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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: fishing reels
Date back to 12th-century china.
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In the beginning,
They were very basic devices
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Used only
For storing extra line.
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But by the 1800s,
Craftsmen in britain and america
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Reinvented the reel
When they gave it a drag system
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For landing feisty fish.
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These flycasters could hook
The big one at any moment,
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And that's when a precision
Fishing reel will come in handy.
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To make a fly-fishing reel,
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00:01:28,241 --> 00:01:32,137
They start
With a solid aluminum puck.
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The puck turns on a lathe
As a computerized cutter
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00:01:35,586 --> 00:01:37,896
Contours it to shape
It into a spool.
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00:01:39,827 --> 00:01:42,793
A different tool
Machines a center hole.
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The focus then moves
To the other side
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00:01:47,965 --> 00:01:50,517
As another tool
Completes the spool shape.
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The dimensions must be exact
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If this fishing reel
Is to perform flawlessly.
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They drill holes to both
Reduce the weight of the spool
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00:02:02,689 --> 00:02:06,241
And provide some ventilation
For wet fishing line.
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They cut windows
Into the other side
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For an attractive look
That further lightens the reel.
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00:02:13,206 --> 00:02:17,413
Next, another aluminum puck
Is transformed into a frame
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00:02:17,517 --> 00:02:19,586
For the spool and other parts.
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00:02:19,689 --> 00:02:23,724
The frame goes into a bath of
Soapy water and plastic pellets,
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00:02:23,827 --> 00:02:26,413
Which rub the part clean.
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00:02:26,517 --> 00:02:31,758
The final touch
Is a black oxide finish.
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00:02:31,862 --> 00:02:35,241
They now transform
This aluminum bar into feet,
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00:02:35,344 --> 00:02:39,241
Which will be used to mount
The reel to the fishing rod.
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A laser engraves the company
Name onto these attachments.
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00:02:43,862 --> 00:02:47,482
It also does a bit of
Custom engraving on the frame.
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00:02:51,241 --> 00:02:55,137
A worker now inserts
A bronze bushing into the center
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00:02:55,241 --> 00:03:00,965
Of the spool and uses
Hydraulic force to entrench it.
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00:03:05,034 --> 00:03:07,482
He then positions
A stainless steel ball
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On top of the bushing.
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He activates a press
That drives the ball through it
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00:03:12,620 --> 00:03:15,965
To expand the bushing to
The correct internal dimension.
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00:03:20,655 --> 00:03:23,379
Another worker
Applies a counterweight
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00:03:23,482 --> 00:03:25,275
To one side of the spool.
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00:03:25,379 --> 00:03:26,482
This bit of stainless steel
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Will offset the weight
Of the spool handle.
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She installs the spool's
Magnetic locking mechanism.
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00:03:34,586 --> 00:03:38,551
This molded polymer part
Has a tiny magnet inside.
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She applies
A second magnet to it,
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Followed by a release button.
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One final magnet
And an aluminum cap,
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And this assembly is complete.
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00:03:54,793 --> 00:03:59,172
She now installs part
Of the drag-engagement system.
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00:03:59,275 --> 00:04:01,655
It's this system that will
Create the necessary resistance
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00:04:01,758 --> 00:04:05,172
On the fishing line
For battling a big fish.
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She applies adhesive to screws
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And then uses them to attach the
Footing to the fly-reel frame,
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Using a screwdriver to set it
To a specific torque.
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00:04:23,206 --> 00:04:26,275
She then resumes
The assembly of the drag system
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00:04:26,379 --> 00:04:30,275
By placing a rubber "O" ring
In the frame's center groove.
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She installs
The thrust-bearing ring,
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00:04:32,724 --> 00:04:34,758
Which can be rotated
By the fly-fisher
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To adjust the drag setting.
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00:04:49,793 --> 00:04:54,344
And it's now time to attach the
Spool to the fishing-reel frame.
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00:04:54,448 --> 00:04:56,827
She turns it to check
The drag setting
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And adjusts it
To its starting point.
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She secures the setting
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By inserting a pin
Into the bearing.
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Then she removes the center
Locking screw temporarily
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00:05:16,275 --> 00:05:19,758
To assemble the knob base
To the thrust bearing.
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She reinstalls the screw
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00:05:27,344 --> 00:05:30,137
And covers the assembly
With the drag knob.
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She turns the spool
For a final inspection,
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Confirming that this fishing
Reel operates smoothly.
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00:05:42,758 --> 00:05:45,310
And now it's ready
To put a positive spin
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On any fishing experience.
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Narrator:
A fresh coat of latex paint
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Is a surefire way
To spruce up a home.
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Latex is a term
For acrylic or vinyl resins.
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Latex paint is water-based,
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So it has less odor
Than alkaline paint.
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It also cleans up
Without any harsh solvents.
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00:06:17,931 --> 00:06:21,344
All you need is soap and water.
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The paint factory
Produces an uncolored base.
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The store then tints that base
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To the color
Ordered by the customer.
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00:06:33,896 --> 00:06:38,448
Latex paint contains water,
Latex for adhesion,
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Titanium dioxide,
Calcium carbonate,
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00:06:42,034 --> 00:06:45,448
Potassium,
Zinc for mildew resistance,
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And whatever additives
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The particular
Type of paint requires.
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For example, if it's paint
Designed for metal,
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A rust inhibitor.
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They pump the water
Into a large mixing tank.
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00:07:02,137 --> 00:07:05,379
Then they add a thickening agent
And stabilizer
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To prevent the ingredients
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From settling
To the bottom of the tank
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00:07:08,379 --> 00:07:12,758
And to the bottom of the can
Once the paint is packaged.
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00:07:12,862 --> 00:07:16,000
A vacuum duct
Sucks up the waste.
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One at a time,
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All the ingredients
Except the latex go in.
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There's a specific mixing time
After each ingredient
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Because proper blending
Is critical for quality.
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Now they pump
The tank's contents
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Into another mixing tank
That contains the latex.
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After four to six hours
Of blending,
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The industrial-sized batch
Of paint base is finally ready.
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The factory subjects
A sample from every batch
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To extensive
Quality-control testing.
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This viscometer measures
The thickness of the paint.
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00:08:03,241 --> 00:08:05,965
This test assesses
How well the dry ingredients
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Have dispersed within the mix.
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This tells them whether
The mix is blended well enough
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To move into the second tank
Containing the latex.
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Technicians
Also conduct color tests,
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00:08:19,827 --> 00:08:23,379
Adding recipes of liquid
Colorants to a gallon sample.
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This is to ensure the shade
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Comes out exactly
The way it's supposed to.
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To check
If the paint covers well,
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They brush it onto test paper.
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The stripes provide a contrast
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So that any defects
In the paint,
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Such as foam or grit, will show.
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00:08:47,137 --> 00:08:49,827
This test evaluates
Tint strength.
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00:08:54,586 --> 00:08:57,137
Once the paint sample dries,
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00:08:57,241 --> 00:08:58,827
They analyze
Its color properties
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00:08:58,931 --> 00:09:02,103
With a machine
Called a spectrophotometer.
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Once the batch
Passes inspection,
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It proceeds to packaging.
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00:09:08,413 --> 00:09:13,655
Latex paint contains about
60% water, which corrodes metal,
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00:09:13,758 --> 00:09:18,310
So the steel cans are lined
With an anti-rust coating.
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00:09:20,413 --> 00:09:25,137
The cans run over
A glue applicator,
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00:09:25,241 --> 00:09:26,482
Then over a label,
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00:09:26,586 --> 00:09:28,551
Which instantly
Sticks to the adhesive.
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00:09:39,827 --> 00:09:42,379
The next stop
Is a filling machine.
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Each can sits on a scale
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That's positioned
Under a dispensing nozzle.
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00:09:47,379 --> 00:09:49,620
Once the scale detects
The correct net weight,
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00:09:49,724 --> 00:09:51,241
It triggers the nozzle to stop.
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From the filling machine
To a lid dispenser
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That drops a cover
Onto each can.
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00:10:11,413 --> 00:10:14,137
Then it's on to
What's called a lid press.
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00:10:14,241 --> 00:10:16,655
As each can passes underneath,
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00:10:16,758 --> 00:10:20,551
A row of cylinders
Gradually presses in the lid.
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00:10:24,551 --> 00:10:26,931
The next machine,
Called a baler,
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Attaches a curved handle
Made of steel wire.
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00:10:31,758 --> 00:10:33,689
It locks the handle ends
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00:10:33,793 --> 00:10:37,068
Into metal disks
On both sides of the can.
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00:10:43,206 --> 00:10:45,448
The factory varies
Its formulations
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00:10:45,551 --> 00:10:49,275
To produce paint in lusters
Ranging from flat to high gloss
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00:10:49,379 --> 00:10:52,275
And for interior
And exterior use,
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Making sure it's got every
Possible application covered.
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Narrator:
Looms for handweaving cloth
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Have become increasingly
Sophisticated over time.
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00:11:15,620 --> 00:11:18,862
But the basic concept
Still remains the same --
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00:11:18,965 --> 00:11:22,000
Weaving horizontal threads,
Called weft threads,
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00:11:22,103 --> 00:11:24,827
Through vertical threads,
Called warp threads,
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00:11:24,931 --> 00:11:27,931
To create the patterns
In the cloth.
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00:11:34,000 --> 00:11:36,103
The loom lifts
Selected warp threads.
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00:11:36,206 --> 00:11:39,655
The weaver passes the weft
Thread between the warp threads,
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Then uses a beater
To pack the weft tightly.
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00:11:44,103 --> 00:11:46,689
They construct
The loom's frame out of ash,
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Which is strong enough
To withstand the pulling
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00:11:49,586 --> 00:11:51,724
Of up to thousands of threads.
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00:11:54,689 --> 00:11:58,241
Workers submerge
The frame pieces in mineral oil
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To prevent the wood
From drying out.
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00:12:02,758 --> 00:12:06,310
They assemble the frame pieces
With heavy-duty nuts and bolts,
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00:12:06,413 --> 00:12:09,482
Then mount high-strength
Plastic brackets
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For attaching
The various components,
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00:12:11,724 --> 00:12:13,137
Such as the cloth beam
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00:12:13,241 --> 00:12:15,896
That grabs and moves
The finished cloth.
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00:12:17,931 --> 00:12:21,482
They wrap sandpaper around
The beam's adhesive surface
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00:12:21,586 --> 00:12:24,724
To grab the cloth
Without damaging it.
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00:12:28,586 --> 00:12:32,137
Elsewhere,
Workers make the loom's cables
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00:12:32,241 --> 00:12:34,655
Out of high-strength
Stainless steel.
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00:12:34,758 --> 00:12:37,758
These cables maneuver
Harnesses that lift
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00:12:37,862 --> 00:12:39,379
And lower the warp threads.
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00:12:39,482 --> 00:12:42,379
After cutting
Each cable to length,
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She forms a loop
Through a cable crimp.
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00:12:45,482 --> 00:12:49,793
Then she locks the loop with
This heavy-duty crimping tool.
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00:12:53,793 --> 00:12:55,896
On one of the frame pieces,
They mount a metal plate
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00:12:56,000 --> 00:12:59,931
Bearing the loom's model
And serial numbers.
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00:13:00,034 --> 00:13:03,689
They assemble the pulley system
On which the harness cables run.
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00:13:03,793 --> 00:13:07,689
They thread the plastic pulleys
Onto a steel axle
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00:13:07,793 --> 00:13:13,000
And position the axle with
Steel disks called stop collars.
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00:13:18,724 --> 00:13:20,758
A spring lever
Helps each harness
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00:13:20,862 --> 00:13:23,793
Lift its respective warp thread.
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00:13:23,896 --> 00:13:26,586
After hammering a pin
Into each lever,
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They hook a wire to the pin,
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00:13:30,655 --> 00:13:33,965
Then squeeze the wire closed
So that it can't unhook.
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00:13:37,172 --> 00:13:41,206
They attach a chain to an eyelet
On one side of the spring lever.
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00:13:41,310 --> 00:13:43,551
Shortening
Or lengthening this chain
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00:13:43,655 --> 00:13:46,103
Adjusts the tension
Of the harness.
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00:13:47,931 --> 00:13:51,689
Like the pulleys,
The spring levers
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00:13:51,793 --> 00:13:55,241
Go onto an axle
Across the loom's frame.
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00:13:58,620 --> 00:14:01,034
Another loom component,
Called the warp beam,
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00:14:01,137 --> 00:14:05,620
Has holes which hold metal hoops
That guide the warp threads.
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00:14:05,724 --> 00:14:07,827
A brake drum on the side
195
00:14:07,931 --> 00:14:12,137
Provides counterforce
To keep the threads taut.
196
00:14:12,241 --> 00:14:13,793
At the front of the loom,
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00:14:13,896 --> 00:14:16,310
They install foot pedals
Called treadles.
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00:14:16,413 --> 00:14:20,482
The weaver uses them to lift
And lower the warp threads.
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00:14:20,586 --> 00:14:22,827
Next comes the beater,
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00:14:22,931 --> 00:14:27,000
Which the weaver uses to pack
The weft thread into the fabric.
201
00:14:27,103 --> 00:14:32,000
The pulley system for
The harness cables goes on top.
202
00:14:32,103 --> 00:14:36,103
This computer-controlled device,
Called a dobby head,
203
00:14:36,206 --> 00:14:37,793
Lifts and lowers
The warp threads
204
00:14:37,896 --> 00:14:40,206
According to the programmed
Weaving pattern.
205
00:14:40,310 --> 00:14:44,551
Each harness cable
Hooks onto the dobby head,
206
00:14:44,655 --> 00:14:46,862
Goes around one of the pulleys,
207
00:14:46,965 --> 00:14:50,103
And attaches
To a hook on the harness.
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00:14:55,448 --> 00:14:59,344
The factory checks
Every dobby head on a test loom
209
00:14:59,448 --> 00:15:03,034
To ensure the device outputs the
Programmed patterns correctly.
210
00:15:10,034 --> 00:15:12,931
Next, workers
Install the spring levers
211
00:15:13,034 --> 00:15:16,275
That help the harness
Lift the warp threads.
212
00:15:16,379 --> 00:15:20,103
Each lever hooks onto a spring,
Which attaches to a chain,
213
00:15:20,206 --> 00:15:23,000
Which connects to a harness.
214
00:15:26,172 --> 00:15:31,758
They install the warp beam
At the back of the loom.
215
00:15:31,862 --> 00:15:35,068
The weaver installs the hoops
And warp threads
216
00:15:35,172 --> 00:15:36,413
On the warp beam.
217
00:15:36,517 --> 00:15:38,103
As the loom weaves,
218
00:15:38,206 --> 00:15:42,068
The cloth beam gently moves
The emerging fabric forward.
219
00:15:42,172 --> 00:15:43,241
The weft thread
220
00:15:43,344 --> 00:15:46,413
Is wrapped around a bobbin
Called a shuttle.
221
00:15:46,517 --> 00:15:49,896
This pattern requires
A two-weft-thread technique
222
00:15:50,000 --> 00:15:51,413
That uses a second shuttle
223
00:15:51,517 --> 00:15:55,103
Suspended
In front of the weaver.
224
00:15:55,206 --> 00:15:59,172
The loom keeps the threads
Evenly taut,
225
00:15:59,275 --> 00:16:02,241
Producing a consistent
And uniform weave --
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00:16:02,344 --> 00:16:06,310
The hallmarks of a beautiful,
Quality cloth.
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00:16:17,931 --> 00:16:20,172
Narrator:
Until the mid-19th century,
228
00:16:20,275 --> 00:16:23,000
Mother nature
Was the only producer of ice,
229
00:16:23,103 --> 00:16:26,517
And the idea of man-made ice
Seemed preposterous.
230
00:16:26,620 --> 00:16:28,172
It was a florida doctor who,
231
00:16:28,275 --> 00:16:30,344
In need of ice to cool
Feverish patients,
232
00:16:30,448 --> 00:16:32,000
Invented the ice machine.
233
00:16:32,103 --> 00:16:34,827
The technology
Took a few years to refine,
234
00:16:34,931 --> 00:16:37,551
And then
They were ready to chill.
235
00:16:40,896 --> 00:16:44,103
Today's commercial ice makers
Churn out ice on demand,
236
00:16:44,206 --> 00:16:46,137
Allowing restaurants
And other businesses
237
00:16:46,241 --> 00:16:50,482
To keep things cool
At all times.
238
00:16:50,586 --> 00:16:54,931
To make one, machinery folds the
Edges of stainless-steel sheets
239
00:16:55,034 --> 00:16:57,413
So they can be assembled
Into the icemaker frame
240
00:16:57,517 --> 00:16:59,827
And exterior panels.
241
00:17:01,931 --> 00:17:04,965
Meanwhile,
Copper uncoils over a roller,
242
00:17:05,068 --> 00:17:08,034
Which removes the curl
From the metal.
243
00:17:08,137 --> 00:17:13,206
A machine spiked with blades
Then punches the copper.
244
00:17:13,310 --> 00:17:17,379
In one action, it cuts
Numerous slits in the strip
245
00:17:17,482 --> 00:17:20,448
And slices it
To the correct length.
246
00:17:23,068 --> 00:17:27,931
The notched strips are now ready
To be assembled into a grid.
247
00:17:28,034 --> 00:17:32,724
This grid is part
Of the evaporator.
248
00:17:32,827 --> 00:17:36,551
It's here the liquid refrigerant
Will evaporate
249
00:17:36,655 --> 00:17:40,620
As it pulls heat from the water
To freeze it into ice cubes.
250
00:17:45,517 --> 00:17:48,896
This copper tubing
Is central to that process.
251
00:17:49,000 --> 00:17:51,068
An automated arm bends it
252
00:17:51,172 --> 00:17:54,241
Into a configuration
Called the serpentine,
253
00:17:54,344 --> 00:17:57,172
Producing a coil that will fit
On the back with the evaporator.
254
00:17:57,275 --> 00:18:01,965
As liquid refrigerant
Moves through it,
255
00:18:02,068 --> 00:18:05,137
It will draw heat
Out of the water.
256
00:18:05,241 --> 00:18:07,655
This machine
Flattens the tubing,
257
00:18:07,758 --> 00:18:10,793
Giving it greater surface
Contact with the evaporator
258
00:18:10,896 --> 00:18:13,724
To facilitate heat transfer.
259
00:18:15,758 --> 00:18:18,482
Then it's into
A big washing machine
260
00:18:18,586 --> 00:18:22,379
To remove any oils
Or oxides on the parts.
261
00:18:24,931 --> 00:18:27,965
A worker now applies strips
Of tin silver solder
262
00:18:28,068 --> 00:18:30,827
To the evaporator's back plate.
263
00:18:30,931 --> 00:18:35,172
This acid solution
Will act as a bonding agent.
264
00:18:35,275 --> 00:18:38,206
He then places the evaporator,
Solder side down,
265
00:18:38,310 --> 00:18:42,172
On the serpentine tubing
And locks the assembled parts
266
00:18:42,275 --> 00:18:43,758
In an iron rig.
267
00:18:48,655 --> 00:18:52,586
He hoists the rig into an oven
To melt the solder strips
268
00:18:52,689 --> 00:18:54,241
Between the back plate
And tubing,
269
00:18:54,344 --> 00:18:57,000
Fusing the parts together.
270
00:18:59,793 --> 00:19:02,413
Then it's into
An ultrasonic bath,
271
00:19:02,517 --> 00:19:04,724
Where high-frequency sound waves
272
00:19:04,827 --> 00:19:07,896
Clean off
Lingering contaminants.
273
00:19:08,000 --> 00:19:11,413
An inspector now
Examines the evaporator
274
00:19:11,517 --> 00:19:15,931
To confirm that the parts
Have been solidly fused.
275
00:19:16,034 --> 00:19:19,206
Next, he installs pipes
On an icemaker's side panel.
276
00:19:19,310 --> 00:19:24,172
These are the lines that supply
Refrigerant to the machine.
277
00:19:24,275 --> 00:19:27,862
He turns the assembly around
And removes the caps
278
00:19:27,965 --> 00:19:32,689
On the compressor to connect it
To a network of pipes.
279
00:19:32,793 --> 00:19:35,862
The compressor will force
Refrigerant through these pipes
280
00:19:35,965 --> 00:19:38,655
In a continuous cycle
Of heating and cooling
281
00:19:38,758 --> 00:19:40,620
To eventually produce ice.
282
00:19:45,275 --> 00:19:49,586
He brazes the joints
To seal the connections.
283
00:19:53,275 --> 00:19:56,517
He attaches a fan
To another side panel.
284
00:19:56,620 --> 00:20:00,689
It will blow cool air onto the
Radiator to cool the refrigerant
285
00:20:00,793 --> 00:20:03,586
And help convert it
Back into a liquid.
286
00:20:06,034 --> 00:20:09,241
Now he pumps the refrigerant
Into the system and measures
287
00:20:09,344 --> 00:20:13,413
The flow to ensure
It receives a precise amount.
288
00:20:13,517 --> 00:20:17,413
Meanwhile, at another station,
They assemble the ice bin.
289
00:20:20,758 --> 00:20:24,000
It's time to test this icemaker.
290
00:20:24,103 --> 00:20:25,689
Water flows continuously
291
00:20:25,793 --> 00:20:28,034
Over the surface
Of the evaporator grid
292
00:20:28,137 --> 00:20:32,241
As the temperature inside
The cells drops below freezing.
293
00:20:39,448 --> 00:20:42,344
Impurities, like minerals,
Are washed away
294
00:20:42,448 --> 00:20:44,344
As the water turns to ice,
295
00:20:44,448 --> 00:20:48,000
And the result
Is crystal-clear cubes,
296
00:20:48,103 --> 00:20:52,068
Almost 6 1/2 pounds
In just 15 minutes.
297
00:20:57,827 --> 00:21:03,000
Finally, they install
The front panel on the unit.
298
00:21:05,551 --> 00:21:07,482
This job is done,
299
00:21:07,586 --> 00:21:10,137
And it's time for
A little liquid refreshment...
300
00:21:10,241 --> 00:21:12,551
On ice, of course.
301
00:21:22,827 --> 00:21:25,724
If you have any comments
About the show,
302
00:21:25,827 --> 00:21:27,586
Or if you'd like to suggest
Topics for future shows,
303
00:21:27,689 --> 00:21:30,965
Drop us a line at...
24772
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