:19:04,068
THEY'LL BE USED TO ATTACH
THE SHOVEL BLADE.
312
00:19:07,689 --> 00:19:10,931
MEANWHILE, ANOTHER TECHNICIAN
APPLIES A RUBBER GASKET
313
00:19:10,931 --> 00:19:12,827
TO THE END OF THE SHANK.
314
00:19:12,827 --> 00:19:16,344
THE GASKET HAS HOLES
THAT KEEP THE NUTS OPEN.
315
00:19:16,344 --> 00:19:19,103
HE PLACES THE SHOVEL BLADE
ON THE ASSEMBLY,
316
00:19:19,103 --> 00:19:21,482
ALIGNING THE HOLES
WITH THE NUTS.
317
00:19:21,482 --> 00:19:25,172
HE SECURES THE SHOVEL BLADE
TO THE SHANK WITH SCREWS.
318
00:19:28,620 --> 00:19:32,103
IT'S NONCONDUCTIVE FROM
THE HANDLE TO THE METAL BLADE,
319
00:19:32,103 --> 00:19:36,448
SO THE USER CAN SAFELY GRIP IT
AT ALMOST ANY SPOT.
320
00:19:37,275 --> 00:19:39,413
APART FROM BEING NONCONDUCTIVE,
321
00:19:39,413 --> 00:19:42,137
THIS SHOVEL MUST ALSO
BE HEAVY-DUTY.
322
00:19:44,655 --> 00:19:46,241
TO TEST ITS STRENGTH,
323
00:19:46,241 --> 00:19:49,241
AN INSPECTOR INSERTS
THE BLADE INTO A MACHINE.
324
00:19:52,379 --> 00:19:54,655
ONCE HE HAS DETERMINED
THE TEST AREA,
325
00:19:54,655 --> 00:19:57,068
THE CHAIN IS CONNECTED
TO A CONTAINER FILLED
326
00:19:57,068 --> 00:20:00,379
WITH SAND BAGS
THAT WEIGH 250 POUNDS.
327
00:20:02,896 --> 00:20:05,448
HE LOWERS THE PLATFORM
THAT HOLDS THE LOAD
328
00:20:05,448 --> 00:20:07,517
AND OBSERVES THE HANDLE.
329
00:20:07,517 --> 00:20:13,206
IF THE HANDLE BENDS BUT DOESN'T
BREAK, IT'S SUFFICIENTLY STRONG.
330
00:20:13,206 --> 00:20:16,448
THE INSPECTOR PLACES THE SHOVEL
IN ANOTHER TESTER
331
00:20:16,448 --> 00:20:19,793
AND RUNS 10,000 VOLTS
OF ELECTRICITY THROUGH THE TOOL
332
00:20:19,793 --> 00:20:24,137
TO MEASURE THE LEAKAGE
AT THE END OF THE HANDLE.
333
00:20:24,137 --> 00:20:28,275
IF IT'S MINIMAL, HE ASSIGNS THE
SHOVEL A UNIQUE SERIAL NUMBER
334
00:20:28,275 --> 00:20:29,931
AND BRANDS IT AS CERTIFIED
335
00:20:29,931 --> 00:20:32,103
ACCORDING TO
ELECTRICAL STANDARDS.
336
00:20:35,137 --> 00:20:39,448
ON SITE, A NONCONDUCTIVE TOOL
CAN BE INDISPENSABLE,
337
00:20:39,448 --> 00:20:41,931
PROVIDING THE USER A SAFE HANDLE
338
00:20:41,931 --> 00:20:45,137
ON A POTENTIALLY
DANGEROUS SITUATION.
28037
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