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Narrator: AS THE MUSIC INDUSTRY
WENT DIGITAL,
2
00:00:54,275 --> 00:00:57,379
THE TURNTABLE SEEMED DESTINED
FOR THE SCRAP HEAP.
3
00:00:57,379 --> 00:01:01,206
BUT THIS ANALOG TECHNOLOGY
DEFIED PREDICTIONS AND SURVIVED.
4
00:01:01,206 --> 00:01:03,413
WITH A SOUND
THAT'S ARGUABLY FULLER
5
00:01:03,413 --> 00:01:06,172
AND MORE NATURAL
THAN COMPRESSED DIGITAL FORMATS,
6
00:01:06,172 --> 00:01:10,000
THIS RETRO TECHNOLOGY
IS ATTRACTING NEW FANS.
7
00:01:13,724 --> 00:01:17,689
IN AN AGE WHEN MEDIA PLAYERS
ARE DIGITIZED AND POCKET-SIZED,
8
00:01:17,689 --> 00:01:19,517
THE TURNTABLE PLAYS ON.
9
00:01:21,241 --> 00:01:24,034
THE USE OF HIGH-TECH COMPOSITES
LIKE CARBON FIBER
10
00:01:24,034 --> 00:01:26,586
PUTS A MODERN SPIN
ON THIS TECHNOLOGY,
11
00:01:26,586 --> 00:01:30,310
BRINGING THE RECORD PLAYER
INTO THE 21st CENTURY.
12
00:01:32,724 --> 00:01:36,310
PRODUCTION STARTS WITH
A THICK SQUARE OF CAST ACRYLIC.
13
00:01:36,310 --> 00:01:38,310
THE TECHNICIAN DRILLS A HOLE
IN THE CENTER.
14
00:01:38,310 --> 00:01:39,931
IT WILL BE A REFERENCE POINT
15
00:01:39,931 --> 00:01:44,620
AS HE TRANSFORMS THIS SQUARE
INTO THE TURNTABLE PLATTER.
16
00:01:44,620 --> 00:01:46,413
A COMPUTERIZED TOOL
17
00:01:46,413 --> 00:01:49,103
CUTS A CIRCLE SHAPE
OUT OF THE SQUARE.
18
00:01:52,172 --> 00:01:55,241
THE DISC THEN SPINS WHILE
ANOTHER COMPUTER-GUIDED TOOL
19
00:01:55,241 --> 00:01:56,551
ENLARGES THE CENTER HOLE
20
00:01:56,551 --> 00:01:59,827
TO SIZE IT
FOR THE PLATTER'S MAIN BEARING.
21
00:01:59,827 --> 00:02:03,241
THE NEXT TOOL PRECISELY CUTS
THE SURFACE OF THE DISC
22
00:02:03,241 --> 00:02:05,034
TO GIVE IT THE CORRECT ANGLE.
23
00:02:09,275 --> 00:02:12,793
COMPUTERIZED TOOLS TRANSFORM
THIS SMALL ALUMINUM DISC
24
00:02:12,793 --> 00:02:15,241
INTO THE COUNTERWEIGHT'S
MAIN COMPONENT.
25
00:02:15,241 --> 00:02:17,413
THE COUNTERWEIGHT
BALANCES THE TONE ARM
26
00:02:17,413 --> 00:02:20,758
TO KEEP THE STYLUS
IN THE GROOVE OF AN L.P.
27
00:02:20,758 --> 00:02:22,241
THEY SLOPE THE SURFACE
28
00:02:22,241 --> 00:02:26,034
AND CUT HOLES FOR ATTACHMENTS
AND FOR INSTALLING THE PART.
29
00:02:27,241 --> 00:02:31,000
FINALLY, THEY CUT A TRIANGLE
OUT OF THE CIRCLE.
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00:02:33,275 --> 00:02:37,931
THIS TAKES THE PART
TO ITS FINAL SHAPE AND WEIGHT...
31
00:02:37,931 --> 00:02:39,689
FROM A FLAT DISC
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00:02:39,689 --> 00:02:42,172
TO A PRECISELY CRAFTED
COUNTERWEIGHT.
33
00:02:44,655 --> 00:02:48,068
NEXT, THE PLATFORM
FOR THE TONE ARM TAKES SHAPE.
34
00:02:48,068 --> 00:02:50,206
IT'S DESIGNED
TO CRADLE ALL THE PARTS
35
00:02:50,206 --> 00:02:51,827
AT THE END OF THE TONE ARM,
36
00:02:51,827 --> 00:02:54,965
INCLUDING A CYLINDRICAL HOUSING
FOR A SPRING MECHANISM
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00:02:54,965 --> 00:02:59,206
AND AN EGG-SHAPED HOUSING
CONTAINING A BEARING.
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00:02:59,206 --> 00:03:01,689
A TECHNICIAN
NOW ASSEMBLES THE TONE ARM,
39
00:03:01,689 --> 00:03:04,827
BEGINNING WITH A TAPERED TUBE
MADE OF CARBON FIBER.
40
00:03:04,827 --> 00:03:07,655
IT'S A HIGH-TECH COMPOSITE
THAT'S EXTREMELY STIFF,
41
00:03:07,655 --> 00:03:11,586
SO THERE SHOULD BE NO STRUCTURAL
WEAKNESS IN THIS CRUCIAL PART.
42
00:03:11,586 --> 00:03:14,344
THE TECHNICIAN THREADS
A PREASSEMBLED WIRING LOOM
43
00:03:14,344 --> 00:03:16,034
THROUGH THE ARM TUBE.
44
00:03:16,034 --> 00:03:19,275
IT'S SPECIAL WIRE
FOR HIGH-FREQUENCY TRANSFER.
45
00:03:19,275 --> 00:03:21,620
THESE WIRES
HAVE BEEN ENCASED IN COPPER
46
00:03:21,620 --> 00:03:23,551
TO KEEP OUT AMBIENT RADIATION
47
00:03:23,551 --> 00:03:26,724
THAT WOULD INTERFERE
WITH THE TONE ARM'S OPERATION.
48
00:03:26,724 --> 00:03:30,448
THE CARBON-FIBER TUBE
ALSO ACTS AS A RADIATION SHIELD.
49
00:03:30,448 --> 00:03:33,206
HE MIXES EPOXY RESIN
THAT HE THEN DABS AROUND
50
00:03:33,206 --> 00:03:35,206
THE INNER RIM
OF THE BEARING HOUSING,
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00:03:35,206 --> 00:03:38,379
WHICH HAS BY NOW BEEN EQUIPPED
WITH THE BEARING.
52
00:03:41,137 --> 00:03:44,068
HE INSERTS THE TONE ARM TUBE
INTO THE HOUSING.
53
00:03:48,103 --> 00:03:51,620
THE TUBE ADHERES
TO THE GLUE-COATED RIM,
54
00:03:51,620 --> 00:03:53,827
BUT BEFORE IT TOTALLY BONDS,
55
00:03:53,827 --> 00:03:57,137
THE TECHNICIAN SCRUTINIZES
THE ALIGNMENT.
56
00:03:57,137 --> 00:03:59,241
HE MAKES ADJUSTMENTS IF NEEDED,
57
00:03:59,241 --> 00:04:00,827
AND THEN HE'LL CLAMP
THE ASSEMBLY
58
00:04:00,827 --> 00:04:03,413
TO ALLOW THE GLUE TO CURE.
59
00:04:05,620 --> 00:04:08,275
WITH THE TURNTABLE TONE ARM
NOW UPRIGHT,
60
00:04:08,275 --> 00:04:11,068
HE SOLDERS THE WIRES THAT
ARE PROTRUDING FROM THE JOINT
61
00:04:11,068 --> 00:04:13,275
TO EXTERNAL WIRING
FOR THE AMPLIFIER.
62
00:04:16,827 --> 00:04:19,275
AND ONCE ALL THE CONNECTIONS
HAVE BEEN MADE,
63
00:04:19,275 --> 00:04:23,172
HE INSERTS THE WIRES
INTO THE METAL JOINT.
64
00:04:24,931 --> 00:04:26,448
ENSCONCED IN THIS JOINT,
65
00:04:26,448 --> 00:04:28,689
THE CONNECTIONS
ARE WELL-PROTECTED
66
00:04:28,689 --> 00:04:31,655
AND CAN'T BE PULLED APART.
67
00:04:33,172 --> 00:04:35,068
HE EQUIPS
THE MAIN COUNTERWEIGHT COMPONENT
68
00:04:35,068 --> 00:04:39,034
WITH TWO THICK STEEL BEAMS
FOR BALANCE.
69
00:04:39,034 --> 00:04:41,206
HE SLIDES THE COUNTERWEIGHT
ONTO A THIRD BEAM,
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00:04:41,206 --> 00:04:44,310
WHICH HAS BEEN INSTALLED
IN THE EGG-SHAPED HOUSING.
71
00:04:44,310 --> 00:04:47,724
THIS COMPLETES
THE TURNTABLE TONE ARM.
72
00:04:50,586 --> 00:04:55,103
NEXT, THEY ENCASE THE ELECTRIC
MOTOR IN ITS METAL HOUSING.
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00:04:57,793 --> 00:05:00,068
AND THEY BUILD THE RECORD DECK.
74
00:05:00,068 --> 00:05:02,655
THEY MOUNT THE MOTOR
TO THE TWO-TIERED DECK,
75
00:05:02,655 --> 00:05:04,827
DESIGNED TO ABSORB
ANY VIBRATION.
76
00:05:04,827 --> 00:05:07,379
THE ALUMINUM SUB-CHASSIS
IS NEXT.
77
00:05:07,379 --> 00:05:10,275
THEY LINK IT TO THE MOTOR
WITH A DRIVE BELT,
78
00:05:10,275 --> 00:05:12,965
THEN THEY GIVE THE BELT-DRIVE
SYSTEM A TEST SPIN
79
00:05:12,965 --> 00:05:14,724
TO CONFIRM
THAT IT RUNS SMOOTHLY.
80
00:05:16,379 --> 00:05:18,517
THEY NOW INSTALL
THE ACRYLIC PLATTER,
81
00:05:18,517 --> 00:05:20,931
FELT MAT, AND TONE ARM.
82
00:05:20,931 --> 00:05:23,448
WITH THIS TURNTABLE
NOW FULLY ASSEMBLED,
83
00:05:23,448 --> 00:05:26,137
IT'S TIME FOR THE VINYL TEST.
84
00:05:26,137 --> 00:05:27,724
THE RECORD SPINS,
85
00:05:27,724 --> 00:05:30,620
AND THE STYLUS TRACES
THE GROOVES.
86
00:05:30,620 --> 00:05:34,620
THE ANALOG SOUND
FILLS THE ROOM...
87
00:05:34,620 --> 00:05:39,034
PROVING THIS TECHNOLOGY
STANDS THE TEST OF TIME.
88
00:05:50,551 --> 00:05:52,586
Narrator:
THE FIRST MODERN STEAM ENGINE
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00:05:52,586 --> 00:05:55,413
WAS INVENTED IN ENGLAND
IN THE EARLY 1700s,
90
00:05:55,413 --> 00:05:57,827
HELPING LAUNCH
THE INDUSTRIAL REVOLUTION.
91
00:05:57,827 --> 00:06:00,793
TODAY THERE'S A RETURN
TO STEAM POWER.
92
00:06:00,793 --> 00:06:02,517
DUE TO ITS DIFFERENT
CONFIGURATION
93
00:06:02,517 --> 00:06:03,965
AND COMBUSTION PROCESS,
94
00:06:03,965 --> 00:06:06,310
A STEAM ENGINE
PRODUCES LESS POLLUTION
95
00:06:06,310 --> 00:06:10,862
THAN A REGULAR
INTERNAL-COMBUSTION ENGINE.
96
00:06:10,862 --> 00:06:12,758
THIS STEAM ENGINE BURNS FUEL
97
00:06:12,758 --> 00:06:15,344
IN AN EXTERNAL
COMBUSTION CHAMBER.
98
00:06:15,344 --> 00:06:18,620
THE RESULTING HEAT TURNS WATER
INTO PRESSURIZED STEAM
99
00:06:18,620 --> 00:06:21,103
THAT ENTERS THE CYLINDERS,
PUSHING PISTONS,
100
00:06:21,103 --> 00:06:24,517
TURNING A CRANKSHAFT
THAT POWERS THE DRIVE TRAIN.
101
00:06:24,517 --> 00:06:27,551
BECAUSE THIS ENGINE DOESN'T
BURN FUEL INSIDE THE CYLINDERS
102
00:06:27,551 --> 00:06:29,758
LIKE A TRADITIONAL CAR ENGINE,
103
00:06:29,758 --> 00:06:32,586
IT CAN RUN ON ANY TYPE
OR MIXTURE OF FUELS
104
00:06:32,586 --> 00:06:35,137
WITH FEWER EMISSIONS.
105
00:06:35,137 --> 00:06:38,241
THE CIRCULAR ENGINE BLOCK
IS MADE OF ALUMINUM.
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00:06:38,241 --> 00:06:40,068
TECHNICIANS INSTALL STUDS
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00:06:40,068 --> 00:06:43,241
TO HOLD SIX
STAINLESS-STEEL CYLINDERS.
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00:06:43,241 --> 00:06:45,689
DUE TO THE CONSTANT EXPOSURE
TO STEAM,
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00:06:45,689 --> 00:06:49,655
ALL ENGINE PARTS ARE MADE
OF RUSTPROOF MATERIALS.
110
00:06:49,655 --> 00:06:53,172
THE TECHNICIANS INSERT A PISTON
INTO EACH CYLINDER.
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00:06:53,172 --> 00:06:54,413
THE PISTON IS ALUMINUM
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00:06:54,413 --> 00:06:57,137
WITH A HEAT-RESISTANT CARBON CAP
AND GLIDER
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00:06:57,137 --> 00:06:59,862
TO ISOLATE IT
FROM THE CYLINDER WALL.
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00:06:59,862 --> 00:07:03,413
THEY CONNECT THE PISTON RODS
TO THE CRANKSHAFT IN THE CENTER
115
00:07:03,413 --> 00:07:05,275
WITH A SPECIALLY DESIGNED
COMPONENT
116
00:07:05,275 --> 00:07:06,862
CALLED A SPIDER BEARING.
117
00:07:06,862 --> 00:07:10,172
THIS BEARING IS DESIGNED
TO MODIFY THE PISTON STROKE,
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00:07:10,172 --> 00:07:13,206
PRODUCING A SMOOTHER ROTATION
OF THE CRANKSHAFT
119
00:07:13,206 --> 00:07:15,413
AND MORE POWER TO THE ENGINE.
120
00:07:15,413 --> 00:07:19,068
UNLIKE A TRADITIONAL CAR ENGINE,
WITH CYLINDERS ARRANGED IN LINE,
121
00:07:19,068 --> 00:07:21,689
THESE CYLINDERS
ARE IN A RADIAL CONFIGURATION
122
00:07:21,689 --> 00:07:24,448
AND THEREFORE EQUIDISTANT
FROM THE CENTER.
123
00:07:24,448 --> 00:07:28,344
THIS PREVENTS THE ENGINE FROM
WARPING UNDER HIGH TEMPERATURES.
124
00:07:28,344 --> 00:07:31,413
THEY PLACE A COUNTERBALANCE
OVER THEIR SPIDER BEARING
125
00:07:31,413 --> 00:07:34,275
TO FURTHER SMOOTH THE MOTION
OF THE CRANKSHAFT.
126
00:07:34,275 --> 00:07:37,827
NOW THEY INSTALL A PUSHROD
OVER EACH CYLINDER.
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00:07:37,827 --> 00:07:39,413
IT OPERATES A VALVE,
128
00:07:39,413 --> 00:07:43,206
WHICH LETS STEAM ENTER THE
CYLINDER AND MOVE THE PISTON.
129
00:07:43,206 --> 00:07:48,413
THEY INSERT THE BASE OF EACH
PUSHROD INTO A GUIDE RING...
130
00:07:48,413 --> 00:07:51,206
THEN ATTACH THE CYLINDER HEADS,
131
00:07:51,206 --> 00:07:53,724
EACH OF WHICH
HOUSES A STEAM-ENTRY VALVE.
132
00:07:53,724 --> 00:07:57,000
THEY INSERT THE PUSHROD
INTO THE VALVE.
133
00:08:01,241 --> 00:08:03,241
THEN, TO COMPLETE
THE ENGINE ASSEMBLY,
134
00:08:03,241 --> 00:08:04,620
THEY INSTALL THE CAM,
135
00:08:04,620 --> 00:08:08,482
WHICH PUSHES THE PUSHRODS
AS THE SHAFT SPINS.
136
00:08:08,482 --> 00:08:11,310
THE FACTORY HOOKS UP
EVERY COMPLETED ENGINE
137
00:08:11,310 --> 00:08:14,655
FOR A COUPLE OF ROUNDS
OF PERFORMANCE TESTING.
138
00:08:14,655 --> 00:08:16,965
FIRST, A TRIAL RUN
USING AIR PRESSURE
139
00:08:16,965 --> 00:08:18,448
TO CHECK FOR LEAKS
140
00:08:18,448 --> 00:08:21,655
AND TO VERIFY THAT ALL
COMPONENTS OPERATE CORRECTLY.
141
00:08:21,655 --> 00:08:23,241
IF EVERYTHING'S FINE,
142
00:08:23,241 --> 00:08:25,965
THEN THEY REPEAT THE PROCESS
WITH STEAM PRESSURE.
143
00:08:28,413 --> 00:08:31,517
THIS TYPE OF STEAM ENGINE CAN
POWER MANY TYPES OF MACHINES,
144
00:08:31,517 --> 00:08:34,000
FROM CARS, TRUCKS, AND BOATS,
145
00:08:34,000 --> 00:08:36,551
TO ELECTRIC GENERATORS
AS WE SEE HERE.
146
00:08:36,551 --> 00:08:39,689
IN A VEHICLE, IT DOESN'T REQUIRE
A TRANSMISSION
147
00:08:39,689 --> 00:08:43,758
BECAUSE IT PRODUCES
SO MUCH ROTATIONAL POWER.
148
00:08:43,758 --> 00:08:45,931
NOW FOR THE HEAT EXCHANGER,
149
00:08:45,931 --> 00:08:50,275
THE COMPONENT WHICH TURNS WATER
INTO ENGINE-POWERING STEAM.
150
00:08:50,275 --> 00:08:52,344
TECHNICIANS USE
A MOTORIZED WHEEL
151
00:08:52,344 --> 00:08:54,689
TO WIND 20 FEET
OF STAINLESS-STEEL TUBING
152
00:08:54,689 --> 00:08:56,517
INTO A COIL.
153
00:08:58,551 --> 00:09:00,931
THEY BIND THE COIL
WITH STEEL THREAD,
154
00:09:00,931 --> 00:09:02,862
PUTTING A STITCH
IN BETWEEN EACH TUBE
155
00:09:02,862 --> 00:09:05,379
TO CREATE A MINUTE GAP.
156
00:09:05,379 --> 00:09:08,551
THAT WAY, WHEN FUEL BURNS
IN THE COMBUSTION CHAMBER,
157
00:09:08,551 --> 00:09:11,517
THE HEAT CAN TRAVEL
OVER AND IN BETWEEN THE TUBES,
158
00:09:11,517 --> 00:09:14,724
HEATING THE WATER INSIDE
FASTER AND MORE EFFICIENTLY
159
00:09:14,724 --> 00:09:16,103
THAN IF THE HEAT WOULD CONTACT
160
00:09:16,103 --> 00:09:19,344
ONLY THE COILS' TOP
AND BOTTOM SURFACES.
161
00:09:19,344 --> 00:09:25,000
THE RESULT -- SUPERHEATED STEAM
IN JUST FIVE SECONDS.
162
00:09:29,586 --> 00:09:32,000
THEY STACK SIX OF THESE COILS,
163
00:09:32,000 --> 00:09:34,206
ONE TO FEED STEAM
TO EACH CYLINDER.
164
00:09:34,206 --> 00:09:35,689
THIS NEST OF TUBES
165
00:09:35,689 --> 00:09:38,896
FORM THE ENGINE'S
PRIMARY HEAT EXCHANGER.
166
00:09:38,896 --> 00:09:41,827
THEY TEST IT
USING ANY NUMBER OF FUELS,
167
00:09:41,827 --> 00:09:45,862
EVEN WASTE FUELS WHICH WOULD
OTHERWISE BE DISCARDED,
168
00:09:45,862 --> 00:09:47,551
SUCH AS USED MOTOR OIL
169
00:09:47,551 --> 00:09:51,206
AND USED VEGETABLE OIL
FROM RESTAURANT FRYERS.
170
00:09:51,206 --> 00:09:55,172
VIRTUALLY ANYTHING THAT BURNS
WILL DO THE JOB.
171
00:09:55,172 --> 00:09:57,241
THE FUEL COMBUSTS
AT LOW PRESSURE,
172
00:09:57,241 --> 00:10:00,620
NOT AT HIGH PRESSURE
AS IN A GAS OR DIESEL ENGINE.
173
00:10:00,620 --> 00:10:03,275
THAT MEANS BURNING FOSSIL FUELS
TO MAKE STEAM
174
00:10:03,275 --> 00:10:06,034
PRODUCES FAR FEWER
GREENHOUSE GASES,
175
00:10:06,034 --> 00:10:08,862
AND MOST HYDROCARBONS
BURN OFF COMPLETELY
176
00:10:08,862 --> 00:10:11,172
WITHIN THE SEALED
COMBUSTION CHAMBER.
177
00:10:11,172 --> 00:10:14,310
YOU NEVER HAVE TO REFILL
OR TOP OFF THE WATER
178
00:10:14,310 --> 00:10:17,379
BECAUSE A CONDENSER COOLS
THE STEAM BACK INTO WATER,
179
00:10:17,379 --> 00:10:19,793
WHICH THEN RECIRCULATES.
180
00:10:19,793 --> 00:10:22,068
WATER IS NOT ONLY
THE WORKING FLUID --
181
00:10:22,068 --> 00:10:24,965
IT ALSO ACTS
AS THE ENGINE LUBRICANT,
182
00:10:24,965 --> 00:10:27,551
SO THE STEAM ENGINE
DOESN'T REQUIRE MOTOR OIL.
183
00:10:29,689 --> 00:10:31,448
BESIDES FUEL COMBUSTION,
184
00:10:31,448 --> 00:10:34,551
THIS MODERN STEAM ENGINE
CAN RUN OFF OTHER HEAT SOURCES,
185
00:10:34,551 --> 00:10:35,689
SUCH AS SOLAR HEAT
186
00:10:35,689 --> 00:10:38,827
AND EXHAUST HEAT
FROM FURNACES OR ENGINES.
187
00:10:50,482 --> 00:10:53,034
Narrator: THERE WAS A TIME
WHEN THE PLAYGROUND EQUIPMENT
188
00:10:53,034 --> 00:10:56,068
IN THE LOCAL PARK OR SCHOOLYARD
WAS PRETTY BASIC STUFF --
189
00:10:56,068 --> 00:10:59,620
A SET OF SWINGS, A SLIDE,
MAYBE A SEE-SAW OR TWO.
190
00:10:59,620 --> 00:11:01,172
TODAY'S PLAYGROUND EQUIPMENT
191
00:11:01,172 --> 00:11:04,068
IS FAR MORE VARIED,
IMAGINATIVE, AND COLORFUL,
192
00:11:04,068 --> 00:11:06,862
DESIGNED TO STIMULATE
CHILDREN'S MINDS
193
00:11:06,862 --> 00:11:09,793
AS WELL AS EXERCISE
THEIR BODIES.
194
00:11:12,379 --> 00:11:15,275
SLIDE DOWN, CLIMB ON,
WRIGGLE THROUGH.
195
00:11:15,275 --> 00:11:17,482
THERE'S NO END
TO HOW KIDS CAN FROLIC
196
00:11:17,482 --> 00:11:19,034
ON MODULAR PLAY STRUCTURES
197
00:11:19,034 --> 00:11:21,724
OR ON THIS BUBBLE-BELLY
DINOSAUR.
198
00:11:25,241 --> 00:11:27,689
TO MAKE
THE DINOSAUR'S NECK AND LEGS,
199
00:11:27,689 --> 00:11:29,034
AN AUTOMATED BAND SAW
200
00:11:29,034 --> 00:11:32,620
CUTS LONG STEEL TUBES
TO SPECIFIC LENGTHS.
201
00:11:38,137 --> 00:11:41,310
THE TUBE FOR THE NECK
IS 5 1/2 FEET LONG.
202
00:11:41,310 --> 00:11:44,344
WORKERS CURVE IT
IN A BENDING PRESS.
203
00:11:44,344 --> 00:11:46,379
A LEVEL HELPS THEM
GET IT JUST RIGHT.
204
00:11:51,620 --> 00:11:54,275
NEXT, THEY WELD ON
TWO STEEL PLATES.
205
00:11:54,275 --> 00:11:58,793
THESE WILL SUPPORT PLASTIC SEATS
ON WHICH KIDDIES CAN SIT.
206
00:11:58,793 --> 00:12:00,482
WORKERS ALSO WELD ON BARS
207
00:12:00,482 --> 00:12:03,586
FOR ATTACHING THE NECK
TO THE BODY.
208
00:12:03,586 --> 00:12:06,206
THEY WELD ANCHORING TABS
AND SUPPORTING BARS
209
00:12:06,206 --> 00:12:09,275
TO THE FOUR STEEL-TUBE LEGS.
210
00:12:09,275 --> 00:12:11,862
WORKERS SANDBLAST
THE LEGS AND NECK
211
00:12:11,862 --> 00:12:13,931
WITH STAINLESS-STEEL GRIT.
212
00:12:13,931 --> 00:12:16,068
THE SANDBLASTING GUN
SHOOTS THE GRIT
213
00:12:16,068 --> 00:12:19,068
AT A SPEED OF 435 MILES AN HOUR.
214
00:12:19,068 --> 00:12:22,793
THIS ROUGHENS THE SURFACE,
ENABLING PAINT TO BETTER ADHERE.
215
00:12:24,689 --> 00:12:27,551
AFTER APPLYING
AN UNDERCOAT OF GRAY PRIMER,
216
00:12:27,551 --> 00:12:30,655
WORKERS SPRAY ON A COAT
OF PLASTIC-BASED PAINT.
217
00:12:30,655 --> 00:12:35,000
THE PAINT IS THEN BAKED ON,
WHICH MAXIMIZES ITS DURABILITY.
218
00:12:37,344 --> 00:12:40,275
MEANWHILE, A COMPUTER-GUIDED
ENGRAVING MACHINE
219
00:12:40,275 --> 00:12:43,310
CARVES AN EDUCATIONAL DESIGN
INTO A PANEL
220
00:12:43,310 --> 00:12:46,517
MADE OF TRIPLE-LAYERED
POLYETHYLENE PLASTIC.
221
00:12:46,517 --> 00:12:50,103
PANELS LIKE THIS BLOCK THE OPEN
SIDES OF PLAYGROUND EQUIPMENT,
222
00:12:50,103 --> 00:12:52,896
PREVENTING CHILDREN
FROM FALLING THROUGH.
223
00:12:56,344 --> 00:12:59,206
TO CONSTRUCT THE DINOSAUR'S
BUBBLE-SHAPED BODY,
224
00:12:59,206 --> 00:13:00,620
WORKERS BOLT TOGETHER
225
00:13:00,620 --> 00:13:05,482
TWO HALF-SPHERES MADE
OF MOLDED POLYETHYLENE PLASTIC.
226
00:13:05,482 --> 00:13:09,517
THEY POSITION THE BUBBLE BODY
ON THE LEGS...
227
00:13:15,034 --> 00:13:17,206
...THEN BOLT THEM TOGETHER
FROM THE INSIDE.
228
00:13:17,206 --> 00:13:19,896
THEY BOLT THE NECK TO THE BODY.
229
00:13:19,896 --> 00:13:21,482
THE NECK
HAS SINCE BEEN OUTFITTED
230
00:13:21,482 --> 00:13:24,931
WITH PLASTIC SEATS
AND THE DINO'S PLASTIC HEAD.
231
00:13:24,931 --> 00:13:26,724
THEY FINISH OFF THE DINOSAUR
232
00:13:26,724 --> 00:13:30,137
WITH A METAL LABEL
BEARING PRODUCT INFORMATION.
233
00:13:30,137 --> 00:13:32,931
THIS FACTORY PRODUCES
SEVERAL COMPONENTS
234
00:13:32,931 --> 00:13:34,827
FOR ITS MODULAR PLAY STRUCTURES,
235
00:13:34,827 --> 00:13:38,586
SUCH AS A CLIMBING NET
MADE OF GALVANIZED STEEL CABLE.
236
00:13:38,586 --> 00:13:41,172
THE HARD CABLE
IS PADDED IN POLYURETHANE.
237
00:13:41,172 --> 00:13:43,103
WORKERS USE HYDRAULIC SCISSORS
238
00:13:43,103 --> 00:13:45,241
TO CUT THE REQUIRED LENGTHS
OF CABLE...
239
00:13:45,241 --> 00:13:46,620
THEN A CABLE STRIPPER
240
00:13:46,620 --> 00:13:49,655
TO SLICE OFF A LITTLE MORE
THAN AN INCH OF POLYURETHANE
241
00:13:49,655 --> 00:13:52,655
FROM THE ENDS OF CERTAIN CABLES.
242
00:13:52,655 --> 00:13:54,827
WORKERS THEN CAP
EACH EXPOSED END
243
00:13:54,827 --> 00:13:56,172
WITH A SLEEVED ALUMINUM RING.
244
00:13:56,172 --> 00:13:59,758
THEY CRIMP THE SLEEVE
WITH A 44-TON PRESS.
245
00:13:59,758 --> 00:14:01,413
THE RINGS WILL BE BOLTED
246
00:14:01,413 --> 00:14:04,068
TO THE PLAY STRUCTURE'S FRAME
AND ANCHORING SYSTEM.
247
00:14:06,551 --> 00:14:09,896
FINALLY, WORKERS ASSEMBLE
THE CABLES INTO A GRID,
248
00:14:09,896 --> 00:14:13,000
LOCKING EACH INTERSECTION
WITH A PLASTIC CONNECTOR.
249
00:14:13,000 --> 00:14:16,103
TO ENSURE THEY WON'T RUST
FROM EXPOSURE TO THE ELEMENTS,
250
00:14:16,103 --> 00:14:18,724
THE CONNECTORS'
CENTRAL SCREW AND CORNER RIVETS
251
00:14:18,724 --> 00:14:20,620
ARE MADE OF STAINLESS STEEL.
252
00:14:20,620 --> 00:14:24,655
ON THE MODULAR PLAY STRUCTURE,
THE CHILDREN WALK ON A PLATFORM.
253
00:14:24,655 --> 00:14:27,068
IT'S CONSTRUCTED
FROM THICK STEEL SHEETS,
254
00:14:27,068 --> 00:14:30,448
PERFORATED
BY A ROBOTIC LASER CUTTER.
255
00:14:30,448 --> 00:14:32,448
AFTER BENDING THE SHEET
IN A PRESS
256
00:14:32,448 --> 00:14:33,896
TO THE REQUIRED SHAPE --
257
00:14:33,896 --> 00:14:36,344
THIS IS THE CORNER SECTION
OF THE PLATFORM --
258
00:14:36,344 --> 00:14:38,965
WORKERS HEAT IT IN AN OVEN...
259
00:14:38,965 --> 00:14:42,000
THEN SUBMERGE IT
IN A VAT OF POLYVINYL,
260
00:14:42,000 --> 00:14:44,448
WHICH INSTANTLY ADHERES
TO THE HOT METAL.
261
00:14:48,793 --> 00:14:53,172
THEY BUILD UP A GOOD COAT --
ABOUT A 10th OF AN INCH THICK --
262
00:14:55,896 --> 00:14:58,655
THEN LET THE EXCESS DRIP OFF.
263
00:15:05,000 --> 00:15:08,482
THEY BLAST THE ENTIRE PIECE
WITH AN AIRGUN.
264
00:15:08,482 --> 00:15:09,724
THIS CLEARS THE HOLES
265
00:15:09,724 --> 00:15:12,206
AND PRODUCES A TEXTURED,
ANTI-SLIP SURFACE.
266
00:15:16,620 --> 00:15:19,482
SINCE PLAYGROUND EQUIPMENT
REMAINS OUTDOORS,
267
00:15:19,482 --> 00:15:22,000
ALL THE PAINTS AND PLASTICS
ARE U.V.-TREATED
268
00:15:22,000 --> 00:15:23,965
TO RESIST FADING.
269
00:15:25,310 --> 00:15:28,137
BESIDES BEING DURABLE,
THE EQUIPMENT IS DESIGNED
270
00:15:28,137 --> 00:15:30,655
TO MEET
ALL REQUIRED SAFETY STANDARDS
271
00:15:30,655 --> 00:15:33,034
SO THAT PARENTS
CAN HAVE PEACE OF MIND
272
00:15:33,034 --> 00:15:35,000
WHILE THEIR CHILDREN HAVE FUN.
273
00:15:50,517 --> 00:15:52,931
Narrator: FOOD JUST SLIDES OFF
NONSTICK COOKWARE'S
274
00:15:52,931 --> 00:15:55,344
REMARKABLY SLIPPERY SURFACE.
275
00:15:55,344 --> 00:15:58,034
IN 1938, AN AMERICAN CHEMIST
276
00:15:58,034 --> 00:16:00,551
WAS EXPERIMENTING
WITH REFRIGERATION GASES.
277
00:16:00,551 --> 00:16:02,482
A WAXY SUBSTANCE FORMED.
278
00:16:02,482 --> 00:16:04,965
YEARS LATER,
WHEN BONDED TO COOKWARE,
279
00:16:04,965 --> 00:16:07,379
IT GAINED A NONSTICK REPUTATION.
280
00:16:10,655 --> 00:16:12,275
WHEN IT'S TIME TO FRY,
281
00:16:12,275 --> 00:16:15,620
USING A NONSTICK PAN
AVERTS A MESSY SITUATION.
282
00:16:15,620 --> 00:16:17,000
THE NONSTICK COATING
283
00:16:17,000 --> 00:16:19,965
IS ONE OF THE SLIPPERIEST
SOLID MATERIALS ON EARTH.
284
00:16:19,965 --> 00:16:22,517
CALLED POLYTETRAFLUOROETHYLENE,
285
00:16:22,517 --> 00:16:26,482
THE NAME IS A BIT OF A MOUTHFUL,
BUT THE APPEAL IS SIMPLE.
286
00:16:26,482 --> 00:16:30,034
FOOD WON'T GET STUCK
ON THIS NONSTICK SURFACE.
287
00:16:30,034 --> 00:16:34,517
TO MAKE THE ALUMINUM PAN,
THEY USE 70% RAW MATERIAL
288
00:16:34,517 --> 00:16:38,620
AND 30% LEFTOVERS FROM PRIOR
PRODUCTION OF POTS AND PANS.
289
00:16:38,620 --> 00:16:40,413
THEY FIRE IT TO A MOLTEN STATE
290
00:16:40,413 --> 00:16:42,551
AND FILTER IT
TO REMOVE CONTAMINANTS.
291
00:16:42,551 --> 00:16:46,793
THE LIQUID ALUMINUM FLOWS
INTO VERTICAL RECTANGULAR MOLDS.
292
00:16:46,793 --> 00:16:48,965
A JACKET OF WATER
AROUND THE MOLDS
293
00:16:48,965 --> 00:16:52,724
COOLS THE ALUMINUM TO TAKE IT
FROM A LIQUID TO A SOLID.
294
00:16:52,724 --> 00:16:55,586
A CRANE EXTRACTS THE CAST SLABS.
295
00:16:55,586 --> 00:16:57,689
THEY'RE HEADING
TO A HEATING CHAMBER
296
00:16:57,689 --> 00:16:59,379
TO SOFTEN THE SLABS.
297
00:16:59,379 --> 00:17:02,724
THIS WILL ALLOW THE METAL
TO BE SHAPED AND FORMED.
298
00:17:02,724 --> 00:17:06,862
A SAW SLICES THE SLABS IN TWO
AND TRIMS THE ENDS.
299
00:17:06,862 --> 00:17:09,206
MORE BLADES SCRAPE THE TOP
AND BOTTOM
300
00:17:09,206 --> 00:17:11,068
TO REMOVE IMPURITIES.
301
00:17:11,068 --> 00:17:14,000
A CONVEYOR REPEATEDLY FEEDS
THE SHORTER SLABS
302
00:17:14,000 --> 00:17:15,551
TO HEATED ROLLERS.
303
00:17:15,551 --> 00:17:17,655
GUIDES AT THE SIDE
MAINTAIN THE WIDTH,
304
00:17:17,655 --> 00:17:19,862
WHILE THE ROLLERS COMPRESS
THE ALUMINUM,
305
00:17:19,862 --> 00:17:24,103
TAKING THE THICKNESS
DOWN TO ABOUT .2 OF AN INCH.
306
00:17:24,103 --> 00:17:27,620
THE ROLLING ALSO ELONGATES
THE SLAB SUBSTANTIALLY.
307
00:17:27,620 --> 00:17:30,241
IT STARTS OUT
AT 6 1/2 FEET LONG,
308
00:17:30,241 --> 00:17:32,103
AND AFTER A FEW MINUTES
OF ROLLING,
309
00:17:32,103 --> 00:17:35,551
IT'S BEEN STRETCHED
TO WELL OVER 100 YARDS.
310
00:17:37,000 --> 00:17:38,448
PIZZA-CUTTER-STYLE BLADES
311
00:17:38,448 --> 00:17:41,758
TRIM THE EDGES
OF THE ALUMINUM SHEET.
312
00:17:41,758 --> 00:17:45,724
ANOTHER ROLLER WINDS
THE ALUMINUM INTO A BIG COIL.
313
00:17:48,827 --> 00:17:50,206
THEY THEN UNWIND IT
314
00:17:50,206 --> 00:17:53,310
AND SQUEEZE THE ALUMINUM
TO FLATTEN IT.
315
00:17:53,310 --> 00:17:56,482
MACHINERY NOW PULLS
THE LONG ALUMINUM SHEET FORWARD
316
00:17:56,482 --> 00:17:59,827
TO A 132-TON PUNCH PRESS.
317
00:17:59,827 --> 00:18:02,172
THIS POWERFUL PRESS
FORCES THE METAL
318
00:18:02,172 --> 00:18:04,103
AROUND A FRYING-PAN-SHAPED DIE
319
00:18:04,103 --> 00:18:06,586
AND THEN PUNCHES OUT THE SHAPE.
320
00:18:06,586 --> 00:18:08,758
THE FRESHLY FORMED
ALUMINUM FRYING PAN
321
00:18:08,758 --> 00:18:11,482
FALLS ONTO A CONVEYOR BELOW.
322
00:18:11,482 --> 00:18:15,034
THE LEFTOVER ALUMINUM WILL BE
USED TO MAKE NEW FRYING PANS.
323
00:18:15,034 --> 00:18:18,448
THE PANS NOW RIDE A CONVEYOR
THROUGH A WASHING STATION,
324
00:18:18,448 --> 00:18:22,310
WHERE THEY'RE CLEANED AND THEN
TREATED WITH SODIUM HYDROXIDE.
325
00:18:22,310 --> 00:18:24,275
THIS OPENS THE PORES
OF THE METAL
326
00:18:24,275 --> 00:18:27,551
TO ALLOW AN ENAMEL COATING
TO STICK TO THE OUTSIDE
327
00:18:27,551 --> 00:18:31,620
AND THE NONSTICK FINISH
TO ADHERE TO THE INSIDE.
328
00:18:31,620 --> 00:18:33,310
A WORKER INSPECTS THE PANS
329
00:18:33,310 --> 00:18:36,517
AND PLACES THEM UPSIDE-DOWN
ON SPRAY FIXTURES.
330
00:18:36,517 --> 00:18:38,689
IT'S A TIGHT FIT
TO SHIELD THE INSIDE
331
00:18:38,689 --> 00:18:42,034
FROM THE ENAMEL SPRAY
THAT COMES NEXT.
332
00:18:42,034 --> 00:18:45,034
THE PANS SPIN ON THE FIXTURES
AND TWIRL BY THE SPRAY NOZZLES
333
00:18:45,034 --> 00:18:47,137
FOR AN EVEN APPLICATION
OF ENAMEL
334
00:18:47,137 --> 00:18:48,758
TO THE EXTERIOR OF THE PANS.
335
00:18:48,758 --> 00:18:52,448
A CLEAR, GLOSSY COAT FOLLOWS.
336
00:18:52,448 --> 00:18:55,448
THE FRYING PANS TRANSFER
TO A DRYER CONVEYOR.
337
00:18:55,448 --> 00:18:58,379
THE HOT AIR PULLS OUT WATER
FROM THE ENAMEL COATING,
338
00:18:58,379 --> 00:19:03,034
AND THE COLOR GOES FROM GRAY
TO CHALKY WHITE.
339
00:19:03,034 --> 00:19:04,620
AN AUTOMATED SQUEEGEE
340
00:19:04,620 --> 00:19:07,551
SILK-SCREENS THE COMPANY'S NAME
AND OTHER INFORMATION
341
00:19:07,551 --> 00:19:10,241
ONTO THE PAN BOTTOMS.
342
00:19:11,068 --> 00:19:13,034
THEY NOW ENTER
A LONG CURING OVEN
343
00:19:13,034 --> 00:19:16,448
HEATED TO 1,040 DEGREES
FAHRENHEIT.
344
00:19:16,448 --> 00:19:18,793
THE CURE TOUGHENS THE ENAMEL,
345
00:19:18,793 --> 00:19:21,206
DEEPENS THE COLOR
SO IT TURNS GRAY AGAIN,
346
00:19:21,206 --> 00:19:23,344
AND IT ADDS GLOSS.
347
00:19:23,344 --> 00:19:26,103
A SUCTIONING DEVICE
PICKS UP THE PAN
348
00:19:26,103 --> 00:19:28,931
AND TURNS IT AROUND
FOR THE INSIDE COATINGS.
349
00:19:28,931 --> 00:19:31,241
A SPRAYER APPLIES
A SPECIAL PRIMER
350
00:19:31,241 --> 00:19:34,310
THAT WILL MAKE THE NONSTICK
COATING ADHERE TO THE PAN.
351
00:19:34,310 --> 00:19:36,620
IT THEN APPLIES
THE NONSTICK COATING.
352
00:19:36,620 --> 00:19:38,620
THE PANS RECEIVE TWO LAYERS
353
00:19:38,620 --> 00:19:41,448
OF THIS NONSTICK
SYNTHETIC SUBSTANCE.
354
00:19:41,448 --> 00:19:43,551
THE SUCTIONING DEVICE
RELEASES THE PAN,
355
00:19:43,551 --> 00:19:46,172
AND IT LANDS UPSIDE DOWN.
356
00:19:46,172 --> 00:19:48,827
THEN THE PANS JOURNEY
THROUGH THE OVEN AGAIN
357
00:19:48,827 --> 00:19:50,689
TO CURE THE NONSTICK FINISH
358
00:19:50,689 --> 00:19:53,689
AT AROUND 800 DEGREES
FAHRENHEIT.
359
00:19:53,689 --> 00:19:55,965
ON EXIT, WATER RAINS DOWN
360
00:19:55,965 --> 00:19:59,344
TO COOL THE PANS
AND RINSE OFF ANY CONTAMINANTS.
361
00:19:59,344 --> 00:20:01,724
THEN THEY GO THROUGH
AN INFRARED-LIGHT CHAMBER
362
00:20:01,724 --> 00:20:03,517
TO DRY OFF.
363
00:20:03,517 --> 00:20:07,758
FROM A PLAIN SHELL TO A PAN WITH
AN ENAMEL FINISH ON THE OUTSIDE
364
00:20:07,758 --> 00:20:10,310
AND A NONSTICK COATING
ON THE INSIDE,
365
00:20:10,310 --> 00:20:13,413
THE TRANSFORMATION
HAS TAKEN JUST ONE HOUR.
366
00:20:13,413 --> 00:20:15,413
A WORKER NOW AIMS A LASER
367
00:20:15,413 --> 00:20:17,551
AND ALIGNS IT
WITH LETTERING ON THE BOTTOM,
368
00:20:17,551 --> 00:20:20,344
ALLOWING HIM TO PUNCH HOLES
IN A PRECISE LOCATION
369
00:20:20,344 --> 00:20:22,724
ON THE SIDE OF THE PAN.
370
00:20:22,724 --> 00:20:24,689
HE SLIDES PINS INTO THE HOLES
371
00:20:24,689 --> 00:20:27,931
AND SLOTS THEM THROUGH HOLES
IN THE HANDLE FITTING.
372
00:20:27,931 --> 00:20:30,172
USING A RAM,
HE FLATTENS THE PINS
373
00:20:30,172 --> 00:20:33,620
TO RIVET THE HANDLE TO THE PAN.
374
00:20:33,620 --> 00:20:38,655
NOW, NO MATTER WHAT'S COOKING,
CLEANUP SHOULD GO SMOOTHLY.
375
00:20:51,689 --> 00:20:54,206
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
376
00:20:54,206 --> 00:20:56,655
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
377
00:20:56,655 --> 00:20:58,655
DROP US A LINE AT...
378
00:20:59,758 --> 00:21:02,827
--Captions by VITAC--
www.vitac.com
379
00:21:02,827 --> 00:21:05,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
30299
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