17x13 - Turbochargers/Enchiladas/Watches

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Narrator:
a turbocharger harnesses
a vehicle's exhaust gases

To compress fresh air,
forcing the pressurized air

Into the engine's
combustion chamber

For a turbocharged performance.

With it, a small engine can be
as powerful as a larger one,

Using energy
that would otherwise disappear

Out the tailpipe.

The exhaust gas turbocharger
is an invention

That dates back over a century,
but in recent years

The concept has literally
been picking up speed.

Design tweaks
and the use of lighter materials

Mean a bigger boost to
engine output

So a small engine
can be as powerful as

A larger one
without guzzling extra fuel.

Production begins
at the foundry,

An overhead sprayer blows sand
into the shaped cavity

Of this box.

The spraying action activates
a binder applied to the sand.

This causes a chemical reaction
that solidifies the particles.

The worker extracts the hardened
sand shape from the box.

The shape is called a core.

It will be used to
mold the inside

Of the turbocharger's housing.

He files down any little bumps
and rough edges.

He then pipes adhesive
around the border

Of a second sand mold
and glues the first part to it

To build up the core.

He applies a putty-like compound
to the seam to plug any gaps.

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Meanwhile, another worker
uses a different technique

To make smaller cores.

He rocks the box,

And this causes sand
to flow into a shaped cavity.

The sand has been mixed
with heat-sensitive chemicals.

He aims a flame
at an opening in the box

As burners warm it
from the sides.

This triggers a reaction
that hardens the sand inside

So it takes the shape
of the cavity.

The result is another smaller
turbocharger core.

These snail-shaped sand cones
are now ready for casting.

He places the cores in a mold

Which is also made
of hardened sand.

Machinery lifts the bottom half
of the mold to the top half,

Essentially closing the mold.

He pours molten aluminum
into it,

And it flows into the spaces

Between the cores
and outer mold.

The aluminum solidifies
in a minute,

And the molds tumble
onto to a conveyor,

Revealing the cast
turbocharger parts.

They are connected by
hardened flow lines.

After separating the parts,

They ship them to
the turbocharger factory.

Here, computerized tools
carve and contour

The aluminum part to
specifications so precise,

They are measured
in thousandths of an inch.

This is the turbocharger housing
before the work was done...

And after.

Using a computerized probe,

A technician looks for
irregularities.

Even miniscule ones
will need to be fixed.

It's now time to assemble
all the parts.

The worker inserts a bearing
into one end

Of the iron center housing.

He lubricates a second bearing
and slots it into the other end.

These bearings
will ultimately support a shaft

With a turbine on one end
and a compressor on the other.

He adds a metal collar and
a third bearing to the assembly.

He caps the bearing parts
with a metal plate.

It will keep lubricant
from spilling out

When the turbocharger spins.

He flips
the center housing around

And installs a metal heat shield
on the bottom.

He inserts the shaft
and turbine wheel assembly.

He installs the compressor wheel
on the other end of the shaft.

He heats the wheel briefly,
causing it to expand,

Which allows it to be pushed
further down the shaft.

Once cold, it shrinks to
the shaft for a tight fit.

Next, a machine called
a vibration sort rig

Spins the compressor
at a high speed

As a computer analyzes it
for vibrations.

Even the slightest tremor
indicates an imbalance.

The computer also detects
the source of the problem

So it can be fixed.

He grinds the compressor nose
ever so slightly

To balance the part.

He now nestles the compressor

Into the curled
aluminum housing.

It's a shape that's designed to
funnel air into the engine.

He secures the compressor to
the housing with a metal ring.

He fits the turbine end
into its housing.

It, too,
has the distinctive curl

To pipe the exhaust gases
in the right direction.

A blast of air now simulates the
effect of those exhaust gases,

Spinning the turbine to
power the compressor.

It takes about 15 minutes to
build one of these turbos.

Once installed in an engine,
it's full speed ahead.

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Narrator: "enchilada" means
dipped in chili in spanish.

And true to its name,
these stuffed corn tortillas

Are typically smothered in sweet
and mildly spicy chili sauce.

First cooked up by native
mexicans centuries ago,

Enchiladas are an ancient food,

But they are definitely
not passé.

In modern times,

The enchilada has become
a metaphor for having it all.

"The whole enchilada" means
there's no holding back.

There are numerous enchilada
recipes today.

This black bean
and veggie version

Starts with a filling sauce.

It's a chili-flavored
tomato puree.

They add organic corn, a firm
variety that's mildly sweet.

That means the flavor won't
clash with the chili spice.

Spiraling blades fold the corn
into the filling sauce.

The mixing action is gentle to
keep the kernels intact.

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The next ingredient is tofu,
diced into cubes.

Like the corn, it's a firm type
for a more substantial texture.

The firm tofu
is also quite porous,

So it readily absorbs
the flavors

Of the enchilada filling sauce.

They green up the sauce with
chunks of organic zucchini,

Uniformly diced
with the skins on.

Black beans are next, already
cooked with the juices drained.

This completes
the enchilada filling sauce.

They cool it to preserve
its thick consistency

And overall freshness.

And now they are ready to wrap.

They pump measured amounts
of the black bean

And vegetable mixture
onto each tortilla.

And here the chilling of the
filling pays off.

A warmer, runnier sauce would
spill out and make a mess,

But this cool, thick sauce
stays where they put it,

In the middle of the tortilla.

Workers now
roll the tortillas

Around the black bean
and veggie mix.

There is a trick to this.

If the tortilla is rolled too
tightly, there could be leakage.

Too loose, and the enchiladas
could come undone.

A perfectly rolled enchilada
fits neatly into the trays.

They place the enchiladas
seam-side down in the container.

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Elsewhere in the factory,

They sauté various chili powders
in flour and oil.

They liquefy this flavorful mix
with vegetable broth.

Mixing blades blend
the simmering ingredients,

And the flavors intensify.

It thickens to
a gravy-like consistency.

And as one would do with gravy,

They strain out any lumps
or impurities.

What exits the sieve
is pure enchilada chili sauce.

Next, it flows into a dispenser.

The nozzle head is the exact
same length as the enchiladas,

Ensuring complete coverage as
the sauce is pumped onto them.

The enchiladas are now
swimming in chili sauce,

Imbuing the dish
with mild spice.

The chili sauce also serves

To keep the tortillas moist
during cooking.

They sprinkle on
freeze-dried chives.

This herb adds an onion-y nuance
to the dish.

Every few minutes,
they pull a tray

Off the production line
and weigh it to confirm

That the portion size is right.

They churn out


At this factory.

Next, it's into the freezer
to preserve the enchiladas

At arctic-like temperatures.

It's a new day
and a new shift of workers.

They place the enchiladas
on a conveyor

En route to the packaging line.

It takes just one minute
to wrap and box



Technology and humans team up
to get the job done fast.

Enchiladas have come a long way
over the centuries --

From a simple meal
first whipped up

By the mayans of mexico
to a mass-produced frozen meal.

Today, they are consumed
in countries around the world.

And with these frozen versions,
mealtime is no trouble at all.

Just heat and eat.

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Narrator: the mechanism
inside a wristwatch

That measures time
and moves the hands accordingly

Is called the movement.

High-end watches
typically use traditional,

Very intricate
mechanical movements.

Such premium watches are made up
of a multitude of components,

Requiring hundreds
of manufacturing

And assembly operations.

Luxury wristwatches are made of
top-quality materials,

Often precious metals.

They are crafted with
painstaking precision,

Partly by
traditional watchmakers,

Partly by high-tech machines.

The main section
of the watch case

Starts out as
a block of metal --

Stainless steel for this model.

A press stamps
the preliminary shape,

Which a computer-guided
milling machine then finalizes.

Another computer-guided machine
drills a hole on the side

For the stem and crown, the
manual watch-winding mechanism.

This tool refines the edges.

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Next,
using an abrasive tool,

They manually etch the surface

To give it
a brushed metal finish.

Then they apply
some polishing compound

To a felt buffing wheel
and polish the entire surface.

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Certain models undergo a second
polishing performed by a robot.

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The two other parts
of the watch case,

The back and the ring
around the watch face,

Called the bezel,

Are made the same way
as this main section.

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To produce the movement,

They cut a square brass plate

And stamp it into
a preliminary shape.

This computer-guided mill
then refines it

To the correct thickness.

The next computer-guided machine
makes several slots and holes.

This part,
called the main plate,

Is the base upon which
all the movement's components

Will be assembled.

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The milling process
leaves behind

Traces of metal dust
and oil on the surface,

So the main plate
undergoes a thorough washing

With water and solvent.

Once dry,
a computerized inspection device

Examines the plate
from three dimensions,

Verifying that every last detail
is precisely as it should be.

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Then the last machine cuts
the final circular shape.

The main plate is now
technically perfect.

Only finishing steps remain.

First, to remove tool marks,

They sand-blast the surface to
give it an even matte finish.

Here's what the plate looks like
before sand-blasting and after.

Another computer-guided tool
etches tiny circles

Onto the main plate surface
to produce a pearl-like effect.

This next component,
called the bridge,

Covers most of the parts
assembled onto the main plate,

And itself holds
a number of parts.

After a laser engraves
the company name,

They fill the lettering
with varnish.

They put the bridge
into an automated machine

That etches a brush finish
and wipes off the varnish.

Some varnish residue
remains inside the letters,

Making them more visible.

Next, a robot sets a jewel into
each hole in the main plate.

Jewels are tiny,
cup-shaped synthetic rubies.

Each jewel will hold one of
the movement's moving parts

In a drop of lubricating oil.

After installing two barrels
containing a spring each,

The watchmaker positions
four wheels.

These form the gear train that
moves the hands of the watch.

Next, he mounts the auxiliary
main plate on top.

This sandwiches the barrels
and gear train,

Holding them in place.

Then the escapement,
the regulating mechanism.

Winding the watch fully coils
the springs inside the barrels.

The escapement paces the springs

As they slowly unwind
and turn the gear train.

Now a robot takes over,

Squirting a drop of oil
in each jewel.

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Meanwhile, a laser
engraves the watch brand name

And logo
into the oscillating weight.

This component is a heavy metal
disk first stamped in a press,

Then refined by high-precision
computer-guided tools.

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Narrator:
the oscillating weight is an
automatic winding mechanism.

This weight,
located on the back side

Of the movement,
automatically winds the watch

As it's on your wrist.

Therefore, the more often
you wear the watch,

The less often
you have to wind it manually

By turning the crown.

The watchmaker connects
the oscillating weight

To the springs
which move the gear train

So that the weight will shift
backwards and forwards

With any wrist movement,

Automatically coiling
the springs.

On the front side
of the movement,

He screws in the date indicator
and the dial.

The dial is comprised
of two brass plates,

The top one
coated in oxidized copper

With cutouts to show
the bottom one,

Which is painted with
this company's secret formula

Of glow-in-the-dark pigments.

Next, a machine mounts
the brass hour and minute hands.

This operation
is automated

Because applying
even slightly too much pressure

Could damage the tiny,
delicate hands.

Now for the watch case.

After twisting an arched ring
called the bezel

Onto the front of the main case,

He slides a plastic gasket
into it...

Then positions the main case
onto to a press...

Cleans the crystal...

Then presses it forcefully
into the bezel.

The gasket seals the minute gap
between the crystal

And the bezel so that water
can't seep inside the case.

Next, the stem and crown.

Then on the back of the case,
the casing circle,

A ring that comes between
the movement and the case.

Here, too,
a gasket seals the gap

To make the case
water-resistant.

He installs the ring in crystal
that form the back of the case.

He applies grease so that
it twists on smoothly.

He closes it tightly
with a tool.

Then the fully assembled case

Goes off to be tested
for water-resistance.

If it passes,
it comes back to the watchmaker

To receive the movement.

He removes the crown
and the case back,

Cleans the movement,
then places it in the case.

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Next, he squirts grease
in the crown hole

And reinstalls the crown.

This time, because
the movement is in place,

The crown stem
connects to the two springs

So that turning the crown
now winds them.

The watchmaker affixes
the movement in the case

With several tiny clamps
and screws.

Then he closes up the back
for the last time.

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After checking that
the movement works properly,

He has just one last component
to assemble to the watch head.

This particular watch company
has developed

A unique protective device
that goes over the crown.

A computer-guided mill
shapes it out of

The same type of metal
as the case so that,

Aesthetically,
it blends seamlessly.

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The watchmaker
screws the device to the case

So that it bridges the crown.

The device has a lever,
the tension of which

The watchmaker carefully adjusts
with the help of this gauge.

The lever closes the device
tightly over the crown,

Immobilizing the crown so that
it can't be turned accidentally.

Finally,
they mount the watch head

On an automated machine
which closes the back tightly.

This is critical
for water-resistance.

Every single watch head
this factory manufactures

Must pass several
quality-control tests

To ensure time-keeping accuracy
and water-resistance.

For water-resistance, they first
test using air pressure.

Then actual water tests.

First a low-pressure test
in 4 inches of water.

Then a high-pressure test
in 410 yards of water,

Which far exceeds
the 328-yard depth

To which the watch is guaranteed
to be water-resistant.

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Finally it's time to assemble
and attach the watch strap,

Either a link bracelet
in matching metal

Or a strap
made of fine leather,

A fitting finale
to this luxury wristwatch,

The elegant product
of precision technology

And time-honored tradition.

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