Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:22,758 --> 00:00:25,931
Narrator:
Today on "How it's made"...
2
00:00:25,931 --> 00:00:28,344
Fiberglass insulation...
3
00:00:32,448 --> 00:00:34,275
...Wooden ducks...
4
00:00:37,758 --> 00:00:39,862
...Gumball machines...
5
00:00:43,310 --> 00:00:45,931
...And exhaust systems.
6
00:00:52,310 --> 00:00:56,379
It's pink and fluffy,
And it keeps us warm.
7
00:00:56,379 --> 00:00:58,965
Fiberglass insulation
Is a great way
8
00:00:58,965 --> 00:01:01,172
To prevent heat loss
From our buildings.
9
00:01:01,172 --> 00:01:04,551
It has a woolly texture,
But it is, as the name suggests,
10
00:01:04,551 --> 00:01:07,689
Made of very fine threads
Of glass.
11
00:01:07,689 --> 00:01:12,310
That's why it's sometimes
Referred to as glass wool.
12
00:01:15,344 --> 00:01:18,965
Fiberglass insulation
Will reduce energy consumption,
13
00:01:18,965 --> 00:01:20,758
But it also reduces waste
14
00:01:20,758 --> 00:01:24,241
Because it's made from at least
35% recycled glass.
15
00:01:24,241 --> 00:01:27,000
The recipe also includes
What's called the batch --
16
00:01:27,000 --> 00:01:29,793
A lot of sand and smaller
Portions of soda ash,
17
00:01:29,793 --> 00:01:31,965
Limestone, and other minerals.
18
00:01:31,965 --> 00:01:37,034
The glass, called cullet,
Used to be bottles and windows.
19
00:01:37,034 --> 00:01:41,344
This will be
Its second recycling.
20
00:01:41,344 --> 00:01:43,137
The cullet and batch ingredients
21
00:01:43,137 --> 00:01:45,137
Spill onto
A conveyer-belt system,
22
00:01:45,137 --> 00:01:48,379
Which transports it all
To an electric furnace.
23
00:01:48,379 --> 00:01:50,517
The conveyer
Moves back and forth
24
00:01:50,517 --> 00:01:53,724
To evenly distribute the cullet
And batch ingredients.
25
00:01:53,724 --> 00:01:57,310
They seep down
And melt into a previous mix,
26
00:01:57,310 --> 00:02:00,551
Which is now a pool of glass
At the bottom of the furnace.
27
00:02:08,068 --> 00:02:10,827
The glass liquid
Now flows out of the furnace
28
00:02:10,827 --> 00:02:12,310
And into sloped channels.
29
00:02:15,068 --> 00:02:16,620
Inside these channels,
30
00:02:16,620 --> 00:02:20,310
The temperature is kept red-hot
By natural-gas burners.
31
00:02:20,310 --> 00:02:23,241
This keeps the glass mix
In a liquid form,
32
00:02:23,241 --> 00:02:26,827
As it oozes out of the holes
In the bottoms of the channels.
33
00:02:30,034 --> 00:02:33,103
The melted glass falls about
3 feet into a spinning bowl.
34
00:02:33,103 --> 00:02:35,482
It's called a fiberizer.
35
00:02:35,482 --> 00:02:37,103
The spinning action
Flings the glass
36
00:02:37,103 --> 00:02:38,862
Through thousands of holes
In the bowl,
37
00:02:38,862 --> 00:02:42,931
Creating thousands
Of feathery glass fibers.
38
00:02:42,931 --> 00:02:45,827
Gas and compressed air pull the
Fibers, stretching them thinner.
39
00:02:48,310 --> 00:02:51,413
The process is a lot like
Making cotton candy,
40
00:02:51,413 --> 00:02:54,586
And the spun glass
Even has a similar texture.
41
00:02:54,586 --> 00:02:59,172
But the fibers will soon become
Even more like cotton candy.
42
00:02:59,172 --> 00:03:03,103
Nozzles spray them
With a polymer glue tinted pink.
43
00:03:06,586 --> 00:03:08,137
The now-pink and sticky fibers
44
00:03:08,137 --> 00:03:11,413
Drop into a hole
In the ground and amass.
45
00:03:11,413 --> 00:03:12,896
Then a conveyer belt
46
00:03:12,896 --> 00:03:15,931
Takes the mounds of sticky glass
To an oven.
47
00:03:18,724 --> 00:03:21,448
Steel plates compress the pack
As it enters the oven
48
00:03:21,448 --> 00:03:24,137
That's heated
To 500 degrees fahrenheit.
49
00:03:24,137 --> 00:03:27,000
Hot air blows through it,
Setting the glue.
50
00:03:28,793 --> 00:03:33,310
As the pack exits the oven,
Circular saws cut through it,
51
00:03:33,310 --> 00:03:35,862
Making 15-
To 24-inch-wide strips
52
00:03:35,862 --> 00:03:37,551
That are called lanes.
53
00:03:37,551 --> 00:03:41,896
The lanes pass by a series
Of poles that push them apart.
54
00:03:45,793 --> 00:03:49,482
Next, an ink jet
Brands each lane with a number
55
00:03:49,482 --> 00:03:52,448
That conveys the "R" value.
56
00:03:52,448 --> 00:03:55,724
"R" stands for
"Resistance to heat flow."
57
00:03:55,724 --> 00:03:58,482
It's a measure of how well
The insulation will stop heat
58
00:03:58,482 --> 00:04:02,655
From going through the roof and
Your energy bill along with it.
59
00:04:07,551 --> 00:04:11,724
A chopper with big steel teeth
Now cuts the lanes,
60
00:04:11,724 --> 00:04:14,724
Making chunks
That could easily be installed
61
00:04:14,724 --> 00:04:16,655
In an attic or wall.
62
00:04:21,827 --> 00:04:25,034
After chopping,
The conveyer belt accelerates,
63
00:04:25,034 --> 00:04:29,172
Transporting the fiberglass
Batts to the next station.
64
00:04:32,862 --> 00:04:36,000
A few at a time,
The batts plunge down a chute,
65
00:04:36,000 --> 00:04:38,034
To a mechanical arm
66
00:04:38,034 --> 00:04:41,172
Which slides the batts
Into a compression chamber.
67
00:04:41,172 --> 00:04:44,551
There, a hydraulic ram
Squishes the batts down,
68
00:04:44,551 --> 00:04:47,137
Reducing their bulk
5 to 10 times.
69
00:04:47,137 --> 00:04:51,068
This compaction will make them
Easier to transport.
70
00:04:58,689 --> 00:05:01,931
Now another ram
Comes from the side
71
00:05:01,931 --> 00:05:04,517
And pushes the stack
Of compressed batts forward
72
00:05:04,517 --> 00:05:06,103
Into a spout.
73
00:05:06,103 --> 00:05:09,000
The spout
Is a hollow batt-shaped frame.
74
00:05:09,000 --> 00:05:12,551
A worker
Pulls a plastic bag over it.
75
00:05:14,793 --> 00:05:18,034
Then the ram pushes
The fiberglass-insulation batt
76
00:05:18,034 --> 00:05:20,000
Into the plastic bag,
77
00:05:20,000 --> 00:05:22,793
And the process begins again.
78
00:05:32,241 --> 00:05:34,724
A conveyer belt
Transports the batt-filled bags
79
00:05:34,724 --> 00:05:37,206
To a machine
That heat-seals them.
80
00:05:39,000 --> 00:05:43,137
Then they're sent off
To be installed.
81
00:05:59,965 --> 00:06:02,931
Narrator: for centuries,
Hunters have used wooden ducks
82
00:06:02,931 --> 00:06:05,517
To lure live ones
To within shooting range.
83
00:06:05,517 --> 00:06:08,724
Stringing together decoys
And floating them in the water,
84
00:06:08,724 --> 00:06:12,103
Hunters trick the birds down
From the sky with duck calls.
85
00:06:12,103 --> 00:06:15,862
Nowadays, hunters generally
Prefer cheaper, plastic decoys.
86
00:06:15,862 --> 00:06:19,310
Wooden ducks are mostly
Decorative items for the home.
87
00:06:20,724 --> 00:06:24,896
This company's flock
Includes males, females,
88
00:06:24,896 --> 00:06:26,896
And androgynous models
Like this one.
89
00:06:26,896 --> 00:06:28,827
This more elaborate male
Is inspired
90
00:06:28,827 --> 00:06:32,344
By another aquatic bird,
The loon.
91
00:06:32,344 --> 00:06:35,448
To make them, these craftsmen
Use eastern white pine
92
00:06:35,448 --> 00:06:37,758
Because it's easy to carve
And has a nice grain.
93
00:06:37,758 --> 00:06:41,896
First, a machine shapes
A 2-inch-thick slab.
94
00:06:41,896 --> 00:06:44,172
They cut the slab lengthwise.
95
00:06:44,172 --> 00:06:46,896
They'll use four to six
Of these smaller pieces
96
00:06:46,896 --> 00:06:48,965
To make most of the duck's body.
97
00:06:48,965 --> 00:06:53,448
The birds range in size from
Baby ducks just 4 inches long
98
00:06:53,448 --> 00:06:56,551
To geese at more than
19 inches long.
99
00:06:56,551 --> 00:06:58,206
A craftsman now applies
100
00:06:58,206 --> 00:07:01,034
A generous amount
Of carpenter's glue
101
00:07:01,034 --> 00:07:02,586
To one side of the wood.
102
00:07:02,586 --> 00:07:04,793
Using a lot
Ensures a strong bond
103
00:07:04,793 --> 00:07:06,793
And prevents splitting later on.
104
00:07:09,275 --> 00:07:12,758
The pieces then go
Into what's called a wood clamp.
105
00:07:12,758 --> 00:07:15,793
He tightens a vice,
Squeezing them together.
106
00:07:15,793 --> 00:07:18,862
It takes about two hours
For the pieces to bond properly.
107
00:07:18,862 --> 00:07:24,620
Then he'll shave away the excess
Glue and even up the surfaces.
108
00:07:24,620 --> 00:07:26,000
Once that's done,
109
00:07:26,000 --> 00:07:29,000
They run the block
Over what's called a joiner.
110
00:07:29,000 --> 00:07:31,965
A roller with 3 blades
Shaves about 3/4 of an inch
111
00:07:31,965 --> 00:07:36,379
From what will become
The top and bottom of the duck.
112
00:07:36,379 --> 00:07:38,793
Each model
Has three wooden patterns
113
00:07:38,793 --> 00:07:42,000
For the top, the bottom,
And the profile.
114
00:07:42,000 --> 00:07:45,000
Here, a worker traces the
Outline of the bird's profile
115
00:07:45,000 --> 00:07:46,413
In pencil on the wood.
116
00:07:46,413 --> 00:07:48,137
Since this is a small model,
117
00:07:48,137 --> 00:07:50,482
He'll make two birds
With one block.
118
00:07:52,965 --> 00:07:55,965
Using a band saw,
He trims along the trace line.
119
00:07:55,965 --> 00:07:58,241
This company
Recycles the cutoffs
120
00:07:58,241 --> 00:08:02,551
Into fireplace kindling
And shavings for farm stables.
121
00:08:02,551 --> 00:08:05,793
Next, he uses another pattern
To create the top of the bird.
122
00:08:05,793 --> 00:08:08,310
These patterns provide
Only the general shape
123
00:08:08,310 --> 00:08:09,586
Of a particular model.
124
00:08:09,586 --> 00:08:12,000
The craftsman
Will later carve the details
125
00:08:12,000 --> 00:08:14,620
Using smaller electric tools
And by hand.
126
00:08:17,172 --> 00:08:19,965
Now he sands the wood
With a pneumatic drum sander --
127
00:08:19,965 --> 00:08:23,827
A tube of pressurized air with
Sandpaper stretched over it.
128
00:08:23,827 --> 00:08:26,758
He uses higher pressure
For sharper curves,
129
00:08:26,758 --> 00:08:28,793
Lower pressure for softer edges.
130
00:08:28,793 --> 00:08:30,655
To sculpt the bird's plumage,
131
00:08:30,655 --> 00:08:33,137
The craftsman
Uses this band sander
132
00:08:33,137 --> 00:08:36,413
Whose rounded edge
Presses sandpaper into the wood.
133
00:08:36,413 --> 00:08:38,896
Here, he makes
Three long grooves --
134
00:08:38,896 --> 00:08:41,862
One on top, and one
On each side of the duck.
135
00:08:43,965 --> 00:08:47,068
The head's made from a different
Piece of wood than the body.
136
00:08:47,068 --> 00:08:49,896
Here, he sands down the piece
To smooth out the curves.
137
00:08:52,482 --> 00:08:55,172
Using various shaping tools
And the band sander,
138
00:08:55,172 --> 00:08:57,793
He sculpts the bird's
Head and bill area,
139
00:08:57,793 --> 00:09:01,034
Then the underside and rear end
Of this waddling duck.
140
00:09:01,034 --> 00:09:04,517
He also carves depressions
For eye sockets to come later.
141
00:09:09,034 --> 00:09:10,862
Here, he puts glue on the neck
142
00:09:10,862 --> 00:09:13,206
To attach it
To the rest of the body.
143
00:09:15,275 --> 00:09:16,620
Using a nail gun,
144
00:09:16,620 --> 00:09:19,793
He reinforces the area
With two nails on each side.
145
00:09:19,793 --> 00:09:22,482
To hide the nails
And smooth out the neck,
146
00:09:22,482 --> 00:09:24,482
The craftsman uses wood putty.
147
00:09:24,482 --> 00:09:27,000
Once it dries,
He'll sand it smooth.
148
00:09:29,551 --> 00:09:33,275
Next, he tints the duck bill
Using an orange wood stain...
149
00:09:35,310 --> 00:09:39,103
...Then a forest-green stain
To tint the head and neck areas.
150
00:09:39,103 --> 00:09:42,413
Males have colorful feathers
To better attract mates.
151
00:09:42,413 --> 00:09:44,655
Females
Have more neutral colors
152
00:09:44,655 --> 00:09:48,068
To blend into their surroundings
And protect their ducklings.
153
00:09:48,068 --> 00:09:50,551
The craftsman
Covers the duck's lower body
154
00:09:50,551 --> 00:09:52,137
With a clear wood stain.
155
00:09:52,137 --> 00:09:55,482
This way, the natural grain
Of the wood shows through.
156
00:09:55,482 --> 00:09:59,137
The front gets a clear but
Darker stain to mark the chest.
157
00:09:59,137 --> 00:10:03,068
And darker stain also highlights
The plumage in the long grooves.
158
00:10:03,068 --> 00:10:05,758
Then, some green accents
For the feathers
159
00:10:05,758 --> 00:10:07,379
On the sides in the back.
160
00:10:10,379 --> 00:10:15,724
Next, two coats of white paint
To mark the duck's collar.
161
00:10:15,724 --> 00:10:19,206
Then he glues plastic eyes
In the eye sockets.
162
00:10:19,206 --> 00:10:23,517
The irises are black, brown,
Or red, depending on the model.
163
00:10:23,517 --> 00:10:26,689
He then sprays on a protective,
Water-based varnish,
164
00:10:26,689 --> 00:10:28,620
And elevates the duck on nails
165
00:10:28,620 --> 00:10:31,793
So that the underside will dry
Along with the rest.
166
00:10:31,793 --> 00:10:35,379
Finally, the craftsman rubs
The entire carving in wood wax.
167
00:10:35,379 --> 00:10:38,344
This makes the varnish
Appear uneven in places,
168
00:10:38,344 --> 00:10:41,000
Giving the duck
A worn, antique finish,
169
00:10:41,000 --> 00:10:43,758
Like he's been
Around the pond a few times.
170
00:10:47,034 --> 00:10:50,931
The prices of wooden ducks vary
According to size and detail.
171
00:10:50,931 --> 00:10:54,068
$500 will buy you
This magnificent canada goose
172
00:10:54,068 --> 00:10:57,620
With wings stretched and ready
For a graceful landing.
173
00:11:07,758 --> 00:11:09,310
Narrator:
For a century,
174
00:11:09,310 --> 00:11:11,758
There have been machines
To give us gumballs.
175
00:11:11,758 --> 00:11:16,241
Vending machines that dispensed
Gumballs were introduced in 1907
176
00:11:16,241 --> 00:11:19,000
On a new york city
Subway platform.
177
00:11:19,000 --> 00:11:22,586
Today's machines are more modern
Versions of the originals,
178
00:11:22,586 --> 00:11:25,896
But they still perform,
Basically, the same function.
179
00:11:30,310 --> 00:11:34,172
The gumball machine is all about
Instant gratification.
180
00:11:34,172 --> 00:11:38,241
Insert a coin, turn a handle,
And out comes the merchandise.
181
00:11:40,758 --> 00:11:42,551
To make a gumball machine,
182
00:11:42,551 --> 00:11:46,000
A designer first sketches out
The exact proportions.
183
00:11:48,689 --> 00:11:51,965
Then, a worker ladles molten
Zinc into a holding furnace,
184
00:11:51,965 --> 00:11:54,206
Where a steel plunger
Pushes the metal
185
00:11:54,206 --> 00:11:58,310
Through a die that forms
A gumball machine base.
186
00:11:58,310 --> 00:12:02,448
A mechanical claw removes the
Newly shaped base from the die
187
00:12:02,448 --> 00:12:05,827
And places it
On a conveyor belt to cool.
188
00:12:08,241 --> 00:12:09,827
A similar die shapes
189
00:12:09,827 --> 00:12:13,034
The coin mechanism handle
And drive gears.
190
00:12:16,448 --> 00:12:19,586
A worker places a braided hose
With a natural-gas flame
191
00:12:19,586 --> 00:12:23,413
Under a mold that will shape
The gumball-dispensing chute.
192
00:12:26,206 --> 00:12:29,275
He pours piping-hot
Liquid aluminum into the mold.
193
00:12:29,275 --> 00:12:32,586
The flame below warms the mold
Enough to prevent condensation,
194
00:12:32,586 --> 00:12:34,068
Which would ruin the shape.
195
00:12:34,068 --> 00:12:36,689
But the mold is still cooler
Than the aluminum,
196
00:12:36,689 --> 00:12:40,586
And that allows it to solidify
Into a chute shape in seconds.
197
00:12:42,724 --> 00:12:46,068
Now, using a punch press,
A worker trims the waste away
198
00:12:46,068 --> 00:12:48,758
From the lid
For the gumball machine.
199
00:12:51,620 --> 00:12:54,689
They also trim the front plate
Of the coin mechanism,
200
00:12:54,689 --> 00:12:57,000
Using a similar press.
201
00:13:01,551 --> 00:13:05,103
A computerized cutter mills out
A hole in the top of the globe
202
00:13:05,103 --> 00:13:06,793
That will hold the gumballs.
203
00:13:06,793 --> 00:13:09,344
The globe is made
Of shatterproof plastic.
204
00:13:16,275 --> 00:13:17,620
At another station,
205
00:13:17,620 --> 00:13:19,620
They press the base
Of the gumball machine
206
00:13:19,620 --> 00:13:21,758
Against
A cloth-covered buffing wheel
207
00:13:21,758 --> 00:13:25,034
To give it a shine.
208
00:13:25,034 --> 00:13:28,034
A worker now assembles
The coin mechanism,
209
00:13:28,034 --> 00:13:31,103
Layering the front plate,
The coin carrier,
210
00:13:31,103 --> 00:13:34,655
The back plate,
And ending with a cam,
211
00:13:34,655 --> 00:13:39,586
The part that ensures the
Coin mechanism moves clockwise.
212
00:13:39,586 --> 00:13:41,413
She screws it tightly together,
213
00:13:41,413 --> 00:13:44,172
Then inserts the handle
On the front plate.
214
00:13:44,172 --> 00:13:47,620
The handle will turn the coins
That pay for the gumballs.
215
00:13:50,206 --> 00:13:53,620
She places a little spacer and
Drive gear on the handle stem
216
00:13:53,620 --> 00:13:56,379
That protrudes through the back
Of the assembly
217
00:13:56,379 --> 00:13:59,413
And then screws the drive gear
Onto the handle stem.
218
00:14:01,965 --> 00:14:04,413
Now it's time
To put the money up front.
219
00:14:04,413 --> 00:14:06,206
They insert a coin in the slot
220
00:14:06,206 --> 00:14:09,206
And turn the handle
To make sure the system works.
221
00:14:13,310 --> 00:14:15,724
People in many countries
Like gumballs,
222
00:14:15,724 --> 00:14:19,241
And so these coin mechanisms
Can be made to accept currencies
223
00:14:19,241 --> 00:14:20,724
From around the world.
224
00:14:20,724 --> 00:14:24,275
They can also be used in other
Types of vending machines.
225
00:14:29,000 --> 00:14:31,655
Now they spray powder paint
Onto the lids,
226
00:14:31,655 --> 00:14:35,000
Giving them a coating that's
Almost 1/16 of an inch thick.
227
00:14:35,000 --> 00:14:37,068
They bake the paint
Onto the lids
228
00:14:37,068 --> 00:14:41,413
At 400 degrees fahrenheit
For 25 minutes.
229
00:14:41,413 --> 00:14:44,172
Now it's time
To put all the pieces together.
230
00:14:44,172 --> 00:14:46,931
They place the dispensing wheels
In hoppers,
231
00:14:46,931 --> 00:14:50,034
Then cover them with a part
That stops free gumballs
232
00:14:50,034 --> 00:14:51,655
From spilling out.
233
00:14:51,655 --> 00:14:54,620
The next part
Is the adaptor ring,
234
00:14:54,620 --> 00:14:58,137
And the plastic globes
Fit on top of them.
235
00:15:01,241 --> 00:15:04,965
They place aluminum rings
On top of the globes.
236
00:15:04,965 --> 00:15:08,206
Then they slide two side rods
Through the top rings,
237
00:15:08,206 --> 00:15:10,586
Down into the bottom
Of the globes.
238
00:15:12,586 --> 00:15:14,482
They screw them down
Very tightly,
239
00:15:14,482 --> 00:15:16,551
And then they set
The assembly aside.
240
00:15:18,827 --> 00:15:21,241
Now they place
Plastic bodies on bases
241
00:15:21,241 --> 00:15:23,862
And install the chute doors
On the front.
242
00:15:29,275 --> 00:15:32,275
They place the chute covers
In the plastic body...
243
00:15:34,965 --> 00:15:38,310
...And mount the coin mechanism
Just above the chute.
244
00:15:40,310 --> 00:15:43,206
Next, they slide
The globe assemblies
245
00:15:43,206 --> 00:15:48,068
Over center rods and
Onto the plastic foundations.
246
00:15:48,068 --> 00:15:51,655
They put a lid on every globe...
247
00:15:51,655 --> 00:15:53,689
And then lock them on.
248
00:16:00,068 --> 00:16:03,793
And now we're at
The vending part of the story.
249
00:16:03,793 --> 00:16:05,655
Gumball, anyone?
250
00:16:14,586 --> 00:16:16,793
Narrator:
The job it does is exhausting.
251
00:16:16,793 --> 00:16:19,620
The exhaust system
On your vehicle
252
00:16:19,620 --> 00:16:22,724
Gets rid of harmful gases
That could damage the engine.
253
00:16:22,724 --> 00:16:24,482
It also cleans up
The gases a bit
254
00:16:24,482 --> 00:16:26,758
Before venting them
Into the air.
255
00:16:26,758 --> 00:16:30,379
A properly functioning exhaust
System does another big job --
256
00:16:30,379 --> 00:16:33,000
Muffling the airborne noise
Of the engine.
257
00:16:38,586 --> 00:16:40,896
It's a system
Of metal tubes and plates
258
00:16:40,896 --> 00:16:43,379
We only seem to notice
When it breaks down.
259
00:16:43,379 --> 00:16:45,689
And when it does,
Everyone can hear it.
260
00:16:48,344 --> 00:16:49,689
To make an exhaust system,
261
00:16:49,689 --> 00:16:52,793
A mechanical puller draws
A stainless-steel strip
262
00:16:52,793 --> 00:16:54,310
Up into a punch press,
263
00:16:54,310 --> 00:16:57,655
Shuffling it back and forth
To allow for a precise cut
264
00:16:57,655 --> 00:16:59,241
With little waste.
265
00:17:04,931 --> 00:17:07,448
The press brings 60 tons
Of force to bear
266
00:17:07,448 --> 00:17:09,689
As it pushes the steel
Into a die.
267
00:17:09,689 --> 00:17:12,344
It punches out a baffle shape
With holes in it,
268
00:17:12,344 --> 00:17:17,310
Which will form the skeleton
For the muffler box.
269
00:17:17,310 --> 00:17:19,517
The finished baffles
Fall onto a conveyor
270
00:17:19,517 --> 00:17:21,862
And go into a storage cage.
271
00:17:24,137 --> 00:17:27,034
Now a long steel tube
Tumbles to automated blades
272
00:17:27,034 --> 00:17:30,379
Which score the tube crosswise
To prevent denting
273
00:17:30,379 --> 00:17:32,379
And then cut it
To produce smaller tubes
274
00:17:32,379 --> 00:17:34,034
That go inside a muffler.
275
00:17:34,034 --> 00:17:36,620
A circular saw descends
On another tube
276
00:17:36,620 --> 00:17:39,068
To make a tail pipe.
277
00:17:39,068 --> 00:17:44,206
Its length depends on
The type of muffler being made.
278
00:17:44,206 --> 00:17:46,724
A louver machine
Spins and punctures
279
00:17:46,724 --> 00:17:48,379
One of the inside tubes.
280
00:17:48,379 --> 00:17:51,551
The holes will regulate airflow
In the muffler.
281
00:17:53,655 --> 00:17:55,103
A cnc bending machine
282
00:17:55,103 --> 00:17:57,655
Grips and bends a pipe
In several spots.
283
00:17:57,655 --> 00:18:01,517
This is how they make inlet,
Intermediate, and outlet tubes.
284
00:18:01,517 --> 00:18:04,724
These tubes run the length
Of the exhaust system.
285
00:18:11,551 --> 00:18:14,620
Then they place a tube
In a circular hydraulic vice,
286
00:18:14,620 --> 00:18:17,620
Which pinches the end down
To a prescribed diameter
287
00:18:17,620 --> 00:18:19,551
To allow
For further assembly.
288
00:18:21,206 --> 00:18:24,758
A worker now places two baffles
In a jig.
289
00:18:24,758 --> 00:18:27,551
He fits the tubes
Through the holes in the baffles
290
00:18:27,551 --> 00:18:29,793
So that the tubes
Connect the baffles.
291
00:18:31,172 --> 00:18:34,068
Three mandrels
Slide into the tubes.
292
00:18:34,068 --> 00:18:37,793
The mandrels expand, locking
The tubes to the baffles.
293
00:18:37,793 --> 00:18:40,241
Then they contract
And slide out.
294
00:18:40,241 --> 00:18:43,137
Now the baffles and tubes
Are one piece.
295
00:18:45,793 --> 00:18:48,620
Next, a robotic arm
Picks up metal sheets,
296
00:18:48,620 --> 00:18:51,448
Which will become the outer skin
Of the muffler box.
297
00:18:51,448 --> 00:18:54,310
It pushes them
Under an oval mold.
298
00:18:54,310 --> 00:18:57,413
Another arm
With numerous rollers on it
299
00:18:57,413 --> 00:19:01,310
Moves up and wraps the steel
Around the oval form.
300
00:19:01,310 --> 00:19:03,344
Then a metal block
Moves over the ends,
301
00:19:03,344 --> 00:19:04,758
Double-folding them.
302
00:19:04,758 --> 00:19:06,413
This locks them together,
303
00:19:06,413 --> 00:19:09,517
And it completes the assembly
Of the muffler's outside skin.
304
00:19:17,862 --> 00:19:20,620
Magnets pick up the new skin,
And, sliding on rails,
305
00:19:20,620 --> 00:19:23,206
They relay it
To a mechanical claw
306
00:19:23,206 --> 00:19:25,413
Which, in turn,
Feeds it to a flanger.
307
00:19:28,068 --> 00:19:30,103
The flanger bends the edges,
308
00:19:30,103 --> 00:19:33,310
Creating a lip on either end
Of the muffler skin.
309
00:19:33,310 --> 00:19:34,965
A carousel turns,
310
00:19:34,965 --> 00:19:38,482
And a mechanical claw transfers
The newly flanged muffler skin
311
00:19:38,482 --> 00:19:40,000
To the stuffing position.
312
00:19:45,000 --> 00:19:48,448
Hydraulic pushers press the
Pre-assembled baffles and tubes
313
00:19:48,448 --> 00:19:50,896
Inside the skin.
314
00:19:50,896 --> 00:19:52,931
After the muffler is stuffed,
315
00:19:52,931 --> 00:19:56,586
The robotic claw transfers it
To a conveyor belt.
316
00:19:59,862 --> 00:20:03,068
Next, a worker presses each end
Of the muffler
317
00:20:03,068 --> 00:20:06,034
Against a set
Of steel expansion fingers.
318
00:20:06,034 --> 00:20:09,103
The fingers move forward
Into holes in the muffler.
319
00:20:09,103 --> 00:20:11,862
They expand and lock
The baffles and tubes inside
320
00:20:11,862 --> 00:20:15,517
To form one solid,
Internal unit.
321
00:20:15,517 --> 00:20:17,241
Grippers place the muffler
322
00:20:17,241 --> 00:20:20,551
On a spinning machine
That will fasten the caps on.
323
00:20:24,758 --> 00:20:28,448
Rollers press against the flared
Edges of the revolving muffler,
324
00:20:28,448 --> 00:20:31,517
Tightly locking the end cap
To the rest of the body.
325
00:20:37,862 --> 00:20:40,931
Here, you see the rolling
In slow motion.
326
00:20:40,931 --> 00:20:44,275
It takes only a few revolutions
To do the job.
327
00:20:56,793 --> 00:20:59,000
Then the roller backs away,
328
00:20:59,000 --> 00:21:01,586
And a mechanical arm
Grabs the muffler
329
00:21:01,586 --> 00:21:03,965
And transfers it
To a conveyor belt.
330
00:21:07,137 --> 00:21:08,862
Now these mufflers are ready
331
00:21:08,862 --> 00:21:11,586
To help keep the traffic noise
At a minimum.
332
00:21:18,034 --> 00:21:20,310
If you have any comments
About the show,
333
00:21:20,310 --> 00:21:23,172
Or if you'd like to suggest
Topics for future shows,
334
00:21:23,172 --> 00:21:24,931
Drop us a line at...
335
00:21:24,931 --> 00:21:26,965
--captions by vitac--
Www.Vitac.Com
336
00:21:26,965 --> 00:21:28,965
Captions paid for by
Discovery communications, inc.
27778
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.