How It's Made (2001–…): Season 11, Episode 12 - Induction Cooktops/Truck Scales/Tetra Pak Containers/Harmonicas - full transcript
Discover how induction cooktops ,truck scales, tetra pak containers, and harmonicas are made.
Narrator:
MANKIND HAS ALWAYS COOKED
FOOD,
USING EVERYTHING
FROM CAMPFIRES AND BARBECUES
TO GAS AND ELECTRIC STOVE
TOPS.
NOW HE CAN USE
AN INDUCTION COOKTOP.
IT DOESN'T NEED A FIRE, A
FLAME,
OR A RED-HOT BURNER.
IT USES INNOVATIVE
COOKING TECHNOLOGY
OUR ANCESTORS
NEVER DREAMT POSSIBLE
AND WOULD SWEAR WAS PURE
MAGIC.
AN INDUCTION COOKTOP DOESN'T
USE
TRADITIONAL COOKING ELEMENTS
ABOVE OR BELOW
THE COOKING SURFACE.
IT USES COPPER INDUCTION COILS
THAT GENERATE HIGH-FREQUENCY
ELECTROMAGNETIC FIELDS.
THESE FIELDS
EXCITE THE MOLECULES IN THE
PAN,
CREATING HEAT
ONLY IN THE COOKWARE ITSELF.
THAT'S WHY THE YOLK REMAINS
COLD
AND ONLY WHAT TOUCHES THE PAN
COOKS.
THE MAGIC STARTS
WITH A PUNCHING PRESS
THAT STAMPS
COMPUTER-GENERATED SHAPES
INTO SHEETS
OF COLD-ROLLED STEEL.
THESE CUTOUTS FIX THE POSITION
OF THE INDUCTION COILS THAT
SIT
UNDER THE GLASS SURFACE.
A PRESS BREAK BENDS
THE FOUR SIDES OF THE STEEL
SO IT WILL HOLD
A GLASS-CERAMIC TOP IN PLACE.
IN THE MEANTIME, A MACHINE
SPRAY-PAINTS THE BURNER BOX,
THE VISIBLE PART OF THE
COOKTOP.
A TECHNICIAN AFFIXES THE
LABELS
AND THE POWER CORD
ONTO A HOUSING BOX
THAT WILL CONCEAL THE
INDUCTION
ELECTRONICS AND COILS.
SHE SECURES THE POWER CORD
FOR STRAIN RELIEF.
SHE THEN ATTACHES
THE POWER-CORD GROUND
AND A SYSTEM GROUND WIRE
TO THE HOUSING BOX.
SHE PLACES A COVER ON THE BOX
AND SCREWS IT INTO PLACE.
ANOTHER TECHNICIAN PUTS
TOGETHER
THE INDUCTION ELECTRONICS.
THESE ASSEMBLIES
OF CIRCUIT BOARDS, COOLING
FANS,
AND SEMICONDUCTORS
DRIVE THE COOKTOP.
SHE COVERS THE ELECTRONICS
WITH INSULATION
AND A METAL CARRIER PLATE
THAT WILL SUPPORT
THE INDUCTION COILS.
THEN SHE FEEDS
THE USER-INTERFACE WIRES
THROUGH THE TOP
OF THE COIL-CARRIER PLATE.
THE TECHNICIAN
SCREWS THE CARRIER PLATE
AND THE ELECTRONIC ASSEMBLIES
TOGETHER,
THEN GROUNDS THE ELECTRONICS.
PROTECTIVE TAPE
AROUND THE OPENINGS
WILL PREVENT
THE USER-INTERFACE WIRES
FROM RUBBING
AGAINST THE COIL-CARRIER
PLATE.
AND SOME INSULATION WILL
PROTECT
THE ELECTRONIC ASSEMBLIES.
SHE CLOSES THAT SIDE
OF THE ELECTRONIC HOUSING BOX
AND ATTACHES
ALL THE POWER CABLES.
A SHEET OF INSULATION GOES
ON THE FLIP SIDE OF THE BOX,
WHERE SHE MOUNTS THE
ELECTROMAGNETIC-COIL
ASSEMBLIES.
THE IRON SLUGS
ON THE BACK OF EACH COIL POD
HELP DISTRIBUTE
THE ELECTROMAGNETIC ENERGY
TO THE COOKWARE EVENLY.
SHE CONNECTS THE COIL ASSEMBLY
TO THE SYSTEM BOARD.
THEN SHE PLACES THE REMAINING
FOUR COIL ASSEMBLIES
ONTO THE CARRIER PLATE
AND CONNECTS THEIR LEADS
TO THE SYSTEM BOARD.
MEANWHILE, ANOTHER TECHNICIAN
ASSEMBLES THE COMPONENTS
OF A GLASS
TOUCH-USER-INTERFACE PANEL.
SHE CONNECTS THE INTERFACE
TO THE STEEL HOLDER
THAT WAS BENT INTO SHAPE
AT THE START
AND IS NOW ATTACHED
TO THE BLACK BURNER BOX.
SHE COVERS THE COOKING SURFACE
AND CONTROL PANEL
WITH AN ATTRACTIVE
STAINLESS-STEEL FRAME,
THEN CONNECTS THE SYSTEM BOARD
TO THE CONTROL PANEL.
SHE CLOSES UP THE OTHER SIDE
OF THE BURNER BOX.
THEN SHE BOLTS EVERYTHING DOWN
TO COMPLETE THE COOKTOP.
A TECHNICIAN TESTS THE UNIT.
USING A METAL OBJECT TO
ACTIVATE
THE ELECTROMAGNETIC FIELD,
HE VERIFIES THAT THE CONTROLS
RESPOND PROPERLY.
HE MAKES SURE ALL FIVE
INDUCTION COILS ARE WORKING
AND THE POWER OUTPUT
FROM EACH COIL IS CORRECT.
THE CONTROL PANEL
CONFIRMS IT'S A SUCCESS.
CLEAN, SAFE,
AND ENERGY-EFFICIENT,
INDUCTION COOKTOPS MAKE
COOKING FOOD QUICK AND EASY.
Narrator:
AT A HIGHWAY WEIGH STATION,
INSPECTORS WEIGH EACH
TRANSPORT
TRUCK ON A ROAD-LEVEL SCALE
TO CALCULATE TAXES
ON THE GOODS IT'S HAULING
AND TO MAKE SURE THE LOAD
DOESN'T EXCEED SAFETY LIMITS.
YOU ALSO FIND TRUCK SCALES
AT GRAIN SILOS, QUARRIES,
AND OTHER SITES
THAT MOVE BULK PRODUCTS.
THE KEY TO THIS ENORMOUS SCALE
IS THE TINY COMPONENT
CALLED A STRAIN GAUGE,
WHICH SENDS SIGNALS
TO THE SCALE'S COMPUTER
WHEN COMPRESSED.
THEY MAKE THE STRAIN GAUGE
FROM A LAMINATE
BY BONDING PAPER-THIN SHEETS
OF NICKEL-IRON FOIL,
EPOXY, AND TEFLON IN A PRESS.
THEN THEY COAT THE LAMINATE
IN A LIGHT-SENSITIVE CHEMICAL
AND APPLY A PLASTIC FILM
WITH AN IMAGE OF STRAIN GAUGES
IN NEGATIVE FORMAT.
THEN THEY EXPOSE THE SETUP
TO ULTRAVIOLET LIGHT.
THE LIGHT-SENSITIVE CHEMICAL
REACTS,
IMPRINTING THE IMAGES INTO
THE LAMINATE'S METAL SURFACE.
NOW THEY HAVE ROWS
OF STRAIN GAUGES.
AN INSPECTOR EXAMINES
EVERY GAUGE
AND MARKS ANY FLAWS
TO BE DISCARDED.
NOW A TECHNICIAN MEASURES
HOW MUCH VOLTAGE
FLOWS THROUGH EACH GAUGE.
IF IT'S TOO LOW, SHE RAISES IT
BY RUBBING OFF A MICROSCOPIC
AMOUNT OF SURFACE METAL.
WHEN THE STRAIN GAUGES ARE
FINISHED, THEY CUT THEM APART
AND SEND THEM
TO THE LOAD CELL DEPARTMENT.
THERE, WORKERS DELICATELY TAPE
FOUR STRAIN GAUGES
INTO EACH STAINLESS-STEEL
LOAD CELL.
THEN THEY SOLDER
ELECTRICAL WIRING TO EACH ONE.
THE WIRES ALL RUN
TO A CIRCUIT BOARD
AT ONE END OF THE LOAD CELL.
AND FROM THE LOAD CELL,
WIRING RUNS TO THE SCALE'S
COMPUTER READOUT.
THE SMALLEST AMOUNT
OF MOISTURE OR DIRT
WOULD CAUSE A STRAIN GAUGE
TO MALFUNCTION,
SO THEY WELD A CUP OVER EACH
ONE
TO HERMETICALLY SEAL IT
WITHIN THE LOAD CELL.
EVERY FINISHED LOAD CELL
UNDERGOES
A QUALITY-CONTROL CHECK
TO VERIFY
THAT IT WORKS PROPERLY.
THE TESTING MACHINE
APPLIES WEIGHT IN INCREMENTS
UNTIL IT HITS THE MAXIMUM
WEIGHT
THE CELL CAN BEAR --
34,000 KILOGRAMS,
OR 75,000 POUNDS.
THE TRUCK-SCALE STRUCTURE
IN WHICH THEY'LL INSTALL
THE LOAD CELLS
IS CALLED THE WEIGHBRIDGE.
THEY BEGIN ASSEMBLING IT
UPSIDE DOWN,
WITH A SURFACE
MADE OF STEEL PLATES.
TO BUILD THE BASE
OF THE WEIGHBRIDGE,
THEY LAY OUT A GRID OF THICK
STEEL TUBES AND CROSSBEAMS.
WORKERS LOWER A GUIDE TO HELP
THEM ALIGN THE PARTS
PERFECTLY.
BENEATH EACH LOAD CELL IS A
PIN.
IN ORDER TO WEIGH ACCURATELY,
A LOAD CELL HAS TO BE LEVEL,
SO IT'S CRITICAL TO MAKE SURE
THIS PIN IS LEVEL
BEFORE WELDING ON THE BULKHEAD
THAT HOLDS IT.
ONCE FULLY WELDED,
THE WEIGHBRIDGE IS ASSEMBLED
AND READY FOR PAINTING.
THE PAINT EQUIPMENT
LACES THE POWDERED PAINT
WITH A POSITIVE
ELECTRICAL CHARGE
AND THE WEIGHBRIDGE
WITH A NEGATIVE ONE.
THIS EVENLY DRAWS
THE PAINT PARTICLES
ONTO THE STEEL LIKE A MAGNET.
IN ANOTHER DEPARTMENT,
THEY ASSEMBLE THE STEEL STAND
ON WHICH THE LOAD CELL WILL
SIT.
A WELDER TACKS
THE PIECES TOGETHER,
THEN A ROBOT
DOES THE FULL WELDING.
NOW THAT ALL PARTS ARE READY,
FINAL ASSEMBLY
OF THE TRUCK SCALE CAN BEGIN.
THE WEIGHBRIDGE,
RIGHT-SIDE UP NOW,
CONTAINS EIGHT LOAD CELLS
AT DIFFERENT LOCATIONS.
THE FIRST STEP IS TO INSTALL
EACH LOAD-CELL STAND
INTO ITS RESPECTIVE POSITION.
THEY INSERT A LINK
ON EACH SIDE OF THE STAND.
THEY POSITION THE LOAD CELL
AT THE TOP OF THE LINKS...
...AND THE BULKHEAD PIN
AT THE BOTTOM.
THEN THEY CLOSE UP THE
LOCATION
WITH AN ACCESS PLATE.
THE LAST STEP
IS TO CALIBRATE THE SCALE.
THEY LAY A 10,000-POUND WEIGHT
ON DIFFERENT PARTS OF THE
SCALE
TO CHECK IF THE DIGITAL
READOUT
IS ACCURATE.
IT TAKES A LOT OF TIME
TO GET A TRUCK SCALE JUST
RIGHT,
[weight]
BUT IT'S DEFINITELY
WORTH THE "WAIT."
Narrator:
TETRA PAK CONTAINERS
KEEP DRINKS AND FOOD PRODUCTS
SAFE TO CONSUME FOR UP TO A
YEAR
WITHOUT REFRIGERATION OR THE
USE
OF ADDITIONAL PRESERVATIVES.
MADE MOSTLY FROM PAPER,
THEY'RE RECYCLABLE
INTO THINGS LIKE EGG CARTONS,
PAPER TOWELS, AND TOILET
PAPER.
A TETRA PAK CONTAINER
IS PACKAGING BUILT WITH NATURE
AND FRESHNESS IN MIND.
TETRA PAK CONTAINERS
HOLD ALL SORTS OF FOOD
PRODUCTS,
FROM SMOOTHIES TO FINE WINES.
THE PACKAGE GIVES PRODUCTS
A LONG SHELF LIFE
BECAUSE OF ITS SPECIAL LAYERS
--
THE PLASTIC LAYER,
THE PAPERBOARD, AND THE FOIL.
A PLASTIC COATING
MAKES THE PACKAGE LEAKPROOF.
TETRA PAK CONTAINERS
ARE MADE ENTIRELY
FROM RECYCLABLE MATERIALS.
THE FIRST STEP TO MAKING THEM
IS PRINTING.
A WORKER SELECTS
THE APPROPRIATE PRINTING
PLATES
FOR A GIVEN CUSTOMER
AND APPLIES THEM TO THE
CYLINDER
OF THE PRINTING PRESS.
THE PRESS TRANSFERS ONE COLOR
AT
A TIME TO THE PAPERBOARD LAYER
USING SOLVENT-FREE INK.
A TETRA PAK CONTAINER
CAN HAVE UP TO SIX COLORS.
AT FULL SPEED,
IT TAKES ONLY MINUTES TO
PRINT.
A STROBE LIGHT
VISUALLY STOPS THE MOTION,
HELPING THE PRESSMAN CHECK
THE QUALITY OF THE PRINTING.
A WORKER FEEDS
THE PRINTED PAPERBOARD
INTO A LAMINATION MACHINE
THAT WILL JOIN IT WITH
THE PLASTIC AND FOIL LAYERS.
AT THE SAME TIME,
A WORKER LOADS A ROLL
OF MICRO-THIN ALUMINUM FOIL
INTO THE LAMINATOR.
A GAS FLAME HEAT-TREATS
THE PAPERBOARD
TO ENSURE ADHESION
TO THE PLASTIC LAYER.
THE LAMINATOR EXTRUDES
LIQUEFIED PLASTIC
BETWEEN THE ROLL OF ALUMINUM
AND THE HEATED PAPERBOARD.
ROLLERS SQUEEZE
ALL THE LAYERS TOGETHER.
THE PRINTED PAPERBOARD, WITH
ALL
ITS PROTECTIVE LAYERS APPLIED,
THEN COMES OFF THE BACK END
OF THE LAMINATOR
IN A LARGE MASTER ROLL.
THE OPERATOR THREADS IT
INTO A CUTTING MACHINE
CALLED A SLITTER.
IT CUTS AND WINDS THE PRINTED
MATERIAL ONTO INDIVIDUAL
ROLLS.
THE SLITTER'S KNIVES CUT
THE MATERIAL INTO FOUR LANES,
EACH OF WHICH BECOMES
A SMALLER ROLL.
THE OPERATOR TRIMS THE EXCESS
MATERIAL FROM EACH ROLL.
THEN A CONVEYOR SYSTEM
SENDS THE ROLLS FOR SHIPPING
TO A PACKER TO BE FILLED
WITH THEIR PRODUCT.
AT THE PACKER'S PLANT,
AN OPERATOR LOADS THE ROLL
OF FLAT PACKAGES
INTO A FILLING MACHINE BUILT
AND INSTALLED BY TETRA PAK.
TENSION ROLLERS
GUIDE THE MATERIAL
INTO THE FILLING MACHINE
WHERE IT IS STERILIZED.
THE MACHINE THEN FORMS
AND SEALS THE MATERIAL
INTO ONE CONTINUOUS TUBE.
AND A LITTLE FURTHER DOWN,
THE MACHINE FILLS THE TUBE
WITH PRODUCT.
IT THEN CUTS THE TUBE INTO
INDIVIDUALLY SEALED
PACKAGES...
AND DROPS THEM
INTO A CHUTE FOR FOLDING.
IT EJECTS THE FINISHED
PACKAGES
ONTO A CONVEYOR BELT.
FINALLY, IT SENDS THE PACKAGES
ON THEIR WAY TO THE CUSTOMER.
LIGHTWEIGHT, COMPACT,
AND RECYCLABLE,
TETRA PAK CONTAINERS
ARE ECO-FRIENDLY,
AND THAT'S CERTAINLY SOMETHING
TO CELEBRATE
OVER A GLASS OF FINE WINE.
Narrator: THERE ARE TWO
MAIN TYPES OF HARMONICAS.
A DIATONIC HARMONICA
HAS 10 MOUTH HOLES.
IT PLAYS A 7-NOTE MAJOR SCALE
IN A SINGLE KEY OF MUSIC.
A CHROMATIC HARMONICA
HAS UP TO 16 HOLES,
PLUS A SPECIAL SLIDE MECHANISM
TO PRODUCE EXTRA NOTES
SO IT CAN PLAY IN ANY KEY.
[ HARMONICA PLAYS MELODY ]
AS AIR GOES THROUGH A
HARMONICA,
SO DOES SALIVA,
WHICH IS WHY THEY MAKE
THE INNER STRUCTURE
FROM A TYPE OF WOOD
THAT DOESN'T EXPAND OR SMELL
WITH REPEATED EXPOSURE
TO MOISTURE.
MAKING A STANDARD
CHROMATIC HARMONICA
BEGINS WITH A BLOCK OF
PEARWOOD
MEASURING
ABOUT 5 1/2 BY 1 1/4 INCHES.
THEY RUN IT AGAINST A CUTTER
THAT CARVES A ROW
OF AIR CHAMBERS FRONT AND
BACK.
THIS PRODUCES THE COMPONENT
KNOWN AS THE COMB.
A PRESS STAMPS SLOTS IN
A MILLIMETER-THICK BRASS PLATE
THAT WILL HOLD THE REEDS.
THE PLATE WILL EVENTUALLY GO
ON TOP OF THE COMB,
ITS SLOTS ALIGNING
WITH THE COMB'S AIR CHAMBERS.
ANOTHER MACHINE CUTS REEDS
FROM BRASS-BASED METAL
SPECIALLY
FORMULATED BY THIS COMPANY
TO PRODUCE QUALITY SOUND
AND BE CORROSION-RESISTANT.
WORKING ONE SIZE AT A TIME,
THEY CUT A BATCH
OF A FEW HUNDRED REEDS.
THEY TEST A REED FROM EACH
BATCH
WITH A TUNING MACHINE,
PLUCKING IT TO SEE IF IT
PRODUCES THE CORRECT PITCH.
THE SIZE AND PROFILE OF A REED
DETERMINES THE NOTE IT
PRODUCES.
THE LONGER IT IS, THE LOWER
THE NOTE, AND VICE VERSA.
NOW THEY RIVET THE REEDS
TO THE REED PLATE --
ONE REED FOR EACH NOTE.
CONSECUTIVE REEDS GO
ON OPPOSITE SIDES OF THE
PLATE.
WITH THIS CONFIGURATION,
BLOWING INTO THE HARMONICA
VIBRATES ONE REED,
WHILE DRAWING AIR OUT
VIBRATES THE OTHER.
THEY FLATTEN EACH RIVET
ON ONE SIDE OF THE PLATE.
THIS FASTENS THE REED SECURELY
AT THE BOTTOM,
LEAVING THE REST FREE
TO VIBRATE.
IF NECESSARY,
THEY FILE THE REED DOWN
SO THE SLOT DOESN'T OBSTRUCT
ITS MOVEMENT.
[ HUMMING ]
NOW A TUNING SPECIALIST
GETS TO WORK.
SHE PLAYS EACH REED ON THE
PLATE
AND COMPARES THE TONE
TO A PERFECTLY TUNED SET
OF REEDS FOR REFERENCE.
IF THE PITCH IS OFF, SHE
ADJUSTS
IT WITH A BIT OF FILING.
[ HIGH-PITCHED HUMMING ]
ONCE THE REED PLATE IS IN
TUNE,
IT GOES ON TOP OF THE COMB,
THE REEDS AND SLOTS ALIGNING
WITH THE COMB'S AIR CHAMBERS.
WORKERS ATTACH THE PARTS
WITH STEEL NAILS
THAT HAVE A BRASS PLATING
TO PREVENT CORROSION.
NOW FOR THE TWO-PIECE COVER
THAT ENCLOSES
THESE INTERNAL COMPONENTS.
FOR STANDARD MODELS, THE
FACTORY
USES STAINLESS STEEL,
STARTING WITH A SHEET
THAT'S LESS THAN
A HALF A MILLIMETER THICK.
FANCIER HARMONICAS HAVE
SILVER- OR GOLD-PLATED COVERS.
THE SHEET GOES THROUGH A PRESS
THAT HAS A SERIES OF DIES.
THEY PROGRESSIVELY STAMP OUT
THE COVER PIECES,
FIRST EMBOSSING THE ARTWORK,
THEN CUTTING THE SIZE,
THEN FORMING THE SHAPE.
WORKERS SANDWICH THE COMB
BETWEEN THE TWO COVER PIECES,
THEN ATTACH EVERYTHING
WITH EITHER BRASS-PLATED NAILS
OR BRASS- OR NICKEL-PLATED
SCREWS.
CHROMATIC HARMONICAS HAVE
A MOUTHPIECE OVER THE
BLOWHOLES.
IT'S USUALLY MADE
OF CHROME-PLATED BRASS
THAT THEY CURVE SLIGHTLY
IN A PRESS.
THE MOUTHPIECE SHIELDS THE
LIPS
FROM A SLIDE MECHANISM INSIDE.
THAT MECHANISM
HAS THREE PARTS --
A SLIDE WITH A BUTTON
POSITIONED
IN BETWEEN TWO PLATES.
THEY SCREW THE MOUTHPIECE
ONTO THE FRONT OF THE
HARMONICA.
WHEN YOU PRESS
THE MOUTHPIECE BUTTON,
IT REDIRECTS THE AIR,
RAISING THE NOTES HALF A TONE.
NO HARMONICA LEAVES THE
FACTORY
WITHOUT A SOUND TEST.
RATHER THAN BLOW
INTO EVERY INSTRUMENT,
THE TESTING DEPARTMENT
USES A MACHINE
THAT BLOWS AIR IN AND OUT.
[ HARMONICAS PLAYING ]
LAST STOP
IS THE CLEANING DEPARTMENT.
THERE, WORKERS INSPECT
FOR SCRATCHES,
THEN POLISH AND PACKAGE
SO THAT EACH AND EVERY
HARMONICA
WILL LOOK AS GOOD AS IT
SOUNDS.
[ HARMONICA PLAYS MELODY ]
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
DROP US A LINE AT...
MANKIND HAS ALWAYS COOKED
FOOD,
USING EVERYTHING
FROM CAMPFIRES AND BARBECUES
TO GAS AND ELECTRIC STOVE
TOPS.
NOW HE CAN USE
AN INDUCTION COOKTOP.
IT DOESN'T NEED A FIRE, A
FLAME,
OR A RED-HOT BURNER.
IT USES INNOVATIVE
COOKING TECHNOLOGY
OUR ANCESTORS
NEVER DREAMT POSSIBLE
AND WOULD SWEAR WAS PURE
MAGIC.
AN INDUCTION COOKTOP DOESN'T
USE
TRADITIONAL COOKING ELEMENTS
ABOVE OR BELOW
THE COOKING SURFACE.
IT USES COPPER INDUCTION COILS
THAT GENERATE HIGH-FREQUENCY
ELECTROMAGNETIC FIELDS.
THESE FIELDS
EXCITE THE MOLECULES IN THE
PAN,
CREATING HEAT
ONLY IN THE COOKWARE ITSELF.
THAT'S WHY THE YOLK REMAINS
COLD
AND ONLY WHAT TOUCHES THE PAN
COOKS.
THE MAGIC STARTS
WITH A PUNCHING PRESS
THAT STAMPS
COMPUTER-GENERATED SHAPES
INTO SHEETS
OF COLD-ROLLED STEEL.
THESE CUTOUTS FIX THE POSITION
OF THE INDUCTION COILS THAT
SIT
UNDER THE GLASS SURFACE.
A PRESS BREAK BENDS
THE FOUR SIDES OF THE STEEL
SO IT WILL HOLD
A GLASS-CERAMIC TOP IN PLACE.
IN THE MEANTIME, A MACHINE
SPRAY-PAINTS THE BURNER BOX,
THE VISIBLE PART OF THE
COOKTOP.
A TECHNICIAN AFFIXES THE
LABELS
AND THE POWER CORD
ONTO A HOUSING BOX
THAT WILL CONCEAL THE
INDUCTION
ELECTRONICS AND COILS.
SHE SECURES THE POWER CORD
FOR STRAIN RELIEF.
SHE THEN ATTACHES
THE POWER-CORD GROUND
AND A SYSTEM GROUND WIRE
TO THE HOUSING BOX.
SHE PLACES A COVER ON THE BOX
AND SCREWS IT INTO PLACE.
ANOTHER TECHNICIAN PUTS
TOGETHER
THE INDUCTION ELECTRONICS.
THESE ASSEMBLIES
OF CIRCUIT BOARDS, COOLING
FANS,
AND SEMICONDUCTORS
DRIVE THE COOKTOP.
SHE COVERS THE ELECTRONICS
WITH INSULATION
AND A METAL CARRIER PLATE
THAT WILL SUPPORT
THE INDUCTION COILS.
THEN SHE FEEDS
THE USER-INTERFACE WIRES
THROUGH THE TOP
OF THE COIL-CARRIER PLATE.
THE TECHNICIAN
SCREWS THE CARRIER PLATE
AND THE ELECTRONIC ASSEMBLIES
TOGETHER,
THEN GROUNDS THE ELECTRONICS.
PROTECTIVE TAPE
AROUND THE OPENINGS
WILL PREVENT
THE USER-INTERFACE WIRES
FROM RUBBING
AGAINST THE COIL-CARRIER
PLATE.
AND SOME INSULATION WILL
PROTECT
THE ELECTRONIC ASSEMBLIES.
SHE CLOSES THAT SIDE
OF THE ELECTRONIC HOUSING BOX
AND ATTACHES
ALL THE POWER CABLES.
A SHEET OF INSULATION GOES
ON THE FLIP SIDE OF THE BOX,
WHERE SHE MOUNTS THE
ELECTROMAGNETIC-COIL
ASSEMBLIES.
THE IRON SLUGS
ON THE BACK OF EACH COIL POD
HELP DISTRIBUTE
THE ELECTROMAGNETIC ENERGY
TO THE COOKWARE EVENLY.
SHE CONNECTS THE COIL ASSEMBLY
TO THE SYSTEM BOARD.
THEN SHE PLACES THE REMAINING
FOUR COIL ASSEMBLIES
ONTO THE CARRIER PLATE
AND CONNECTS THEIR LEADS
TO THE SYSTEM BOARD.
MEANWHILE, ANOTHER TECHNICIAN
ASSEMBLES THE COMPONENTS
OF A GLASS
TOUCH-USER-INTERFACE PANEL.
SHE CONNECTS THE INTERFACE
TO THE STEEL HOLDER
THAT WAS BENT INTO SHAPE
AT THE START
AND IS NOW ATTACHED
TO THE BLACK BURNER BOX.
SHE COVERS THE COOKING SURFACE
AND CONTROL PANEL
WITH AN ATTRACTIVE
STAINLESS-STEEL FRAME,
THEN CONNECTS THE SYSTEM BOARD
TO THE CONTROL PANEL.
SHE CLOSES UP THE OTHER SIDE
OF THE BURNER BOX.
THEN SHE BOLTS EVERYTHING DOWN
TO COMPLETE THE COOKTOP.
A TECHNICIAN TESTS THE UNIT.
USING A METAL OBJECT TO
ACTIVATE
THE ELECTROMAGNETIC FIELD,
HE VERIFIES THAT THE CONTROLS
RESPOND PROPERLY.
HE MAKES SURE ALL FIVE
INDUCTION COILS ARE WORKING
AND THE POWER OUTPUT
FROM EACH COIL IS CORRECT.
THE CONTROL PANEL
CONFIRMS IT'S A SUCCESS.
CLEAN, SAFE,
AND ENERGY-EFFICIENT,
INDUCTION COOKTOPS MAKE
COOKING FOOD QUICK AND EASY.
Narrator:
AT A HIGHWAY WEIGH STATION,
INSPECTORS WEIGH EACH
TRANSPORT
TRUCK ON A ROAD-LEVEL SCALE
TO CALCULATE TAXES
ON THE GOODS IT'S HAULING
AND TO MAKE SURE THE LOAD
DOESN'T EXCEED SAFETY LIMITS.
YOU ALSO FIND TRUCK SCALES
AT GRAIN SILOS, QUARRIES,
AND OTHER SITES
THAT MOVE BULK PRODUCTS.
THE KEY TO THIS ENORMOUS SCALE
IS THE TINY COMPONENT
CALLED A STRAIN GAUGE,
WHICH SENDS SIGNALS
TO THE SCALE'S COMPUTER
WHEN COMPRESSED.
THEY MAKE THE STRAIN GAUGE
FROM A LAMINATE
BY BONDING PAPER-THIN SHEETS
OF NICKEL-IRON FOIL,
EPOXY, AND TEFLON IN A PRESS.
THEN THEY COAT THE LAMINATE
IN A LIGHT-SENSITIVE CHEMICAL
AND APPLY A PLASTIC FILM
WITH AN IMAGE OF STRAIN GAUGES
IN NEGATIVE FORMAT.
THEN THEY EXPOSE THE SETUP
TO ULTRAVIOLET LIGHT.
THE LIGHT-SENSITIVE CHEMICAL
REACTS,
IMPRINTING THE IMAGES INTO
THE LAMINATE'S METAL SURFACE.
NOW THEY HAVE ROWS
OF STRAIN GAUGES.
AN INSPECTOR EXAMINES
EVERY GAUGE
AND MARKS ANY FLAWS
TO BE DISCARDED.
NOW A TECHNICIAN MEASURES
HOW MUCH VOLTAGE
FLOWS THROUGH EACH GAUGE.
IF IT'S TOO LOW, SHE RAISES IT
BY RUBBING OFF A MICROSCOPIC
AMOUNT OF SURFACE METAL.
WHEN THE STRAIN GAUGES ARE
FINISHED, THEY CUT THEM APART
AND SEND THEM
TO THE LOAD CELL DEPARTMENT.
THERE, WORKERS DELICATELY TAPE
FOUR STRAIN GAUGES
INTO EACH STAINLESS-STEEL
LOAD CELL.
THEN THEY SOLDER
ELECTRICAL WIRING TO EACH ONE.
THE WIRES ALL RUN
TO A CIRCUIT BOARD
AT ONE END OF THE LOAD CELL.
AND FROM THE LOAD CELL,
WIRING RUNS TO THE SCALE'S
COMPUTER READOUT.
THE SMALLEST AMOUNT
OF MOISTURE OR DIRT
WOULD CAUSE A STRAIN GAUGE
TO MALFUNCTION,
SO THEY WELD A CUP OVER EACH
ONE
TO HERMETICALLY SEAL IT
WITHIN THE LOAD CELL.
EVERY FINISHED LOAD CELL
UNDERGOES
A QUALITY-CONTROL CHECK
TO VERIFY
THAT IT WORKS PROPERLY.
THE TESTING MACHINE
APPLIES WEIGHT IN INCREMENTS
UNTIL IT HITS THE MAXIMUM
WEIGHT
THE CELL CAN BEAR --
34,000 KILOGRAMS,
OR 75,000 POUNDS.
THE TRUCK-SCALE STRUCTURE
IN WHICH THEY'LL INSTALL
THE LOAD CELLS
IS CALLED THE WEIGHBRIDGE.
THEY BEGIN ASSEMBLING IT
UPSIDE DOWN,
WITH A SURFACE
MADE OF STEEL PLATES.
TO BUILD THE BASE
OF THE WEIGHBRIDGE,
THEY LAY OUT A GRID OF THICK
STEEL TUBES AND CROSSBEAMS.
WORKERS LOWER A GUIDE TO HELP
THEM ALIGN THE PARTS
PERFECTLY.
BENEATH EACH LOAD CELL IS A
PIN.
IN ORDER TO WEIGH ACCURATELY,
A LOAD CELL HAS TO BE LEVEL,
SO IT'S CRITICAL TO MAKE SURE
THIS PIN IS LEVEL
BEFORE WELDING ON THE BULKHEAD
THAT HOLDS IT.
ONCE FULLY WELDED,
THE WEIGHBRIDGE IS ASSEMBLED
AND READY FOR PAINTING.
THE PAINT EQUIPMENT
LACES THE POWDERED PAINT
WITH A POSITIVE
ELECTRICAL CHARGE
AND THE WEIGHBRIDGE
WITH A NEGATIVE ONE.
THIS EVENLY DRAWS
THE PAINT PARTICLES
ONTO THE STEEL LIKE A MAGNET.
IN ANOTHER DEPARTMENT,
THEY ASSEMBLE THE STEEL STAND
ON WHICH THE LOAD CELL WILL
SIT.
A WELDER TACKS
THE PIECES TOGETHER,
THEN A ROBOT
DOES THE FULL WELDING.
NOW THAT ALL PARTS ARE READY,
FINAL ASSEMBLY
OF THE TRUCK SCALE CAN BEGIN.
THE WEIGHBRIDGE,
RIGHT-SIDE UP NOW,
CONTAINS EIGHT LOAD CELLS
AT DIFFERENT LOCATIONS.
THE FIRST STEP IS TO INSTALL
EACH LOAD-CELL STAND
INTO ITS RESPECTIVE POSITION.
THEY INSERT A LINK
ON EACH SIDE OF THE STAND.
THEY POSITION THE LOAD CELL
AT THE TOP OF THE LINKS...
...AND THE BULKHEAD PIN
AT THE BOTTOM.
THEN THEY CLOSE UP THE
LOCATION
WITH AN ACCESS PLATE.
THE LAST STEP
IS TO CALIBRATE THE SCALE.
THEY LAY A 10,000-POUND WEIGHT
ON DIFFERENT PARTS OF THE
SCALE
TO CHECK IF THE DIGITAL
READOUT
IS ACCURATE.
IT TAKES A LOT OF TIME
TO GET A TRUCK SCALE JUST
RIGHT,
[weight]
BUT IT'S DEFINITELY
WORTH THE "WAIT."
Narrator:
TETRA PAK CONTAINERS
KEEP DRINKS AND FOOD PRODUCTS
SAFE TO CONSUME FOR UP TO A
YEAR
WITHOUT REFRIGERATION OR THE
USE
OF ADDITIONAL PRESERVATIVES.
MADE MOSTLY FROM PAPER,
THEY'RE RECYCLABLE
INTO THINGS LIKE EGG CARTONS,
PAPER TOWELS, AND TOILET
PAPER.
A TETRA PAK CONTAINER
IS PACKAGING BUILT WITH NATURE
AND FRESHNESS IN MIND.
TETRA PAK CONTAINERS
HOLD ALL SORTS OF FOOD
PRODUCTS,
FROM SMOOTHIES TO FINE WINES.
THE PACKAGE GIVES PRODUCTS
A LONG SHELF LIFE
BECAUSE OF ITS SPECIAL LAYERS
--
THE PLASTIC LAYER,
THE PAPERBOARD, AND THE FOIL.
A PLASTIC COATING
MAKES THE PACKAGE LEAKPROOF.
TETRA PAK CONTAINERS
ARE MADE ENTIRELY
FROM RECYCLABLE MATERIALS.
THE FIRST STEP TO MAKING THEM
IS PRINTING.
A WORKER SELECTS
THE APPROPRIATE PRINTING
PLATES
FOR A GIVEN CUSTOMER
AND APPLIES THEM TO THE
CYLINDER
OF THE PRINTING PRESS.
THE PRESS TRANSFERS ONE COLOR
AT
A TIME TO THE PAPERBOARD LAYER
USING SOLVENT-FREE INK.
A TETRA PAK CONTAINER
CAN HAVE UP TO SIX COLORS.
AT FULL SPEED,
IT TAKES ONLY MINUTES TO
PRINT.
A STROBE LIGHT
VISUALLY STOPS THE MOTION,
HELPING THE PRESSMAN CHECK
THE QUALITY OF THE PRINTING.
A WORKER FEEDS
THE PRINTED PAPERBOARD
INTO A LAMINATION MACHINE
THAT WILL JOIN IT WITH
THE PLASTIC AND FOIL LAYERS.
AT THE SAME TIME,
A WORKER LOADS A ROLL
OF MICRO-THIN ALUMINUM FOIL
INTO THE LAMINATOR.
A GAS FLAME HEAT-TREATS
THE PAPERBOARD
TO ENSURE ADHESION
TO THE PLASTIC LAYER.
THE LAMINATOR EXTRUDES
LIQUEFIED PLASTIC
BETWEEN THE ROLL OF ALUMINUM
AND THE HEATED PAPERBOARD.
ROLLERS SQUEEZE
ALL THE LAYERS TOGETHER.
THE PRINTED PAPERBOARD, WITH
ALL
ITS PROTECTIVE LAYERS APPLIED,
THEN COMES OFF THE BACK END
OF THE LAMINATOR
IN A LARGE MASTER ROLL.
THE OPERATOR THREADS IT
INTO A CUTTING MACHINE
CALLED A SLITTER.
IT CUTS AND WINDS THE PRINTED
MATERIAL ONTO INDIVIDUAL
ROLLS.
THE SLITTER'S KNIVES CUT
THE MATERIAL INTO FOUR LANES,
EACH OF WHICH BECOMES
A SMALLER ROLL.
THE OPERATOR TRIMS THE EXCESS
MATERIAL FROM EACH ROLL.
THEN A CONVEYOR SYSTEM
SENDS THE ROLLS FOR SHIPPING
TO A PACKER TO BE FILLED
WITH THEIR PRODUCT.
AT THE PACKER'S PLANT,
AN OPERATOR LOADS THE ROLL
OF FLAT PACKAGES
INTO A FILLING MACHINE BUILT
AND INSTALLED BY TETRA PAK.
TENSION ROLLERS
GUIDE THE MATERIAL
INTO THE FILLING MACHINE
WHERE IT IS STERILIZED.
THE MACHINE THEN FORMS
AND SEALS THE MATERIAL
INTO ONE CONTINUOUS TUBE.
AND A LITTLE FURTHER DOWN,
THE MACHINE FILLS THE TUBE
WITH PRODUCT.
IT THEN CUTS THE TUBE INTO
INDIVIDUALLY SEALED
PACKAGES...
AND DROPS THEM
INTO A CHUTE FOR FOLDING.
IT EJECTS THE FINISHED
PACKAGES
ONTO A CONVEYOR BELT.
FINALLY, IT SENDS THE PACKAGES
ON THEIR WAY TO THE CUSTOMER.
LIGHTWEIGHT, COMPACT,
AND RECYCLABLE,
TETRA PAK CONTAINERS
ARE ECO-FRIENDLY,
AND THAT'S CERTAINLY SOMETHING
TO CELEBRATE
OVER A GLASS OF FINE WINE.
Narrator: THERE ARE TWO
MAIN TYPES OF HARMONICAS.
A DIATONIC HARMONICA
HAS 10 MOUTH HOLES.
IT PLAYS A 7-NOTE MAJOR SCALE
IN A SINGLE KEY OF MUSIC.
A CHROMATIC HARMONICA
HAS UP TO 16 HOLES,
PLUS A SPECIAL SLIDE MECHANISM
TO PRODUCE EXTRA NOTES
SO IT CAN PLAY IN ANY KEY.
[ HARMONICA PLAYS MELODY ]
AS AIR GOES THROUGH A
HARMONICA,
SO DOES SALIVA,
WHICH IS WHY THEY MAKE
THE INNER STRUCTURE
FROM A TYPE OF WOOD
THAT DOESN'T EXPAND OR SMELL
WITH REPEATED EXPOSURE
TO MOISTURE.
MAKING A STANDARD
CHROMATIC HARMONICA
BEGINS WITH A BLOCK OF
PEARWOOD
MEASURING
ABOUT 5 1/2 BY 1 1/4 INCHES.
THEY RUN IT AGAINST A CUTTER
THAT CARVES A ROW
OF AIR CHAMBERS FRONT AND
BACK.
THIS PRODUCES THE COMPONENT
KNOWN AS THE COMB.
A PRESS STAMPS SLOTS IN
A MILLIMETER-THICK BRASS PLATE
THAT WILL HOLD THE REEDS.
THE PLATE WILL EVENTUALLY GO
ON TOP OF THE COMB,
ITS SLOTS ALIGNING
WITH THE COMB'S AIR CHAMBERS.
ANOTHER MACHINE CUTS REEDS
FROM BRASS-BASED METAL
SPECIALLY
FORMULATED BY THIS COMPANY
TO PRODUCE QUALITY SOUND
AND BE CORROSION-RESISTANT.
WORKING ONE SIZE AT A TIME,
THEY CUT A BATCH
OF A FEW HUNDRED REEDS.
THEY TEST A REED FROM EACH
BATCH
WITH A TUNING MACHINE,
PLUCKING IT TO SEE IF IT
PRODUCES THE CORRECT PITCH.
THE SIZE AND PROFILE OF A REED
DETERMINES THE NOTE IT
PRODUCES.
THE LONGER IT IS, THE LOWER
THE NOTE, AND VICE VERSA.
NOW THEY RIVET THE REEDS
TO THE REED PLATE --
ONE REED FOR EACH NOTE.
CONSECUTIVE REEDS GO
ON OPPOSITE SIDES OF THE
PLATE.
WITH THIS CONFIGURATION,
BLOWING INTO THE HARMONICA
VIBRATES ONE REED,
WHILE DRAWING AIR OUT
VIBRATES THE OTHER.
THEY FLATTEN EACH RIVET
ON ONE SIDE OF THE PLATE.
THIS FASTENS THE REED SECURELY
AT THE BOTTOM,
LEAVING THE REST FREE
TO VIBRATE.
IF NECESSARY,
THEY FILE THE REED DOWN
SO THE SLOT DOESN'T OBSTRUCT
ITS MOVEMENT.
[ HUMMING ]
NOW A TUNING SPECIALIST
GETS TO WORK.
SHE PLAYS EACH REED ON THE
PLATE
AND COMPARES THE TONE
TO A PERFECTLY TUNED SET
OF REEDS FOR REFERENCE.
IF THE PITCH IS OFF, SHE
ADJUSTS
IT WITH A BIT OF FILING.
[ HIGH-PITCHED HUMMING ]
ONCE THE REED PLATE IS IN
TUNE,
IT GOES ON TOP OF THE COMB,
THE REEDS AND SLOTS ALIGNING
WITH THE COMB'S AIR CHAMBERS.
WORKERS ATTACH THE PARTS
WITH STEEL NAILS
THAT HAVE A BRASS PLATING
TO PREVENT CORROSION.
NOW FOR THE TWO-PIECE COVER
THAT ENCLOSES
THESE INTERNAL COMPONENTS.
FOR STANDARD MODELS, THE
FACTORY
USES STAINLESS STEEL,
STARTING WITH A SHEET
THAT'S LESS THAN
A HALF A MILLIMETER THICK.
FANCIER HARMONICAS HAVE
SILVER- OR GOLD-PLATED COVERS.
THE SHEET GOES THROUGH A PRESS
THAT HAS A SERIES OF DIES.
THEY PROGRESSIVELY STAMP OUT
THE COVER PIECES,
FIRST EMBOSSING THE ARTWORK,
THEN CUTTING THE SIZE,
THEN FORMING THE SHAPE.
WORKERS SANDWICH THE COMB
BETWEEN THE TWO COVER PIECES,
THEN ATTACH EVERYTHING
WITH EITHER BRASS-PLATED NAILS
OR BRASS- OR NICKEL-PLATED
SCREWS.
CHROMATIC HARMONICAS HAVE
A MOUTHPIECE OVER THE
BLOWHOLES.
IT'S USUALLY MADE
OF CHROME-PLATED BRASS
THAT THEY CURVE SLIGHTLY
IN A PRESS.
THE MOUTHPIECE SHIELDS THE
LIPS
FROM A SLIDE MECHANISM INSIDE.
THAT MECHANISM
HAS THREE PARTS --
A SLIDE WITH A BUTTON
POSITIONED
IN BETWEEN TWO PLATES.
THEY SCREW THE MOUTHPIECE
ONTO THE FRONT OF THE
HARMONICA.
WHEN YOU PRESS
THE MOUTHPIECE BUTTON,
IT REDIRECTS THE AIR,
RAISING THE NOTES HALF A TONE.
NO HARMONICA LEAVES THE
FACTORY
WITHOUT A SOUND TEST.
RATHER THAN BLOW
INTO EVERY INSTRUMENT,
THE TESTING DEPARTMENT
USES A MACHINE
THAT BLOWS AIR IN AND OUT.
[ HARMONICAS PLAYING ]
LAST STOP
IS THE CLEANING DEPARTMENT.
THERE, WORKERS INSPECT
FOR SCRATCHES,
THEN POLISH AND PACKAGE
SO THAT EACH AND EVERY
HARMONICA
WILL LOOK AS GOOD AS IT
SOUNDS.
[ HARMONICA PLAYS MELODY ]
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