All language subtitles for S23E07 - Oil Pressure Sensors; Large Format Printing; Heavy Equipment Simulators; Head & Neck Restraints (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]1
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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: in motor vehicles,
An oil pressure sensor
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Is a critical part
Of the engine.
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As oil lubricates,
Cools and cleans the motor,
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This sensor constantly
Measures the pressure
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And signals a problem before
It causes serious damage
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To the engine.
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Screwed to the engine block
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And connected
To the car's computer,
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The sensor can detect
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The smallest change
In oil pressure.
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The computer relays
The information
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To the gauge on the dashboard.
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It allows the driver to tell
At a glance
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If there's a pressure problem
Under the hood.
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To manufacture
Motor oil sensors,
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A robot picks up
A perforated ceramic board
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And transfers it to a carriage.
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The carriage shuttles the board
Into a screen printing machine.
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It squeegees
Palladium silver paste onto it,
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Creating a pattern for a sensor
Around each of the holes.
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The silver will serve
As an electrical conductor.
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A trip through a long oven
Bakes the silver paste
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Onto the ceramic.
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Then it's back to
The screen printing machine.
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This time, the squeegee applies
A green glass glaze
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Onto the silver.
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The pattern leaves some
Of the silver exposed
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For the attachment of components
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Like capacitors and diodes.
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A robot then applies
Those components
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Faster than you can
Blink an eye.
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The next robot transfers
Terminals to the sensors.
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To align the prongs
Of the terminal
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With exposed silver
On the sensor,
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The robot takes a picture
And sends it to the computer.
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The computer then guides
The positioning.
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It all happens in a flash.
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00:03:05,931 --> 00:03:08,586
Once the terminal has been
Soldered to the sensor,
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Another robot dispenses
Adhesive around the components.
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This seals the circuitry
From the oil
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That will flow
Through the center hole.
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The next robot places
A silicon chip on the sensor,
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Covering and sealing
The center hole.
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This chip will react
To changes in oil pressure.
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Another robot bonds
The silicon chip
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To the circuitry
Using aluminum wire
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That's thinner
Than a human hair.
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This completes
The electrical connection.
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An employee now inserts the ends
Of the sensors in a fixture
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And breaks them
Along score lines.
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This separates them
Into strips of five.
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She transfers the strip
To a machine
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That bends the terminals
To a precise shape.
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She snaps the ceramic along
More score lines
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To separate the strips of five
Into single sensors.
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Next, she connects the terminals
To posts in plastic housing.
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After soldering them in place,
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She folds the rest
Of the sensor over them.
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She then places brass shells
In a carrier.
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She inserts two rubber o rings
In the shells --
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A large one and a smaller one
Around the center hole.
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The robots take it from here.
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The first one picks up
The sensor assembly,
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And using a camera as a guide,
Transfers it to the brass shell.
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Then it's over to
A press and crimp station.
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The top tool applies pressure
To compress the o rings
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00:05:02,551 --> 00:05:05,931
As forming tools crimp the shell
Around the sensor.
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An applicator coats the threads
Of the brass shell with sealant.
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When dry, this sealant will
Enhance the sensor's fit
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To the engine
To prevent oil leakage.
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A test hit probes each sensor,
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Performing
A full electrical evaluation.
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It also applies air pressure
To test for leaks.
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After passing the test,
The oil sensor is complete.
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Narrator: businesses looking
To advertise
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Will often commission
A printing company
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To produce
A large poster or banner.
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The quality of
Large format printing
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Is better than ever
Thanks to digital technology.
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Commercial equipment
Can typically print a banner
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Up to 16 feet high
By 150 feet wide.
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If the required size is larger,
It's printed in sections,
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Then joined together.
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A prepress technician
Preps the clients' design
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For printing --
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Adjusting colors, sectioning,
And adding a bleed.
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This is a blind border
Around the design
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Because the machines can't print
All the way to the edge.
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Then it's time to load
A roll-to-roll printing machine
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With weather resistant
Vinyl mesh.
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They feed the leading edge
Of the roll into the machine
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00:07:06,931 --> 00:07:09,517
And pull it through
The output end.
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This aligns the vinyl
So that the printing
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Won't come out crooked.
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They slip a cardboard tube
Over the roller
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Which will receive
The printed vinyl
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And tape on the leading edge.
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If this job required printing
On a ridged material,
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They'd be using
A flatbed printer
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Rather than the roll-to-roll.
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Both machines print
With ink-jet technology,
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Similar to
A home computer printer.
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However, rather than using
Dye-based inks,
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They're typically solvent-based.
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They're designed to withstand
Outdoor conditions
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For three to five years.
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The machine uses
The standard ink-jet colors --
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Black, yellow, cyan,
And magenta.
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It also includes light cyan
And light magenta
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To provide additional
Shade variations.
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The machine has 12 print heads,
2 per color.
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Each head has 256 nozzles.
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Once daily, they're put through
A full cleaning procedure
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To prevent clogging.
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The print head moves
Back and forth across the vinyl.
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The computer guides
The individual nozzles
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To deposit dots of ink
At specific spots.
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All those colored dots together
Form the printed design.
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The first 6 inches the machine
Prints are a color bar test
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To make sure that every nozzle
Is working properly.
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The printing of
The actual design follows.
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The printed vinyl banner
Exits the machine
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And winds around
The receiving roller.
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Then they mount the roll
Onto another machine,
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Which trims off the excess
Vinyl and the bleed
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With rotary blades.
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When the banner is compromised
Of sections,
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Workers connect them.
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First they align the edges,
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Then they bond the joint
Temporarily with masking tape.
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They flick a switch
To project laser lines,
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Which indicate the width
And center of the weld.
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00:09:33,724 --> 00:09:35,689
The weld will permanently
Connect the sections
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On the reverse side.
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Turning the banner facedown,
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Workers align the joint
With the center line.
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A magnetic strip secures
The banner to the table
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To prevent it from shifting,
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00:09:47,896 --> 00:09:51,241
And a vacuum pulls
The banner taut.
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At the same time,
A hot air welder fuses the joint
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With heat-activated
Adhesive tape.
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Then they flip the banner
Faceup again
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00:10:00,517 --> 00:10:02,551
And remove the temporary tape.
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00:10:10,310 --> 00:10:13,931
The last step is to reinforce
The perimeter with webbing --
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The material used
For seat belts.
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This gives the banner
A nice finished edge.
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00:10:19,379 --> 00:10:21,793
It also creates a strong border
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In which to secure grommets
For hanging the banner.
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Workers apply the grommets
Manually with a pneumatic press.
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A banner typically has a grommet
Every 24 inches,
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Plus 3 in each corner.
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To hang the banner,
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You run bungee cords
Through the grommets,
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Pull taut, then hook the ends
To plates affixed
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To the building facade.
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A few screws for reinforcement,
And you're done.
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Wind passes right through
The tiny holes of the vinyl mesh
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So the banner doesn't billow.
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Narrator: when you're learning
How to operate heavy equipment,
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One wrong move can cause damage
Or injuries.
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That's why it's becoming more
Common to train on a simulator,
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00:11:18,931 --> 00:11:21,655
Which can replicate
Real-life scenarios
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From typical maneuvers
To emergency situations.
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00:11:28,965 --> 00:11:32,413
Whether learning to operate
A crane, backhoe, or excavator,
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00:11:32,517 --> 00:11:35,310
It's safer for a trainee
To make rookie mistakes
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At a virtual work site.
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The instructor simply installs
Heavy equipment controls
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And loads
The appropriate software.
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Then the simulator
Is all set to replicate
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How the equipment maneuvers.
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A heavy equipment simulator
Begins life
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As a series of
3-d technical drawings.
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Mechanical engineering
Technicians plug in the details
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Of the customer's order,
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Including foot pedals
And joysticks
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To control the equipment's
Various movements.
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Then assembly can begin.
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Following the plans,
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Technicians build
The steel motion platform
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Which replicates the movement
Of the cab.
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Its base has wheels
For rolling the simulator
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From one location to another.
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This drive controls
The three actuators
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Which raise, lower,
And tilt the platform.
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Once the technicians have
Installed and wired up
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All three actuators,
They install the platform cover.
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00:12:48,000 --> 00:12:50,482
Next, they mount
The height-adjustable seat.
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00:12:50,586 --> 00:12:52,965
At its base,
Enclosed in a bellow,
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00:12:53,068 --> 00:12:55,586
Is a pneumatic suspension
System.
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This enables the seat
To realistically bounce or jerk
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00:12:58,758 --> 00:13:01,655
In response to the action
Being simulated.
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Meanwhile,
Another technician assembles
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00:13:04,689 --> 00:13:07,068
The simulator's control box.
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He mounts
The joystick controller
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00:13:08,862 --> 00:13:11,827
And connects its wiring
To a cable inside.
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00:13:16,000 --> 00:13:19,551
The cable leads to a connector
On the base of the box.
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That connector simply plugs into
The motion platform
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Right next
To the operator's seat.
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The box attaches securely
With large screw knobs,
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Making it easy to disconnect
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00:13:32,586 --> 00:13:35,379
And switch to different kinds
Of simulations.
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00:13:39,793 --> 00:13:43,793
The foot pedals are mounted
To a separate platform.
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00:13:43,896 --> 00:13:46,034
Technicians attach it
To the motion platform
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00:13:46,137 --> 00:13:48,241
With two screws.
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00:13:48,344 --> 00:13:49,758
Like the control box,
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The idea is to be able to switch
This pedal platform easily
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For a different one.
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The simulator's cab
Is now fully assembled
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00:13:58,517 --> 00:14:01,275
And it moves just like
A real one.
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00:14:06,620 --> 00:14:10,551
The virtual view from the cab,
Spans five l.C.D. Screens
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00:14:10,655 --> 00:14:14,689
To give the trainee a realistic
Perspective of the work site.
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00:14:19,482 --> 00:14:21,793
After installing
The screen supports,
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00:14:21,896 --> 00:14:23,965
Workers mount the screens.
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00:14:28,482 --> 00:14:30,551
The configuration mimics
The window layout
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00:14:30,655 --> 00:14:32,379
Of the typical cab.
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00:14:35,551 --> 00:14:39,482
The simulation runs on software
That's designed in-house.
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00:14:39,586 --> 00:14:42,931
However, the client can further
Customize the program
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00:14:43,034 --> 00:14:45,862
For a specific make and model
Of heavy equipment
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00:14:45,965 --> 00:14:49,344
Or to simulate specific
Scenarios that might arise
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00:14:49,448 --> 00:14:51,655
On a particular work site.
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00:14:51,758 --> 00:14:54,517
The simulator has
Five different computers.
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00:14:54,620 --> 00:14:57,413
Three of them run
The seat movement, the screens,
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00:14:57,517 --> 00:15:00,413
And a small touch screen
To the trainee's right.
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00:15:00,517 --> 00:15:02,517
That screen displays
The buttons, knobs,
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00:15:02,620 --> 00:15:06,068
And levers of
The heavy equipment's dashboard.
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00:15:06,172 --> 00:15:08,862
The fourth computer calculates
229
00:15:08,965 --> 00:15:11,206
The physics
Of the simulated environment
230
00:15:11,310 --> 00:15:13,310
Such as the excavator's
Digging movement
231
00:15:13,413 --> 00:15:15,931
And the corresponding
Soil movement.
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00:15:18,000 --> 00:15:20,793
The fifth computer manages
The training scenarios.
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00:15:20,896 --> 00:15:22,137
For instance,
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00:15:22,241 --> 00:15:24,310
An instructor can program
Adverse weather conditions
235
00:15:24,413 --> 00:15:29,551
To make the exercise
More difficult.
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00:15:29,655 --> 00:15:32,068
To simulate a different piece
Of equipment,
237
00:15:32,172 --> 00:15:34,896
The instructor simply switches
The joystick and pedals
238
00:15:35,000 --> 00:15:36,724
If necessary
239
00:15:36,827 --> 00:15:39,068
And loads
The appropriate software.
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00:15:42,000 --> 00:15:44,965
In the simulator, the trainee
Has the same perspective
241
00:15:45,068 --> 00:15:49,310
He or she would have
In the real-life cab.
242
00:15:49,413 --> 00:15:51,724
Three reflective markers
On the helmet
243
00:15:51,827 --> 00:15:54,965
Enable an infrared camera
Mounted above the screens
244
00:15:55,068 --> 00:15:57,034
To track the trainee's
Head movements.
245
00:15:57,137 --> 00:15:59,448
This prompts the software
246
00:15:59,551 --> 00:16:01,724
To display
The corresponding view.
247
00:16:15,655 --> 00:16:17,068
Narrator:
Tragedy on the racetrack
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00:16:17,172 --> 00:16:18,793
Led to the development
Of the head and neck restraint
249
00:16:18,896 --> 00:16:21,068
In the 1980s.
250
00:16:21,172 --> 00:16:24,206
Investigations had revealed
A deadly trend in motor sports.
251
00:16:24,310 --> 00:16:26,827
With the driver's body
Restrained,
252
00:16:26,931 --> 00:16:28,586
The head moved violently
In a crash,
253
00:16:28,689 --> 00:16:30,931
Causing fracture
To the base of the skull.
254
00:16:31,034 --> 00:16:33,896
Clearly,
More restraint was needed.
255
00:16:37,482 --> 00:16:39,724
Attached to a helmet,
A head and neck restraint
256
00:16:39,827 --> 00:16:42,827
Is designed to save
The racer's skull.
257
00:16:42,931 --> 00:16:44,689
It has become required
Equipment
258
00:16:44,793 --> 00:16:47,413
In many racing organizations.
259
00:16:49,379 --> 00:16:50,689
To make these restraints,
260
00:16:50,793 --> 00:16:53,827
They mix plastic
And carbon fiber pellets.
261
00:16:53,931 --> 00:16:56,310
The carbon fiber fortifies
The plastic,
262
00:16:56,413 --> 00:16:58,172
Which is made
From castor bean oil
263
00:16:58,275 --> 00:17:00,655
Instead of petroleum products.
264
00:17:03,517 --> 00:17:04,896
A machine melts the mixture
265
00:17:05,000 --> 00:17:07,482
And injects it into a mold
Under pressure
266
00:17:07,586 --> 00:17:10,655
To produce the base structure
For the restraint.
267
00:17:10,758 --> 00:17:14,793
The operator breaks off
What's known as the sprue --
268
00:17:14,896 --> 00:17:16,551
Plastic that's solidified
In the channels
269
00:17:16,655 --> 00:17:20,068
Leading to the mold.
270
00:17:20,172 --> 00:17:23,241
He trims the plastic
And carbon fiber overflow
271
00:17:23,344 --> 00:17:25,068
From around the edges.
272
00:17:25,172 --> 00:17:28,620
This overflow is known
In the industry as "Flash."
273
00:17:31,379 --> 00:17:35,931
He hangs the parts to cure
Over a 24-hour period.
274
00:17:36,034 --> 00:17:40,310
The next day, the employee
Clamps the part in a jig
275
00:17:40,413 --> 00:17:42,413
And activates
Computerized tools.
276
00:17:42,517 --> 00:17:45,034
The first one drills holes
For tethering restraint
277
00:17:45,137 --> 00:17:46,793
To the helmet.
278
00:17:46,896 --> 00:17:51,103
Another trims it
To its final size.
279
00:17:51,206 --> 00:17:54,448
An automated hot knife
Now cuts nylon tether material
280
00:17:54,551 --> 00:17:56,620
To the correct length.
281
00:17:59,103 --> 00:18:01,827
Then it's over to
A computerized sewing machine
282
00:18:01,931 --> 00:18:06,310
To stitch the tether
Around a chrome fitting.
283
00:18:06,413 --> 00:18:09,000
The stitching pattern has been
Designed by an engineer
284
00:18:09,103 --> 00:18:11,344
To withstand
The force of impact.
285
00:18:17,551 --> 00:18:20,310
The operator then stitches
On a label,
286
00:18:20,413 --> 00:18:22,310
Which says the tether's design
Has been sanctioned
287
00:18:22,413 --> 00:18:26,137
By both american and european
Racing organizations.
288
00:18:33,172 --> 00:18:36,241
Next, using a dye
Powered by bursts of air,
289
00:18:36,344 --> 00:18:38,310
A worker punches out
Shoulder pads
290
00:18:38,413 --> 00:18:40,310
From cushion foam.
291
00:18:44,310 --> 00:18:46,482
The next member of the team
Slides the shoulder pads
292
00:18:46,586 --> 00:18:50,034
Into casings made of
Fire-resistant cotton.
293
00:18:50,137 --> 00:18:52,344
It's a snug fit,
294
00:18:52,448 --> 00:18:54,793
And without
A special installation tool,
295
00:18:54,896 --> 00:18:56,724
The job wouldn't go smoothly.
296
00:19:00,413 --> 00:19:02,482
By folding the pad
Into the tool
297
00:19:02,586 --> 00:19:04,551
And then inserting it
Into the long case,
298
00:19:04,655 --> 00:19:06,724
There are no bunch ups.
299
00:19:11,827 --> 00:19:14,068
Some head and neck restraints
Are adjustable
300
00:19:14,172 --> 00:19:17,206
So drivers can find
A more comfortable fit.
301
00:19:17,310 --> 00:19:19,793
They assemble those restraints
In three pieces
302
00:19:19,896 --> 00:19:24,206
With the adjustable fittings
In the joints.
303
00:19:24,310 --> 00:19:26,551
The employee then paints
Adhesive primer
304
00:19:26,655 --> 00:19:29,896
Onto the base structure
Of the head and neck restraint.
305
00:19:36,586 --> 00:19:37,689
He coats most of the plastic
306
00:19:37,793 --> 00:19:39,827
And carbon fiber surface
With it.
307
00:19:39,931 --> 00:19:44,103
He applies neoprene padding
To the primed surface.
308
00:19:44,206 --> 00:19:48,620
The padding is adhesive backed
And it bonds instantly.
309
00:19:52,275 --> 00:19:54,620
He attaches the tether
To the back of the restraint
310
00:19:54,724 --> 00:19:56,896
With plastic clips and screws.
311
00:20:02,310 --> 00:20:04,000
Using hook and loop tape,
312
00:20:04,103 --> 00:20:06,241
He secures the shoulder pads
To the other side
313
00:20:06,344 --> 00:20:08,000
Of the restraint's yoke.
314
00:20:14,103 --> 00:20:17,103
Another worker applies
More certification labels.
315
00:20:17,206 --> 00:20:19,275
They signify that
The actual structure
316
00:20:19,379 --> 00:20:22,137
Of the head and neck restraint
Meets standards.
317
00:20:27,793 --> 00:20:31,068
They now test
A randomly selected restraint.
318
00:20:31,172 --> 00:20:33,310
A hydraulic arm
Pulls the tethers
319
00:20:33,413 --> 00:20:35,448
Until the restraint snaps,
320
00:20:35,551 --> 00:20:39,448
Mimicking the force
Of a violent impact.
321
00:20:39,551 --> 00:20:42,241
The restraint withstands more
Than what's required
322
00:20:42,344 --> 00:20:44,931
And breaks in the right place.
323
00:20:47,310 --> 00:20:49,931
Next, an employee attaches
A head and neck restraint
324
00:20:50,034 --> 00:20:54,206
To the helmet using the tethers.
325
00:20:54,310 --> 00:20:58,758
Two crash dummies
Put the restraints to the test.
326
00:20:58,862 --> 00:21:01,000
The one on the left
Isn't wearing a restraint
327
00:21:01,103 --> 00:21:04,206
While the right one is.
328
00:21:04,310 --> 00:21:08,068
Steady nerves and a steady head
Could save a racer's life,
329
00:21:08,172 --> 00:21:11,862
And a head and neck restraint
Definitely improves the odds.
26558
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