25x11 - Downhill Ski Bindings, Immersion Parts Washers, Mining Ventilation, Pencil Sha...

[bunniefuu]

Narrator: the binding is
the most important component

Of a downhill ski.

It attaches the ski boot
to the ski.

It prevents injury by releasing
the boot if the skier falls.

Also, an integrated brake
engages upon release,

Stopping the ski
from sliding down the hill.

Every downhill ski binding
has a toe and heel piece.

The toe usually
releases sideways in a fall,

And the heel releases upward.

The earliest bindings were made
of heavy stamped steel

And had no safety release.

Today's bindings are made
of lightweight material,

Such as extruded aluminum

And fiberglass reinforced
plastic.

Using 3 d software,

The research
and development team

Designs the binding
along with the molds and dyes

Used to manufacture
the components.

The team produces
a prototype of each component

And uses three dimensional
measuring tools

To verify the specifications.

Workers paint the visible
aluminum and plastic components

Then cure them in an oven
for 40 minutes.

They also dry them
at room temperature

For 24 hours.

This company produces
high end racing models,

As well as less expensive models

For beginner
to intermediate skiers.

This aluminum housing
is for the toe piece

Of a racing binding.

They screw on plastic tabs

To keep the metal from damaging
the plastic ski boot.

Then workers assemble
the indicator,

Which is used to adjust
the release setting.

The release setting determines
how much torque is needed

To trigger the binding
to release the ski boot.

The torque is generated

By the weight
of the skier falling.

They place
a bronze and aluminum ball joint

In the metal base.

The ball joint acts

As the rotational center
of the toe piece

When it releases.

They lubricate the ball joint
with grease

Before putting the base
in an assembly fixture.

Then they add
the toe piece housing...

And a plastic cap
with a white line on the side.

As they screw down the cap,

It compresses
the spring underneath.

They test
the finished toe piece.

This machine stamps
the company logo

On the heel piece of a binding
that's designed

For beginner
to intermediate skiers.

This one is made of
fiberglass reinforced plastic

With a clear polyurethane
protective cover.

You press the heel piece
with the ski pole

To get in and out of the ski.

Next, they mount a heel piece
to a base

And assemble
the internal mechanism.

This includes a screw down cap

That sets the internal spring
to a specific release setting.

An automated machine
tests each heel and toe piece

To make sure the mechanism
functions correctly.

Another machine
unscrews the cap halfway

To lower the release setting
to the midpoint.

Next, a metal pin
connects the pivoting top

Of the heel piece to the base.

This setting tool locks the pin
in its lateral position.

Now, workers mount the ski brake
to the heel piece.

The ski boot maintains pressure
on the brake

To keep it in the off position.

In a ski accident,
the fall releases that pressure,

Triggering the brake.

After the binding

Has been adjusted
to the length of the ski boot,

Workers insert a notching pin
that locks the heel piece

To the mounting plate
of the ski.

These plastic caps hide the
heads of the lateral metal pin.

Finally, workers connect
this lever to the notching pin.

You simply
pull it up and back

To disengage the pin
and adjust for boot length.

The company subjects random
samples from the production line

To rigorous
quality control tests.

Bindings are made
to international standards.

These standards dictate

How they're supposed to react
to falls.

Provided the binding
is correctly set

For the skier's weight,
boot size, and skiing ability,

These standards ensure

The ski boot releases
in an accident

But doesn't
inadvertently release

If the skier hits a big bump.

Narrator:
removing oil, heavy soils,

Scale, or rust stains on
a piece of metal can be tough.

This is where
industrial cleaning technologies

Come in handy.

Immersion parts washers

Use degreasing
and descaling compounds

To clean metal.

They also use ultrasound
to literally shake off the muck.

An immersion parts washer

Agitates water mixed
with an industrial detergent

To clean a mechanical part
or piece of metal.

A pneumatic lift mechanism

Moves the platform
up and down inside the tank

As the water heats
to about 150 degrees.

A robot loads stainless steel
into a laser cutter,

Using suction cups
to manipulate the sheet metal.

A cnc cutter uses
a 2,500 watt laser

To cut the steel,

Following a layout
entered in a cad system.

The layout maximizes
the number of parts

Made out of a single sheet.

The machine parts come out
on an unloading platform

Where an operator performs
a visual inspection.

He takes the parts
to a cnc folding table.

The machine bends
the sheet metal

To form the outside shell
of the immersion parts washer.

This is also called
the tank skin.

A hydraulic bending machine
makes flanges in the sheet metal

To reinforce the tank walls

And provide a surface
for welding.

This high end
sheet metal forming technique

Allows workers to produce
a series of parts

For multiple units.

A worker assembles
the machine parts

On a welding fixture.

He uses clamps
to hold the pieces in place

As he welds them together
using an electric mig torch.

Welding such a thin sheet
of stainless steel

Is a tricky job

Because it's more susceptible
to warping from the heat.

The tank goes through
a 24 hour leak test

Before painting.

A painter applies
epoxy and acrylic hybrid

Electrostatic powder coat.

The coat combines
the protective strength of epoxy

And the resilience of acrylic.

The painter places the tank
in a massive curing chamber...

And sets the oven time
and temperature.

The baking process
gives the powder coat

A grainy, textured finish.

A worker grinds down
the weld profiles

And polishes the top tank walls
with fine sandpaper.

Another worker
brings in the lift arm

And inserts it in the tank.

He puts the bearing support
mechanism in place

And bolts it onto the tank.

He inserts the rollers

That will support and guide
the lift arm...

Then drives a shaft
through the bearings.

He installs
the pneumatic cylinder

Behind the bearing support

And pins it
on top of the lift arm.

He brings in the agitator pump

And installs its


Next to the bearing support.

A plumber installs the fittings
for the tank filter.

The filter removes
contamination and debris

From the cleaning solution.

A worker installs the platform
and bolts it on the lift arm.

He installs a rack
on the platform.

It's made of grainy fiberglass

To prevent the pieces
from shifting

During a cleaning cycle.

After testing the movement

Of the lift arm
and platform assembly,

Workers install
the steel lid on the tank...

And attach its hinge.

Then they check
the fit of the lid.

An electrician makes
the connections

For the heat
and timer controls...

And screws the electric panel
onto the side of the tank.

He closes the electric box,

Then tests the lift arm,
the lid, and the agitator pump.

As the lift arm moves up,

The platform lifts clean parts
out of the water.

Washers like this one
can clean anything

From automotive castings
to printing press parts.

Narrator: in an underground mine,

Ventilation is critical
for the safety of the miners.

Above ground fans
can either blow in fresh air

Or they can suck out toxic gases
using ventilation ducts

Suspended from the ceiling
of the mine shaft.

The black ventilation ducts
are made of fiberglass.

The yellow ducts
are made of vinyl

Reinforced with steel wire.

Both are designed to withstand
negative pressure

When drawing out gases

And positive pressure
when blowing in air.

To manufacture
sections of fiberglass duct,

They use a steel mandrel.

Workers wrap plastic
around the mandrel

To prevent the fiberglass
from sticking.

They also wrap cardboard around
one end of each duct section

To increase its diameter.

Next, they start up
the fiberglass winding machine.

It draws 29 strands
of fiberglass roving

Through a bath of resin,

Then winds them in a helical pattern
up and down the mandrel,

Building up a layer between


Depending on the application.

The regular end is called
the spigot.

The wide end is called the bell.

The spigot of one duct section

Fits snugly
inside the bell of the next.

This way, multiple sections
can be connected to each other.

Workers embed d rings

At regular intervals
along the top.

These rings are used
to suspend the ducts

From the mine shaft ceiling.

Once the winding is finished,
workers cut the roving...

And roll
the fiberglass covered mandrel

Into a large oven for curing.

It takes about 30 minutes
to cure the resin

On a duct this size.

Once it's cured,
they extract the mandrel.

They saw through the middle
of the fiberglass duct

To dmde it into two
shorter ducts of equal length.

Each has a bell end
and a spigot end.

Workers use a hand saw

To cut and shape some pieces
into fittings.

Fittings are angled
or "y" shaped pieces

That connect two
straight pieces,

Allowing
the route of the ducting

To turn or branch out.

They connect the cut pieces
with galvanized metal tape,

Then they seal the gaps

With strips of fiberglass cloth
saturated with resin.

To make spiral duct,

They weld together
sheets of vinyl

To create a wider sheet.

On one end of the tube,
they weld in a ring

Made of galvanized wire rope.

At the other end of the tube,

They weld in
an adjustable coupler.

To connect duct sections,

The ring of one section

Fits into the coupler
of the next one.

They mount the tube
on the guide bar

Of the spiral winding machine.

The machine applies steel wire
to reinforce the vinyl.

It also enables the duct section
to collapse into a compact hoop.

As it works its way
down the tube,

The machine covers the wire
with a strip of vinyl.

It welds the vinyl to the tube,
forming a pocket

That both locks the wire
in position

And protects it from wear.

When the machine reaches
the opposite end of the tube,

They cut the wire
and remove the duct section.

The last step
is to attach hangers

At 2 foot intervals.

The hangers are used
to suspend the ventilation ducts

From the mine ceiling.

Spiral ducts
are the easiest type

Of ventilation to transport
and install

Because they're collapsible
and lightweight.

However, they can get damaged
in high traffic work areas,

So mines prefer to use

Sturdier fiberglass
ventilation ducts.

Narrator: before the
pencil sharpener,

People used knives
to sharpen the tips of pencils.

It was in the mid 19th century

When a french inventor
came up with a clever tool...

A little box with a blade
and a cone shaped opening.

Just twist the pencil into it,

And it makes
a very precise point.

The pencil sharpener has been
a favorite of pencil pushers

For over 150 years.

With a few twists,

It can hone
the graphite tip of a pencil

To a very fine point.

To make pencil sharpeners,

They start with high carbon
steel for the blades.

The steel unwinds
through a straightener,

Then a feeder serves it up
to a punchcutter.

It cuts out five blades
in one action,

Complete with assembly holes
in the center.

It also embosses
the company logo onto it.

This machine can generate

Well over


In an hour.

A worker distributes the blades
onto a conveyor

That will take them to an oven.

The temperature inside
is 1,500 degrees.

The blades slowly circle
in the oven.

This step takes


Exposure to the intense heat
and a quick cooldown in oil

Harden the blades,

But it also
leaves them tarnished.

So they drain the oil

By spinning the blades
in a perforated drum.

Then they add a mix
of dried corn

And polishing paste
to the blades.

The drum tosses the blades
in the polishing medium

For six 6 to 12 hours.

This restores them,

As we see
in this before and after shot.

A circular feeder sorts them
into a single file

And racks them on a metal rod.

Once on the rod,

A machine grinds a cutting edge
into all of the blades at once.

Next,
they manufacture the housing

For the pencil sharpener blades.

A circular saw
cuts a ridged magnesium bar

To the correct length.

The magnesium blocks
tumble into a feeder,

Which funnels them
into a stamping machine.

The machine stamps
the company logo

Onto the top
and lower side of the blocks.

Machinery moves

The pencil sharpener bodies
forward to a drill

That bores cone shaped,
pencil sized holes into them.

A second drill
carves holes in the top

For screwing the blades into
the pencil sharpener bodies.

A little metal rod shoves
the pencil sharpener bodies

Out of the machine
and into a bin.

A worker plunges
the pencil sharpener bodies

Into five chemical baths.

Each bath has
a different formula.

The chemicals soften the edges
of the magnesium bodies,

Making the surface shinier.

A worker spreads
the pencil sharpener bodies

Across a mesh conveyor.

The conveyor takes them
through a dryer

To remove any residue

Left behind
by the chemical solutions.

These pencil sharpener bodies
are now ready to receive blades.

A feeder system delivers them
to an assembly station.

The screws funnel

Into an automated screwdriver
at the assembly point.

A mechanism slides the blades

Into the pencil sharpener bodies
as they arrive.

The pencil sharpeners fall
into a bin, ready for retail.

It's taken
many different processes

To produce these magnesium
pencil sharpeners.

Here's a recap of the process.

Over a century and a half
after its invention,

The manual pencil sharpener
is still making life easier.

And in modern factories,

The concept has been honed
to a fine point.