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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: many thrill-seekers
Find zip lines exhilarating.
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00:00:53,655 --> 00:00:55,620
But without
The proper braking system,
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They can quickly
Become terrifying.
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Magnetic brakes are hands-free
And engage automatically.
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00:01:02,344 --> 00:01:03,931
So there's no need to panic.
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Just hang on, enjoy the ride,
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And let the brake
Take care of the landing.
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In early human history,
Zip lines were used
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To transfer supplies
Across dangerous terrain.
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00:01:17,275 --> 00:01:19,862
Today, zip lines
Are popular with tourists
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00:01:19,862 --> 00:01:23,206
And adrenaline junkies
All over the world.
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As the rider approaches
The landing, the brake engages
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00:01:27,137 --> 00:01:30,965
Using magnets that induce eddy
Currents instead of friction.
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This creates enough drag
To stop the ride.
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To make a zip line brake,
They start with a drum.
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00:01:40,034 --> 00:01:44,068
It's made of zinc-coated steel
To prevent rust.
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A worker sends off the zinc
So they can add the magnets.
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He hammers locating pins
Into the metal.
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He applies adhesive
To the sanded areas,
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00:01:56,482 --> 00:02:00,758
Then places magnets
Onto the adhesive.
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00:02:00,758 --> 00:02:04,482
He uses steel pins as a guide.
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00:02:04,482 --> 00:02:08,206
As the adhesive cures,
The magnets bond to the metal.
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00:02:10,310 --> 00:02:13,896
Next, he applies a bonding agent
To a shaft bearing
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00:02:13,896 --> 00:02:16,931
And inserts it
Into the hole in the center.
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00:02:16,931 --> 00:02:18,758
Using a hydraulic press,
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00:02:18,758 --> 00:02:21,413
He drives the bearing
Further into the hole.
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00:02:23,827 --> 00:02:26,724
These rotor arms
Will spin in the magnetic field
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00:02:26,724 --> 00:02:29,862
To create the braking force.
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A worker fits gears
Into two plates
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And bolts the plates to
Each side of the rotor assembly.
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00:02:37,137 --> 00:02:40,172
He tests the rotor arms
And slides the rotor gears
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00:02:40,172 --> 00:02:43,034
Onto the shaft already installed
In the brake drum.
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00:02:45,034 --> 00:02:47,862
He opens the rotors
And spins them.
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He adds a ring of magnets
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To surround the rotors
In a magnetic field.
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00:02:53,448 --> 00:02:55,275
Satisfied with the fit,
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00:02:55,275 --> 00:02:58,655
He removes the rotor assembly
From the drum temporarily
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00:02:58,655 --> 00:03:01,482
And clips springs to the rotor.
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00:03:01,482 --> 00:03:05,965
These reaction springs
Will cushion the braking action.
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00:03:05,965 --> 00:03:10,862
Now a worker reinstalls the
Rotor device in the brake drum.
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00:03:10,862 --> 00:03:13,965
He places the magnetic ring
Back on top.
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00:03:13,965 --> 00:03:17,275
The strong magnetic attraction
Secures it to the assembly.
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00:03:20,068 --> 00:03:24,689
The next part is a large ring
With more gears inside it.
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00:03:24,689 --> 00:03:27,137
He hammers
And then screws it in place.
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00:03:29,896 --> 00:03:33,551
He spins the assembly again
To confirm it's functional.
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00:03:36,965 --> 00:03:40,689
He installs the final two gears
On the end of the shaft.
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00:03:40,689 --> 00:03:44,586
This completes the core
Of the zip line brake.
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00:03:44,586 --> 00:03:47,724
Another employee
Stitches a nylon hand grip
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00:03:47,724 --> 00:03:49,827
To tough, synthetic webbing.
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00:03:49,827 --> 00:03:53,103
When this webbing
Is pulled out of the brake,
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00:03:53,103 --> 00:03:55,068
It will set
The rotor arms in motion
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00:03:55,068 --> 00:03:57,931
To create the eddy currents
That are the braking force.
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00:04:00,000 --> 00:04:02,793
After protecting the brake core
With a metal plate,
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00:04:02,793 --> 00:04:07,000
A worker puts the unit
In a plastic case.
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00:04:07,000 --> 00:04:10,172
He installs a plate on the shaft
For the webbing to sit on,
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00:04:10,172 --> 00:04:12,517
Then loops the webbing
Around it.
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00:04:12,517 --> 00:04:16,310
He also places a drum on top
For the retraction spring.
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00:04:16,310 --> 00:04:19,448
He applies silicone adhesive
Around the drum.
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00:04:19,448 --> 00:04:22,137
This secures
The aluminum base plate.
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00:04:22,137 --> 00:04:25,241
He now inserts
The retraction spring.
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00:04:25,241 --> 00:04:27,758
He caps the spring
With a metal plate
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00:04:27,758 --> 00:04:30,896
And reinforces the clips
With metallic tape.
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00:04:30,896 --> 00:04:35,586
Using a crank, he winds more
Of the webbing into the brake.
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00:04:35,586 --> 00:04:37,448
He tightens the metal shackle
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00:04:37,448 --> 00:04:40,379
That holds the two sections
Of webbing together
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00:04:40,379 --> 00:04:43,034
And winds the rest of it
Into the device.
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00:04:45,862 --> 00:04:48,000
He inserts a guide roller
For the webbing
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00:04:48,000 --> 00:04:50,310
And adds a two-part
Retaining clip.
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00:04:54,758 --> 00:04:57,724
He secures the clip
With a rounded metal pin.
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00:04:59,896 --> 00:05:04,793
This next part is a plastic
Insert for the top of the case.
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00:05:04,793 --> 00:05:09,000
He screws a nut onto the shaft
To lock down the insert.
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00:05:09,000 --> 00:05:12,137
He places the top half of
The case onto the brake assembly
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00:05:12,137 --> 00:05:15,896
And secures it
To the lower half.
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He snaps a dust cover
Onto the case.
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They're now ready to test
This zip line brake system.
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A motor pulls out the webbing
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To simulate different
Body weights
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And different zip lining speeds,
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While a computer analyzes
The brake's performance.
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00:05:34,724 --> 00:05:36,827
With magnetic zip line brakes,
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00:05:36,827 --> 00:05:39,724
Riders can come down
At a wide range of speeds
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00:05:39,724 --> 00:05:42,206
But still slow down
At the same rate,
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Ensuring that everyone
Has a fun but safe ride.
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Narrator: silk fibres
Can be creatively crafted
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Into a variety
Of artistic objects,
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00:06:02,931 --> 00:06:07,379
From paper to fabric
Or even items like lamps.
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The fibres are translucent,
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00:06:09,034 --> 00:06:11,034
So they can take
Bright, white light
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And diffuse it into warm,
Beautiful mood lighting.
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This lamp doesn't have shades.
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Instead, it has
Natural-looking silk flowers
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Which conceal its lights.
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00:06:26,275 --> 00:06:28,689
The lamp base
Is made of branches.
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To create
This functional artwork,
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The artisan begins
With a roving.
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A roving is a bundle of fibres
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00:06:36,931 --> 00:06:40,413
Harvested from a silk moth
Caterpillar's cocoon.
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They've been cleaned
And straightened.
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She places the roving
In a nylon mesh bag,
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Then submerges it
In a specially formulated dye.
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She heats the dye
To 185 degrees,
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00:06:56,965 --> 00:06:59,137
Then sprinkles in
More powdered dye
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To produces splashes
Of bolder colors.
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00:07:04,724 --> 00:07:08,000
After a couple of minutes,
She removes the roving...
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...And rinses off
The excess dye.
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She hangs the roving on a rack
Until it's completely dry.
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Roving is typically spun into
Thread to make silk fabric,
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But this artisan
Has a different technique.
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She spreads a sheet of tulle
On her work table.
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Then she gently separates
The fine, hair-like fibres
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And lays them out on the tulle.
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Each pile will be turned into
A flower for the lamp.
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She folds over the tulle
To create a barrier
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That keeps the fibers
From sticking to her hands.
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She prepares the fibres
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For the textile medium
She'll apply next,
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A polymer adhesive.
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00:08:04,862 --> 00:08:06,758
She saturates each pile
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00:08:06,758 --> 00:08:10,448
With water containing a few
Drops of dishwashing detergent
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To open up the fibres.
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00:08:12,413 --> 00:08:15,103
Then she sponges up
The excess water
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00:08:15,103 --> 00:08:18,206
And soaks up any other
Remaining moisture with a towel
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00:08:18,206 --> 00:08:21,379
So the medium
Does not become diluted.
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00:08:21,379 --> 00:08:25,655
Now she's ready
To apply the polymer adhesive.
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As the fibres absorb the medium,
They fuse together,
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00:08:29,034 --> 00:08:31,931
Forming a sheet
Of silk fibre paper.
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00:08:37,931 --> 00:08:39,896
After folding back the tulle,
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00:08:39,896 --> 00:08:43,103
She begins molding each paper
Into a flower.
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She spreads the paper
Over a balloon
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And lets it dry overnight.
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With a few simple steps,
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She has transformed
A colorless roving
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Into colorful sheets
Of moldable silk fibre paper.
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00:09:05,448 --> 00:09:08,000
The next day,
She pops the balloon.
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The silk fibre paper
Holds its round shape.
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00:09:21,758 --> 00:09:23,827
Using the textile medium again,
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00:09:23,827 --> 00:09:27,827
She glues her silk fibre flowers
To juniper branches.
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She secures them
With a needle and thread,
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Matching the thread color
To the silk
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So that it blends in.
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She further sculpts the flowers
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With a stitch or two
In select spots.
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00:09:48,724 --> 00:09:53,137
And dabs textile medium
On the thread to secure it.
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00:09:53,137 --> 00:09:56,413
Then she glues in a second,
Slightly smaller flower,
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Creating two layers of petals.
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00:10:01,793 --> 00:10:04,103
She takes some fibres
She dyed green
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And glues them under the blooms
To form wispy leaves.
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00:10:14,586 --> 00:10:17,931
Finally, to turn this sculpture
Into a functioning lamp,
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00:10:17,931 --> 00:10:20,965
She places a battery powered
L.E.D. Push light
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00:10:20,965 --> 00:10:23,103
In the center of each flower.
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The lamp needs no inner wiring
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00:10:39,793 --> 00:10:43,000
And doesn't need
To be plugged into an outlet.
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You simply press
The middle of each flower
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To turn its hidden push light
On or off.
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A simple sculpture by day,
And a gentle light by night.
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Narrator:
Round hay balers automatically
Roll hay into large bundles.
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00:11:11,586 --> 00:11:15,931
They can also wrap the rolled
Hay in twine or plastic.
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00:11:15,931 --> 00:11:18,137
This american invention
Allows farmers
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To put down their pitchforks and
Leave the work to the machines.
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The invention of the round baler
Was a farming breakthrough.
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Round bales of hay
Stayed drier than square ones.
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Making a round hay baler
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00:11:40,724 --> 00:11:43,965
Starts with a computerized
Fiber-optic laser.
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00:11:43,965 --> 00:11:47,724
It cuts steel sheaths into
The shape of the side panels
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00:11:47,724 --> 00:11:51,931
And makes holes for hardware
And machine components.
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00:11:51,931 --> 00:11:53,896
Once the cuts have been made,
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00:11:53,896 --> 00:11:56,551
Workers remove
The leftover materials.
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00:11:56,551 --> 00:11:59,551
They'll be recycled
Into new steel sheets.
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00:11:59,551 --> 00:12:01,517
Next, the baler side panel
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Goes to a computerized
Hydraulic folder.
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00:12:06,379 --> 00:12:10,000
It bends the edges of the panel
To prepare it for assembly.
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00:12:12,758 --> 00:12:15,241
With the side panel
Clamped in a fixture,
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00:12:15,241 --> 00:12:20,379
A worker slides bolts into
A part called the doubler plate.
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00:12:20,379 --> 00:12:24,551
This plate will be used
To reinforce the panel.
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00:12:24,551 --> 00:12:28,275
He welds the heads of the bolts
To the doubler plate.
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The bolts protrude up
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00:12:29,793 --> 00:12:32,827
So bearings and other parts
Can be attached later.
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He adds other reinforcing parts,
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00:12:40,103 --> 00:12:43,413
Supports for rollers,
And a box for twine.
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00:12:45,344 --> 00:12:47,724
Then it's over
To the paint department.
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00:12:47,724 --> 00:12:50,344
They prime and paint
Both sides of the panel
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00:12:50,344 --> 00:12:51,931
With an epoxy finish
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00:12:51,931 --> 00:12:54,551
In order to protect the steel
From corrosion.
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00:12:57,379 --> 00:13:00,310
After the paint dries,
Cranes lift two panels
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00:13:00,310 --> 00:13:05,103
Over to a fixture that holds
Several baler rollers.
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00:13:05,103 --> 00:13:07,241
Workers insert
The ends of the rollers
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00:13:07,241 --> 00:13:10,206
Into holes in the side panels.
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00:13:10,206 --> 00:13:12,241
They add an auger
For moving the hay
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00:13:12,241 --> 00:13:15,241
Away from the sides
Of the baler.
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00:13:15,241 --> 00:13:19,275
They secure all of these
Components with bolts.
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00:13:19,275 --> 00:13:21,931
Next, they install
A belt-tightening assembly.
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00:13:21,931 --> 00:13:24,275
The bars will hold
The hay-shaping belts
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00:13:24,275 --> 00:13:25,620
At the correct tension.
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00:13:28,034 --> 00:13:30,827
After adding a bearing
To the bottom feed roller,
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00:13:30,827 --> 00:13:33,034
A worker installs sprockets.
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00:13:33,034 --> 00:13:36,517
He also loops chains
Around them.
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00:13:36,517 --> 00:13:38,034
The sprockets and chains
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00:13:38,034 --> 00:13:42,206
Will drive the 14 rollers
In the baler.
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00:13:42,206 --> 00:13:45,034
The next part
Is known as the hay pickup,
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00:13:45,034 --> 00:13:46,448
Because its steel teeth
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00:13:46,448 --> 00:13:50,379
Lift hay from the field
And into the baler.
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00:13:50,379 --> 00:13:53,551
It fits on the front
Of the machine.
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00:13:53,551 --> 00:13:56,103
Now a worker
Installs the wheels.
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00:13:56,103 --> 00:13:58,517
He brushes a lubricant
Onto spindles
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00:13:58,517 --> 00:14:01,413
And inserts them
In the wheel axles.
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00:14:01,413 --> 00:14:05,827
Bolts secure the spindles
To the axles.
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00:14:05,827 --> 00:14:08,379
Then he mounts the wheels
To the spindles
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00:14:08,379 --> 00:14:10,827
And locks them in place
With nuts.
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00:14:15,241 --> 00:14:17,379
Once the two wheels
Are installed,
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00:14:17,379 --> 00:14:20,517
A crane lifts the machine
Into an upright position
213
00:14:20,517 --> 00:14:23,068
In order to install
The rear chamber.
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00:14:28,379 --> 00:14:32,931
A crane lowers the rear chamber
Onto the baler assembly.
215
00:14:32,931 --> 00:14:36,137
As the hay is shaped with
A round bale by the machine,
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00:14:36,137 --> 00:14:40,241
It will gradually expand
In this chamber.
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00:14:40,241 --> 00:14:43,965
These rubber belts will roll
The hay into round bales.
218
00:14:46,551 --> 00:14:49,413
The team loops them
Around tensioning rollers,
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00:14:49,413 --> 00:14:51,724
Arranging them closely together.
220
00:14:57,413 --> 00:14:59,793
A worker joins
The ends of each belt
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00:14:59,793 --> 00:15:02,827
By pushing steel pins
Through riveted lacing.
222
00:15:09,310 --> 00:15:13,310
An employee applies vinyl decals
To the outside of the baler.
223
00:15:18,413 --> 00:15:20,724
The decals display
The company name
224
00:15:20,724 --> 00:15:23,448
And the machine model
In bold graphics.
225
00:15:26,379 --> 00:15:29,241
The machine is equipped
With hydraulic cylinders
226
00:15:29,241 --> 00:15:33,310
So the rear chamber
Can be raised and lowered.
227
00:15:33,310 --> 00:15:36,103
A technician
Syncs the tractor cab monitor
228
00:15:36,103 --> 00:15:40,586
To sensors added to the baler
During the assembly.
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00:15:40,586 --> 00:15:43,862
The sensors indicate
The position of the back gate,
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00:15:43,862 --> 00:15:46,275
The status
Of the bale wrapping equipment,
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00:15:46,275 --> 00:15:48,379
And the moisture level
In the hay.
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00:15:50,413 --> 00:15:52,827
After a complete operational
Check,
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00:15:52,827 --> 00:15:56,586
This baler is ready to give
Farmers or ranchers a break
234
00:15:56,586 --> 00:16:00,103
By automatically creating
Round bales of hay.
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00:16:13,413 --> 00:16:14,724
Narrator: with footwear,
236
00:16:14,724 --> 00:16:18,551
Extremely comfortable
Used to mean extremely ugly.
237
00:16:18,551 --> 00:16:20,137
Not anymore.
238
00:16:20,137 --> 00:16:24,103
Today's comfort shoes don't look
Anything like they used to.
239
00:16:24,103 --> 00:16:26,965
They can be just as stylish
As any other shoe,
240
00:16:26,965 --> 00:16:30,275
But also provide sturdy,
Cushioning foot support.
241
00:16:34,172 --> 00:16:38,517
These comfort shoes come with
Two interchangeable insoles.
242
00:16:38,517 --> 00:16:42,896
One is an anatomically shaped
Footbed with good arch support.
243
00:16:42,896 --> 00:16:45,103
The other
Is a reflexology footbed
244
00:16:45,103 --> 00:16:47,517
That massages your feet
While you walk.
245
00:16:49,931 --> 00:16:52,655
The top of the shoe
Is made of leather.
246
00:16:52,655 --> 00:16:55,620
An operator spreads the cowhide
On a cutting table
247
00:16:55,620 --> 00:16:59,137
And positions
A part-shaped steel die over it.
248
00:16:59,137 --> 00:17:02,655
With a press, he forces the die
Through the leather.
249
00:17:02,655 --> 00:17:04,862
The die has blades
On both sides,
250
00:17:04,862 --> 00:17:07,413
So after cutting
A part for the right shoe,
251
00:17:07,413 --> 00:17:11,034
He flips it over and cuts
The same part for the left shoe.
252
00:17:11,034 --> 00:17:13,620
They stencil on
Guide marks for stitching
253
00:17:13,620 --> 00:17:16,172
And stamp on
A production number.
254
00:17:16,172 --> 00:17:19,137
Due to the natural variations
Between hides,
255
00:17:19,137 --> 00:17:21,068
They cut parts
For a pair of shoes
256
00:17:21,068 --> 00:17:23,758
From the same piece of leather.
257
00:17:23,758 --> 00:17:25,586
A production number
Keeps the parts
258
00:17:25,586 --> 00:17:30,172
From being inadvertently used
On a different pair of shoes.
259
00:17:30,172 --> 00:17:32,448
They place the part
Under a template
260
00:17:32,448 --> 00:17:34,620
And run it through
A lateral knife.
261
00:17:34,620 --> 00:17:39,000
This thins the leather where
It will overlap adjoining parts
262
00:17:39,000 --> 00:17:42,965
So the thickness of the upper
Shoe is uniform throughout.
263
00:17:42,965 --> 00:17:45,000
They apply reinforcement fabric
264
00:17:45,000 --> 00:17:48,034
To the most wear-prone areas
Of the shoe.
265
00:17:48,034 --> 00:17:51,344
This machine bonds these
Adhesive factory enforcements
266
00:17:51,344 --> 00:17:53,758
With pressure and heat.
267
00:17:53,758 --> 00:17:56,172
Now sewers begin
Assembling the upper.
268
00:17:56,172 --> 00:17:58,448
They glue the parts
For the lining together
269
00:17:58,448 --> 00:18:01,103
Because stitches that are
On the inside of the shoe
270
00:18:01,103 --> 00:18:03,620
Can sometimes irritate the foot.
271
00:18:03,620 --> 00:18:06,379
The lining is made
Of soft calf leather,
272
00:18:06,379 --> 00:18:09,551
Except for a small piece of
Rougher goat leather at the back
273
00:18:09,551 --> 00:18:10,931
To grip the heel.
274
00:18:13,310 --> 00:18:17,517
They sew in the lining
One section at a time.
275
00:18:17,517 --> 00:18:22,379
This is the rear section of
The upper, called the heel cap.
276
00:18:22,379 --> 00:18:24,206
After sewing one side,
277
00:18:24,206 --> 00:18:27,931
They insert a foam padding
To cushion the back of the foot.
278
00:18:27,931 --> 00:18:31,517
Then they fold the lining over
To encase the padding.
279
00:18:36,068 --> 00:18:40,034
This machine punches holes and
Embeds eyelets into the upper.
280
00:18:43,965 --> 00:18:47,517
Then a sewer attaches
Two more parts of the upper,
281
00:18:47,517 --> 00:18:49,413
The tongue and the vamp.
282
00:18:53,034 --> 00:18:57,068
Another sewer finishes the upper
By stitching on the vamp ring.
283
00:19:02,172 --> 00:19:05,655
They put the upper into a mold
On a forming machine.
284
00:19:05,655 --> 00:19:09,344
The machine works like an iron,
Applying both heat and pressure
285
00:19:09,344 --> 00:19:12,586
To form the heel cap
Into the perfect shape.
286
00:19:14,586 --> 00:19:17,655
The next forming machine
Uses the same process
287
00:19:17,655 --> 00:19:19,551
To round the toe cap.
288
00:19:29,103 --> 00:19:32,241
Now a sewer stitches a hole
To the upper.
289
00:19:36,344 --> 00:19:39,586
Then they steam the upper
And insert a last.
290
00:19:39,586 --> 00:19:42,137
A last is a foot-shaped
Plastic form
291
00:19:42,137 --> 00:19:45,931
That matches the specific shape
And size of the shoe.
292
00:19:45,931 --> 00:19:48,862
They place the upper
Into a heat setter.
293
00:19:48,862 --> 00:19:52,379
The heat forms the upper
To the shape of the last.
294
00:19:52,379 --> 00:19:53,931
They roll out wrinkles
295
00:19:53,931 --> 00:19:56,758
And flatten any bulges
With heat and pressure.
296
00:19:58,724 --> 00:20:00,000
They place the upper
297
00:20:00,000 --> 00:20:02,310
In a template
Of the shoe's outer sole
298
00:20:02,310 --> 00:20:04,137
And trace the top.
299
00:20:04,137 --> 00:20:06,655
They grind the leather
Below that line.
300
00:20:06,655 --> 00:20:10,172
This roughens the surface
To help with adhesion.
301
00:20:10,172 --> 00:20:11,965
They apply heat-activated glue
302
00:20:11,965 --> 00:20:14,068
To the roughened area
And the sole,
303
00:20:14,068 --> 00:20:17,896
Which is made
Of molded polyurethane.
304
00:20:17,896 --> 00:20:19,965
They let the glue dry.
305
00:20:19,965 --> 00:20:22,137
Then they activate the glue
With a heater
306
00:20:22,137 --> 00:20:25,137
And join the upper and sole.
307
00:20:25,137 --> 00:20:27,793
They place the shoe
In a vacuum press.
308
00:20:27,793 --> 00:20:29,620
The press sucks out the air
309
00:20:29,620 --> 00:20:33,379
While drawing the upper and sole
Tightly together.
310
00:20:33,379 --> 00:20:37,379
Next, they add an anatomically
Shaped footbed insole.
311
00:20:37,379 --> 00:20:39,965
It's made of a moisture
Absorbing combination
312
00:20:39,965 --> 00:20:44,448
Of cork and latex
With leather on top.
313
00:20:44,448 --> 00:20:47,103
Then they lace the shoes
314
00:20:47,103 --> 00:20:50,965
And insert cardboard to support
The shape during transport.
315
00:20:53,034 --> 00:20:55,551
They spray the upper
With a chemical solution
316
00:20:55,551 --> 00:20:57,965
That makes the leather
Water-resistant.
317
00:21:01,000 --> 00:21:04,931
The second set of insoles
Goes in the shoe box.
318
00:21:04,931 --> 00:21:07,137
These shoes are designed
With enough room
319
00:21:07,137 --> 00:21:10,068
To insert a custom
Orthotic device, if needed.
320
00:21:19,275 --> 00:21:21,655
If you have any comments
About the show,
321
00:21:21,655 --> 00:21:24,103
Or you'd like to suggest
Topics for future shows,
322
00:21:24,103 --> 00:21:25,586
Drop us a line at...
26480
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