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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: indycars
Are open-cockpit race cars
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That compete in
The annual indianapolis 500 race
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In the u.S.
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The cars
Are entirely custom-built.
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Even the driver's seat
Is specially contoured
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To the driver's body shape
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And position in which
He or she sits
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Most comfortably in the car.
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The custom-made driver's seat
In an indycar
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Is made of fire-resistant fabric
Over impact-absorbing foam.
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It has openings
At the shoulder, lap, and legs
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For the safety harness.
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To make the seat, they first
Have to produce a template,
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Which is, in itself,
A two-day process.
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Technicians prepare,
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00:01:35,620 --> 00:01:39,241
Then pour an adhesive into
A bag full of foam beads.
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The adhesive contains
Resin and a hardener.
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Once the adhesive seeps in,
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They squeeze out the air
And tie the bag closed.
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They knead the bag
To spread the adhesive
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Over all the foam beads inside.
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00:02:07,827 --> 00:02:10,034
Next, laying the bag flat,
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They spread
The adhesive-saturated beads
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00:02:12,344 --> 00:02:15,103
In an even layer.
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00:02:15,103 --> 00:02:18,758
Then they install a valve...
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00:02:18,758 --> 00:02:21,241
Attach it to a vacuum pump,
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00:02:21,241 --> 00:02:25,206
And suction out
Most of the remaining air.
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00:02:25,206 --> 00:02:29,517
They shape a cavity in the
Middle to fit the driver's body.
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Once they vacuumed out enough
Air to make the bag tight enough
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To hold the shape
Of this cavity...
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...They place it
In the race car's cockpit,
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Pressing the foam beads
As snugly as possible
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Into all the nooks and crannies.
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00:02:44,137 --> 00:02:46,896
This ensures
The car seat will fit properly
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And not shift under the driver.
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The driver now
Has to sit in the car
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So they can
Custom-contour the template
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To his body
In the driving position.
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00:02:58,206 --> 00:03:01,655
Once he's settled comfortably
With hips and shoulders square
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00:03:01,655 --> 00:03:03,413
And wearing his helmet,
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00:03:03,413 --> 00:03:05,172
They begin taking measurements,
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00:03:05,172 --> 00:03:08,689
Starting with the height of his
Head, critical for aerodynamics,
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00:03:08,689 --> 00:03:12,241
And of his sight line over
The hood, critical for safety.
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00:03:12,241 --> 00:03:14,103
Both measurements must conform
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With the racing association's
Strict regulations.
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They also measure the distance
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Between his chest
And the steering wheel
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00:03:21,413 --> 00:03:23,551
And ensure
There's adequate leg clearance
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To enter and exit the cockpit.
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The driver sits down,
Gets out, gets back in
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Several times
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As the technicians measure
And make adjustments.
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00:03:34,758 --> 00:03:38,137
The entire process
Takes about 40 minutes.
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00:03:38,137 --> 00:03:41,620
When it's all done, they run the
Vacuum for another four hours
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And let the foam cure overnight.
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00:03:44,620 --> 00:03:46,000
The next morning,
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00:03:46,000 --> 00:03:49,000
They use a hot knife
To melt a line through the foam
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00:03:49,000 --> 00:03:51,724
And dislodge the template
From the cockpit.
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00:03:51,724 --> 00:03:55,448
The driver returns for a final
Two- to three-hour sitting,
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During which the techs trim
The foam as closely as possible
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To his body contour.
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00:04:02,689 --> 00:04:06,413
The shape now finalized,
They cover the entire surface
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With cloth adhesive tape
And a matte finish.
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This creates
A non-reflective background
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Suitable for laser scanning.
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Onto this dull surface,
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They adhere
Positioning targets --
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Reflective dots
Spaced four inches apart
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That create a grid pattern
Over the entire template.
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The 3-d laser scanner
Reads these reflective dots...
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00:04:40,448 --> 00:04:44,724
...That a computer translates
Into a 3-d image.
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00:04:47,517 --> 00:04:50,448
Specialized software
Then converts this image
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00:04:50,448 --> 00:04:52,068
Into a technical drawing,
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00:04:52,068 --> 00:04:54,137
Which guides an automated router
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00:04:54,137 --> 00:04:57,275
To cut the seat parts
Out of polypropylene foam.
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00:04:57,275 --> 00:05:01,793
This precision-cutting process
Takes four to six hours.
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The router cuts out
Six to eight sections,
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00:05:09,275 --> 00:05:12,586
Which technicians
Then carefully glue together
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Into the full seat.
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They cover the finished seat
In fire-retardant material,
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First applying the fabric
With spray adhesive,
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Then trimming it
To the shape of the seat.
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This foam is quite elastic,
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So it absorbs impact
And protects the driver.
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At the same time, it has memory,
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So after a blow, it regains
Its driver-customized shape.
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Narrator: people have always
Been enchanted
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By the beauty of flowers.
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00:06:05,068 --> 00:06:07,896
It's not surprising
That these jewels of nature,
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Often in artificial form,
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Are used in decorative objects
And arts and crafts projects.
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Paper flowers last forever,
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And you don't have to
Remember to water them.
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These flowers
Are made of saa paper.
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The saa tree
Is a variety of mulberry
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That grows abundantly
Across southeast asia.
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For more than 700 years,
Villagers in northern thailand
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Have been using saa bark
To make paper.
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The paper is used
For crafting items
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Such as umbrellas,
Fans, and flowers.
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They soak the dried bark
In water overnight
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To begin softening it up,
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Boil it over a wood fire
For four hours,
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Then soak it again overnight.
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All of this softens the bark
Into fibrous pulp.
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Next,
They soak the pulp overnight
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In hydrogen peroxide
To whiten it,
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00:07:02,655 --> 00:07:04,482
Then they rinse off the bleach,
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00:07:04,482 --> 00:07:07,689
Which would interfere with
The dying process later on.
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00:07:07,689 --> 00:07:10,724
Workers discard
Any discolored pieces.
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The goal is to make each
Sheet of paper evenly white
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So that it absorbs colored dye
Uniformly.
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Now they load the pulp
Into a mill,
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Which grinds it up
And mixes it with water.
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This process,
Which takes about half an hour,
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Transforms the pieces into soft,
Fluffy, and very soggy fibers.
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What was once tree bark
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Is now ready
To be processed into paper.
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Every single sheet
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Is handcrafted
On fine mesh screens.
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They submerge a screen in water,
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00:07:57,586 --> 00:08:00,931
Then drop in roughly
15 ounces of fibers.
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00:08:00,931 --> 00:08:03,896
They manually stir the water
To spread the fibers
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00:08:03,896 --> 00:08:06,517
In a thin layer
Across the screen.
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They slowly lift the screen
Out of the water
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And press the surface by hand
To smooth it out.
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00:08:14,310 --> 00:08:18,310
The screen then stands in the
Sun for three to four hours,
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Flipped a few times
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Until the fiber's dry
Into a solid sheet of paper.
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To color the paper,
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They fill a basin with hot water
And add a chemical dye.
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They test the color,
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00:08:31,068 --> 00:08:33,896
And if it's just right,
They submerge the sheet.
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The sheet absorbs the dye
Instantly
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In a consistent shade thanks to
The uniformly white base color.
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They hang the sheet outside
To dry in the sun.
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00:08:47,862 --> 00:08:51,827
In three to four hours,
The paper is ready to bloom.
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They cut out flower shapes
With a hand-operated press
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That stamps a sharp metal dye
Through the sheet of paper.
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00:09:03,827 --> 00:09:07,586
Each shape will be a layer
Of petals in a flower.
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There are dyes
In various shapes and sizes.
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00:09:12,172 --> 00:09:15,206
However, the petals they produce
Are flat --
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Not very lifelike --
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00:09:16,689 --> 00:09:20,655
So workers place one petal at
A time on a flower-shaped mold
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00:09:20,655 --> 00:09:22,551
And stamp it with a hot press.
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This permanently shapes
The petals
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To the contour of the mold
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00:09:26,586 --> 00:09:29,965
Almost the same way
A hot iron presses clothes.
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Then it's assembly time.
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To make a rose, they mount
A white ball made of foam,
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Or flower and glue,
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Onto the end
Of a three-inch-long wire.
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They fold the inner petals
Over the ball
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And pinch them together to
Create the center of the rose.
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Then they thread four to five
Petal layers of the same size
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On the wire,
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Bending and pinching those,
As well, to form the rose shape.
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00:10:00,137 --> 00:10:02,172
Once the petals are complete,
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They finish off with
A green paper leaf at the base.
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To make a daisy,
They take a flat flower
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00:10:14,551 --> 00:10:17,448
And glue a brown paper dot
In the middle.
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00:10:17,448 --> 00:10:20,724
Then they glue another
Flat flower beneath it
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00:10:20,724 --> 00:10:23,310
And a leaf base beneath that.
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00:10:31,172 --> 00:10:33,103
To make another type of rose,
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They gently twist
The tips of the petals.
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00:10:39,620 --> 00:10:42,172
Even though
They're made from trees,
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00:10:42,172 --> 00:10:45,724
These artificial flowers
Are environmentally friendly.
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The saa's severed branches and
Stripped bark grow back quickly,
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Providing a renewable supply
Of raw material
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For crafting
Blooming paper bouquets.
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Narrator: weather-wise,
These are turbulent times.
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00:11:11,827 --> 00:11:14,137
There are more storms
And heat waves,
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00:11:14,137 --> 00:11:17,344
And that means an increased
Likelihood of power outages.
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A standby generator
Supplies emergency electricity
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Within seconds of an outage
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So a homeowner can
Ride out the storm in comfort.
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00:11:31,206 --> 00:11:32,758
In today's high-tech world,
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00:11:32,758 --> 00:11:35,517
Staying plugged in
Has never been more important.
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Wired to
A home's electrical system,
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A standby generator
Automatically powers up
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In the event of an outage.
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It assumes the electrical load
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Until the public-utilities
System comes back online.
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With your own standby generator,
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00:11:49,379 --> 00:11:52,448
A power outage
Is never a crisis.
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Production starts
With a stator.
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00:11:54,620 --> 00:11:57,448
It's the stationary core
Of the alternator --
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00:11:57,448 --> 00:12:01,172
The part that converts energy
From the motor to electricity.
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00:12:01,172 --> 00:12:04,896
A press compacts 100 or more
Laminated steel disks
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00:12:04,896 --> 00:12:08,068
To create the stator core.
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00:12:08,068 --> 00:12:12,344
Machinery unwinds steel banding
And wraps it around the stack
194
00:12:12,344 --> 00:12:15,103
To hold the core layers
Together.
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00:12:19,413 --> 00:12:22,586
Machinery lifts the stator core
Out of the assembly device
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00:12:22,586 --> 00:12:25,586
And transfers it
To the next station.
197
00:12:32,448 --> 00:12:34,517
Here, an automated system
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00:12:34,517 --> 00:12:37,931
Insulates the numerous slots
In the core.
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00:12:39,241 --> 00:12:43,896
As the core turns, a machine
Cuts, forms, and inserts
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00:12:43,896 --> 00:12:47,724
Synthetic insulating fabric
Into each slot.
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00:12:51,827 --> 00:12:54,172
Meanwhile, at another station,
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00:12:54,172 --> 00:12:58,172
An automated system winds
Copper wire onto a mandrel.
203
00:13:00,551 --> 00:13:02,862
The slots in the mandrel
Are the same size
204
00:13:02,862 --> 00:13:04,758
As the insulated slots
In the core.
205
00:13:06,586 --> 00:13:11,551
This configures the copper
Windings to fit the core slots.
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00:13:11,551 --> 00:13:14,793
But first, a technician
Slides the copper coils
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00:13:14,793 --> 00:13:16,827
Onto a threading tool.
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00:13:19,931 --> 00:13:23,344
This tool maintains
The configuration of the coils
209
00:13:23,344 --> 00:13:26,482
To prepare them for installation
In the stator core.
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00:13:28,758 --> 00:13:32,000
They wind more bundles
Of copper wire.
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00:13:34,379 --> 00:13:37,482
Once all the windings
Have been correctly arranged
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00:13:37,482 --> 00:13:38,896
On the threading tool,
213
00:13:38,896 --> 00:13:40,862
The technician
Is ready to transfer them
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00:13:40,862 --> 00:13:42,586
To the stator core.
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00:13:44,724 --> 00:13:48,620
He places the stator
On top of the threading tool
216
00:13:48,620 --> 00:13:51,103
And activates a hydraulic device
217
00:13:51,103 --> 00:13:53,482
That pushes the wires
Up through the tool
218
00:13:53,482 --> 00:13:56,000
And into the slots
Of the stator core.
219
00:13:57,724 --> 00:14:01,241
The device retracts,
And he removes the stator.
220
00:14:01,241 --> 00:14:05,586
The copper wires transform the
Stator into an electromagnet,
221
00:14:05,586 --> 00:14:08,379
Which is critical
For electrical generation.
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00:14:08,379 --> 00:14:10,655
He trims the ends of the wires
223
00:14:10,655 --> 00:14:14,000
And sets the leftovers aside
For recycling.
224
00:14:15,931 --> 00:14:19,758
He slides insulating sleeves
Onto the ends.
225
00:14:21,241 --> 00:14:24,275
Then it's into
The lacing machine.
226
00:14:26,000 --> 00:14:29,758
This machine crochets
A string wrap around the bundles
227
00:14:29,758 --> 00:14:32,241
To hold the wires together.
228
00:14:32,241 --> 00:14:34,551
It also pulls in
Any loose strands
229
00:14:34,551 --> 00:14:37,793
To keep them from snagging
On generator components.
230
00:14:37,793 --> 00:14:41,137
With the wiring
Precisely wound and wrapped,
231
00:14:41,137 --> 00:14:43,862
This important
Generator component
232
00:14:43,862 --> 00:14:45,862
Is ready
For the finishing touch --
233
00:14:45,862 --> 00:14:47,862
A clear varnish.
234
00:14:47,862 --> 00:14:52,172
The lid closes on the tank,
And a vacuum pulls air out.
235
00:14:52,172 --> 00:14:56,758
The tank then fills with clear
Varnish to coat the stators.
236
00:14:56,758 --> 00:14:59,689
The varnish fills in any gaps
In the windings.
237
00:15:01,586 --> 00:15:05,655
They transfer the stators to
An oven and bake on the varnish.
238
00:15:05,655 --> 00:15:09,448
Once hardened, the varnish
Insulates the entire assembly.
239
00:15:13,931 --> 00:15:16,655
The next technician
Connects the stator lead wires
240
00:15:16,655 --> 00:15:18,482
To a testing machine.
241
00:15:20,137 --> 00:15:24,448
The machine applies high-voltage
Pulses to the wire windings
242
00:15:24,448 --> 00:15:26,206
And monitors the output
243
00:15:26,206 --> 00:15:29,827
For anything that could
Cause generator failure.
244
00:15:29,827 --> 00:15:32,413
The stator passes the test.
245
00:15:34,000 --> 00:15:37,413
A technician now positions
An outer casing and an end cap
246
00:15:37,413 --> 00:15:38,862
On top of the stator,
247
00:15:38,862 --> 00:15:41,206
Followed by
A steel pressing plate.
248
00:15:43,827 --> 00:15:47,068
A hydraulic arm then provides
The muscle power needed
249
00:15:47,068 --> 00:15:50,551
To fit the casing and cap snugly
To the stator.
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00:15:52,931 --> 00:15:54,827
Coming up next,
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00:15:54,827 --> 00:15:57,827
The generator stator
Joins the rotor and engine,
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00:15:57,827 --> 00:16:00,896
And the result
Is purely electric.
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Narrator:
The average home may contain
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00:16:18,275 --> 00:16:21,068
Over 100 electrical appliances
And devices.
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00:16:21,068 --> 00:16:24,172
When there's a power blackout,
Everything shuts down.
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00:16:24,172 --> 00:16:27,827
A standby generator
Restores electricity in seconds
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00:16:27,827 --> 00:16:30,896
To keep the refrigerator running
And the heat on.
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00:16:30,896 --> 00:16:35,172
In an extended power outage,
A generator can be a life saver.
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00:16:37,448 --> 00:16:40,965
To produce the alternator's
Rotating part, the rotor,
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00:16:40,965 --> 00:16:43,896
The technician
Stacks laminated steel disks
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00:16:43,896 --> 00:16:47,068
To the same height
As the stator core.
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00:16:47,068 --> 00:16:51,206
He lubricates the opening
In the center of the disks.
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00:16:51,206 --> 00:16:52,724
He inserts a shaft,
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00:16:52,724 --> 00:16:55,379
And a press pushes it
Into the stack
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00:16:55,379 --> 00:16:57,655
To complete the installation.
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00:16:59,310 --> 00:17:04,655
Powered by the generator engine,
The shaft will spin the rotor.
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00:17:04,655 --> 00:17:06,724
The technician
Installs steel rods
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00:17:06,724 --> 00:17:08,827
To maintain the disks' alignment
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00:17:08,827 --> 00:17:12,275
And then removes the rotor
From the assembly device.
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00:17:12,275 --> 00:17:16,206
He fits more rods to it
On a slight angle.
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00:17:16,206 --> 00:17:18,206
They'll act as conductors
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00:17:18,206 --> 00:17:21,758
And stabilize
The rotor's electrical output.
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00:17:21,758 --> 00:17:26,655
He slides aluminum caps
Onto both ends of the rotor.
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00:17:26,655 --> 00:17:30,379
Then it's over
To an automated welder.
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00:17:31,793 --> 00:17:34,344
The machine grips the rotor
At both ends
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00:17:34,344 --> 00:17:35,586
And slowly turns it
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00:17:35,586 --> 00:17:39,034
As a robot welds both caps
To the rotor body.
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00:17:41,310 --> 00:17:46,103
Welded in place, the caps
Secure the aluminum rods.
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00:17:47,655 --> 00:17:49,896
The aluminum solder
Used in the weld
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00:17:49,896 --> 00:17:54,517
Is conductive and will create
An electrical connection.
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00:17:54,517 --> 00:17:58,344
The technician unclamps the
Rotor from the welding machine
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00:17:58,344 --> 00:18:01,758
And then tucks insulation
Into slots on the sides.
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00:18:03,448 --> 00:18:05,551
The rotor then goes for a spin
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00:18:05,551 --> 00:18:08,724
In a machine
That winds bands of copper wire
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00:18:08,724 --> 00:18:11,068
Around the insulated sections.
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00:18:11,068 --> 00:18:14,241
These wires
Will act as electromagnets
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00:18:14,241 --> 00:18:17,241
And help
Produce electrical current.
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00:18:17,241 --> 00:18:19,793
They tie string around the wire,
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00:18:19,793 --> 00:18:22,827
Add bearings
And a copper collector ring,
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00:18:22,827 --> 00:18:26,586
And bake an insulating varnish
Onto the entire rotor.
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00:18:26,586 --> 00:18:30,655
They're now ready to assemble
The standby generator.
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00:18:30,655 --> 00:18:35,310
Using a lift, the technician
Lowers the engine into position.
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00:18:35,310 --> 00:18:39,000
He joins the rotor shaft
To the engine crankshaft.
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00:18:42,827 --> 00:18:46,034
To secure the assembly,
He drives a very long bolt
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00:18:46,034 --> 00:18:48,241
Through the rotor
To the crankshaft
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00:18:48,241 --> 00:18:50,965
And tightens it
To a specific torque.
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00:18:50,965 --> 00:18:53,413
Next up is the stator.
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00:18:53,413 --> 00:18:55,482
It will provide a magnetic field
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00:18:55,482 --> 00:18:58,620
To advance the flow of electrons
In the rotor.
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00:18:59,862 --> 00:19:03,689
The technician slides the stator
Onto the rotor.
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00:19:06,103 --> 00:19:08,275
A steel end bracket is next.
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00:19:08,275 --> 00:19:11,103
It aligns the rotor
And the stator.
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00:19:14,724 --> 00:19:17,413
He forces the bracket
Into place.
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00:19:20,379 --> 00:19:24,034
To secure the alignment,
He installs four long bolts
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00:19:24,034 --> 00:19:27,379
From the end bracket
To the engine-adapter plate.
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00:19:28,724 --> 00:19:32,344
He anchors the stator and rotor
To the generator base
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00:19:32,344 --> 00:19:34,896
And adds special rubber mounts
Under the supports
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00:19:34,896 --> 00:19:37,137
To buffer vibrations.
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00:19:37,137 --> 00:19:40,413
He attaches
A motorized carbon brush
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00:19:40,413 --> 00:19:42,689
To copper rings
On the rotor shaft.
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00:19:42,689 --> 00:19:45,448
The brush will collect
Electricity from the shaft
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00:19:45,448 --> 00:19:48,413
And transfer it
To the generator controller.
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00:19:48,413 --> 00:19:51,586
He secures it to the end bracket
With screws.
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00:19:51,586 --> 00:19:54,241
He connects the wiring harness
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00:19:54,241 --> 00:19:58,034
That moves electricity from
The brush to the controller.
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00:20:00,896 --> 00:20:04,000
He links the other end
Of the harness to the engine.
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00:20:07,724 --> 00:20:10,655
He plugs in a sensor
To monitor oil pressure
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00:20:10,655 --> 00:20:13,758
And makes all the other
Electrical connections.
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00:20:16,586 --> 00:20:21,758
Next up is a panel through which
He runs some of the wiring.
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00:20:21,758 --> 00:20:24,586
It acts as a separator
To prevent entanglements
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00:20:24,586 --> 00:20:27,344
And also supports
The fuel regulator.
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00:20:31,172 --> 00:20:35,034
Other parts include a muffler
To help dampen engine noise
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00:20:35,034 --> 00:20:38,241
And a controller
That converts generated power
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00:20:38,241 --> 00:20:39,689
To the correct voltage.
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00:20:42,482 --> 00:20:45,896
The assembly of this
Standby generator is complete.
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00:20:45,896 --> 00:20:47,517
The technician fuels up
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00:20:47,517 --> 00:20:51,034
And runs it first
At partial capacity,
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00:20:51,034 --> 00:20:53,862
Then to the max.
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00:20:53,862 --> 00:20:57,137
The test confirms there's no
Wavering in electrical output.
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00:20:59,896 --> 00:21:01,172
Once encased
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00:21:01,172 --> 00:21:04,448
In a neutral-colored
Corrosion-resistant shell,
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00:21:04,448 --> 00:21:08,068
The standby generator
Blends into the background,
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00:21:08,068 --> 00:21:09,793
But in a power outage,
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00:21:09,793 --> 00:21:13,034
Its contribution
Will definitely be noticed.
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00:21:22,172 --> 00:21:24,896
If you have any comments
About the show,
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00:21:24,896 --> 00:21:27,689
Or if you'd like to suggest
Topics for future shows,
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00:21:27,689 --> 00:21:30,137
Drop us a line at...
27358
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