HOW IT WORKS | Fridge, Bobsled, Wellington Boots, Wheelie bins | Episode 31 | Free Documentary

the show that reveals how extraordinary items in our world are designed constructed and produced see the engineering the technology and Big Ideas that make the world go around find out how it [Music] works [Music] coming up want to experience racing at over 140 km an hour we'll show you the technology behind a record-breaking Bob slle they're the miracle mud proof boots that allow wearers to walk through water but what exactly goes into making Wellies and it's a tough job that bin men just can't refuse we reveal why wheelie bins are the business when it comes to collecting the [Music] rubbish but first with all being there it's late at night you're hungry and your fanciest snack time to raid the fridge but have you ever stopped to consider how this amazing invention Works to build these handy cabinets that we take for granted you need steel it's used to make most fridge exteriors which are fabricated at a factory like this one a 160 ton press stamps the individual Parts out of the steel roll the process has 36 different steps and is watched by a vigilance quality control [Music] manager a fridge is a necessity in Modern Life it's estimated that in Britain there are over 40 million fridges keeping our food and drinks chilled inside but how do they give them that smooth finish on the outside opposite forces attract so in the painting process the metallic parts are negatively charged while the paint sprayer is positively charged this makes the paint stick in a smooth layer a fridge is made up of two key sections with seen the outer shell pressed and painted this raw plastic material will be used to build the interior powerful ovens heat the plastic to 220° C in this soft molten form it's rolled out into wide sheets this roll of plastic is then cut to size using a razor blade and carried on to the next stage of production where it will be shaped over 2 and A2 million refrigerators are thrown away in the UK every year which has created something of a fridge Mountain to combat This Modern legislation requires that fridges must be made more environmentally friendly than they were in the past the plastic sheets are loaded into a vacuum forming machine here they're blown up the template is pushed inside and the air is sucked out the plastic clings to the mold which forms a perfect new fridge [Music] interior water cooling hardens the plastic into its new shape and it's ready to [Music] go the interior will be fitted into the steel cabinet exterior and the space in between filled with an insulating hydrocarbon foam but before that's done the two finished pieces have to be put together the outer steel shell provides the structure the inner plastic Linings are fitted inside and they include an all important hole for the insulation [Music] injection the cavity between the two parts can now be filled with the insulation each unit is loaded into the machine and held firmly in place here they are attached to a nozzle which injects the liquefied insulation into the spaces between the steel and plastic the foam expands and hardens which both seals the unit together and helps insulate the fridge as a whole the foam can be seen expanding when we view the process in real time this expanding type insulation used to be made with ozone depleting CFCs or chlorocarbons manufacturers switched to hydrocarbon compounds in the mid 1990s and theyve used them instead ever since with the structure of the fridge complete the techn technology that regulates the temperature can now be [Music] installed fridges work by transferring heat away from the inside of the cabinet the food inside isn't cooled directly the secret is in the use of a hydrocarbon refrigerant these chemicals carry heat away from the interior through a series of pipes to the outside as the heat is removed the food is gradually to be chilled refrigerants boil at very low temperatures any residual heat in the food or the fridge cabinet itself is transferred to the liquid it boils and the steam then passes rapidly through a network of pipes taking the heat with [Music] it as the steam passes through the pipes and out of the fridge the Heat heat is released the hydrocarbon then returns to the reservoir where it cools before being pumped back into the system the pump or compressor is the final part in the process it keeps the cooling agent circulating around the cabinet the system must be airtight to work so everything's welded for the perfect seal finally all the shelves drawers and boxes that are used to store your shopping are out added to complete the fridge a protective layer of cellophane is wrapped around the finished unit and it's packed up ready to be sold so the next time you're raing the fridge give thanks for the Innovative invention that keeps Modern Life so [Music] chilled [Music] a pair of Hightech blades a small handle and a good deal of determination it sounds simple but anyone striving to make it in the high stakes highspeed sport of Bob sledding needs stamina skill and courage but even the experts need the best possible sled to make it to the top or bottom the modern sled is built around a steel frame but there are a lot of different materials used in the construction process the sled is made using about 150 different pieces from the basic frame and aerodynamic shell to the runners the sled will travel on it will be exposed to enormous stresses it has to reach a cruising speed of around 145 km an hour to be competitive it will also have to withstand up to f g of force as it Corners so the welds holding it together must be exceptionally strong the runners too have to be perfectly milled the slightest imperfection will cause drag and slow the sled down so they have to be very carefully [Music] crafted [Music] the ideal width for the modern bob sled is around 68 cm any larger and drag is increased which again will slow the vehicle down in a sport where milliseconds count a winning sled has to be perfect the engineers construct the structure for the sled led to within 1/10th of a MM accuracy to ensure it's as fast as [Music] possible while the structure is being built another group of mechanics can produce the outer shell it's made with a combination of fiberglass coated with a thick layer of polyester [Music] resin the resin layers of built up gradually until a solid shell is completed it's then left to [Music] dry once it's completely solidified the mechanics will cut the shell down to the perfect size Precision aerodynamics are vital to ensure the finished sled will produce the fastest possible speeds using a circular saw they cut the newly fabricated outer hole to the required shape but they're very careful to vacuum as they go fiberglass dust can be very dangerous if it's inhaled into the lungs as the different pieces are completed the basic outer shape of a competition grade Bob slur begins to emerge but how can the engineers be sure they've got the design right intensive testing takes place using scale models and a wind tunnel long before any construction work even begins this level of technology means the engineers can test new designs to see how their modifications affect performance tiny details such as the shape of the driver's helmet can have a big impact on the speed of the sled the final element that is vital to a winning bob sled is the runners the exact compounds that go into these Precision Blades are a closely guarded secret but different Alloys include iron copper and phosphorus they're attached to movable struts on the bottom of the sled using ordinary nuts and bolts but before the Riders take to the course the runners are polished to remove any imperfections the slightest scratch or bump will increase drag but how does the driver steer his sled the man at the front is in charge beneath the aerodynamic Co is a simple cont rtion made of pulleys and handles this is the steering mechanism it's connected directly to the Front Runners and pulling one side of the other turns the sled left or right once the whole unit is completed the only thing that remains is to try it out Bob sledding is a sport that depends on three main factors first the power and aggression of the Riders second the quality of the sled and third how well it's driven down the track if all the construction testing and training have come together it's finally down to the Riders to make their sled a medal-winning success [Music] still to come Wellington Boots Are chopped up and worn down to ensure they'll take as much of a kicking as you can give them and rubbish day isn't usually a colorful experience but we'll show you how the makers inject some into the popular wheelie [Music] bin [Music] looks like rain again we get a lot of that in the UK which may explain why it was an Englishman who invented one of the world's most famous waterproof boots the Wellington the modern welli is an all rubber Affair that's used in a variety of environments from chemical factories and emergency situations to the bog standard muddy field the original Wellington boot was invented by the Duke of Wellington but was made out of leather later they were made using the resin of the rubber tree which grows in warm tropical climates however producing natural rubber became very expensive so manufacturers turned to cheaper synthetic Alternatives like polyurethane the chemicals contained in these enormous Vats will be mixed together vigorously when they combine and set they will create the ideal compound for a sturdy pair of boots for a variety of different shades coloring is added into the mixture before the chemical process that makes the synthetic rubber begins using large drums on Wheels the staff will mix a new batch of about 1,000 L of the raw material this chemical concoction will then be very carefully transported to the factory floor here it's hooked up to the boot production machine and the process can begin but how are these boots made well it's actually quite a simple process the liquid polyurethane will be poured into a boot-shaped mold where a chemical reaction will cause the rubbery material to expand it then solidifies into the boot shape however if you made boots like this they'd be solid you wouldn't actually be able to get your feet into them but that's where all these spare legs come into the process these metallic feet come in all sizes once inserted into the mold the polyurethane material will form the boots around this substitute foot and this is the heart of the production process first the workers spray solvent into the mold this this works like a non-stick frying pan and stops the polyurethane mixture from sticking next the operator will place a stocking in the mold this will form the inside of the boot and make it more comfortable to wear some models call for steel tip toe caps which are fitted next and finally an inner sole is added to give your foot grip inside the boot and the Machine is put to work once the mold is sealed a pipe is attached and the polyurethane chemical mix is pumped in gauges monitor the pressure and an inspector also takes regular samples to ensure the mixture is right this single Factory can produce about 600,000 pairs of boots every year when the machine opens up brand new boots emerge complete with a handy sole as turnover is high robots are used to improve productivity but much of the work is still done by hand the new wellingtons will have rough edges when they emerge from the mold so the boots are trimmed and any extra rubber nubbins removed they're then passed on for quality control to inspect and test these versatile waterproof boots aren't just used for stomping through puddles they will end up working in a variety of extreme environments so they need to withstand abrasive substances as well as wear and tear testing includes flexing the sole through over 100,000 Paces to be sure it can last the distance next the steel tips are tested they should protect the toes from any heavy objects being dropped on them they have to survive the impact of a 20 kg weight and the boots themselves must be durable but flexible material samples are stretched to over four times their normal length to determine how much stress they can withstand when the batch has passed all the necessary quality controls they're marked up with the company logo ready to be sent out to the stores so just like the legendary Juke who defeated Napoleon at walaloo the boots that bear his name promise victory in the battle to keep our feet dry [Music] every year the UK throws out an enormous 434 million tons of rubbish from plastic wrapping to newspapers and even Garden waste it all has to go somewhere and the first Port of Call isn't the dump or the rubbish truck it's a wheelie bin This Modern replacement for the old dust bin is a colorful upgrade to the rubbish removal system a key feature to its design is it compatibility with the rubbish truck's lifting mechanism previously bins were made out of metal this was ideal for storing all the different rubbish that people would throw out including hot ashes from Home Fires and cookers however with central heating electric cookers and fewer homes with fireplaces modern bins don't need to be as heat resistant they do however need to be robust [Music] production of a modern rugged wheelie bin starts out at a factory like this one these containers are filled with the raw material that's used to make the bins granulated plastic vacuum hoses suck the plastic into the molding machine where it's superheated to melting point at 260° C it's turned into liquid and can be molded into the shape of the new bin in just 60 seconds about 1 million wheelie bins are made in the UK every year using this technique the injection molding takes place inside this enormous machine and each new unit emerges from the other side this hot jet of molten plastic is what fills each mold to become a new bin in order to help with recycling some European manufacturers color code their bins this is done by adding colored granulat to the basic [Music] [Music] mixture however it's a gradual process output is carefully monitored bins that are not the right color will have to be rejected it takes a few attempts before the colored granules combine properly in the mix to create the exact shade required the First new units to emerge take on progressively darker Shades until the right color is finally produced the rejected bins are recycled they're ground down to be reused at a later date [Music] once the bins have sufficiently cooled they can receive the accessories that give them their nickname two solid wheels are fitted on a metal axle to help make them more maneuverable a handy lid is also fitted and an efficient design means it only takes two taps with a hammer to seal it firmly into place the lid keeps the smell in and the fox is out we bins were first built in Germany in the 1970s but they didn't make it over to the UK until the80s one useful feature of this modern design is this handy lifting system it means binmen no longer need to lift heavy smelly bins by hand wheelie bins come in all shapes and sizes but whether we should recycle more or just make less rubbish the millions of wheelie bins throughout Britain will continue to help us shift that way [Music] [Music] tast

Channel: Free Documentary

Views: 623,950

Keywords: Free Documentary, Documentaries, Full documentary, HD documentary, BBC documentary, How it Works, How It's Made (TV Program), Bobsled, Fridge, Wellington Boot (Garment), Wheelie Bin, Hot its made, How it works bobsled, Cool Runnings (Film), Ice, New, Bobsleigh (Sport)

Id: 5_lAHEZvH34

Length: 23min 25sec (1405 seconds)

Published: Fri Dec 05 2014