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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Today on "How it's made"...
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In 2004, british scientists
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Extracted a substance
Called graphene from graphite,
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Which is the material used
To make pencils.
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They won the nobel prize
For this discovery
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And left their mark
On physics history.
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Scientists continue to explore
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Graphene's extraordinary
Potential.
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These silicon chips
Are dyed with thin flecks
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Of carbon, known as graphene.
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Just one atom thick
And transparent,
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Graphene can sniff out chemicals
In the air
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And disease enzymes in blood.
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This lab manufactures graphene
Using a process known
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As chemical vapor deposition.
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A technician loads a capsule
Containing a copper foil sheet
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Into a furnace.
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He screws a cap
On the end of the capsule
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And shuts the furnace.
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He activates a system
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That uses argon gas
To drive out oxygen.
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When the furnace reaches
About 1,800 degrees fahrenheit,
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Methane gas and hydrogen
Are added.
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A reaction occurs that deposits
Graphene onto the foil.
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Graphene can't be seen
With the naked eye.
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A technician applies
Tiny gold contacts
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To a silicon wafer
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And then submerges it in solvent
To rinse off the excess gold.
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The remaining gold bits
Serve as electrical contacts.
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A dip in acetone cleans off
More of the loose flakes,
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And a final rinse
In alcohol removes the rest.
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Using a diamond-tip scribe,
He scores the silicon wafer
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And breaks it
Along the score lines,
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Creating rectangular chips.
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Another technician
Deposits liquid plastic
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Onto the transparent graphene
On the copper foil.
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He locks the foil in a machine
Called a spin coater.
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00:03:00,724 --> 00:03:03,482
It spins at 3,000 r.P.M.
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This spreads the plastic
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Evenly across the graphene film
On the foil.
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It also accelerates
The plastic's curing process.
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He then separates
The plastic-coated graphene
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From the copper foil.
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To do this,
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He clips a wire
To set of tweezers.
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Using the tweezers,
He picks up a small piece
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Of the plastic, graphene,
And copper sandwich
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And plunges it in the water.
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The tweezers apply an electrical
Charge through the copper,
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Causing bubbles
To form in the water.
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These bubbles lift the graphene
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And plastic film
Away from the copper.
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The graphene now clings
Only to the plastic backing.
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He scoops the plastic-backed
Graphene square
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Out of the water using
A large piece of plastic.
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To remove contaminants,
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He immerses the square
In a series of solutions.
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In the last solution,
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He slides the square
Off the carrier.
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And the square floats freely.
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He picks up the silicon chip
With tweezers
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And uses it to retrieve
The floating graphene
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And plastic square.
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It now sits on the silicon chip.
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After taping metal stencils
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Over three of
The graphene-covered chips,
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He suspends them
Above gold pellets
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In a machine known as
The evaporator.
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He closes the evaporator,
Then turns up the heat.
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A vacuum pulls the gold
Toward the stencils
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As it evaporates.
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The gold and exposed graphene
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Adhere to one another
As they cool and solidify.
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The technician removes
The stencils from the chips,
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Revealing gold
Horizontal runners
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Between the gold contacts.
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He transfers the chip
To a plasma etcher.
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He activates the chip,
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And plasma gas
Floods the chamber.
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The gas strips off any graphene
That's not protected by gold.
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Only the gold contacts
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And gold-covered graphene
Runners remain on the chip.
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Solvent dissolves
The plastic backing
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On the graphene runners,
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Taking the protective gold
With it, leaving only graphene.
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The technician now
Has a graphene sensor chip.
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It's time
To test its sensory powers
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Using antibodies
For a certain disease protein.
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The antibodies attach
To the surface of the graphene.
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She tests the signal
From the chip
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To confirm that
It reads the protein correctly.
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This graphene chip
Is ready to act
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As a high-tech sixth sense.
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Narrator:
The world's smallest car
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Has held the guinness book
Of world records title
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For more than 50 years.
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Designed and manufactured
In the u.K.,
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It's about 6 feet long
And 3 feet wide.
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It fits one driver
But no passengers.
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Intended as a commuter vehicle,
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The world's smallest car
Travels up to 40 miles per hour.
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Technicians craft the body
In molds section by section.
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First, they spread
An epoxy resin
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In the customer's color choice.
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00:06:46,172 --> 00:06:47,827
Once the resin cures,
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They lay a sheet
Of fiberglass matting
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00:06:49,793 --> 00:06:51,827
And impregnate it with resin.
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This bonds the matting
To the gelcoat layer.
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Narrower strips of matting
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Are applied
Around the perimeter.
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Certain areas are reinforced
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With a more porous fiberglass
Matting to absorb more resin.
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Finally, a second layer
Of fiberglass matting and resin
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Is set over the entire mold.
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The molds cure for a day.
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When they're ready,
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The body sections
Are extracted from their molds.
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This is the main section.
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The gelcoat forms a smooth
And shiny finish
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On the sturdy fiberglass
Underneath.
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00:07:48,655 --> 00:07:51,275
Using a saw equipped
With a small blade,
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00:07:51,275 --> 00:07:54,965
Technicians smooth the edges
Of the fiberglass.
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00:08:00,655 --> 00:08:03,344
Elsewhere in the factory,
Technicians weld together
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00:08:03,344 --> 00:08:06,206
The car's lightweight
Aluminum gas tank.
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00:08:06,206 --> 00:08:08,827
It holds 1 gallon of gas.
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00:08:13,724 --> 00:08:15,517
They drill a hole through it...
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00:08:18,758 --> 00:08:22,103
Then weld on the filler tube
And screw on the cap.
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00:08:23,758 --> 00:08:26,103
The car runs on three wheels --
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Two at the front and one driven
By the engine at the back.
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00:08:31,034 --> 00:08:34,000
Technicians assemble
The wheel hubs,
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00:08:34,000 --> 00:08:36,344
Then mount them
Onto the triangular suspension
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00:08:36,344 --> 00:08:38,275
Of the axle.
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They flip over the steel chassis
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00:08:42,586 --> 00:08:45,586
And install the disc brakes
On each wheel.
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00:08:49,689 --> 00:08:52,000
On the rear wheel,
They mount a sprocket,
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00:08:52,000 --> 00:08:56,310
Which allows the engine to drive
A chain that rotates the wheel.
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00:08:56,310 --> 00:08:59,000
They connect the shock absorber
On the rear wheel
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00:08:59,000 --> 00:09:01,275
To a mount underneath the body
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00:09:01,275 --> 00:09:03,103
And install
Hydraulic brake lines
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00:09:03,103 --> 00:09:06,413
And brake calipers
On all three wheels.
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00:09:06,413 --> 00:09:09,655
They bolt the wheels
And tires onto the wheel hubs.
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00:09:09,655 --> 00:09:13,758
Each tire is about 6 inches
In diameter.
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00:09:13,758 --> 00:09:15,896
After installing
The one-cylinder engine
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00:09:15,896 --> 00:09:20,172
In the middle of the body,
Technicians bolt on the chassis.
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00:09:20,172 --> 00:09:22,586
They connect the shock absorber
On the rear wheel
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00:09:22,586 --> 00:09:25,758
To a mount underneath the body.
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00:09:25,758 --> 00:09:27,724
They install all the electrical
Components,
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00:09:27,724 --> 00:09:29,827
Such as the headlight,
The brake lights,
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00:09:29,827 --> 00:09:33,137
The turn signals and the wiper.
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00:09:33,137 --> 00:09:35,551
The car can be ordered
With an electric engine,
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In which case they install
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00:09:36,896 --> 00:09:39,620
Four 12-volt
Rechargeable batteries.
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00:09:42,551 --> 00:09:45,896
The car has a rack-and-pinion
Steering system.
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00:09:45,896 --> 00:09:48,482
The steering column is attached
To a circular gear,
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00:09:48,482 --> 00:09:50,034
Called a pinion.
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00:09:50,034 --> 00:09:51,827
When the driver
Turns the steering wheel
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00:09:51,827 --> 00:09:53,137
In one direction,
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00:09:53,137 --> 00:09:56,448
The pinion moves in that
Direction along the rack.
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The rack is a track with teeth,
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Connected by rods
To the front wheels.
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It moves and turns the wheels,
Steering the car.
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The vehicle
Is mechanically complete.
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00:10:09,000 --> 00:10:13,517
Now, they install the windshield
And windows,
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00:10:13,517 --> 00:10:16,379
Sealing the aluminum frames
With silicone.
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00:10:23,931 --> 00:10:27,137
Inside, they mount the steering
Wheel and the dashboard,
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00:10:27,137 --> 00:10:29,551
Which houses the speedometer,
Turn signal light,
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00:10:29,551 --> 00:10:32,586
And high beams.
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00:10:32,586 --> 00:10:33,965
They hang the door,
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00:10:33,965 --> 00:10:37,517
Which has been fitted with
Chromed hinges and a handle.
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The style is consistent
With the 1960s design
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Of the car.
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They finish the job
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With the installation
Of a vinyl driver seat,
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Gas tank, and windshield
Washer fluid reservoir.
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The world's smallest car
Is ready to hit the road
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And make a big impression.
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Force testers pull
And compress products
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00:11:22,379 --> 00:11:23,931
To their breaking point.
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00:11:25,103 --> 00:11:27,103
They're used in labs
And factories
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00:11:27,103 --> 00:11:30,172
To evaluate a product's quality.
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00:11:30,172 --> 00:11:32,379
A force tester
Verifies that an object
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00:11:32,379 --> 00:11:36,000
Meets the manufacturer's
Required specifications.
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Force testers are built
To pull and compress.
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Here, a tester arm
Bears down on a pencil.
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It determines how much
Force can be applied
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Before the pencil bends
Or breaks.
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Measurements are displayed
On a screen.
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00:12:01,344 --> 00:12:04,206
In the 1930s,
Basic force gauges
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00:12:04,206 --> 00:12:08,517
Were attached to cranes
To measure a product's strength.
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00:12:08,517 --> 00:12:11,137
Today's force testers
Are high-tech.
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00:12:11,137 --> 00:12:15,965
They have digital displays
And computerized controls.
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00:12:15,965 --> 00:12:18,137
An assembler starts
By screwing brackets
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00:12:18,137 --> 00:12:22,517
Into a steel base
For the main computer board.
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00:12:22,517 --> 00:12:25,310
The computer board comes next.
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00:12:25,310 --> 00:12:27,344
He uses nuts, called standoffs,
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00:12:27,344 --> 00:12:30,379
To raise it
Above the steel plate.
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00:12:30,379 --> 00:12:32,965
This creates an air space
Between the two,
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00:12:32,965 --> 00:12:35,724
Preventing electrical shorting.
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00:12:35,724 --> 00:12:37,620
Throughout the assembly,
The technician
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00:12:37,620 --> 00:12:41,551
Wears an electrostatic
Discharge band on his wrist.
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00:12:41,551 --> 00:12:45,000
This arrests static electricity
To prevent damage to the parts.
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00:12:46,586 --> 00:12:48,241
He screws the motor drive board
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00:12:48,241 --> 00:12:49,655
To the force tester base
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00:12:49,655 --> 00:12:52,310
And moves on to
The next batch of parts.
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00:12:52,310 --> 00:12:54,448
They include the power
Supply board,
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00:12:54,448 --> 00:12:56,758
A mechanism to turn the unit on,
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00:12:56,758 --> 00:12:59,310
And an emergency stop assembly.
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00:12:59,310 --> 00:13:01,517
He routes the wires
For the power switches
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00:13:01,517 --> 00:13:04,413
And installs
The push buttons.
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00:13:07,758 --> 00:13:11,000
He connects a ribbon cable
To the main circuit board.
213
00:13:13,448 --> 00:13:15,655
Then, he attaches the other end
Of the cable
214
00:13:15,655 --> 00:13:17,655
To the motor drive board.
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00:13:17,655 --> 00:13:20,310
This allows them to communicate.
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00:13:20,310 --> 00:13:24,034
Finally, he completes
The power supply connections.
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00:13:26,931 --> 00:13:28,206
Another member of the team
218
00:13:28,206 --> 00:13:30,000
Assembles
A vertical support rail
219
00:13:30,000 --> 00:13:32,034
To an aluminum base.
220
00:13:32,034 --> 00:13:35,551
This rail is the backbone
Of the tester.
221
00:13:35,551 --> 00:13:38,965
It supports the force arm
And the track it moves on.
222
00:13:41,310 --> 00:13:44,310
He attaches the track
To the support rail.
223
00:13:46,275 --> 00:13:47,931
Using an alignment tool,
224
00:13:47,931 --> 00:13:51,000
He slides the shuttle
Into the grooves of the track,
225
00:13:51,000 --> 00:13:53,620
Then confirms it moves freely.
226
00:14:00,724 --> 00:14:03,689
He's ready to mount
The force arm to the shuttle.
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00:14:05,724 --> 00:14:08,344
A long, threaded rod,
Known as a lead screw,
228
00:14:08,344 --> 00:14:10,413
Is fastened to the force arm.
229
00:14:15,655 --> 00:14:17,137
The lead screw rotates,
230
00:14:17,137 --> 00:14:21,724
Allowing the force arm
To move up and down.
231
00:14:21,724 --> 00:14:24,724
He lowers an aluminum cover
Over the force arm assembly
232
00:14:24,724 --> 00:14:26,827
And secures it to the base.
233
00:14:26,827 --> 00:14:29,379
One side of the casing is open.
234
00:14:29,379 --> 00:14:34,103
He'll install an accordion-style
Rubber curtain to it later.
235
00:14:34,103 --> 00:14:36,862
Next, he threads a rubber belt
Around a pulley,
236
00:14:36,862 --> 00:14:41,275
Which is attached to the end
Of the lead screw.
237
00:14:41,275 --> 00:14:43,965
He installs the motor
And wraps the other end
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00:14:43,965 --> 00:14:46,517
Of the rubber belt
Around the motor pulley.
239
00:14:49,448 --> 00:14:51,896
The motor drive assembly
Turns the lead screw
240
00:14:51,896 --> 00:14:53,758
To move the force arm.
241
00:14:57,448 --> 00:14:59,689
The base is now mounted
With the electronics
242
00:14:59,689 --> 00:15:01,620
To the force tester frame.
243
00:15:05,758 --> 00:15:07,586
After connecting switches
That limit
244
00:15:07,586 --> 00:15:09,896
The force arm's
Range of movement,
245
00:15:09,896 --> 00:15:11,793
He installs an encoder
On the motor
246
00:15:11,793 --> 00:15:16,724
To provide feedback
On speed and power.
247
00:15:16,724 --> 00:15:20,137
The electronics are covered
With a tough plastic casing.
248
00:15:21,379 --> 00:15:23,655
Next up is a slotted table.
249
00:15:25,448 --> 00:15:28,931
He clips a computer tablet
To the tester.
250
00:15:28,931 --> 00:15:30,931
An adjustable bracket
Is attached,
251
00:15:30,931 --> 00:15:33,344
Which is used for changing
The screen's position
252
00:15:33,344 --> 00:15:35,310
As desired.
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00:15:35,310 --> 00:15:38,172
A force tester doesn't just
Bear down on things.
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It also pulls things apart.
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A technician conducts
A pull test
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On a piece of nylon cord.
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He activates the force arm.
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The force arm pulls the cord
As it grips the base.
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The tester measures
The peak force required
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To pull the cord apart.
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The results are displayed
Instantly on the control screen.
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00:16:05,310 --> 00:16:06,827
There are different
Force testers
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For different applications.
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But the purpose
Is always the same --
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Pull and compress objects
In order to test their limits.
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Narrator: one of the ways
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A manufacturer
Can package a product
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Is in a composite can.
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It's a cylindrical container
Made of cardboard
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With a moisture barrier lining.
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Composite cans
Are less expensive to produce
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Than glass
Or metal containers.
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00:16:48,862 --> 00:16:50,551
And they're recyclable.
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00:16:52,758 --> 00:16:55,965
Many products are packaged
In composite cans,
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Everything
From automotive grease
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To parmesan cheese.
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00:17:00,000 --> 00:17:03,103
The cans are cardboard
With an interior lining
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That prevents it
From absorbing moisture.
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00:17:06,000 --> 00:17:08,896
The top can be a sifter,
A pull-tab cap,
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00:17:08,896 --> 00:17:12,551
A ring and plug,
Or peel-off foil.
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00:17:12,551 --> 00:17:14,206
To make composite cans,
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00:17:14,206 --> 00:17:16,689
They begin winding
A strip of thin paper
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00:17:16,689 --> 00:17:20,551
Over a long steel rod,
Called a mandrel.
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00:17:20,551 --> 00:17:23,517
The machine applies glue
To the top of the strip.
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00:17:27,344 --> 00:17:31,413
Simultaneously, two strips
Of cardboard wind off rolls
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00:17:31,413 --> 00:17:33,724
And pass over a glue applicator,
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00:17:33,724 --> 00:17:36,758
Which coats their underside
With adhesive.
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00:17:38,413 --> 00:17:41,034
Then these overlapping
Twin strips
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00:17:41,034 --> 00:17:45,206
Wind around the coated
Paper-wrapped mandrel.
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00:17:45,206 --> 00:17:47,206
The adhesive binds the layers,
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00:17:47,206 --> 00:17:49,586
Producing
A two-ply cardboard tube
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00:17:49,586 --> 00:17:53,413
With an interior
Moistureproof lining.
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00:17:53,413 --> 00:17:55,862
The machine pushes the tube
Off the mandrel
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00:17:55,862 --> 00:17:58,724
To an automated circular saw.
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00:17:58,724 --> 00:18:02,103
The saw cuts the tube
Into shorter pieces.
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00:18:02,103 --> 00:18:03,310
They fall into a bin,
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00:18:03,310 --> 00:18:05,931
Which feeds
The labeling machine.
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00:18:05,931 --> 00:18:08,379
Suction cups pick up
The sheet of labels
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00:18:08,379 --> 00:18:10,344
And run it over a glue roller.
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00:18:10,344 --> 00:18:13,896
It applies adhesive
To the back side.
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00:18:13,896 --> 00:18:15,827
A vacuum carpet
Carries the label
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00:18:15,827 --> 00:18:18,379
Onto another set of mandrels.
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00:18:18,379 --> 00:18:21,275
The machine slips the tube
Onto the mandrel,
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00:18:21,275 --> 00:18:24,103
Then wraps the label
Around the tube.
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00:18:24,103 --> 00:18:26,344
Next, knives cut
The spinning tube
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00:18:26,344 --> 00:18:28,275
Into seven cans.
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00:18:30,448 --> 00:18:33,620
The can-making line
Has been slowed by our camera.
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00:18:35,000 --> 00:18:38,413
At the regular output speed
Of 250 cans per minute,
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All you'd see is a blur.
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00:18:42,206 --> 00:18:43,586
A pusher moves the cans
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00:18:43,586 --> 00:18:45,620
Toward a device
Called an upender,
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00:18:45,620 --> 00:18:48,310
Which stands each can upright.
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00:18:51,655 --> 00:18:54,275
The cans then
Spin through a gluer,
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00:18:54,275 --> 00:18:57,448
Which applies a bead
Of adhesive along the top rim.
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00:19:00,517 --> 00:19:05,068
Meanwhile, another station lines
Up the closures in single file.
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00:19:06,275 --> 00:19:08,827
These cans
Are for parmesan cheese,
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00:19:08,827 --> 00:19:12,758
So the tops are plastic sifters.
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00:19:12,758 --> 00:19:16,241
They go one by one
Onto a carousel.
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00:19:16,241 --> 00:19:18,965
The tops align with cans
On another carousel
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00:19:18,965 --> 00:19:20,620
With perfect timing.
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00:19:24,448 --> 00:19:27,068
A plunger pushes the top
About a 1/2 inch
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00:19:27,068 --> 00:19:29,413
Into the glued rim of the can.
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00:19:34,241 --> 00:19:36,344
As the cans exit the machine,
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00:19:36,344 --> 00:19:39,241
A conveyer
Turns them upside down.
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00:19:42,068 --> 00:19:44,137
The cans reach the end
Of the line,
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00:19:44,137 --> 00:19:47,103
Where workers stack them
On shipping pallets.
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00:19:49,206 --> 00:19:52,724
The parmesan cheese producer
Will receive them like this --
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00:19:52,724 --> 00:19:55,068
Open end up, ready for filling.
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00:19:59,586 --> 00:20:01,689
To make the metal bottom
For the can,
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00:20:01,689 --> 00:20:05,000
A punch press stamps
Circles out of a strip of tin
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00:20:05,000 --> 00:20:08,379
That's been coated
With a food-safe lacquer.
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00:20:08,379 --> 00:20:11,551
The gold-colored coating
Prevents the tin from rusting
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00:20:11,551 --> 00:20:15,034
When it comes into contact
With the moisture in the cheese.
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00:20:17,310 --> 00:20:19,793
The next machine
Uses forming rollers
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00:20:19,793 --> 00:20:22,586
To shape the rim
That will grip the can.
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This production line
Is making composite cans
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00:20:30,068 --> 00:20:32,068
For grease cartridges.
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00:20:32,068 --> 00:20:35,793
Mechanics use them in a device
Similar to a caulking gun.
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00:20:35,793 --> 00:20:37,068
For this product,
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00:20:37,068 --> 00:20:40,275
The cardboard tube
Has a plastic-coated liner.
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The liner is heat-sealed
To the cardboard
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00:20:44,689 --> 00:20:47,689
To prevent grease
From leaking out.
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00:20:49,413 --> 00:20:51,482
The closure
Is a rigid aluminum top
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00:20:51,482 --> 00:20:53,931
That you remove with a pull tab.
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00:20:53,931 --> 00:20:55,689
This machine, called a seamer,
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00:20:55,689 --> 00:20:59,000
Crimps the metal edge tightly
Around the can's rim.
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00:21:00,758 --> 00:21:03,137
As the cans exit the machine,
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00:21:03,137 --> 00:21:06,137
A computer
Takes measurements of each top.
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00:21:06,137 --> 00:21:08,241
If it doesn't meet
Specifications,
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00:21:08,241 --> 00:21:10,896
The machine ejects the can
From the line.
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00:21:13,310 --> 00:21:15,000
The cans that pass inspection
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00:21:15,000 --> 00:21:17,206
Continue on
To the packaging area,
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00:21:17,206 --> 00:21:20,310
Where an employee
Does one last visual inspection
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00:21:20,310 --> 00:21:23,068
Before shipping
To the grease manufacturer.
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00:21:27,724 --> 00:21:29,758
Once a composite can is empty,
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00:21:29,758 --> 00:21:32,275
The cardboard can be
Separated from the metal
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And tossed into a recycling bin.
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