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Narrator: as the music industry
Went digital,
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00:00:54,275 --> 00:00:57,379
The turntable seemed destined
For the scrap heap.
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00:00:57,379 --> 00:01:01,206
But this analog technology
Defied predictions and survived.
4
00:01:01,206 --> 00:01:03,413
With a sound
That's arguably fuller
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00:01:03,413 --> 00:01:06,172
And more natural
Than compressed digital formats,
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00:01:06,172 --> 00:01:10,000
This retro technology
Is attracting new fans.
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00:01:13,724 --> 00:01:17,689
In an age when media players
Are digitized and pocket-sized,
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00:01:17,689 --> 00:01:19,517
The turntable plays on.
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00:01:21,241 --> 00:01:24,034
The use of high-tech composites
Like carbon fiber
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Puts a modern spin
On this technology,
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00:01:26,586 --> 00:01:30,310
Bringing the record player
Into the 21st century.
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00:01:30,310 --> 00:01:32,724
[ classical music plays]
13
00:01:32,724 --> 00:01:36,310
Production starts with
A thick square of cast acrylic.
14
00:01:36,310 --> 00:01:38,310
The technician drills a hole
In the center.
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00:01:38,310 --> 00:01:39,931
It will be a reference point
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00:01:39,931 --> 00:01:44,620
As he transforms this square
Into the turntable platter.
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00:01:44,620 --> 00:01:46,413
A computerized tool
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00:01:46,413 --> 00:01:49,103
Cuts a circle shape
Out of the square.
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00:01:52,172 --> 00:01:55,241
The disc then spins while
Another computer-guided tool
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00:01:55,241 --> 00:01:56,551
Enlarges the center hole
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00:01:56,551 --> 00:01:59,827
To size it
For the platter's main bearing.
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00:01:59,827 --> 00:02:03,241
The next tool precisely cuts
The surface of the disc
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00:02:03,241 --> 00:02:05,034
To give it the correct angle.
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00:02:09,275 --> 00:02:12,793
Computerized tools transform
This small aluminum disc
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00:02:12,793 --> 00:02:15,241
Into the counterweight's
Main component.
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00:02:15,241 --> 00:02:17,413
The counterweight
Balances the tone arm
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00:02:17,413 --> 00:02:20,758
To keep the stylus
In the groove of an l.P.
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00:02:20,758 --> 00:02:22,241
They slope the surface
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00:02:22,241 --> 00:02:26,034
And cut holes for attachments
And for installing the part.
30
00:02:27,241 --> 00:02:31,000
Finally, they cut a triangle
Out of the circle.
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00:02:33,275 --> 00:02:37,931
This takes the part
To its final shape and weight...
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00:02:37,931 --> 00:02:39,689
From a flat disc
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00:02:39,689 --> 00:02:42,172
To a precisely crafted
Counterweight.
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00:02:44,655 --> 00:02:48,068
Next, the platform
For the tone arm takes shape.
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00:02:48,068 --> 00:02:50,206
It's designed
To cradle all the parts
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00:02:50,206 --> 00:02:51,827
At the end of the tone arm,
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00:02:51,827 --> 00:02:54,965
Including a cylindrical housing
For a spring mechanism
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00:02:54,965 --> 00:02:59,206
And an egg-shaped housing
Containing a bearing.
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00:02:59,206 --> 00:03:01,689
A technician
Now assembles the tone arm,
40
00:03:01,689 --> 00:03:04,827
Beginning with a tapered tube
Made of carbon fiber.
41
00:03:04,827 --> 00:03:07,655
It's a high-tech composite
That's extremely stiff,
42
00:03:07,655 --> 00:03:11,586
So there should be no structural
Weakness in this crucial part.
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00:03:11,586 --> 00:03:14,344
The technician threads
A preassembled wiring loom
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00:03:14,344 --> 00:03:16,034
Through the arm tube.
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00:03:16,034 --> 00:03:19,275
It's special wire
For high-frequency transfer.
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00:03:19,275 --> 00:03:21,620
These wires
Have been encased in copper
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00:03:21,620 --> 00:03:23,551
To keep out ambient radiation
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00:03:23,551 --> 00:03:26,724
That would interfere
With the tone arm's operation.
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00:03:26,724 --> 00:03:30,448
The carbon-fiber tube
Also acts as a radiation shield.
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00:03:30,448 --> 00:03:33,206
He mixes epoxy resin
That he then dabs around
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00:03:33,206 --> 00:03:35,206
The inner rim
Of the bearing housing,
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00:03:35,206 --> 00:03:38,379
Which has by now been equipped
With the bearing.
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00:03:41,137 --> 00:03:44,068
He inserts the tone arm tube
Into the housing.
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00:03:48,103 --> 00:03:51,620
The tube adheres
To the glue-coated rim,
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00:03:51,620 --> 00:03:53,827
But before it totally bonds,
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00:03:53,827 --> 00:03:57,137
The technician scrutinizes
The alignment.
57
00:03:57,137 --> 00:03:59,241
He makes adjustments if needed,
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00:03:59,241 --> 00:04:00,827
And then he'll clamp
The assembly
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00:04:00,827 --> 00:04:03,413
To allow the glue to cure.
60
00:04:05,620 --> 00:04:08,275
With the turntable tone arm
Now upright,
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00:04:08,275 --> 00:04:11,068
He solders the wires that
Are protruding from the joint
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00:04:11,068 --> 00:04:13,275
To external wiring
For the amplifier.
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00:04:16,827 --> 00:04:19,275
And once all the connections
Have been made,
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00:04:19,275 --> 00:04:23,172
He inserts the wires
Into the metal joint.
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00:04:24,931 --> 00:04:26,448
Ensconced in this joint,
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00:04:26,448 --> 00:04:28,689
The connections
Are well-protected
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00:04:28,689 --> 00:04:31,655
And can't be pulled apart.
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00:04:33,172 --> 00:04:35,068
He equips
The main counterweight component
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00:04:35,068 --> 00:04:39,034
With two thick steel beams
For balance.
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00:04:39,034 --> 00:04:41,206
He slides the counterweight
Onto a third beam,
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00:04:41,206 --> 00:04:44,310
Which has been installed
In the egg-shaped housing.
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00:04:44,310 --> 00:04:47,724
This completes
The turntable tone arm.
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00:04:50,586 --> 00:04:55,103
Next, they encase the electric
Motor in its metal housing.
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00:04:57,793 --> 00:05:00,068
And they build the record deck.
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00:05:00,068 --> 00:05:02,655
They mount the motor
To the two-tiered deck,
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00:05:02,655 --> 00:05:04,827
Designed to absorb
Any vibration.
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00:05:04,827 --> 00:05:07,379
The aluminum sub-chassis
Is next.
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00:05:07,379 --> 00:05:10,275
They link it to the motor
With a drive belt,
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00:05:10,275 --> 00:05:12,965
Then they give the belt-drive
System a test spin
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00:05:12,965 --> 00:05:14,724
To confirm
That it runs smoothly.
81
00:05:16,379 --> 00:05:18,517
They now install
The acrylic platter,
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00:05:18,517 --> 00:05:20,931
Felt mat, and tone arm.
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00:05:20,931 --> 00:05:23,448
With this turntable
Now fully assembled,
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00:05:23,448 --> 00:05:26,137
It's time for the vinyl test.
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00:05:26,137 --> 00:05:27,724
The record spins,
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00:05:27,724 --> 00:05:30,620
And the stylus traces
The grooves.
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The analog sound
Fills the room...
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Proving this technology
Stands the test of time.
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[ classical music plays]
90
00:05:50,551 --> 00:05:52,586
Narrator:
The first modern steam engine
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00:05:52,586 --> 00:05:55,413
Was invented in england
In the early 1700s,
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00:05:55,413 --> 00:05:57,827
Helping launch
The industrial revolution.
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00:05:57,827 --> 00:06:00,793
Today there's a return
To steam power.
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00:06:00,793 --> 00:06:02,517
Due to its different
Configuration
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00:06:02,517 --> 00:06:03,965
And combustion process,
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00:06:03,965 --> 00:06:06,310
A steam engine
Produces less pollution
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00:06:06,310 --> 00:06:10,862
Than a regular
Internal-combustion engine.
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00:06:10,862 --> 00:06:12,758
This steam engine burns fuel
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00:06:12,758 --> 00:06:15,344
In an external
Combustion chamber.
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00:06:15,344 --> 00:06:18,620
The resulting heat turns water
Into pressurized steam
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00:06:18,620 --> 00:06:21,103
That enters the cylinders,
Pushing pistons,
102
00:06:21,103 --> 00:06:24,517
Turning a crankshaft
That powers the drive train.
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00:06:24,517 --> 00:06:27,551
Because this engine doesn't
Burn fuel inside the cylinders
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00:06:27,551 --> 00:06:29,758
Like a traditional car engine,
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00:06:29,758 --> 00:06:32,586
It can run on any type
Or mixture of fuels
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00:06:32,586 --> 00:06:35,137
With fewer emissions.
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00:06:35,137 --> 00:06:38,241
The circular engine block
Is made of aluminum.
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00:06:38,241 --> 00:06:40,068
Technicians install studs
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To hold six
Stainless-steel cylinders.
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00:06:43,241 --> 00:06:45,689
Due to the constant exposure
To steam,
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00:06:45,689 --> 00:06:49,655
All engine parts are made
Of rustproof materials.
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00:06:49,655 --> 00:06:53,172
The technicians insert a piston
Into each cylinder.
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00:06:53,172 --> 00:06:54,413
The piston is aluminum
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00:06:54,413 --> 00:06:57,137
With a heat-resistant carbon cap
And glider
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To isolate it
From the cylinder wall.
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00:06:59,862 --> 00:07:03,413
They connect the piston rods
To the crankshaft in the center
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00:07:03,413 --> 00:07:05,275
With a specially designed
Component
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00:07:05,275 --> 00:07:06,862
Called a spider bearing.
119
00:07:06,862 --> 00:07:10,172
This bearing is designed
To modify the piston stroke,
120
00:07:10,172 --> 00:07:13,206
Producing a smoother rotation
Of the crankshaft
121
00:07:13,206 --> 00:07:15,413
And more power to the engine.
122
00:07:15,413 --> 00:07:19,068
Unlike a traditional car engine,
With cylinders arranged in line,
123
00:07:19,068 --> 00:07:21,689
These cylinders
Are in a radial configuration
124
00:07:21,689 --> 00:07:24,448
And therefore equidistant
From the center.
125
00:07:24,448 --> 00:07:28,344
This prevents the engine from
Warping under high temperatures.
126
00:07:28,344 --> 00:07:31,413
They place a counterbalance
Over their spider bearing
127
00:07:31,413 --> 00:07:34,275
To further smooth the motion
Of the crankshaft.
128
00:07:34,275 --> 00:07:37,827
Now they install a pushrod
Over each cylinder.
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00:07:37,827 --> 00:07:39,413
It operates a valve,
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00:07:39,413 --> 00:07:43,206
Which lets steam enter the
Cylinder and move the piston.
131
00:07:43,206 --> 00:07:48,413
They insert the base of each
Pushrod into a guide ring...
132
00:07:48,413 --> 00:07:51,206
Then attach the cylinder heads,
133
00:07:51,206 --> 00:07:53,724
Each of which
Houses a steam-entry valve.
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00:07:53,724 --> 00:07:57,000
They insert the pushrod
Into the valve.
135
00:08:01,241 --> 00:08:03,241
Then, to complete
The engine assembly,
136
00:08:03,241 --> 00:08:04,620
They install the cam,
137
00:08:04,620 --> 00:08:08,482
Which pushes the pushrods
As the shaft spins.
138
00:08:08,482 --> 00:08:11,310
The factory hooks up
Every completed engine
139
00:08:11,310 --> 00:08:14,655
For a couple of rounds
Of performance testing.
140
00:08:14,655 --> 00:08:16,965
First, a trial run
Using air pressure
141
00:08:16,965 --> 00:08:18,448
To check for leaks
142
00:08:18,448 --> 00:08:21,655
And to verify that all
Components operate correctly.
143
00:08:21,655 --> 00:08:23,241
If everything's fine,
144
00:08:23,241 --> 00:08:25,965
Then they repeat the process
With steam pressure.
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00:08:28,413 --> 00:08:31,517
This type of steam engine can
Power many types of machines,
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00:08:31,517 --> 00:08:34,000
From cars, trucks, and boats,
147
00:08:34,000 --> 00:08:36,551
To electric generators
As we see here.
148
00:08:36,551 --> 00:08:39,689
In a vehicle, it doesn't require
A transmission
149
00:08:39,689 --> 00:08:43,758
Because it produces
So much rotational power.
150
00:08:43,758 --> 00:08:45,931
Now for the heat exchanger,
151
00:08:45,931 --> 00:08:50,275
The component which turns water
Into engine-powering steam.
152
00:08:50,275 --> 00:08:52,344
Technicians use
A motorized wheel
153
00:08:52,344 --> 00:08:54,689
To wind 20 feet
Of stainless-steel tubing
154
00:08:54,689 --> 00:08:56,517
Into a coil.
155
00:08:58,551 --> 00:09:00,931
They bind the coil
With steel thread,
156
00:09:00,931 --> 00:09:02,862
Putting a stitch
In between each tube
157
00:09:02,862 --> 00:09:05,379
To create a minute gap.
158
00:09:05,379 --> 00:09:08,551
That way, when fuel burns
In the combustion chamber,
159
00:09:08,551 --> 00:09:11,517
The heat can travel
Over and in between the tubes,
160
00:09:11,517 --> 00:09:14,724
Heating the water inside
Faster and more efficiently
161
00:09:14,724 --> 00:09:16,103
Than if the heat would contact
162
00:09:16,103 --> 00:09:19,344
Only the coils' top
And bottom surfaces.
163
00:09:19,344 --> 00:09:25,000
The result -- superheated steam
In just five seconds.
164
00:09:29,586 --> 00:09:32,000
They stack six of these coils,
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00:09:32,000 --> 00:09:34,206
One to feed steam
To each cylinder.
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00:09:34,206 --> 00:09:35,689
This nest of tubes
167
00:09:35,689 --> 00:09:38,896
Form the engine's
Primary heat exchanger.
168
00:09:38,896 --> 00:09:41,827
They test it
Using any number of fuels,
169
00:09:41,827 --> 00:09:45,862
Even waste fuels which would
Otherwise be discarded,
170
00:09:45,862 --> 00:09:47,551
Such as used motor oil
171
00:09:47,551 --> 00:09:51,206
And used vegetable oil
From restaurant fryers.
172
00:09:51,206 --> 00:09:55,172
Virtually anything that burns
Will do the job.
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00:09:55,172 --> 00:09:57,241
The fuel combusts
At low pressure,
174
00:09:57,241 --> 00:10:00,620
Not at high pressure
As in a gas or diesel engine.
175
00:10:00,620 --> 00:10:03,275
That means burning fossil fuels
To make steam
176
00:10:03,275 --> 00:10:06,034
Produces far fewer
Greenhouse gases,
177
00:10:06,034 --> 00:10:08,862
And most hydrocarbons
Burn off completely
178
00:10:08,862 --> 00:10:11,172
Within the sealed
Combustion chamber.
179
00:10:11,172 --> 00:10:14,310
You never have to refill
Or top off the water
180
00:10:14,310 --> 00:10:17,379
Because a condenser cools
The steam back into water,
181
00:10:17,379 --> 00:10:19,793
Which then recirculates.
182
00:10:19,793 --> 00:10:22,068
Water is not only
The working fluid --
183
00:10:22,068 --> 00:10:24,965
It also acts
As the engine lubricant,
184
00:10:24,965 --> 00:10:27,551
So the steam engine
Doesn't require motor oil.
185
00:10:29,689 --> 00:10:31,448
Besides fuel combustion,
186
00:10:31,448 --> 00:10:34,551
This modern steam engine
Can run off other heat sources,
187
00:10:34,551 --> 00:10:35,689
Such as solar heat
188
00:10:35,689 --> 00:10:38,827
And exhaust heat
From furnaces or engines.
189
00:10:50,482 --> 00:10:53,034
Narrator: there was a time
When the playground equipment
190
00:10:53,034 --> 00:10:56,068
In the local park or schoolyard
Was pretty basic stuff --
191
00:10:56,068 --> 00:10:59,620
A set of swings, a slide,
Maybe a see-saw or two.
192
00:10:59,620 --> 00:11:01,172
Today's playground equipment
193
00:11:01,172 --> 00:11:04,068
Is far more varied,
Imaginative, and colorful,
194
00:11:04,068 --> 00:11:06,862
Designed to stimulate
Children's minds
195
00:11:06,862 --> 00:11:09,793
As well as exercise
Their bodies.
196
00:11:12,379 --> 00:11:15,275
Slide down, climb on,
Wriggle through.
197
00:11:15,275 --> 00:11:17,482
There's no end
To how kids can frolic
198
00:11:17,482 --> 00:11:19,034
On modular play structures
199
00:11:19,034 --> 00:11:21,724
Or on this bubble-belly
Dinosaur.
200
00:11:25,241 --> 00:11:27,689
To make
The dinosaur's neck and legs,
201
00:11:27,689 --> 00:11:29,034
An automated band saw
202
00:11:29,034 --> 00:11:32,620
Cuts long steel tubes
To specific lengths.
203
00:11:38,137 --> 00:11:41,310
The tube for the neck
Is 5 1/2 feet long.
204
00:11:41,310 --> 00:11:44,344
Workers curve it
In a bending press.
205
00:11:44,344 --> 00:11:46,379
A level helps them
Get it just right.
206
00:11:51,620 --> 00:11:54,275
Next, they weld on
Two steel plates.
207
00:11:54,275 --> 00:11:58,793
These will support plastic seats
On which kiddies can sit.
208
00:11:58,793 --> 00:12:00,482
Workers also weld on bars
209
00:12:00,482 --> 00:12:03,586
For attaching the neck
To the body.
210
00:12:03,586 --> 00:12:06,206
They weld anchoring tabs
And supporting bars
211
00:12:06,206 --> 00:12:09,275
To the four steel-tube legs.
212
00:12:09,275 --> 00:12:11,862
Workers sandblast
The legs and neck
213
00:12:11,862 --> 00:12:13,931
With stainless-steel grit.
214
00:12:13,931 --> 00:12:16,068
The sandblasting gun
Shoots the grit
215
00:12:16,068 --> 00:12:19,068
At a speed of 435 miles an hour.
216
00:12:19,068 --> 00:12:22,793
This roughens the surface,
Enabling paint to better adhere.
217
00:12:24,689 --> 00:12:27,551
After applying
An undercoat of gray primer,
218
00:12:27,551 --> 00:12:30,655
Workers spray on a coat
Of plastic-based paint.
219
00:12:30,655 --> 00:12:35,000
The paint is then baked on,
Which maximizes its durability.
220
00:12:37,344 --> 00:12:40,275
Meanwhile, a computer-guided
Engraving machine
221
00:12:40,275 --> 00:12:43,310
Carves an educational design
Into a panel
222
00:12:43,310 --> 00:12:46,517
Made of triple-layered
Polyethylene plastic.
223
00:12:46,517 --> 00:12:50,103
Panels like this block the open
Sides of playground equipment,
224
00:12:50,103 --> 00:12:52,896
Preventing children
From falling through.
225
00:12:56,344 --> 00:12:59,206
To construct the dinosaur's
Bubble-shaped body,
226
00:12:59,206 --> 00:13:00,620
Workers bolt together
227
00:13:00,620 --> 00:13:05,482
Two half-spheres made
Of molded polyethylene plastic.
228
00:13:05,482 --> 00:13:09,517
They position the bubble body
On the legs...
229
00:13:15,034 --> 00:13:17,206
...Then bolt them together
From the inside.
230
00:13:17,206 --> 00:13:19,896
They bolt the neck to the body.
231
00:13:19,896 --> 00:13:21,482
The neck
Has since been outfitted
232
00:13:21,482 --> 00:13:24,931
With plastic seats
And the dino's plastic head.
233
00:13:24,931 --> 00:13:26,724
They finish off the dinosaur
234
00:13:26,724 --> 00:13:30,137
With a metal label
Bearing product information.
235
00:13:30,137 --> 00:13:32,931
This factory produces
Several components
236
00:13:32,931 --> 00:13:34,827
For its modular play structures,
237
00:13:34,827 --> 00:13:38,586
Such as a climbing net
Made of galvanized steel cable.
238
00:13:38,586 --> 00:13:41,172
The hard cable
Is padded in polyurethane.
239
00:13:41,172 --> 00:13:43,103
Workers use hydraulic scissors
240
00:13:43,103 --> 00:13:45,241
To cut the required lengths
Of cable...
241
00:13:45,241 --> 00:13:46,620
Then a cable stripper
242
00:13:46,620 --> 00:13:49,655
To slice off a little more
Than an inch of polyurethane
243
00:13:49,655 --> 00:13:52,655
From the ends of certain cables.
244
00:13:52,655 --> 00:13:54,827
Workers then cap
Each exposed end
245
00:13:54,827 --> 00:13:56,172
With a sleeved aluminum ring.
246
00:13:56,172 --> 00:13:59,758
They crimp the sleeve
With a 44-ton press.
247
00:13:59,758 --> 00:14:01,413
The rings will be bolted
248
00:14:01,413 --> 00:14:04,068
To the play structure's frame
And anchoring system.
249
00:14:06,551 --> 00:14:09,896
Finally, workers assemble
The cables into a grid,
250
00:14:09,896 --> 00:14:13,000
Locking each intersection
With a plastic connector.
251
00:14:13,000 --> 00:14:16,103
To ensure they won't rust
From exposure to the elements,
252
00:14:16,103 --> 00:14:18,724
The connectors'
Central screw and corner rivets
253
00:14:18,724 --> 00:14:20,620
Are made of stainless steel.
254
00:14:20,620 --> 00:14:24,655
On the modular play structure,
The children walk on a platform.
255
00:14:24,655 --> 00:14:27,068
It's constructed
From thick steel sheets,
256
00:14:27,068 --> 00:14:30,448
Perforated
By a robotic laser cutter.
257
00:14:30,448 --> 00:14:32,448
After bending the sheet
In a press
258
00:14:32,448 --> 00:14:33,896
To the required shape --
259
00:14:33,896 --> 00:14:36,344
This is the corner section
Of the platform --
260
00:14:36,344 --> 00:14:38,965
Workers heat it in an oven...
261
00:14:38,965 --> 00:14:42,000
Then submerge it
In a vat of polyvinyl,
262
00:14:42,000 --> 00:14:44,448
Which instantly adheres
To the hot metal.
263
00:14:48,793 --> 00:14:53,172
They build up a good coat --
About a 10th of an inch thick --
264
00:14:55,896 --> 00:14:58,655
Then let the excess drip off.
265
00:15:05,000 --> 00:15:08,482
They blast the entire piece
With an airgun.
266
00:15:08,482 --> 00:15:09,724
This clears the holes
267
00:15:09,724 --> 00:15:12,206
And produces a textured,
Anti-slip surface.
268
00:15:16,620 --> 00:15:19,482
Since playground equipment
Remains outdoors,
269
00:15:19,482 --> 00:15:22,000
All the paints and plastics
Are u.V.-treated
270
00:15:22,000 --> 00:15:23,965
To resist fading.
271
00:15:25,310 --> 00:15:28,137
Besides being durable,
The equipment is designed
272
00:15:28,137 --> 00:15:30,655
To meet
All required safety standards
273
00:15:30,655 --> 00:15:33,034
So that parents
Can have peace of mind
274
00:15:33,034 --> 00:15:35,000
While their children have fun.
275
00:15:50,517 --> 00:15:52,931
Narrator: food just slides off
Nonstick cookware's
276
00:15:52,931 --> 00:15:55,344
Remarkably slippery surface.
277
00:15:55,344 --> 00:15:58,034
In 1938, an american chemist
278
00:15:58,034 --> 00:16:00,551
Was experimenting
With refrigeration gases.
279
00:16:00,551 --> 00:16:02,482
A waxy substance formed.
280
00:16:02,482 --> 00:16:04,965
Years later,
When bonded to cookware,
281
00:16:04,965 --> 00:16:07,379
It gained a nonstick reputation.
282
00:16:10,655 --> 00:16:12,275
When it's time to fry,
283
00:16:12,275 --> 00:16:15,620
Using a nonstick pan
Averts a messy situation.
284
00:16:15,620 --> 00:16:17,000
The nonstick coating
285
00:16:17,000 --> 00:16:19,965
Is one of the slipperiest
Solid materials on earth.
286
00:16:19,965 --> 00:16:22,517
Called polytetrafluoroethylene,
287
00:16:22,517 --> 00:16:26,482
The name is a bit of a mouthful,
But the appeal is simple.
288
00:16:26,482 --> 00:16:30,034
Food won't get stuck
On this nonstick surface.
289
00:16:30,034 --> 00:16:34,517
To make the aluminum pan,
They use 70% raw material
290
00:16:34,517 --> 00:16:38,620
And 30% leftovers from prior
Production of pots and pans.
291
00:16:38,620 --> 00:16:40,413
They fire it to a molten state
292
00:16:40,413 --> 00:16:42,551
And filter it
To remove contaminants.
293
00:16:42,551 --> 00:16:46,793
The liquid aluminum flows
Into vertical rectangular molds.
294
00:16:46,793 --> 00:16:48,965
A jacket of water
Around the molds
295
00:16:48,965 --> 00:16:52,724
Cools the aluminum to take it
From a liquid to a solid.
296
00:16:52,724 --> 00:16:55,586
A crane extracts the cast slabs.
297
00:16:55,586 --> 00:16:57,689
They're heading
To a heating chamber
298
00:16:57,689 --> 00:16:59,379
To soften the slabs.
299
00:16:59,379 --> 00:17:02,724
This will allow the metal
To be shaped and formed.
300
00:17:02,724 --> 00:17:06,862
A saw slices the slabs in two
And trims the ends.
301
00:17:06,862 --> 00:17:09,206
More blades scrape the top
And bottom
302
00:17:09,206 --> 00:17:11,068
To remove impurities.
303
00:17:11,068 --> 00:17:14,000
A conveyor repeatedly feeds
The shorter slabs
304
00:17:14,000 --> 00:17:15,551
To heated rollers.
305
00:17:15,551 --> 00:17:17,655
Guides at the side
Maintain the width,
306
00:17:17,655 --> 00:17:19,862
While the rollers compress
The aluminum,
307
00:17:19,862 --> 00:17:24,103
Taking the thickness
Down to about .2 of an inch.
308
00:17:24,103 --> 00:17:27,620
The rolling also elongates
The slab substantially.
309
00:17:27,620 --> 00:17:30,241
It starts out
At 6 1/2 feet long,
310
00:17:30,241 --> 00:17:32,103
And after a few minutes
Of rolling,
311
00:17:32,103 --> 00:17:35,551
It's been stretched
To well over 100 yards.
312
00:17:37,000 --> 00:17:38,448
Pizza-cutter-style blades
313
00:17:38,448 --> 00:17:41,758
Trim the edges
Of the aluminum sheet.
314
00:17:41,758 --> 00:17:45,724
Another roller winds
The aluminum into a big coil.
315
00:17:48,827 --> 00:17:50,206
They then unwind it
316
00:17:50,206 --> 00:17:53,310
And squeeze the aluminum
To flatten it.
317
00:17:53,310 --> 00:17:56,482
Machinery now pulls
The long aluminum sheet forward
318
00:17:56,482 --> 00:17:59,827
To a 132-ton punch press.
319
00:17:59,827 --> 00:18:02,172
This powerful press
Forces the metal
320
00:18:02,172 --> 00:18:04,103
Around a frying-pan-shaped die
321
00:18:04,103 --> 00:18:06,586
And then punches out the shape.
322
00:18:06,586 --> 00:18:08,758
The freshly formed
Aluminum frying pan
323
00:18:08,758 --> 00:18:11,482
Falls onto a conveyor below.
324
00:18:11,482 --> 00:18:15,034
The leftover aluminum will be
Used to make new frying pans.
325
00:18:15,034 --> 00:18:18,448
The pans now ride a conveyor
Through a washing station,
326
00:18:18,448 --> 00:18:22,310
Where they're cleaned and then
Treated with sodium hydroxide.
327
00:18:22,310 --> 00:18:24,275
This opens the pores
Of the metal
328
00:18:24,275 --> 00:18:27,551
To allow an enamel coating
To stick to the outside
329
00:18:27,551 --> 00:18:31,620
And the nonstick finish
To adhere to the inside.
330
00:18:31,620 --> 00:18:33,310
A worker inspects the pans
331
00:18:33,310 --> 00:18:36,517
And places them upside-down
On spray fixtures.
332
00:18:36,517 --> 00:18:38,689
It's a tight fit
To shield the inside
333
00:18:38,689 --> 00:18:42,034
From the enamel spray
That comes next.
334
00:18:42,034 --> 00:18:45,034
The pans spin on the fixtures
And twirl by the spray nozzles
335
00:18:45,034 --> 00:18:47,137
For an even application
Of enamel
336
00:18:47,137 --> 00:18:48,758
To the exterior of the pans.
337
00:18:48,758 --> 00:18:52,448
A clear, glossy coat follows.
338
00:18:52,448 --> 00:18:55,448
The frying pans transfer
To a dryer conveyor.
339
00:18:55,448 --> 00:18:58,379
The hot air pulls out water
From the enamel coating,
340
00:18:58,379 --> 00:19:03,034
And the color goes from gray
To chalky white.
341
00:19:03,034 --> 00:19:04,620
An automated squeegee
342
00:19:04,620 --> 00:19:07,551
Silk-screens the company's name
And other information
343
00:19:07,551 --> 00:19:10,241
Onto the pan bottoms.
344
00:19:11,068 --> 00:19:13,034
They now enter
A long curing oven
345
00:19:13,034 --> 00:19:16,448
Heated to 1,040 degrees
Fahrenheit.
346
00:19:16,448 --> 00:19:18,793
The cure toughens the enamel,
347
00:19:18,793 --> 00:19:21,206
Deepens the color
So it turns gray again,
348
00:19:21,206 --> 00:19:23,344
And it adds gloss.
349
00:19:23,344 --> 00:19:26,103
A suctioning device
Picks up the pan
350
00:19:26,103 --> 00:19:28,931
And turns it around
For the inside coatings.
351
00:19:28,931 --> 00:19:31,241
A sprayer applies
A special primer
352
00:19:31,241 --> 00:19:34,310
That will make the nonstick
Coating adhere to the pan.
353
00:19:34,310 --> 00:19:36,620
It then applies
The nonstick coating.
354
00:19:36,620 --> 00:19:38,620
The pans receive two layers
355
00:19:38,620 --> 00:19:41,448
Of this nonstick
Synthetic substance.
356
00:19:41,448 --> 00:19:43,551
The suctioning device
Releases the pan,
357
00:19:43,551 --> 00:19:46,172
And it lands upside down.
358
00:19:46,172 --> 00:19:48,827
Then the pans journey
Through the oven again
359
00:19:48,827 --> 00:19:50,689
To cure the nonstick finish
360
00:19:50,689 --> 00:19:53,689
At around 800 degrees
Fahrenheit.
361
00:19:53,689 --> 00:19:55,965
On exit, water rains down
362
00:19:55,965 --> 00:19:59,344
To cool the pans
And rinse off any contaminants.
363
00:19:59,344 --> 00:20:01,724
Then they go through
An infrared-light chamber
364
00:20:01,724 --> 00:20:03,517
To dry off.
365
00:20:03,517 --> 00:20:07,758
From a plain shell to a pan with
An enamel finish on the outside
366
00:20:07,758 --> 00:20:10,310
And a nonstick coating
On the inside,
367
00:20:10,310 --> 00:20:13,413
The transformation
Has taken just one hour.
368
00:20:13,413 --> 00:20:15,413
A worker now aims a laser
369
00:20:15,413 --> 00:20:17,551
And aligns it
With lettering on the bottom,
370
00:20:17,551 --> 00:20:20,344
Allowing him to punch holes
In a precise location
371
00:20:20,344 --> 00:20:22,724
On the side of the pan.
372
00:20:22,724 --> 00:20:24,689
He slides pins into the holes
373
00:20:24,689 --> 00:20:27,931
And slots them through holes
In the handle fitting.
374
00:20:27,931 --> 00:20:30,172
Using a ram,
He flattens the pins
375
00:20:30,172 --> 00:20:33,620
To rivet the handle to the pan.
376
00:20:33,620 --> 00:20:38,655
Now, no matter what's cooking,
Cleanup should go smoothly.
377
00:20:51,689 --> 00:20:54,206
If you have any comments
About the show,
378
00:20:54,206 --> 00:20:56,655
Or if you'd like to suggest
Topics for future shows,
379
00:20:56,655 --> 00:20:58,655
Drop us a line at...
380
00:20:59,758 --> 00:21:02,827
--captions by vitac--
Www.Vitac.Com
381
00:21:02,827 --> 00:21:05,793
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