All language subtitles for S32E08 - Belts; 3D Metal Printers; Detectable Warning Panels; Model Stirling Engines (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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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:
Today on "How it's made,"
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Belts...
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...3-d metal printers...
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...Detectable warning panels...
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...And model stirling engines.
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Belts have been worn with
Different types of garments
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Since the invention of clothes.
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Made to cinch your waistline,
This accessory is worn with
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Pants, shirts, robes,
Or dresses,
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Making a fashionable addition
To any outfit.
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Durable and flexible, leather
Is the classic material
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Used for belt making.
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This production facility
Manufactures stylish,
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High quality belts
At top speed.
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A designer creates
A belt pattern on her computer
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And sends the design
Electronically
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To the in-house
Laser etching machine.
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A craftsman places
A cowhide on a large table.
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He examines the hide
For any flaws
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And carefully marks each one.
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The cowhides are made from
Meat industry byproducts,
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And most are sourced
From italy.
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A device scans
The shape of the hide
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And the craftsman digitally
Marks the location of the flaws.
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A specialized cutting machine
Uses the marked information
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To create an efficient
Series of cuts.
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This process results
In a high quality product
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With minimal waste.
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Another technician sorts
The various belt lengths
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Into containers,
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Preparing them for
The next step.
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The cutting machine
Is capable of slicing
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Up to 2,400 belts per day.
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The cutting machine creates
Straight, sharp-edged strips.
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The technician feeds the belts
Into a machine
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That bevels the edges at
The rate of 6,000 per day.
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At the next station, a series
Of small suction devices
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Quickly lift and place each
Belt on a conveyor system.
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A stamping machine
Accurately cuts the shape
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Of the belt tip
And the holes for the prong.
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The craftsman stacks a group
Of belts and packs them
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Tightly together,
Then he dyes the edges with ink
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And sands them down.
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These steps complement
The edge dyeing machine process,
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Which can add color
To the belt edges.
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Then the belts are transferred
To a drying machine.
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The edges must be completely dry
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Before they move
To the next step.
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Powered by world war ii
Jeep engines,
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A rotating wooden drum tumbles
The belts,
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While simultaneously
Burnishing the leather.
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This type of machinery
Comes from
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Italy's famous
Leather working region.
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This imported machine,
From milan,
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Rapidly punches out
The pattern of perforations,
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Which make up the belt's
Signature design elements.
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Since the machine's die is less
Than 20 inches long,
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The complex pattern along the
Belt can't be stamped at once.
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Instead, the machine punches out
A section at a time
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Resulting in a production rate
Of 1,400 belts per day.
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A laser etching machine
Burns a second pattern
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Into the leather surface.
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This pattern was created
By the designer
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Prior to production.
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At the next station,
A craftswoman fills the holes
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Of a specially crafted
Two-part metal die
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With nail heads.
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The nail heads are made of
Zinc with a brass finish.
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Using a press,
An operator places the die
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In a waiting repository.
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She removes the top half,
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Ensuring that all of the holes
Are filled with nail heads.
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Then she turns the belt around
And places it over the die
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Before sliding the belt
Inside the press.
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The press affixes the nail heads
To the leather.
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Before attaching the buckle,
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The belts go through
A process called skiving.
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This device shaves off
A section of the leather
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So that when it's folded over,
It won't be too thick.
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A loop is attached
On to the end of the belt,
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Followed by a buckle.
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The craftswoman uses the loop to
Temporarily hold
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The buckle and tag in place.
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The tag contains the belt's
Size, price,
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And brand information.
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Another craftswoman sews the
Belt buckle and tag in place,
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Using 69 weight thread
And a bar tacking stitch.
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This facility manufactures
Nearly 10,000 belts per day.
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This intricate
Leather fashion accessory
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Might be a cinch to wear,
But not to make.
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Narrator: 3-d printers generate
Metal parts for spacecraft,
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Cars, and medical devices,
To name a few.
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3-d printing technology allows
For the production
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Of complex design structures
Which can't be achieved
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Using traditional
Manufacturing methods.
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The 3-d metal printer could
Truly break the mold.
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Thanks to advancements in
Technology,
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It's now possible
To print metal parts.
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This 3-d printer melts
And layers metal powder
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And a part materializes.
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This part will become
A rocket nozzle heat exchanger.
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At the core of the 3-d metal
Printer is the deposition head,
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Which feeds and melts the
The metal powder.
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So far the designing process
Has taken hundreds of hours.
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Tools guided by
The design software transform
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A brass cylinder
Into the nozzle cone.
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The profile of the nozzle cone
Can vary slightly,
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Depending on the parts
The 3-d metal printer
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Will be used to produce.
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Next the powder inlet component
Is added.
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Metal powder will
Flow through this part
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To a mixing chamber and,
Eventually, the nozzle cone.
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Computerized tools
Cut angled channels,
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Delivering different
Metal powders
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To the mixing chamber
With an angular velocity,
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Creating a vortex to
Help blend the powders.
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The part has been nickel plated
And fasteners are installed.
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The technician aligns
The laser delivery channel
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To the powder inlet part,
And screws them together.
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The laser will melt
The metal powder
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As it flows through the inlet.
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She installs latches on the rim
Of the powder inlet part
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And tightly torques the screws
That hold them in place.
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Using the latches, she locks
The mixing chamber to the inlet.
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The latches will help make
Further assembly and disassembly
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Of the 3-d metal printer head
A snap.
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Next, a laser nozzle is screwed
Onto the mixing chamber.
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Then, the technician places
The main nozzle cone
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Over the laser nozzle
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And connects the threaded rim
To the mixing chamber.
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The deposition head
Is now complete.
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Next, another the technician
Mounts the laser system
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To a vertical axis
In the printer housing.
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He runs coolant lines
For the laser
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And attaches
The deposition head,
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Screwing it in place with
A threaded brass collar.
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The laser system and deposition
Head are now integrated.
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First, the powder feeder
Is assembled with
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A substantial base to
Accommodate a feed drive system.
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The technician installs
The feeder shaft
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In the upper half of the base.
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Then, he screws a disc
To the shaft.
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The disc will spin to
Move the metal powder
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Into the printer head system.
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He slides a spring
On to the shaft
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Which helps maintain its
Position.
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Then, he connects the upper half
Of the base to the bottom half.
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He installs an inlet
For carrier gas
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That will be used to move
The powder through tubing
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To the printer head.
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He assembles windows to a lid.
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They'll provide a view
Of the metal powder
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Swirling in the feeder disc,
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So that any problems
Can be identified.
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He press fits the hopper cone
Into a ridged hole in the lid.
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He attaches the hopper
To the cone.
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00:10:00,758 --> 00:10:04,482
He clamps the feeder motor to
The hopper using long screws,
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00:10:04,482 --> 00:10:09,206
Which seals the hopper and turns
It into a pressure vessel.
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The resulting pressure
Will help force the powder
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Through tubing to
The deposition head.
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He installs the lid and hopper
Assembly on the base.
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Once assembly is complete,
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The technician sets
The base on a mount,
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Sliding protruding pins into
Corresponding holes in the lid.
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This completes
The powder feeder.
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The powder feeder now ready
To supply the raw material
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For 3-d printing.
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An operator connects
It to the printer
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And pours metal powder
Into the hopper.
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The system delivers the powder
To the printer head.
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The dispensing and melting
Of the metal powder,
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As well as the layering,
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Are all controlled by
A computer generated program.
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This 3-d printer can manufacture
A part in a few hours,
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So you can sit back
And watch it materialize.
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Narrator:
Detectable warning panels
Are cautionary signals
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For the visually impaired.
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Their specific
Pattern of domed bumps
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Are detectable by touch or with
Walking aid equipment.
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They also serve as
Warning systems
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At intersections
Or on transit platforms,
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Alerting all people
To proceed with caution.
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For the visually impaired,
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These little bumps
On the road aren't a problem.
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They're a solution.
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Embedded in surfaces
At intersections,
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Detectable warning panels
Help people
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Find their way through touch.
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Making a fiberglass polymer
Version of the panels
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Starts with a carefully
Calculated formula.
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Technicians add pigment
To resin paste
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Keeping a close eye
On the scale
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To confirm the amounts
Are correct.
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00:12:05,551 --> 00:12:08,000
Next, a chemical thickener
Is added,
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This ingredient will increase
The viscosity
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To a syrupy consistency.
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Then the ingredients
Are blended together.
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00:12:16,758 --> 00:12:20,620
The agitation from the blender
Causes the mixture to heat,
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00:12:20,620 --> 00:12:22,413
Starting a chemical reaction
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00:12:22,413 --> 00:12:25,103
Which will eventually
Cause solidification.
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00:12:26,344 --> 00:12:29,827
As the mixture thickens,
It turns a vivid color
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00:12:29,827 --> 00:12:33,379
That people with compromised
Vision can still perceive.
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00:12:35,034 --> 00:12:37,034
The technician gauges
The temperature
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00:12:37,034 --> 00:12:41,137
To confirm that the chemical
Reaction isn't too advanced.
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00:12:41,137 --> 00:12:43,034
Then,
The mix is set aside,
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So technicians can
Prepare other ingredients.
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00:12:46,206 --> 00:12:49,758
Rams punch the bag of mineral
Fillers to break up any clumps
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As they flow into a hopper.
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00:12:52,413 --> 00:12:55,172
Stearic acid is added to
Cut the thickening.
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00:12:56,275 --> 00:12:59,517
A computer dispenses
The mineral filler and resin
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00:12:59,517 --> 00:13:01,241
Into a large mixing tank.
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00:13:06,689 --> 00:13:08,551
An operator adds an inhibitor
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00:13:08,551 --> 00:13:11,862
To delay the chemical reaction
As the mixing blade
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00:13:11,862 --> 00:13:14,517
Blends the ingredients
Into a paste.
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00:13:15,137 --> 00:13:17,620
Zinc stearate is added to
The mixture,
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00:13:17,620 --> 00:13:19,413
Which will allow the completed
Panel to release from the mold.
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00:13:22,482 --> 00:13:25,931
Glass bundles, known as
Rovings, then unwind.
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00:13:26,344 --> 00:13:29,689
A blade chops them into
Toothpick sized pieces.
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00:13:30,931 --> 00:13:32,172
The pigment mixture,
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Which has been blended
Into the resin paste,
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Flows on to a plastic liner.
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00:13:38,551 --> 00:13:42,413
Shards of glass fall down
On to the yellow resin mixture.
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00:13:44,551 --> 00:13:47,172
As the machine pulls
The mixture forward,
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00:13:47,172 --> 00:13:49,586
The liner takes
The glass-encrusted resin
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00:13:49,586 --> 00:13:51,758
To the next stage.
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00:13:53,034 --> 00:13:55,275
More resin and a top plastic
Liner,
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00:13:55,275 --> 00:14:00,068
Create an encasing with
The glass in the middle.
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00:14:00,068 --> 00:14:02,758
Rollers squeeze
The encasing together,
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00:14:02,758 --> 00:14:06,413
Forcing the resin to flow
Around the glass shards.
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00:14:06,413 --> 00:14:09,862
The material is compacted
To the desired thickness.
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00:14:09,862 --> 00:14:12,137
Then, the glass
And resin material
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00:14:12,137 --> 00:14:14,551
Cures for 24 hours.
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00:14:14,551 --> 00:14:16,793
This allows
The materials to thicken,
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00:14:16,793 --> 00:14:19,344
So it can be cut into panels.
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00:14:19,344 --> 00:14:23,034
A circular cutting wheel moves
On a carriage across the mat
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00:14:23,034 --> 00:14:24,655
Slicing it to length.
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00:14:26,689 --> 00:14:30,310
The mats are retrieved from the
Machine and stacked.
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00:14:30,310 --> 00:14:33,896
The plastic liners on both
Sides are still intact.
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00:14:36,655 --> 00:14:41,344
Next, the material is weighed
To confirm the specified amount.
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00:14:41,344 --> 00:14:42,620
If more is needed,
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00:14:42,620 --> 00:14:44,896
A technician will adjust
Accordingly.
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00:14:46,448 --> 00:14:48,241
He then peels off the liners.
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00:14:51,413 --> 00:14:55,482
The glass and resin material are
Transferred to a heated mold.
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00:14:55,482 --> 00:14:59,310
The mold applies 500 tons
Of hot pressure.
247
00:14:59,310 --> 00:15:03,068
The material liquefies and flows
Into the crevasses of the mold,
248
00:15:03,068 --> 00:15:05,620
Forcing air out.
249
00:15:05,620 --> 00:15:07,862
As the bumpy panels take shape,
250
00:15:07,862 --> 00:15:11,448
A chemical reaction causes
The material to solidify.
251
00:15:14,000 --> 00:15:16,551
A worker trims
The freshly molded panels
252
00:15:16,551 --> 00:15:18,724
To give them a cleaner line.
253
00:15:20,413 --> 00:15:22,206
And sands the edges smooth.
254
00:15:26,620 --> 00:15:29,517
He clamps the panel to
A fixture at both ends.
255
00:15:32,000 --> 00:15:34,551
The clamps keep
The panel in position
256
00:15:34,551 --> 00:15:36,344
And prevent it from bending.
257
00:15:36,344 --> 00:15:39,172
As mounting holes are drilled
Into the panel.
258
00:15:44,931 --> 00:15:46,931
The technician
Uses an air gun to
259
00:15:46,931 --> 00:15:48,896
Blow off drilling residue
And dust.
260
00:15:52,758 --> 00:15:56,896
This detectable warning panel
Is now ready for installation.
261
00:15:56,896 --> 00:15:59,413
Two craftsmen pipe adhesive
Into channels
262
00:15:59,413 --> 00:16:01,310
At the back of the panel.
263
00:16:01,517 --> 00:16:04,965
The panel is installed in
A recessed part of the curb
264
00:16:04,965 --> 00:16:07,586
And screwed into anchors
In the concrete.
265
00:16:11,620 --> 00:16:13,172
For people with limited vision
266
00:16:13,172 --> 00:16:15,379
Trying to navigate
Their way around,
267
00:16:15,379 --> 00:16:19,172
These tactile panels will make
A difference they can feel.
268
00:16:32,000 --> 00:16:34,000
Narrator: a stirling engine
Produces power
269
00:16:34,000 --> 00:16:37,517
By circulating hot and cold air,
Or other types of gas,
270
00:16:37,517 --> 00:16:39,379
At different temperatures.
271
00:16:39,379 --> 00:16:43,241
Heating expands the gas,
While cooling contracts it.
272
00:16:43,241 --> 00:16:47,206
These alternating reactions move
Up to four pistons at a time,
273
00:16:47,206 --> 00:16:50,206
Driving the machine and the
Pulleys attached to the engine.
274
00:16:53,931 --> 00:16:57,448
This german company manufactures
Model stirling engines
275
00:16:57,448 --> 00:17:01,586
And accessories,
Like this marble tower.
276
00:17:01,586 --> 00:17:04,655
The engine parts move by
A closed loop of air
277
00:17:04,655 --> 00:17:06,965
That circulates
Inside the engine,
278
00:17:06,965 --> 00:17:12,379
Expanding and contracting as
It repeatedly heats and cools.
279
00:17:12,379 --> 00:17:14,620
A specialist designs the engines
280
00:17:14,620 --> 00:17:18,689
And produces digital renderings
For each component.
281
00:17:18,689 --> 00:17:20,344
The dimensions must be accurate
282
00:17:20,344 --> 00:17:23,931
Within 1/1,000
Of a millimeter.
283
00:17:23,931 --> 00:17:27,137
A computer guided turret machine
Shapes the engine's
284
00:17:27,137 --> 00:17:31,724
Cooling cylinder
Out of a solid piece of brass.
285
00:17:31,724 --> 00:17:35,827
Heat escapes brass quickly,
Making it ideal for a component
286
00:17:35,827 --> 00:17:38,206
To rapidly reduce its
Hot air temperature.
287
00:17:40,000 --> 00:17:43,000
The cooled air contracts,
Producing a vacuum
288
00:17:43,000 --> 00:17:46,206
That draws the engine's
Working piston downward.
289
00:17:46,206 --> 00:17:50,310
When reheated, the air expands,
Pushing the piston up.
290
00:17:50,310 --> 00:17:53,931
This repetitive motion
Drives the crankshaft.
291
00:17:53,931 --> 00:17:57,517
The cooling cylinder has
Fins to help diffuse heat,
292
00:17:57,517 --> 00:17:59,965
A hole on top for
The working piston
293
00:17:59,965 --> 00:18:03,103
And another hole on the side
For the displace piston.
294
00:18:05,000 --> 00:18:07,551
After cleaning the cylinder
With compressed air,
295
00:18:07,551 --> 00:18:11,241
A technician performs
A quality control check.
296
00:18:11,241 --> 00:18:14,724
First, he inserts multiple
Test pins into the hole
297
00:18:14,724 --> 00:18:19,000
For the working piston
Until one is the right fit.
298
00:18:19,000 --> 00:18:21,137
This tells him
The diameter measurement.
299
00:18:22,310 --> 00:18:25,482
Using a digital caliper,
The technician measures a series
300
00:18:25,482 --> 00:18:28,689
Of aluminum working pistons
Until he finds the one
301
00:18:28,689 --> 00:18:31,551
That's the correct size
For the hole's diameter.
302
00:18:34,206 --> 00:18:36,689
He inserts the piston
Into the cylinder,
303
00:18:38,034 --> 00:18:40,896
Then holds the cylinder
Upside down.
304
00:18:40,896 --> 00:18:44,931
If the piston falls out slowly,
It's the right size.
305
00:18:44,931 --> 00:18:48,310
The fit must be precise to
Prevent the circulating air
306
00:18:48,310 --> 00:18:50,206
From leaking out
Of the cylinder.
307
00:18:52,068 --> 00:18:53,689
In the assembly area,
308
00:18:53,689 --> 00:18:56,931
Another technician superglues
A crankshaft ball bearing
309
00:18:56,931 --> 00:19:00,689
Into each of the engine's
Stainless steel side frames.
310
00:19:01,551 --> 00:19:05,689
She glues the displace axle
To the displace piston.
311
00:19:05,689 --> 00:19:08,241
The part should fit loosely
In the cooling cylinder
312
00:19:08,241 --> 00:19:10,344
To allow the air
To flow around it,
313
00:19:10,344 --> 00:19:12,379
While moving back and forth
314
00:19:12,379 --> 00:19:15,137
Between the engine's
Heating and cooling zones.
315
00:19:18,034 --> 00:19:20,965
She inserts the displace
Piston into the side hole
316
00:19:20,965 --> 00:19:22,310
Of the cooling cylinder.
317
00:19:24,413 --> 00:19:28,034
Then the heating cylinder is
Mounted over the piston.
318
00:19:28,034 --> 00:19:31,172
The heating cylinder draws heat
Generated by the flame
319
00:19:31,172 --> 00:19:32,862
Into the engine.
320
00:19:32,862 --> 00:19:37,000
She attaches it to the cooling
Cylinder with four screws.
321
00:19:41,482 --> 00:19:44,551
A connecting rod is attached
To the working piston
322
00:19:44,551 --> 00:19:47,275
And the piston is inserted
Into the cooling cylinder.
323
00:19:49,206 --> 00:19:51,965
Next, the technician
Mounts one of the side frames
324
00:19:51,965 --> 00:19:53,344
To the cylinder,
325
00:19:53,344 --> 00:19:56,103
Attaches a rocker arm
To the side frame,
326
00:19:56,103 --> 00:19:58,034
Then puts one end
Of the crankshaft
327
00:19:58,034 --> 00:20:00,103
Through the side frame's
Ball bearing.
328
00:20:03,103 --> 00:20:05,551
She attaches
The second side frame,
329
00:20:05,551 --> 00:20:07,620
By inserting the other end
Of the crankshaft
330
00:20:07,620 --> 00:20:09,103
Through its ball bearing.
331
00:20:13,068 --> 00:20:15,586
She mounts what has been
Assembled so far
332
00:20:15,586 --> 00:20:19,206
On to a wooden base plate,
Then she connects one end
333
00:20:19,206 --> 00:20:22,482
Of the rocker arm to the
Working piston's connecting rod.
334
00:20:24,068 --> 00:20:26,172
The other end of the rocker arm
Is joined
335
00:20:26,172 --> 00:20:28,310
To the crankshaft
Connecting rod,
336
00:20:28,310 --> 00:20:30,793
Which is connected at
A 90-degree angle
337
00:20:30,793 --> 00:20:33,241
To both the rocker arm
And the crankshaft.
338
00:20:34,517 --> 00:20:36,551
On each end of the crankshaft,
339
00:20:36,551 --> 00:20:39,344
A heavy brass flywheel
Is mounted.
340
00:20:39,344 --> 00:20:42,724
The flywheels increase
The momentum of the engine.
341
00:20:42,724 --> 00:20:45,724
To power an accessory
With the stirling engine,
342
00:20:45,724 --> 00:20:48,586
One end of a drive belt
Is run around a pulley
343
00:20:48,586 --> 00:20:51,241
On the accessory,
And the other end of the belt
344
00:20:51,241 --> 00:20:53,344
Around a plastic drive wheel.
345
00:20:58,448 --> 00:21:01,000
The finishing touch is
An engraved brass
346
00:21:01,000 --> 00:21:02,655
Identification plate.
347
00:21:03,793 --> 00:21:05,896
Here's how this engine works.
348
00:21:05,896 --> 00:21:09,793
First, the burner case is filled
With denatured alcohol
349
00:21:09,793 --> 00:21:11,551
And the wick is attached.
350
00:21:11,551 --> 00:21:14,689
The burner case is placed
Under the heating cylinder,
351
00:21:14,689 --> 00:21:17,068
Light the wick,
And let the engine preheat
352
00:21:17,068 --> 00:21:19,034
For 10 to 15 seconds,
353
00:21:19,034 --> 00:21:22,068
Then turn a flywheel to
Kickstart the engine.
354
00:21:22,068 --> 00:21:25,586
The flame heats the air
Inside the heating cylinder.
355
00:21:25,586 --> 00:21:28,448
The hot air expands
Into the cooling cylinder,
356
00:21:28,448 --> 00:21:31,344
Causing the cylinder
To cool and contract.
357
00:21:31,344 --> 00:21:33,827
This moves the working
Piston up and down,
358
00:21:33,827 --> 00:21:37,034
Turning the engine's crankshaft.
29460
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