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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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Wooden barrels...
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Fire hydrants...
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Automotive seats...
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And cathode-ray tubes.
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00:00:53,448 --> 00:00:56,862
In the old days, wooden barrels
Stored all kinds of goods,
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Simply because
They were easy to move.
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00:00:59,068 --> 00:01:02,241
If you couldn't lift them,
You could roll them.
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00:01:02,241 --> 00:01:05,482
Today modern machinery
Has made barrels obsolete,
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00:01:05,482 --> 00:01:08,482
Except for storing
Fine wine and spirits.
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00:01:08,482 --> 00:01:11,206
And so the time-honored
Tradition of barrel making
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Lives on.
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These wooden barrels
Are for storing whiskey.
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They're made
From american white oak
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Cut into pieces called staves.
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The staves go into a planer
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00:01:27,034 --> 00:01:29,000
That shaves them
To about an inch thick.
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00:01:31,413 --> 00:01:34,793
Next, a machine punches
Two quarter-inch holes
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On either side of each stave.
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Dowel pins made of hickory,
A very strong wood,
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Go into these holes
To hold the staves together.
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Workers take the staves,
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Place them on a guide,
And press them together.
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00:01:55,896 --> 00:02:00,586
A smaller piece
Completes the shape.
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00:02:00,586 --> 00:02:02,965
Now it's onto the rounder,
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00:02:02,965 --> 00:02:05,379
A machine that cuts it
Into a circular shape.
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00:02:05,379 --> 00:02:09,137
This creates the barrel's lid,
Or head, as it's called.
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00:02:09,137 --> 00:02:12,103
And each barrel requires two,
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One for the top
And one for the bottom.
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The barrel head
Now goes onto a contraption
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Called the char tunnel.
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00:02:19,551 --> 00:02:22,413
Its gas burners scorch the wood.
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00:02:22,413 --> 00:02:25,206
This charring not only changes
The wood's appearance,
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00:02:25,206 --> 00:02:28,137
It also gives color, flavor,
And aroma
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To the whiskey
This barrel will hold.
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The workers coat the head's edge
With liquid beeswax,
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Which helps them set it
Snugly into the barrel body.
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They run the staves against this
Machine to narrow their ends.
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This gives the barrel
Its characteristic shape,
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With a smaller radius
At the ends than in the middle.
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At the barrel-raising station,
A worker positions an iron hoop
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And starts to assemble
The barrel inside it.
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He selects staves
That vary in width
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In order to use
As few as possible.
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This reduces
The numbers of joints
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And potential leak points.
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He has to be gentle as he lassos
The barrel together.
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00:03:16,965 --> 00:03:19,344
If he pulls that dry wood
Too tight,
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It'll break into pieces.
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A loose hoop gives the wood
Room to expand.
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Next, the barrels pass through
A steam tunnel
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For about 15 minutes.
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This adds moisture to the wood
So it can flex without snapping.
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Workers pull out the barrel and
Remove the top and bottom hoops.
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Sturdier hoops replace them
And are hammered into place.
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Without them,
The barrel would spring apart.
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00:04:00,689 --> 00:04:03,758
Next, two more hoops
Around the body.
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00:04:03,758 --> 00:04:06,379
The wood groans
From the intense pressure
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That forces the staves together,
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But there can't be any gaps
Between the staves,
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00:04:11,103 --> 00:04:14,793
Or else the barrel will leak.
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The barrels pass over
A gas burner
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That blasts a flame inside
Each one to char its interior.
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Seconds later,
Water shoots into the barrel
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To put out the flames.
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00:04:27,655 --> 00:04:30,413
An automated saw
Cuts a v-shaped notch
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Into the top and bottom
Of each barrel.
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This is where the barrel head
Will slide in.
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A fan blows away the sawdust.
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Now a machine removes
The iron hoop on each end.
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A worker pours in a gallon
Of water to cool the barrel,
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00:04:49,689 --> 00:04:51,931
Still hot
From the charring process.
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Then he puts on a barrel head
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00:04:54,103 --> 00:04:57,689
And stronger, permanent
Iron hoops on both ends.
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Now machines remove
The two iron body hoops
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And replace them
With stronger ones.
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These barrels hold their shape
By sheer pressure.
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There's not a drop of glue
Holding them together.
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That gallon of water
Is still inside the barrel.
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Workers drill a hole
In the side,
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Then plug it by hammering in
A rubber stopper with a spout.
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An inspector checks the barrel
For leaks, stamps it approved,
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And labels it with a bar code
For inventory.
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Then they remove the stopper
And out comes the water,
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Turned to steam
Because of the heat.
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The barrels are now ready
To go on to the distillery,
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Where they'll get their fill
Of some fine kentucky whiskey.
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When we return, you see them
On every street corner,
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But how are they made?
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Narrator: fire hydrants
Have been in use
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For more than 200 years.
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In the old days,
Their main purpose
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00:06:06,896 --> 00:06:09,172
Was to supply water
To fight fires,
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00:06:09,172 --> 00:06:10,827
But they also provided
The public
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With a handy water supply.
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Today fire crews
Rely on the nearest hydrant
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To help them douse flames
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Whenever and wherever
They break out.
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Fire hydrants are essential
To every community.
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They need to be instantly
Recognizable, easily accessible,
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And simple to operate.
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The ones in residential areas
Are designed to deliver
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An impressive
1,500 gallons a minute.
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The hydrant-making process
Starts with recycled scrap iron,
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00:06:46,931 --> 00:06:49,275
Along with steel and raw iron.
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Using a magnetic crane,
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Workers load the metals
Into a furnace
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And melt them
At 2,800 degrees fahrenheit.
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This turns the scrap metal
Into molten iron.
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00:07:07,931 --> 00:07:09,448
This superhot mixture
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Is transferred into
A remote-controlled ladle...
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And emptied into
An automated pouring system.
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To cast the hydrants, workers
First make two-part molds
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By compressing a mixture
Of sand and bonding materials.
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One part, called the mold, forms
The hydrant's exterior shape,
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00:07:28,827 --> 00:07:32,413
While the other part, called the
Core, forms the interior shape.
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00:07:34,517 --> 00:07:38,517
An automatic core setter
Positions a core in each mold.
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00:07:41,275 --> 00:07:45,068
Then a conveyer advances
The mold under the pouring box,
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00:07:45,068 --> 00:07:47,482
Which fills the cavity
Between the mold and core
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00:07:47,482 --> 00:07:49,448
With molten iron.
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00:07:53,862 --> 00:07:56,689
After the iron cools
And solidifies,
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The molds enter
A tumbling barrel.
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As they revolve, the sand
Gradually disintegrates,
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Freeing the iron casting inside.
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00:08:07,379 --> 00:08:09,862
Workers drill and thread
The hydrant castings
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00:08:09,862 --> 00:08:11,724
To prepare them for assembly.
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00:08:16,482 --> 00:08:19,551
Then they preassemble
And paint them.
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00:08:28,448 --> 00:08:30,896
The fire hydrant's
Internal workings,
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Called the valve assembly,
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00:08:32,551 --> 00:08:35,482
Allow water to flow through
When the hydrant's open.
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00:08:39,655 --> 00:08:42,758
A series of rubber "O" rings
On the main valve
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00:08:42,758 --> 00:08:44,827
Will prevent leaks
When the hydrant is closed.
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00:08:47,862 --> 00:08:51,448
Now the hydrant is ready
For final assembly.
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Workers attach
The nozzle section
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00:08:58,068 --> 00:08:59,862
To the top of the hydrant barrel
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00:08:59,862 --> 00:09:03,931
And fasten nozzle cap chains
With a crimping tool.
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00:09:11,482 --> 00:09:15,896
Using a torque wrench, they
Attach cast-iron safety rings.
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00:09:15,896 --> 00:09:17,241
These rings are designed
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00:09:17,241 --> 00:09:19,931
To disengage the top
From the bottom of the hydrant
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00:09:19,931 --> 00:09:22,586
So it doesn't get damaged
If a vehicle hits it.
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00:09:24,586 --> 00:09:28,000
Workers clamp the water-main
Connector into place
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00:09:28,000 --> 00:09:30,655
And pressurize the hydrant
To normal city pressure
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00:09:30,655 --> 00:09:32,620
To check for leaks.
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00:09:35,034 --> 00:09:38,620
Using a hoist, they lower the
Preassembled nozzle section
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00:09:38,620 --> 00:09:40,000
Over the stem...
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00:09:43,965 --> 00:09:46,551
And fasten it
To the water-main connector
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With stainless steel bolts.
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00:09:53,724 --> 00:09:57,758
They lower the bonnet
Into place...
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Bolt it to the nozzle section...
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00:10:01,551 --> 00:10:05,379
Then open the hydrant
For a high-pressure test.
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They turn the operating nut
To allow water to flow through.
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00:10:16,862 --> 00:10:19,379
But first, they have to
Force out the air
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Inside the hydrant with water.
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00:10:34,931 --> 00:10:37,655
Workers transfer
The finished hydrant to a pallet
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00:10:37,655 --> 00:10:40,241
And apply final paint touch-ups.
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Some fire hydrants
That were installed
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00:10:49,344 --> 00:10:53,103
More than 100 years ago
Are still in use today.
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Coming up, it's a cushy job,
But somebody's got to do it.
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Narrator: most people
Don't pay too much attention
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To car seating, but this feature
Has come a long way
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Since the car was invented
In the 19th century.
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Back then, seats had no springs
And not much padding.
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00:11:18,827 --> 00:11:22,034
So you could feel
Every bump on the road.
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00:11:22,034 --> 00:11:25,896
In today's car seats,
We have a much easier ride.
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00:11:30,344 --> 00:11:33,275
Padded and belted,
Modern automotive seats
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00:11:33,275 --> 00:11:36,103
Are designed to be safe
And comfortable.
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The components
Are manufactured separately
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00:11:38,827 --> 00:11:41,689
And shipped to this factory
For assembly.
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They arrive as needed
On the production line
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So there's not
A lot of stockpiling.
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It means the flow of parts
Into this plant
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Has to be highly organized
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Because they make
Over 400 seat variations here.
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The parts are carted
To the assembly line
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00:12:01,827 --> 00:12:03,827
In the order they're needed.
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00:12:06,482 --> 00:12:09,724
On this assembly line,
There are 60 workers,
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Each with specific tasks
To perform.
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00:12:14,586 --> 00:12:17,965
They receive a build ticket
For each part and scan it.
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00:12:17,965 --> 00:12:21,172
This allows a central computer
To track production
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00:12:21,172 --> 00:12:23,413
And verify that the right parts
Are being used
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00:12:23,413 --> 00:12:25,379
To build the right seat.
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00:12:27,275 --> 00:12:30,793
An operator tucks
The seat-warmer pad and cables
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00:12:30,793 --> 00:12:34,793
Into the cushioning
For the bottom half of the seat.
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00:12:34,793 --> 00:12:37,965
She loosely places the fabric
Cover over the assembly
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00:12:37,965 --> 00:12:40,551
And attaches it with wire.
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00:12:44,275 --> 00:12:46,827
Then it's over
To the next station,
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00:12:46,827 --> 00:12:49,586
Where the operator completes
The upholstery job.
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00:12:49,586 --> 00:12:53,827
Each worker has just 88 seconds
To perform his or her tasks,
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00:12:53,827 --> 00:12:57,310
So there's no sitting down
On this job.
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00:12:57,310 --> 00:12:59,275
They install
A seat-warmer system
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00:12:59,275 --> 00:13:03,758
On the backrest section
Of the seat and cover it.
194
00:13:03,758 --> 00:13:08,000
Then they slide an air bag
Into a special sleeve.
195
00:13:12,689 --> 00:13:14,724
These seats come with springs
196
00:13:14,724 --> 00:13:16,448
That clip on
To their metal framework
197
00:13:16,448 --> 00:13:18,896
To provide lumbar support.
198
00:13:22,965 --> 00:13:26,137
Workers fit the cushion assembly
Onto the spring framework
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00:13:26,137 --> 00:13:27,827
And pull it tight.
200
00:13:35,413 --> 00:13:39,206
They smooth out any wrinkles,
A process called finessing.
201
00:13:39,206 --> 00:13:41,137
Then they install the headrest.
202
00:13:43,758 --> 00:13:46,758
Next they tackle
The lower framework.
203
00:13:46,758 --> 00:13:48,448
They equip it with a mechanism
204
00:13:48,448 --> 00:13:52,068
That adjusts
The height of the seat.
205
00:13:52,068 --> 00:13:55,448
Electrical connectors
Go in next.
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00:13:59,413 --> 00:14:02,103
Then they bolt
The lower framework
207
00:14:02,103 --> 00:14:04,000
To the cushioned backrest.
208
00:14:06,344 --> 00:14:08,689
They attach
The pretensioner apparatus,
209
00:14:08,689 --> 00:14:10,758
Which locks the seat belt
Into position,
210
00:14:10,758 --> 00:14:13,034
Then wire the connector box.
211
00:14:13,034 --> 00:14:16,034
They fit the lower cushioning
On the framework
212
00:14:16,034 --> 00:14:18,413
And add the recliner spring.
213
00:14:20,241 --> 00:14:23,034
A plastic valance
Makes it all look neater.
214
00:14:25,517 --> 00:14:29,413
Now it's time to take this
Driver's seat for a test run.
215
00:14:31,379 --> 00:14:34,137
Inspectors hook it up
To a power source
216
00:14:34,137 --> 00:14:38,172
And make sure the air bag
And seat warmer are operational.
217
00:14:40,517 --> 00:14:42,551
They iron out all the wrinkles
218
00:14:42,551 --> 00:14:45,000
Because the automaker
Will reject any seat
219
00:14:45,000 --> 00:14:47,448
That's less than perfect.
220
00:14:47,448 --> 00:14:49,931
Then they slide
And tilt the seat
221
00:14:49,931 --> 00:14:53,344
To make sure the adjustment
Mechanisms are working properly.
222
00:14:57,482 --> 00:15:01,551
Workers assemble the rear seats
Using the same techniques.
223
00:15:01,551 --> 00:15:05,103
Again, each operator
Gets exactly 88 seconds
224
00:15:05,103 --> 00:15:07,172
To complete his or her job.
225
00:15:07,172 --> 00:15:08,620
When you add it all up,
226
00:15:08,620 --> 00:15:12,724
An entire seat set takes
Just 62 minutes to assemble.
227
00:15:18,862 --> 00:15:22,068
Before they ship
The seat set to the car factory,
228
00:15:22,068 --> 00:15:24,344
They snap a photo
As a production record.
229
00:15:24,344 --> 00:15:26,896
It proves each set
Was in perfect condition
230
00:15:26,896 --> 00:15:28,689
When it left the factory.
231
00:15:33,068 --> 00:15:36,517
Now these seats
Are ready to hit the road.
232
00:15:39,931 --> 00:15:42,206
Workers strap them
Onto delivery pallets
233
00:15:42,206 --> 00:15:46,310
And load them into a big truck,
60 sets at a time.
234
00:15:47,965 --> 00:15:50,241
They'll arrive at the car plant
235
00:15:50,241 --> 00:15:52,137
Just as the vehicles
They were made for
236
00:15:52,137 --> 00:15:54,655
Are rolling off
The assembly line.
237
00:15:54,655 --> 00:15:56,275
Once they're installed,
238
00:15:56,275 --> 00:16:00,413
All you need to do
Is sit back and enjoy the ride.
239
00:16:06,137 --> 00:16:09,931
Next, making the tubes
That bring tvs to life.
240
00:16:15,379 --> 00:16:18,275
Narrator: the crt,
Short for cathode-ray tube,
241
00:16:18,275 --> 00:16:20,275
Produces the image that we see
242
00:16:20,275 --> 00:16:22,793
On our tvs
And computer monitors --
243
00:16:22,793 --> 00:16:25,862
The ones that aren't
Lcd or plasma, that is.
244
00:16:25,862 --> 00:16:27,517
Believe it or not,
245
00:16:27,517 --> 00:16:31,793
The cathode-ray tube
Was invented back in 1879.
246
00:16:34,068 --> 00:16:37,206
A crt is made up
Of two main components,
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A large glass bulb
And an electric gun.
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Crts start
With a molded glass bulb.
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00:16:43,517 --> 00:16:46,137
Workers remove
Microscopic debris
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00:16:46,137 --> 00:16:48,103
With a high-pressure
Water rinse.
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00:16:58,965 --> 00:17:01,206
Then they spray
Hydrofluoric acid
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00:17:01,206 --> 00:17:04,482
To clean the glass
At an atomic level.
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00:17:09,000 --> 00:17:11,724
Phosphor solution
Is poured into the bulb.
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00:17:11,724 --> 00:17:14,896
Phosphor is an organic compound
That emits light
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00:17:14,896 --> 00:17:16,931
When struck by electrons.
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00:17:16,931 --> 00:17:18,931
The phosphor particles settle
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00:17:18,931 --> 00:17:21,724
And form a chemical bond
With the bulb face.
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00:17:22,827 --> 00:17:25,689
Workers pour off
The excess solution...
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00:17:27,379 --> 00:17:29,586
And clamp the bulb over a nozzle
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00:17:29,586 --> 00:17:32,310
That sprays clear lacquer
Over the phosphor.
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00:17:35,586 --> 00:17:39,034
The centrifugal force
Guarantees an even coat.
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00:17:47,206 --> 00:17:50,241
This worker paints a conductive
Coating over the anode button
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00:17:50,241 --> 00:17:53,034
Which will provide a flow path
For the electrons
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00:17:53,034 --> 00:17:55,517
That will light up
The phosphor particles.
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00:18:23,000 --> 00:18:26,413
Meanwhile, another worker
Drops an aluminum pellet
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00:18:26,413 --> 00:18:28,241
Into a tungsten coil.
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00:18:28,241 --> 00:18:33,034
He places the bulb over a vacuum
Device and draws out the air.
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00:18:35,448 --> 00:18:38,758
Then he applies an electrical
Current to the coil.
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00:18:38,758 --> 00:18:41,758
It evaporates
The aluminum pellet,
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00:18:41,758 --> 00:18:43,379
Which spreads
A mirrorlike coating
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00:18:43,379 --> 00:18:45,551
On the inside of the bulb.
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00:18:48,896 --> 00:18:54,310
Now they heat the bulb to 425
Degrees fahrenheit for one hour.
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00:18:54,310 --> 00:18:58,000
This bakes out the lacquer
And any trace of moisture.
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00:19:03,655 --> 00:19:05,586
Using a high-temperature flame,
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00:19:05,586 --> 00:19:09,379
A worker aligns and fuses
A glass neck to the bulb.
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00:19:14,413 --> 00:19:17,689
Then he paints it with the same
Conductive coating.
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00:19:24,000 --> 00:19:26,344
This assembly
Is part of the electron gun
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00:19:26,344 --> 00:19:28,103
That goes inside the bulb.
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00:19:28,103 --> 00:19:31,034
It shoots electrons
At the bulb's phosphor particles
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00:19:31,034 --> 00:19:32,103
That lights them up,
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00:19:32,103 --> 00:19:35,103
Creating the image
We see on screen.
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00:19:36,517 --> 00:19:38,137
Workers stack the grip cups
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00:19:38,137 --> 00:19:40,344
That focus the electrons
On the screen.
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00:19:40,344 --> 00:19:42,206
Then, using beading glass,
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00:19:42,206 --> 00:19:45,034
They align and fuse them
Into position.
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00:19:48,586 --> 00:19:51,206
Robots heat
And affix the beading glass
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00:19:51,206 --> 00:19:54,344
To assemble
The electron-gun components.
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00:19:54,344 --> 00:19:57,965
Then the gun is cooled
With pressurized air.
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00:20:01,172 --> 00:20:03,724
Once cool,
A worker builds up the gun
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00:20:03,724 --> 00:20:07,000
And inserts the completed gun
Assembly into the bulb.
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00:20:14,620 --> 00:20:18,413
Next he positions the bulb
On a glass-blowing lathe
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00:20:18,413 --> 00:20:22,655
And cuts excess glass
From the neck.
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00:20:22,655 --> 00:20:25,827
Using a graphite paddle
And a high-temperature torch,
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00:20:25,827 --> 00:20:29,448
He mates the glass neck
To the electron-gun stem.
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00:20:35,586 --> 00:20:39,241
This ceramic heating coil
Melts that green glass pellet
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00:20:39,241 --> 00:20:41,344
To keep the bulb under vacuum.
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00:20:41,344 --> 00:20:44,862
The tube is heated
To 750 degrees fahrenheit
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00:20:44,862 --> 00:20:48,241
For two hours, and once again
A vacuum is drawn.
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00:20:48,241 --> 00:20:51,758
To minimize image flicker
Over the tube's life-span,
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00:20:51,758 --> 00:20:55,137
Workers condition the bulb
Using a high-voltage coil.
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00:20:55,137 --> 00:20:57,034
It smoothes any rough surfaces
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00:20:57,034 --> 00:21:00,517
That might remain
On the electron gun.
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00:21:00,517 --> 00:21:03,482
Finally, workers apply
Electrical connections
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00:21:03,482 --> 00:21:07,724
To the electron gun to bring
The cathode-ray tube to life.
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00:21:13,517 --> 00:21:15,620
If you have any comments
About the show,
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00:21:15,620 --> 00:21:18,379
Or if you'd like to suggest
Topics for future shows,
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00:21:18,379 --> 00:21:20,034
Drop us a line at...
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