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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Wind generators.
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Pvc gloves.
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Thermoformed glass.
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And fire trucks.
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Wind generators
Harness the power of the wind
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To produce electricity.
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As the turbine's blades revolve,
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They drive a rotor
That generates power.
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This can charge
A set of batteries
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Or even feed
A transmission grid.
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Wind power is a renewable energy
Source that doesn't pollute.
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This type of wind generator
Is a recreational model
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Designed to power a boat
Or a cottage
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With up to 500 watts
Of electricity.
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To make the propeller,
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They lay a template
On a plank of western cedar,
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A rot-resistant wood
That's flexible and durable,
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Yet lightweight enough
For the slightest breeze
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To set it spinning.
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After tracing, they drill a hole
At each end and in the middle,
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Then remove the template and do
A rough cut using a band saw.
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They put the template
Back in place,
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Using those holes they drilled
To align and secure it in place.
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Using a router this time,
They do a precision cut.
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The plank of wood now has
The contour of a propeller.
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The next step
Is to form the profile.
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To do that, they bolt the wood
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Onto the right side
Of a specially designed device
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Called a
Propeller-carving machine.
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On the left side
Is a model propeller.
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After adjusting the model
To the proper angle,
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They start to cut.
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As the machine's roller
Runs over the model,
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It guides a shaver to carve
The wood exactly like the model.
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It takes about eight passes
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To get the propeller's profile
Just right.
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You can see the profile well,
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Once they've marked and cut off
The excess on the ends.
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One side is flat,
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While the other is curved
Like an airplane's wing.
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Now they widen the hole
In the middle of the propeller
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And sand off the ridges
Left by the carving
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Using a low-pressure
Inflatable drum sander.
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It's the only type
Flexible enough
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To really get into the curves.
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Next they check the balancing.
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Watch how a mere penny can throw
Off this perfect equilibrium.
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Finally, a coat
Of waterproof epoxy paint --
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The kind used
On the hulls of boats.
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Now they assemble
The alternator,
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The component
That generates electricity
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When the propeller spins.
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They wrap insulation
Around what's called
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The "Proportional
Electronic regulator"
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And then install it,
Along with wiring,
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Into the alternator's casing.
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00:03:59,689 --> 00:04:04,689
This regulator controls the
Electrical charge and current.
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The propeller
Spins this rotor shaft,
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Creating an electrical charge
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That sends a current from
The alternator to the batteries.
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Once the casing's bolted shut,
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They mount a cooling fan
On the shaft's protruding axle.
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This fan will expel the heat
All that spinning generates.
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Next they assemble the parts
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That make up what's called
The "Lolly shaft" --
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The axis on which
The propeller sits.
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This axis enables the propeller
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To pivot toward the direction
Of the wind
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Without twisting the wires
That run to the batteries.
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Finally, they connect the wires
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From the lolly shaft
To the alternator.
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This rubber cover
Protects the connection
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From the elements.
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Now they assemble what's called
The propeller governor --
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A key component that prevents
The propeller from overspinning
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And breaking down in high winds.
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When the propeller
Spins too fast,
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The centrifugal force
Pulls on these springs.
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This activates
The braking flaps,
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Generating drag
To slow the propeller down.
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Again, precision balancing
Is critical.
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Otherwise, you'll have
A damaging vibration.
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After applying
The manufacturer's decal,
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They mount
The propeller's rudder
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Onto the back end
Of the wing generator's frame.
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On the other end,
They install the alternator,
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Followed by the propeller
And propeller governor,
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Both painted black
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To protect the waterproof
Coating underneath
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From the sun's
Damaging u.V. Rays.
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Narrator: polyvinyl chloride,
Commonly known as "Pvc,"
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Is a durable material
Similar to plastic.
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Pvc gloves are waterproof --
Even chemical-proof.
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All kinds of laborers wear them,
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From commercial fishermen
To oil-refinery workers.
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Pvc gloves are comfortably
Flexible, yet sturdy.
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Production begins
At the cutting station
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With stacked sheets
Of cotton flannel.
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Using a hydraulic cutting
Machine and a series of dies,
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Workers slice through some
20 layers in one fell swoop,
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Cutting out the pieces required
To make cotton gloves.
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Those gloves
Will either be sold as is
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Or used as linings
For pvc gloves.
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The next step
Is to sew the pieces together.
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00:07:01,793 --> 00:07:06,103
It takes a speedy seamstress
Just 30 seconds per hand.
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Next they sew on a wrist
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Made of a stretchy,
Cotton-and-lycra knit.
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This seamstress works
The wristing machine so quickly,
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We had to ask her to slow down
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So that we could actually see
What she's doing.
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Throughout the sewing process,
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These cotton gloves
Have been inside out.
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This next machine
Turns them right-side in,
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Transferring them
Onto a heated hand form.
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The machine then presses
Each glove onto the form.
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The gloves drop down
To a conveyor belt below.
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00:08:09,172 --> 00:08:11,551
It transports them to a worker,
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Who inspects them and pairs
Them up -- left and right.
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Elsewhere in the factory,
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Workers prepare
The pvc solution.
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The recipe varies
According to the glove model,
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But generally consists
Of coloring
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And five to eight
Different chemicals.
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They add in antibacterial,
Antifungal solution
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To combat odor
From hand perspiration.
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To apply the pvc,
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Workers slip a metal form
Into the thumb of each lining,
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Then put the lining
Onto a thumbless hand form.
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If the hand and thumb forms
Were in one piece,
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It would be difficult
To remove the stiff pvc glove
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Without tearing.
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The linings go through
What's called the singer --
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A propane flame that burns off
Any dust or loose threads.
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Then it's into the pvc bath.
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The basin of liquid pvc moves
Upward, coating the liners.
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00:09:40,413 --> 00:09:44,482
As the basin descends,
The excess drips off.
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Then the gloves go for a spin
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Under infrared lamps
For 45 seconds.
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The spinning
Spreads the pvc uniformly
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So that it doesn't accumulate
On the tips of the fingers,
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Forming clumps.
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After a second coat,
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The gloves pass through
A propane-fired furnace
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00:10:08,241 --> 00:10:13,137
For about 20 minutes
At 370 degrees fahrenheit,
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Then through a cooling chamber
For five minutes.
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00:10:17,517 --> 00:10:20,000
For glove models
With extra-strong grip,
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They blow pvc chips
Onto the first coat of pvc
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While it's still wet.
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When the gloves
Go through the furnace,
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The heat embeds the chips.
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After cooling,
The gloves are dried and cured
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And ready to handle
A hard day's work.
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Narrator:
Decorative glass objects
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Can be blown or thermoformed --
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Two very different
Glassmaking techniques.
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In glass blowing,
The artisan shapes hot glass
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By rolling it
And blowing air into it.
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Thermoforming
Is more of a molding process,
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Better suited
For making flat objects.
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When you look at these
Magnificent pieces,
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It's hard to believe they begin
As run-of-the-mill window glass.
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It comes in ready-made panels
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In thicknesses ranging from 1/10
To 4/10 of an inch.
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The first step is to measure
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The overall dimensions
Of the glass panel,
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Then divide it into pieces,
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Each slightly larger
Than the object it will become.
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They'll turn this panel
Into large decorative plates,
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So they divide it
Into three squares,
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Each about 14 inches
In diameter.
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They place each square
Over a paper pattern.
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Using a glass cutter, they score
The shape of the plate.
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Then they apply pressure
With a rubber mallet
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To separate the glass
Along the score line.
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They cut away the excess,
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00:12:08,793 --> 00:12:12,068
Breaking it off
With a few gentle taps.
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Now they position
The plate-shaped glass
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Over a drawing
And begin the artwork.
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First they trace the outline.
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Now they embellish the design
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And fill in the details.
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They use enamel paints
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Specifically designed
For painting on glass.
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00:13:06,827 --> 00:13:08,620
Once the brushwork's done,
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They use a paint gun
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To apply the background colors
And shading.
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The glass has been cut
And decorated,
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But it's still perfectly flat,
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So the final step is to mold it
Using extreme heat,
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Hence the term "Thermoformed."
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The mold they use is made
Of fireproof materials
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00:13:29,827 --> 00:13:33,172
Designed to withstand high
Temperatures inside the oven,
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Known as a kiln.
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00:13:35,172 --> 00:13:38,896
They carefully lay the glass
Over the mold.
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00:13:38,896 --> 00:13:43,310
They mold several different
Pieces at the same time.
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In the intense heat of the kiln,
The glass will melt
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00:13:58,931 --> 00:14:01,551
And take on
The exact shape of the mold
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Right down to the most intricate
Textural detail.
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These small pieces of glass
Will become the paint pots
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00:14:19,931 --> 00:14:22,931
On this glass replica
Of an artist's palette.
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00:14:25,689 --> 00:14:28,379
It takes an hour and a half
For the kiln temperature
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00:14:28,379 --> 00:14:32,896
To climb to a scorching
1,550 degrees fahrenheit.
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00:14:35,551 --> 00:14:38,862
At peak temperature,
They briefly open the kiln
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00:14:38,862 --> 00:14:41,896
To make sure that everything
Is progressing well.
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00:14:41,896 --> 00:14:45,137
The glass at this phase should
Be the consistency of taffy
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00:14:45,137 --> 00:14:47,103
And glowing bright red.
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If it is,
They can close the kiln
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00:14:49,620 --> 00:14:53,344
And begin the cooling phase.
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00:14:53,344 --> 00:14:54,931
Six hours later,
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00:14:54,931 --> 00:14:58,275
The glass pieces have hardened
Into the shape and texture
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00:14:58,275 --> 00:15:00,689
Of the respective molds.
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These plates, spoon rests,
And other pieces
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Are cool enough
To come out of the kiln.
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00:15:20,793 --> 00:15:23,241
The beauty of thermoformed glass
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00:15:23,241 --> 00:15:26,103
Lies in the striking combination
Of transparency
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00:15:26,103 --> 00:15:28,275
And vibrant color.
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00:15:28,275 --> 00:15:31,310
Add to that
The endless shape possibilities,
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00:15:31,310 --> 00:15:34,034
And you've got
Truly functional art.
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Narrator: there are different
Types of fire trucks.
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Pumpers hook up to fire
Hydrants, boost the pressure,
224
00:15:50,793 --> 00:15:53,620
Then shoot water out
Through hoses.
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00:15:53,620 --> 00:15:56,551
Ladder trucks
Elevate firefighters
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00:15:56,551 --> 00:15:59,034
On either a ladder or platform.
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00:15:59,034 --> 00:16:01,724
Rescue trucks have tools
To cut through metal
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00:16:01,724 --> 00:16:04,137
And clear obstructions.
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00:16:10,482 --> 00:16:13,137
Early firefighters
Couldn't do much more
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00:16:13,137 --> 00:16:16,827
Than pass buckets of water
From man to man.
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00:16:16,827 --> 00:16:19,896
The 1720s
Saw the arrival of wagons
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00:16:19,896 --> 00:16:23,758
Carrying water tanks
And hand pumps.
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00:16:23,758 --> 00:16:26,275
Those newfangled pumps
Could spew out
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00:16:26,275 --> 00:16:29,137
An impressive 60 gallons
Of water per minute --
235
00:16:29,137 --> 00:16:32,275
About what you'd get
From two garden hoses.
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00:16:32,275 --> 00:16:35,551
The first horse-drawn fire
Trucks with steam-powered pumps
237
00:16:35,551 --> 00:16:38,793
Went into service in 1852.
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00:16:38,793 --> 00:16:43,275
Gas-powered trucks replaced them
In the early 1900s.
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00:16:52,172 --> 00:16:54,482
This pumper truck can deliver
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00:16:54,482 --> 00:16:57,931
Almost 1,600 gallons of water
Per minute.
241
00:16:57,931 --> 00:17:01,413
Mechanical engineers usually
Custom-design fire trucks
242
00:17:01,413 --> 00:17:03,379
To suit the particular needs
243
00:17:03,379 --> 00:17:06,241
Of the fire department
Placing the order.
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00:17:07,758 --> 00:17:09,655
The truck's body is made
245
00:17:09,655 --> 00:17:13,965
From sheets of marine-grade
Aluminum 2/10-inch thick.
246
00:17:13,965 --> 00:17:16,379
Following
The technical drawings,
247
00:17:16,379 --> 00:17:19,965
Workers cut the aluminum panels
To the sizes required,
248
00:17:19,965 --> 00:17:24,206
Notching certain corners
At a 90-degree angle.
249
00:17:26,827 --> 00:17:28,862
Workers weld the pieces together
250
00:17:28,862 --> 00:17:31,310
To form what's known
As the crew cab.
251
00:17:31,310 --> 00:17:34,310
The crew cab not only carries
The firefighters,
252
00:17:34,310 --> 00:17:37,344
It also houses the control panel
For the water system.
253
00:17:43,724 --> 00:17:47,965
Meanwhile, other workers measure
And then cut pieces of aluminum
254
00:17:47,965 --> 00:17:49,517
To build the subframe
255
00:17:49,517 --> 00:17:51,931
That will support the crew cab
From underneath.
256
00:17:58,310 --> 00:18:01,413
They weld the parts together.
257
00:18:09,275 --> 00:18:10,862
Installing the steps,
258
00:18:10,862 --> 00:18:13,103
Workers leave a gap
Of about half an inch
259
00:18:13,103 --> 00:18:15,724
To enable water to drain down.
260
00:18:18,517 --> 00:18:20,241
They line
The storage compartments
261
00:18:20,241 --> 00:18:21,827
With aluminum sheets,
262
00:18:21,827 --> 00:18:25,862
Using a sander to make textured
Circles on the smooth surface.
263
00:18:25,862 --> 00:18:28,379
This pattern
Will camouflage the scratches
264
00:18:28,379 --> 00:18:32,310
That moving equipment in and out
Will inevitably create.
265
00:18:32,310 --> 00:18:36,034
They use a machine
Called a press brake
266
00:18:36,034 --> 00:18:39,655
To bend the sheets
To the required shape.
267
00:18:39,655 --> 00:18:42,344
Then, using what's known
As a punch press,
268
00:18:42,344 --> 00:18:45,862
They cut holes
For the built-in lights,
269
00:18:45,862 --> 00:18:51,413
The door handles,
And the various control knobs.
270
00:18:51,413 --> 00:18:53,275
Workers now assemble the pieces
271
00:18:53,275 --> 00:18:55,482
And make any necessary
Adjustments
272
00:18:55,482 --> 00:18:57,655
Before painting,
Rather than after,
273
00:18:57,655 --> 00:19:01,310
To avoid damaging the finish.
274
00:19:01,310 --> 00:19:04,724
After this fine-tuning,
They'll disassemble everything
275
00:19:04,724 --> 00:19:07,896
And send the parts
To the paint department.
276
00:19:07,896 --> 00:19:11,310
After that, they'll put it all
Carefully back together.
277
00:19:13,896 --> 00:19:16,827
The full-scale assembly
Can now begin,
278
00:19:16,827 --> 00:19:18,448
Starting with the water pump.
279
00:19:18,448 --> 00:19:21,931
It arrives here ready-made
From the supplier.
280
00:19:21,931 --> 00:19:25,275
Next comes the crew cab.
281
00:19:25,275 --> 00:19:27,137
This one isn't for the pumper,
282
00:19:27,137 --> 00:19:30,206
But rather for a yellow
Rescue vehicle.
283
00:19:34,068 --> 00:19:36,862
The pipes that lead
To and from the water pump
284
00:19:36,862 --> 00:19:39,896
Go into a threading machine.
285
00:19:39,896 --> 00:19:45,620
The pipes are part galvanized
Steel, part stainless steel.
286
00:19:49,586 --> 00:19:51,206
Once they're threaded,
287
00:19:51,206 --> 00:19:54,793
They're ready to be screwed
Into the pump's water outlets.
288
00:19:59,241 --> 00:20:00,827
The drive shaft --
289
00:20:00,827 --> 00:20:03,241
That long piece
Coming from the transmission --
290
00:20:03,241 --> 00:20:06,103
Performs its usual job
Of turning the rear axle
291
00:20:06,103 --> 00:20:08,965
When the truck is in motion.
292
00:20:08,965 --> 00:20:12,172
It also powers the water pump
When the truck is parked,
293
00:20:12,172 --> 00:20:14,000
Fighting a fire.
294
00:20:17,000 --> 00:20:21,068
This control box runs the fire
Truck's electrical system,
295
00:20:21,068 --> 00:20:24,689
Including the flashing
Emergency lights.
296
00:20:24,689 --> 00:20:27,413
Each wire is color-coded,
Number-coded,
297
00:20:27,413 --> 00:20:29,965
And function-coded.
298
00:20:32,551 --> 00:20:34,551
Workers run the wires
299
00:20:34,551 --> 00:20:37,689
From the box to the control
Panel in the crew cab.
300
00:20:44,724 --> 00:20:47,896
Then they hook up the odometer,
Speedometer,
301
00:20:47,896 --> 00:20:50,758
And other dashboard indicators.
302
00:20:53,344 --> 00:20:56,517
They install
Water-pressure gauges,
303
00:20:56,517 --> 00:21:00,206
Adapters for connecting
The hoses to the water system,
304
00:21:00,206 --> 00:21:04,379
And pressure-release valves
For adjusting water pressure.
305
00:21:04,379 --> 00:21:08,172
Lo and behold,
A shiny, new fire truck
306
00:21:08,172 --> 00:21:11,379
Built to a department's
Exact specifications.
307
00:21:11,379 --> 00:21:15,068
Only there's one thing the
Client didn't have to specify --
308
00:21:15,068 --> 00:21:18,275
That it be painted
Fire-engine red.
309
00:21:22,103 --> 00:21:24,793
If you have any comments
About the show,
310
00:21:24,793 --> 00:21:27,482
Or if you'd like to suggest
Topics for future shows,
311
00:21:27,482 --> 00:21:29,000
Drop us a line at...
24960
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