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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: to contain
The sounds of traffic,
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00:00:55,206 --> 00:00:58,586
It's often necessary
To put up a wall of silence.
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Noise-barrier walls
Both absorb traffic noise
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00:01:02,034 --> 00:01:04,482
And shield neighborhoods
From it.
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00:01:04,586 --> 00:01:07,758
With stone or brick-like
Textures on both sides,
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They even look good
On the street.
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00:01:14,206 --> 00:01:16,103
In the 1970s,
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Noise-barrier walls
Were mainly drab concrete.
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00:01:19,758 --> 00:01:21,482
Fast forward to today,
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00:01:21,586 --> 00:01:24,482
And the walls come in a range
Of textures and designs
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00:01:24,586 --> 00:01:26,655
For curb appeal.
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But of course, it's
Their noise-absorbing qualities
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That really improve
The neighborhood.
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00:01:32,379 --> 00:01:33,655
They're made from a wood shaving
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00:01:33,758 --> 00:01:36,034
And cement material
That's very porous,
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Which allows the walls
To absorb sound and entrap it.
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Production starts
With the raw shavings.
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A conveyor delivers them
To a hammer mill.
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Inside, rotating hammers
Force the wood shavings
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00:01:49,620 --> 00:01:51,793
Through a cutting screen.
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This carves them
Into smaller particles
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Of various sizes.
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00:02:02,379 --> 00:02:03,931
It's this combination of sizes
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00:02:04,034 --> 00:02:06,620
That will create
The noise-absorbing pores
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00:02:06,724 --> 00:02:08,448
In the completed wall.
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00:02:11,448 --> 00:02:14,034
They test
A proprietary chemical solution,
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00:02:14,137 --> 00:02:16,379
That will be used
To treat the wood particles,
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00:02:16,482 --> 00:02:19,931
And confirm
It's the right concentration.
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00:02:20,034 --> 00:02:22,896
An auger then mixes it
Into the wood particles
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00:02:23,000 --> 00:02:25,827
Until they're damp
And thoroughly coated.
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Without this treatment,
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00:02:27,310 --> 00:02:30,448
The wood particles
Wouldn't bind with cement.
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00:02:30,551 --> 00:02:33,413
It will also protect the wood
From decay.
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00:02:35,517 --> 00:02:38,793
In another mixer, they add water
And a second chemical solution
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00:02:38,896 --> 00:02:42,310
To further enhance
The binding process.
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The wood particles are now
Primed and ready to be mixed
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00:02:50,793 --> 00:02:56,310
With a powdered mix of limestone
Clay called portland cement.
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00:02:56,413 --> 00:02:58,034
The machine
Works the ingredients
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Until they form
A cohesive material
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00:03:00,448 --> 00:03:02,137
That can be shaped.
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00:03:08,793 --> 00:03:10,689
The next worker
Sprays a release agent
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00:03:10,793 --> 00:03:12,931
Onto the stone-pattern liner.
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00:03:15,413 --> 00:03:19,448
Each mold will form
One noise barrier panel.
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00:03:19,551 --> 00:03:22,034
The team transfers
The wood-and-cement blend
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Into the mold.
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00:03:23,724 --> 00:03:25,068
They work at a steady pace
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00:03:25,172 --> 00:03:28,206
To fill it before the mixture
Begins to dry.
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00:03:33,310 --> 00:03:35,000
Once they've filled it partway,
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00:03:35,103 --> 00:03:37,448
They level
The wood-cement material...
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00:03:39,586 --> 00:03:42,034
...Then compact it
With a tamping tool.
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00:03:43,862 --> 00:03:46,413
Next, they add a steel mesh.
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This mesh will serve
As a skeleton,
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Allowing the wall
To stand strong.
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00:03:52,000 --> 00:03:55,482
They pour freshly mixed concrete
Onto the steel mesh.
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It flows through the mesh
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00:03:57,103 --> 00:03:59,758
And onto the sound-absorbing
Mixture below,
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Binding the two layers together.
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00:04:02,586 --> 00:04:05,724
The worker spreads the concrete
Throughout the mold.
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00:04:07,413 --> 00:04:10,896
He pierces the surface
With a vibrating tool.
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00:04:11,000 --> 00:04:13,517
The vibrations
Consolidate the concrete
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00:04:13,620 --> 00:04:15,758
And eliminate air pockets.
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00:04:17,517 --> 00:04:19,034
The two-person team levels
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00:04:19,137 --> 00:04:22,172
The concrete layer
Using a wood screed.
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00:04:30,724 --> 00:04:35,172
They apply a second layer
Of the noise-absorbing material
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00:04:35,275 --> 00:04:37,103
And level it.
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00:04:46,379 --> 00:04:48,551
They lower
The stone-pattern press lid,
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00:04:48,655 --> 00:04:52,000
Which will mold the pattern
Onto the top side of the panel.
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00:04:54,551 --> 00:04:57,413
They set a 10-ton concrete block
On the mold,
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00:04:57,517 --> 00:04:59,379
And pressure forces
The mold patterns
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Onto both sides of the casting.
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00:05:05,275 --> 00:05:06,793
After a few minutes,
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They remove the lid,
And the imprint is revealed.
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00:05:11,517 --> 00:05:14,586
They quickly cover the panel
Surface with a plastic sheet
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00:05:14,689 --> 00:05:17,000
To prevent any evaporation
Of moisture
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00:05:17,103 --> 00:05:19,206
As the cure continues.
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00:05:19,310 --> 00:05:21,172
If the blend cures too quickly,
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00:05:21,275 --> 00:05:23,413
It could crack.
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After another day,
They remove the tarp
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00:05:25,965 --> 00:05:29,000
And they're ready to extract
The panel from the mold.
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A crane lifts the panel
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And sets it aside
To cure for about a month.
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Built panel by panel,
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These noise-barrier walls can
Become a substantial fortress,
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00:05:45,172 --> 00:05:48,758
Providing a solid defense
Against noise pollution.
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Narrator:
Front-loading washing machines
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Use far less water
Than standard washers.
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00:06:07,103 --> 00:06:09,793
They're gentler on clothes
Because there's no agitator
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00:06:09,896 --> 00:06:12,034
In the middle of the drum.
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00:06:12,137 --> 00:06:13,551
The spin speed is usually
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00:06:13,655 --> 00:06:17,034
About 20 percent faster than
The standard top-load machine,
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00:06:17,137 --> 00:06:19,931
So the clothes
Come out of the wash drier.
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00:06:23,482 --> 00:06:27,000
With gravity helping tumble
The laundry, a front-load washer
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00:06:27,103 --> 00:06:30,965
Is gentler on the clothes
While using less water.
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00:06:31,068 --> 00:06:34,724
Its design can also accommodate
A larger-capacity drum,
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00:06:34,827 --> 00:06:37,000
So you can do bigger loads.
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00:06:37,103 --> 00:06:39,551
The washer's cabinet
Is made of steel.
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00:06:39,655 --> 00:06:42,931
A washing machine is routinely
Exposed to moisture,
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00:06:43,034 --> 00:06:47,275
So they use galvanized steel,
Which doesn't rust.
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00:06:47,379 --> 00:06:50,482
The cabinet base is comprised
Of four pieces,
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Which, together,
Provide more structural strength
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00:06:53,344 --> 00:06:54,896
Than a single piece would.
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00:06:55,000 --> 00:06:58,551
At the corners, workers install
Four screw-in rubber feet
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Which are height-adjustable.
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00:07:00,241 --> 00:07:03,620
This allows the washer
To level on an uneven floor.
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00:07:03,724 --> 00:07:05,827
Next are the two side panels.
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00:07:05,931 --> 00:07:09,068
They are already stamped
To the required shape in a press
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00:07:09,172 --> 00:07:11,310
And coated with baked-on paint.
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00:07:11,413 --> 00:07:14,827
This automated machine installs
Brackets on the inner side
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For mounting components
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Later on.
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00:07:17,448 --> 00:07:20,103
The next automated machine
Attaches the side panels
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00:07:20,206 --> 00:07:21,724
To the cabinet.
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00:07:21,827 --> 00:07:23,517
Rather than welding the edges,
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Which would ruin
The paint finish,
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The machine's punch tools
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00:07:26,827 --> 00:07:29,551
Mechanically
Lock them to the base.
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00:07:29,655 --> 00:07:34,034
A robot then transfers the
Cabinet to the assembly line.
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00:07:35,241 --> 00:07:37,137
Here, workers
Connect the side panels
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00:07:37,241 --> 00:07:39,965
With a structural support
Bracket and power cord,
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00:07:40,068 --> 00:07:41,827
Already installed on it.
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00:07:41,931 --> 00:07:43,517
Workers prepare the rear portion
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00:07:43,620 --> 00:07:46,137
Of the machine's
Two-piece plastic tub.
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00:07:46,241 --> 00:07:50,103
First, a robot mounts
A steel bearing on a press.
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00:07:50,206 --> 00:07:51,827
The press then
Forces the bearing
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00:07:51,931 --> 00:07:55,344
Into a hole at the bottom
Of the inside of the tub.
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00:07:55,448 --> 00:07:59,551
Then the process is repeated
But on the outside of the tub.
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00:07:59,655 --> 00:08:02,689
This pair of bearings
Seals the hole to prevent leaks,
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00:08:02,793 --> 00:08:06,413
And enables the stainless-steel
Wash drum to spin.
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00:08:08,448 --> 00:08:10,655
To counterbalance
The spinning load,
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00:08:10,758 --> 00:08:13,482
They weight the front
Of the drum with a plastic ring,
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00:08:13,586 --> 00:08:17,827
Containing heavy steel balls
Suspended in fluid.
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00:08:17,931 --> 00:08:20,344
Then, they insert the shaft
At the base of the drum
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00:08:20,448 --> 00:08:22,103
Into the tub's bearings
136
00:08:22,206 --> 00:08:24,551
And cover the top of the drum
With the front section
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00:08:24,655 --> 00:08:25,862
Of the tub.
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00:08:25,965 --> 00:08:28,689
It has a rubber gasket
Called a bellow.
139
00:08:28,793 --> 00:08:32,827
The bellow forms a leak-proof
Seal around the drum.
140
00:08:32,931 --> 00:08:35,172
After welding the tub sections
Together,
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00:08:35,275 --> 00:08:37,965
They mount the washer's motor
To the rear.
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00:08:38,068 --> 00:08:41,551
In this stator-rotor motor,
The electric current travels
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00:08:41,655 --> 00:08:44,482
Through the coiled copper wires
Of the motor's stator,
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00:08:44,586 --> 00:08:47,620
Generating pulses
Of electricity.
145
00:08:47,724 --> 00:08:51,137
Those pulses push on magnets
Lining the motor's rotor,
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00:08:51,241 --> 00:08:53,310
Positioned on top.
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00:08:53,413 --> 00:08:55,275
The magnets repel the pulses,
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00:08:55,379 --> 00:08:57,068
And this repeated
Pulse repelling
149
00:08:57,172 --> 00:09:01,655
Drives the drum in the direction
And speed required.
150
00:09:01,758 --> 00:09:05,896
Next, they install a drain hose
On the side of the tub
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00:09:06,000 --> 00:09:08,275
And attach it
With a retainer clip.
152
00:09:10,379 --> 00:09:13,793
They bolt a piece of concrete to
Either side of the drum opening
153
00:09:13,896 --> 00:09:17,172
To counterbalance the weight
Of the motor on the back.
154
00:09:17,275 --> 00:09:20,689
Then, they turn the now-complete
Wash unit on its side
155
00:09:20,793 --> 00:09:23,000
And install it in the cabinet.
156
00:09:26,310 --> 00:09:29,896
Next, they mount the drain pump
In the cabinet base
157
00:09:30,000 --> 00:09:31,827
And connect its wiring.
158
00:09:31,931 --> 00:09:36,137
The pump's job is to remove
Dirty water from the tub.
159
00:09:38,034 --> 00:09:40,034
Four shock absorbers
Are installed
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00:09:40,137 --> 00:09:43,793
Between the bottom
Of the wash unit and the base.
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00:09:43,896 --> 00:09:46,655
These large pistons dampen
Much of the vibration
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00:09:46,758 --> 00:09:49,172
During the wash and spin cycles.
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00:09:50,586 --> 00:09:52,172
Next, the front panel.
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00:09:52,275 --> 00:09:54,655
Like the sides,
It's made of a stamped sheet
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00:09:54,758 --> 00:09:58,068
Of galvanized steel
With a baked-on paint finish.
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00:09:59,655 --> 00:10:01,413
They install and connect
The console,
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00:10:01,517 --> 00:10:04,517
Which houses the machine's
Central control module.
168
00:10:07,482 --> 00:10:10,620
They pull the bellow on the drum
All around the front opening
169
00:10:10,724 --> 00:10:12,551
To seal the perimeter.
170
00:10:16,551 --> 00:10:20,344
They secure it in place
With a wire retainer clip.
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00:10:25,344 --> 00:10:28,517
The hinged door has
A see-through plastic window.
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00:10:28,620 --> 00:10:30,931
Like the rest
Of the machine's metal parts,
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00:10:31,034 --> 00:10:33,620
The door panel
And hardware attaching it
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00:10:33,724 --> 00:10:37,310
Are also made
Of galvanized steel.
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00:10:37,413 --> 00:10:39,758
The back panel
Is left unpainted.
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00:10:39,862 --> 00:10:42,310
After feeding the power cord
Through its hole,
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00:10:42,413 --> 00:10:46,310
Workers screw the panel
To the rest of the cabinet.
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00:10:46,413 --> 00:10:49,000
Then, they complete the cabinet
With the top panel,
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00:10:49,103 --> 00:10:51,551
Which has the baked-on paint
Finish.
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00:10:53,379 --> 00:10:54,827
The front-load washing machine
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00:10:54,931 --> 00:10:59,000
Is now all set
And ready for its first load.
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Narrator: bourbon whiskey
Is uniquely american.
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00:11:10,793 --> 00:11:13,310
The u.S. Congress
Officially recognized it
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00:11:13,413 --> 00:11:15,413
As a product
Distinct to the nation.
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00:11:15,517 --> 00:11:17,862
This amber-hued brew
Was first cooked up
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00:11:17,965 --> 00:11:22,413
By scottish and irish settlers
In late 18th century kentucky.
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00:11:22,517 --> 00:11:24,655
Today,
Production continues there
188
00:11:24,758 --> 00:11:26,896
With the approval of congress.
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00:11:29,068 --> 00:11:32,241
The american government
Regulates the making of bourbon
190
00:11:32,344 --> 00:11:35,862
To keep this native spirit
True to tradition.
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00:11:35,965 --> 00:11:37,689
By law, it must be made
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00:11:37,793 --> 00:11:41,724
From a grain mix
That's at least 51% corn.
193
00:11:41,827 --> 00:11:45,689
Distillers
Often use more for flavor.
194
00:11:45,793 --> 00:11:49,068
Shakers sift out cobs
Or other foreign material,
195
00:11:49,172 --> 00:11:52,379
And the kernels
Head into a grinder.
196
00:11:52,482 --> 00:11:54,931
Inside,
Rollers crush the kernels
197
00:11:55,034 --> 00:11:57,586
To release
The flavor of the starch.
198
00:11:57,689 --> 00:12:01,758
The process leaves larger chunks
Of the corn germ and husks.
199
00:12:01,862 --> 00:12:05,000
Once distilled,
These bits will settle out.
200
00:12:06,965 --> 00:12:08,931
In separate batches, the machine
201
00:12:09,034 --> 00:12:13,724
Also grinds malted barley
And soft red winter wheat.
202
00:12:15,137 --> 00:12:16,724
They cook the corn and blend it
203
00:12:16,827 --> 00:12:20,758
With limestone-rich,
Iron-free kentucky water.
204
00:12:20,862 --> 00:12:22,965
They add the barley,
Winter wheat,
205
00:12:23,068 --> 00:12:26,000
And a bit of mash
From a previous batch.
206
00:12:28,068 --> 00:12:31,241
Along with a special yeast
Formulation, the grain mash
207
00:12:31,344 --> 00:12:34,551
Flows into fermentation tanks
Made of cypress wood.
208
00:12:37,034 --> 00:12:40,551
After 8 to 10 hours,
The yeast works its magic
209
00:12:40,655 --> 00:12:43,931
And the mash
Becomes a bubbling brew.
210
00:12:46,172 --> 00:12:47,344
The bubbling is caused
211
00:12:47,448 --> 00:12:49,965
By the release
Of carbon-dioxide gas
212
00:12:50,068 --> 00:12:53,931
As the grain sugars ferment
And become alcohol.
213
00:12:54,034 --> 00:12:55,275
After three days,
214
00:12:55,379 --> 00:12:57,137
It has fermented
Into a thick liquid
215
00:12:57,241 --> 00:12:59,344
They call 'distiller's beer."
216
00:13:01,068 --> 00:13:05,172
They pump it into a column still
Which boils off the alcohol,
217
00:13:05,275 --> 00:13:08,310
Leaving water
And other substances behind.
218
00:13:08,413 --> 00:13:11,827
The alcoholic vapor rises up
To be condensed into liquid.
219
00:13:11,931 --> 00:13:14,896
After distilling it
A second time,
220
00:13:15,000 --> 00:13:19,689
The alcohol concentration
Rises to a strong 130 proof.
221
00:13:23,103 --> 00:13:26,034
It's clear,
With no noticeable color.
222
00:13:26,137 --> 00:13:28,620
At this stage,
They call it "White dog."
223
00:13:29,862 --> 00:13:32,137
Once water has been added
To dilute the whiskey
224
00:13:32,241 --> 00:13:34,068
To 110 proof,
225
00:13:34,172 --> 00:13:38,827
An employee takes a sample
And sends it to the lab.
226
00:13:38,931 --> 00:13:42,241
There, a technician places
A test tube of the alcohol
227
00:13:42,344 --> 00:13:45,206
Into a gas chromatograph tester.
228
00:13:47,862 --> 00:13:49,724
It vaporizes the alcohol
229
00:13:49,827 --> 00:13:53,862
And then analyzes the flavor
Compounds and alcohol strength.
230
00:13:55,758 --> 00:13:57,655
With approval from the lab,
231
00:13:57,758 --> 00:14:00,931
They're ready
To barrel the batch.
232
00:14:01,034 --> 00:14:04,000
They pump it out of storage
Tanks and into new oak barrels
233
00:14:04,103 --> 00:14:08,413
That have been purposely charred
On the inside.
234
00:14:08,517 --> 00:14:11,482
Charring caramelizes
Naturally occurring wood sugars
235
00:14:11,586 --> 00:14:15,965
To add sweetness
To the alcohol as it ages.
236
00:14:16,068 --> 00:14:19,655
It will also turn the clear
Alcohol an amber color.
237
00:14:23,275 --> 00:14:25,689
Once corked
With a walnut stopper,
238
00:14:25,793 --> 00:14:30,862
The employee rolls the barrel
Into a multi-tiered warehouse.
239
00:14:30,965 --> 00:14:33,758
Here, the bourbon
Will age for many years.
240
00:14:33,862 --> 00:14:35,172
Partway through,
241
00:14:35,275 --> 00:14:37,379
They'll move the barrel
To another level of the building
242
00:14:37,482 --> 00:14:39,931
Due to temperature variations.
243
00:14:40,034 --> 00:14:43,655
This will make the product
More consistent.
244
00:14:43,758 --> 00:14:45,862
After six to seven years,
245
00:14:45,965 --> 00:14:48,931
They uncork the stopper
And insert steel tubes
246
00:14:49,034 --> 00:14:51,241
To draw in ambient air.
247
00:14:53,000 --> 00:14:55,965
This causes the bourbon
To flow freely when tipped,
248
00:14:56,068 --> 00:14:58,931
And it gushes into a trough.
249
00:14:59,034 --> 00:15:03,310
The alcohol has ripened
To a sweet caramel-colored brew.
250
00:15:06,034 --> 00:15:08,896
After they add more water
To make it 90 proof,
251
00:15:09,000 --> 00:15:11,448
It's ready for bottling.
252
00:15:11,551 --> 00:15:14,931
Nozzles fill the bottles
With bourbon right to the neck.
253
00:15:18,034 --> 00:15:22,517
The bottles then circle
Over to the cap applicators.
254
00:15:22,620 --> 00:15:27,172
The applicators spin metal caps,
Screwing them onto the bottles.
255
00:15:29,103 --> 00:15:30,931
The bottles then ride a carousel
256
00:15:31,034 --> 00:15:34,482
And a device
Picks up and applies the labels.
257
00:15:34,586 --> 00:15:37,517
A brush smoothes them
To the bottles.
258
00:15:39,758 --> 00:15:42,103
Down the line, a two-person team
259
00:15:42,206 --> 00:15:47,034
Retrieves the bottles
And dips the caps in hot wax.
260
00:15:47,137 --> 00:15:50,172
The wax quickly dries and
Solidifies to give the bourbon
261
00:15:50,275 --> 00:15:52,103
A better seal.
262
00:15:54,931 --> 00:15:57,310
After several years
In the distillery,
263
00:15:57,413 --> 00:16:00,517
This kentucky bourbon
Has come of age,
264
00:16:00,620 --> 00:16:03,137
And that calls for a toast.
265
00:16:16,344 --> 00:16:18,172
Narrator: the circuit board
266
00:16:18,275 --> 00:16:20,310
Is where the electronic
Components are located,
267
00:16:20,413 --> 00:16:22,275
Along with the electrical
Connections which power them.
268
00:16:22,379 --> 00:16:24,793
In a larger device,
Such as a computer,
269
00:16:24,896 --> 00:16:26,793
The circuit board
Is typically rigid.
270
00:16:26,896 --> 00:16:29,448
When the device is compact,
Like a small camera,
271
00:16:29,551 --> 00:16:31,758
The circuit board
Must be flexible.
272
00:16:31,862 --> 00:16:34,448
It needs to fold to fit inside.
273
00:16:36,103 --> 00:16:39,034
Flexible circuit boards
Are so thin and pliable,
274
00:16:39,137 --> 00:16:41,482
They're nicknamed
Origami circuitry,
275
00:16:41,586 --> 00:16:45,000
After the japanese art
Of paper folding.
276
00:16:45,103 --> 00:16:48,620
At the core of the boards
Is a hair-thin polymer film
277
00:16:48,724 --> 00:16:51,172
That's both bendable
And heat resistant.
278
00:16:51,275 --> 00:16:55,413
The manufacturer produces this
Material for several industries.
279
00:16:55,517 --> 00:16:57,517
In this case,
They cut rolls of it
280
00:16:57,620 --> 00:17:01,310
To the width required for making
Flexible circuit boards.
281
00:17:03,586 --> 00:17:07,344
With a rigid sheet of paper
Lending support from underneath,
282
00:17:07,448 --> 00:17:08,931
The film enters a machine
283
00:17:09,034 --> 00:17:12,241
Which sandwiches it between
Two thin sheets of copper.
284
00:17:12,344 --> 00:17:14,103
A cutter then
Slices the sandwich
285
00:17:14,206 --> 00:17:16,275
Into rectangular sheets.
286
00:17:16,379 --> 00:17:18,620
A cushion of air
Pumped through the conveyor belt
287
00:17:18,724 --> 00:17:21,827
Literally floats sheet
After sheet off the machine
288
00:17:21,931 --> 00:17:25,034
And into a stack.
289
00:17:25,137 --> 00:17:27,793
Each three-layer sheet
Is separated from the next
290
00:17:27,896 --> 00:17:31,517
By the support paper
Called a laminate.
291
00:17:31,620 --> 00:17:35,206
The film at the center has a
Heat-activated adhesive coating,
292
00:17:35,310 --> 00:17:37,241
While the adjoining
Copper surfaces
293
00:17:37,344 --> 00:17:40,862
Have been chemically roughened
To enhance adhesion.
294
00:17:40,965 --> 00:17:44,137
After drawing the layers
Tightly together with a vacuum,
295
00:17:44,241 --> 00:17:45,724
Workers place the laminates
296
00:17:45,827 --> 00:17:48,103
In a high-temperature,
High-pressure chamber
297
00:17:48,206 --> 00:17:49,965
For several hours.
298
00:17:50,068 --> 00:17:53,896
This activates the adhesive,
Bonding the layers.
299
00:17:54,000 --> 00:17:55,724
To test the bond strength,
300
00:17:55,827 --> 00:17:59,000
They burn some adhesive off
A sample of finished laminate
301
00:17:59,103 --> 00:18:02,172
To pry apart the layered edge.
302
00:18:02,275 --> 00:18:05,655
Then, they grab the top copper
Layer with this pulling device
303
00:18:05,758 --> 00:18:07,620
And measure the strength
Required to peel
304
00:18:07,724 --> 00:18:09,689
It off the film.
305
00:18:09,793 --> 00:18:12,862
The laminate's now shipped
To a circuit board factory.
306
00:18:12,965 --> 00:18:14,793
Here, computer-guided machines
307
00:18:14,896 --> 00:18:17,000
Cut them
Into specific-sized panels
308
00:18:17,103 --> 00:18:18,724
And drill tiny holes
For mounting
309
00:18:18,827 --> 00:18:20,827
The electronic components.
310
00:18:22,310 --> 00:18:23,413
Then a coating machine
311
00:18:23,517 --> 00:18:26,172
Uses a combination
Of heat and pressure
312
00:18:26,275 --> 00:18:30,034
To apply a light-sensitive fluid
To the panel's surface.
313
00:18:30,137 --> 00:18:33,379
Technicians load the panel
Into an exposure machine,
314
00:18:33,482 --> 00:18:36,965
In which a computer-guided laser
Scans the circuitry pattern
315
00:18:37,068 --> 00:18:38,758
Onto the coded surface.
316
00:18:38,862 --> 00:18:41,275
A laser is a beam
Of focused light,
317
00:18:41,379 --> 00:18:45,655
So wherever it hits,
The fluid reacts and hardens.
318
00:18:45,758 --> 00:18:49,931
The dark areas
Of unexposed fluid remain soft.
319
00:18:50,034 --> 00:18:53,482
The next machine
Acid-washes the soft areas,
320
00:18:53,586 --> 00:18:55,068
Removing both the fluid
321
00:18:55,172 --> 00:18:57,034
And the copper layer
Underneath it.
322
00:18:57,137 --> 00:19:00,517
Now the only copper remaining
On top of the polymer film
323
00:19:00,620 --> 00:19:03,068
Is in the circuitry pattern.
324
00:19:03,172 --> 00:19:04,413
This inspection device
325
00:19:04,517 --> 00:19:08,275
Meticulously checks
Every single copper circuit.
326
00:19:09,655 --> 00:19:13,241
Next, they remove surface dust
With a sticky roller.
327
00:19:13,344 --> 00:19:14,827
The panel must be pristine
328
00:19:14,931 --> 00:19:17,689
Before receiving the sheet
Of electrical insulation,
329
00:19:17,793 --> 00:19:22,448
A mere .25 of a millimeter
Thick.
330
00:19:22,551 --> 00:19:24,344
Technicians use a magnifier
331
00:19:24,448 --> 00:19:27,000
To carefully match up
Alignment holes on the film
332
00:19:27,103 --> 00:19:30,034
With corresponding
Alignment holes on the panel.
333
00:19:30,137 --> 00:19:32,482
By activating
The film's built-in adhesive
334
00:19:32,586 --> 00:19:34,034
With a soldering iron,
335
00:19:34,137 --> 00:19:38,655
They tack the insulation
To the panel at key spots.
336
00:19:38,758 --> 00:19:41,275
The next step is to fully
Laminate the insulation
337
00:19:41,379 --> 00:19:42,586
To the panel.
338
00:19:42,689 --> 00:19:44,310
Technicians sandwich two panels
339
00:19:44,413 --> 00:19:47,655
At a time between sheets
Of protective plastic.
340
00:19:47,758 --> 00:19:50,172
This protects the surfaces
From the heat and weight
341
00:19:50,275 --> 00:19:52,517
Of the lamination press.
342
00:19:52,620 --> 00:19:55,896
As it forces the insulation film
Deep down onto the panel,
343
00:19:56,000 --> 00:19:59,137
It encapsulates the circuitry.
344
00:19:59,241 --> 00:20:01,689
They load the panels
Into the lamination press,
345
00:20:01,793 --> 00:20:05,241
Apply a vacuum to remove
The air between the layers
346
00:20:05,344 --> 00:20:07,310
And start her up.
347
00:20:07,413 --> 00:20:09,344
For the next hour and a half,
348
00:20:09,448 --> 00:20:12,517
The press simultaneously
Applies high pressure
349
00:20:12,620 --> 00:20:16,965
While heating the panels
To 400 degrees fahrenheit.
350
00:20:17,068 --> 00:20:20,103
When the panels cool
And come out of the press,
351
00:20:20,206 --> 00:20:25,310
Technicians place one at a time
On a circuit board-shaped dye.
352
00:20:25,413 --> 00:20:27,068
Then they release a press
353
00:20:27,172 --> 00:20:29,758
Which forces the panel
Onto the sharp dye,
354
00:20:29,862 --> 00:20:33,103
Slicing away
The excess material.
355
00:20:33,206 --> 00:20:36,000
The flexible circuit board
Is now ready for the company
356
00:20:36,103 --> 00:20:38,931
That installs
The electronic components.
357
00:20:42,206 --> 00:20:44,758
There are two ways
To mount components --
358
00:20:44,862 --> 00:20:47,482
Solder them directly
Onto the board's surface
359
00:20:47,586 --> 00:20:49,206
Or solder tiny prongs
360
00:20:49,310 --> 00:20:51,379
Underneath the components,
Known as leads,
361
00:20:51,482 --> 00:20:53,793
Into the board's mounting holes.
362
00:20:53,896 --> 00:20:55,172
A flexible circuit board
363
00:20:55,275 --> 00:20:57,896
Can have as few
As a dozen components
364
00:20:58,000 --> 00:21:00,724
Or as many as 500.
365
00:21:00,827 --> 00:21:02,000
Technicians can solder
366
00:21:02,103 --> 00:21:05,724
Larger ones
Magnified under a microscope,
367
00:21:05,827 --> 00:21:08,689
But only robots
Can solder smaller ones
368
00:21:08,793 --> 00:21:10,413
Because they're so tiny
369
00:21:10,517 --> 00:21:13,172
And barely visible
To the human eye.
29668
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