Wednesday, November 7, 2018

Radio

Background

The radio receives electromagnetic waves from the air that are sent by a radio transmitter. Electromagnetic waves are a combination of electrical and magnetic fields that overlap. The radio converts these electromagnetic waves, called a signal, into sounds that humans can hear.
Radios are a part of everyday life. Not only are they used to play music or as alarms in the morning, they are also used in cordless phones, cell phones, baby monitors, garage door openers, toys, satellites, and radar. Radios also play an important role in communications for police, fire, industry, and the military. Although there are many types of radios—clock, car, amateur (ham), stereo—all contain the same basic components. 


Radios come in all shapes and sizes, from a little AM/FM "Walkman" to a highly sophisticated, multi-mode transceiver where both the transmitter and receiver are combined in one unit. The most common modes for a broadcast radio are AM (amplitude modulation) and FM (frequency modulation). Other modes used by ham radio operators, industry, and the military are CW (continuous wave using Morse code), SSB (single sideband), digital modes such as telemetry, radio teletype, and PSK (phase shift keying).

History

Guglielmo Marconi successfully sent the first radio message across the Atlantic Ocean in December 1901 from England to Newfoundland. Marconi's radio did not receive voice or music. Rather, it received buzzing sounds created by a spark gap transmitter sending a signal using Morse code.
The radio got its voice on Christmas Eve 1906. As dozens of ship and amateur radio operators listened for the evening's traffic messages, they were amazed to hear a man's voice calling "CQ, CQ" (which means calling all stations, I have messages) instead of the customary dits and dahs of Morse code. The message was transmitted by Professor Reginald Aubrey Fessenden from a small radio station in Brant Rock, Massachusetts.

In the years from 1904 to 1914, the radio went through many refinements with the invention of the diode and triode vacuum tubes. These devices enabled better transmission and reception of voice and music. Also during this time period, the radio became standard equipment on ships crossing the oceans.

The radio came of age during World War I. Military leaders recognized its value for communicating with the infantry and ships at sea. During the WWI, many advancements were made to the radio making it more powerful and compact. In 1923, Edwin Armstrong invented the superhetrodyne radio. It was a major advancement in how a radio worked. The basic principles used in the superhetrodyne radio are still in use today.

On November 2, 1920 the first commercial radio station went on the air in Pittsburgh, Pennsylvania. It was an instant success, and began the radio revolution called the "Golden Age of Radio." The Golden Age of Radio lasted from the early 1920s through the late 1940s when television brought in a whole new era. During this Golden Age, the radio evolved from a simple device in a bulky box to a complex piece of equipment housed in beautiful wooden cabinets. People would gather around the radio and listen to the latest news and radio plays. The radio occupied a similar position as today's television set.

On June 30, 1948 the transistor was successfully demonstrated at Bell Laboratories. The transistor allowed radios to become compact, with the smallest ones able to fit in a shirt pocket. In 1959, Jack Kilby and Robert Noyce received the first patent for the integrated circuit. The space program of the 1960s would bring more advances to the integrated circuit. Now, a radio could fit in the frame of eyeglasses or inside a pair of small stereo earphones. Today, the frequency dial printed on the cabinet has been replaced with light emitting diodes or liquid crystal displays.

Raw Materials

Today's radio consists of an antenna, printed circuit board, resistors, capacitors, coils and transformers, transistors, integrated circuits, and a speaker. All of these parts are housed in a plastic case.

An internal antenna consists of small-diameter insulated copper wire wound around a ferrite core. An external antenna consists of several aluminum tubes that slide within one another.
The printed circuit board consists of a copper-clad pattern cemented to a phenolic board. The copper pattern is the wiring from component to component. It replaces most of the wiring used in earlier radios.

Resistors limit the flow of electricity. They consist of a carbon film deposited on a cylindrical substrate, encased in a plastic (alkyd polyester) housing, with wire leads made of copper.
Capacitors store an electrical charge and allow alternating current to flow through an electrical circuit but prevent direct current from flowing in the same circuit. Fixed capacitors consist of two extended aluminum foil electrodes insulated by polypropylene film, housed in a plastic or ceramic housing with copper wire leads. Variable capacitors have a set of fixed aluminum plates and a set of rotating aluminum plates with an air insulator.

Coils and transformers perform similar functions. Their purpose is to insulate a circuit while transferring energy from one circuit to another. They consist of two or more sets of copper wire coils either wound on an insulator or mounted side-by-side with air as the insulator.
Transistors consist of germanium or silicon encased in a metal housing with copper wire leads. The transistor controls the flow of electricity in a circuit. Transistors replaced vacuum tubes used in earlier radios.

The integrated circuit houses thousands of resistors, capacitors, and transistors into a small and compact package called a chip. This chip is about the size of the nail on the little finger. The chip is mounted in a plastic case with aluminum tabs that allow it to be mounted to a printed circuit board.

Design

Radios consist of many specialized electronic circuits designed to perform specific tasks—radio frequency amplifier, mixer, variable frequency oscillator, intermediate frequency amplifier, detector, and audio amplifier.

The radio frequency amplifier is designed to amplify the signal from a radio broadcast transmitter. The mixer takes the radio signal and combines it with another signal produced by the radio's variable frequency oscillator to produce an intermediate frequency. The variable frequency oscillator is the tuning knob on the radio. The produced intermediate frequency is amplified by the intermediate frequency amplifier. This intermediate signal is sent to the detector which converts the radio signal to an audio signal. The audio amplifier amplifies the audio signal and sends it to the speaker or earphones.

The simplest AM/FM radio will have all of these circuits mounted on a single circuit board. Most of these circuits can be contained in a single integrated circuit. The volume control (a variable resistor), tuning knob (a variable capacitor), speaker, antenna, and batteries can be mounted either on the printed circuit board or in the radio's case.

The Manufacturing
Process

There is no single process for manufacturing a radio. The manufacturing process depends upon the design and complexity of the radio.
 
An example of a standard AM/FM radio.
The simplest radio has a single circuit board housed in a plastic case. The most complex radio has many circuit boards or modules housed in aluminum case. Manufacturers purchase the basic components such as resistors, capacitors, transistors, integrated circuits, etc., from vendors and suppliers. The printed circuit boards, usually proprietary, may be manufactured in house. Many times, manufacturers will purchase complete radio modules from an vendor. Most of the manufacturing operations are performed by robots. These include the printed circuit boards and mounting of the components on the printed circuit board. Mounting of the printed circuit board and controls into the case and some soldering operations are usually done by hand.
  1. The blank printed circuit board consists of a glass epoxy resin with a thin copper film cemented to one or both sides. A light sensitive photoresist film is placed over the copper film. A mask containing the electrical circuitry is placed over the photoresist film. The photoresist film is exposed to ultraviolet light. The photoresist image is developed, transferring the image to the copper film. The unexposed areas dissolve during etching and produce a printed circuit on the board.
  2. Holes are drilled in designated locations on the printed circuit board to accept the components. Then, the board is pre-soldered by dipping it in a bath of hot solder.
  3. Smaller electronic components such as resistors, capacitors, transistors, integrated circuits, and coils are installed in their designated holes on the printed circuit board and soldered to the board. These operations can be performed by hand or by robots.
  4. Larger components such as power transformer, speaker, and antenna are mounted either on the PCB or cabinet with screws or metal spring tabs.
  5. The case that houses the radio can be made either of plastic or aluminum. Plastic cases are made from pellets that are melted and injected into a mold. Aluminum cases are stamped into shape from sheet aluminum by a metal press.
  6. External components not mounted on the printed circuit board can be the antenna, speaker, power transformer, volume, and frequency controls are mounted in the case with either screws, rivets, or plastic snaps. The printed circuit board is then mounted in the case with screws or snaps. The external components are connected and soldered to the printed circuit board with insulated wires made of copper and plastic insulation.

Quality Control

Since most of the components or a radio are manufactured by specialized vendors, the radio manufacturer must rely on those venders to produce quality parts. However, the radio manufacturer will take random samples of each component received and inspect/test them to ensure they meet the required specifications.

Random samples of the final radio assembly are also inspected to ensure quality. The overall unit is inspected for flaws—both physical and electrical. The radio is played to ensure it can select radio frequencies it's design to receive, and that the audio output is within specifications.

Byproducts/Waste

Today's environmental awareness dictates that all waste be disposed of properly. Most byproducts from the construction of a radio can be reclaimed. The etching solutions used in the printed circuit board manufacture are sent to chemical reclamation centers. Scraps from the leads of electronic components are sent to metal waste recovery centers where they are melted to create new products.

The Future

Radios are being combined with computers to connect the computer to the Internet via satellites. Eventually radios will convert from analog to digital broadcasting. Analog signals are subject to fade and interference, digital signals are not. They can produce high quality sound like that found on a CD.

Digital radios can be programmed for specific stations, types of music, news, etc. Eventually, radios will have mini-computers built in to process sounds in numerical patterns "digits" rather than an analog waveform. This will allow listeners to program their radios for favorite radio stations, music type, stock quotes, traffic information, and much more.

Where to Learn More

Books

Carter, Alden R. Radio From Marconi To The Space Age. New York: Franklin Watts, 1987.
Floyd, Thomas L. Electric Circuit Fundamentals. Columbus: Merrill Publishing Company, 1987.
The American Radio Relay League. The ARRL Handbook for Radio Amateurs. Newington, CT: ARRL, 1996.

Other

Canadian Broadcasting Company Web Page. "The Future of Digital Radio.: December 2001. < http://radioworks.cbc.ca/radio/digital-radio/drri.html >.
UC Berkley Web Page. December 2001. < http://www.cs.berkeley.edu/~gribble/cs39c/Comm/radio/radio.html >.
Ernst S. Sibberson

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Basketball

Background

Basketball can make a true claim to being the only major sport that is an American invention. From high school to the professional level, basketball attracts a large following for live games as well as television coverage of events like the National Collegiate Athletic Association (NCAA) annual tournament and the National Basketball Association (NBA) and Women's National Basketball Association (WNBA) playoffs. And it has also made American heroes out of its player and coach legends like Michael Jordan, Larry Bird, Earvin "Magic" Johnson, Sheryl Swoopes, and other great players.


At the heart of the game is the playing space and the equipment. The space is a rectangular, indoor court. The principal pieces of equipment are the two elevated baskets, one at each end (in the long direction) of the court, and the basketball itself. The ball is spherical in shape and is inflated. Basket-balls range in size from 28.5-30 in (72-76 cm) in circumference, and in weight from 18-22 oz (510-624 g). For players below the high school level, a smaller ball is used, but the ball in men's games measures 29.5-30 in (75-76 cm) in circumference, and a women's ball is 28.5-29 in (72-74 cm) in circumference. The covering of the ball is leather, rubber, composition, or synthetic, although leather covers only are dictated by rules for college play, unless the teams agree otherwise. Orange is the regulation color. At all levels of play, the home team provides the ball.

Inflation of the ball is based on the height of the ball's bounce. Inside the covering or casing, a rubber bladder holds air. The ball must be inflated to a pressure sufficient to make it rebound to a height (measured to the top of the ball) of 49-54 in (1.2-1.4 m) when it is dropped on a solid wooden floor from a starting height of 6 ft (1.80 m) measured from the bottom of the ball. The factory must test the balls, and the air pressure that makes the ball legal in keeping with the bounce test is stamped on the ball. During the intensity of high school and college tourneys and the professional playoffs, this inflated sphere commands considerable attention.

History

Basketball is one of few sports with a known date of birth. On December 1, 1891, in Springfield, Massachusetts, James Naismith hung two half-bushel peach baskets at the opposite ends of a gymnasium and out-lined 13 rules based on five principles to his students at the International Training School of the Young Men's Christian Association (YMCA), which later became Springfield College. Naismith (1861-1939) was a physical education teacher who was seeking a team sport with limited physical contact but a lot of running, jumping, shooting, and the hand-eye coordination required in handling a ball. The peach baskets he hung as goals gave the sport the name of basketball. His students were excited about the game, and Christmas vacation gave them the chance to tell their friends and people at their local YMCAs about the game. The association leaders wrote to Naismith asking for copies of the rules, and they were published in the Triangle, the school newspaper, on January 15,1892.

Naismith's five basic principles center on the ball, which was described as "large, light, and handled with the hands." Players
 
A typical basketball is 30-31 in (75-78 cm) in circumference.
could not move the ball by running alone, and none of the players was restricted against handling the ball. The playing area was also open to all players, but there was to be no physical contact between players; the ball was the objective. To score, the ball had to be shot through a horizontal, elevated goal. The team with the most points at the end of an allotted time period wins.
Early in the history of basketball, the local YMCAs provided the gymnasiums, and membership in the organization grew rapidly. The size of the local gym dictated the number of players; smaller gyms used five players on a side, and the larger gyms allowed seven to nine. The team size became generally established as five in 1895, and, in 1897, this was made formal in the rules. The YMCA lost interest in supporting the game because 10-20 basketball players monopolized a gymnasium previously used by many more in a variety of activities. YMCA membership dropped, and basketball enthusiasts played in local halls. This led to the building of basketball gymnasiums at schools and colleges and also to the formation of professional leagues.

Although basketball was born in the United States, five of Naismith's original players were Canadians, and the game spread to Canada immediately. It was played in France by 1893; England in 1894; Australia, China, and India between 1895 and 1900; and Japan in 1900.
From 1891 through 1893, a soccer ball was used to play basketball. The first basketball was manufactured in 1894. It was 32 in (81 cm) in circumference, or about 4 in (10 cm) larger than a soccer ball. The dedicated basketball was made of laced leather and weighed less than 20 oz (567 g). The first molded ball that eliminated the need for laces was introduced in 1948; its construction and size of 30 in (76 cm) were ruled official in 1949.

The rule-setters came from several groups early in the 1900s. Colleges and universities established their rules committees in 1905, the YMCA and the Amateur Athletic Union (AAU) created a set of rules jointly, state militia groups abided by a shared set of rules, and there were two professional sets of rules. A Joint Rules Committee for colleges, the AAU, and the YMCA was created in 1915, and, under the name the National Basketball Committee (NBC) made rules for amateur play until 1979. In that year, the National Federation of State High School Associations began governing the sport at the high school level, and the NCAA Rules Committee assumed rule-making responsibilities for junior colleges, colleges, and the Armed Forces, with a similar committee holding jurisdiction over women's basketball.

Until World War II, basketball became increasingly popular in the United States especially at the high school and college levels. After World War II, its popularity grew around the world. In the 1980s, interest in the game truly exploded because of television exposure. Broadcast of the NCAA Championship Games began in 1963, and, by the 1980s, cable television was carrying regular season college games and even high school championships in some states. Players like Bill Russell, Wilt

Chamberlain, and Lew Alcindor (Kareem Abdul-Jabbar) became nationally famous at the college level and carried their fans along in their professional basketball careers. The women's game changed radically in 1971 when separate rules for women were modified to more closely resemble the men's game. Television interest followed the women as well with broadcast of NCAA championship tourneys beginning in the early 1980s and the formation of the WNBA in 1997.
Internationally, Italy has probably become the leading basketball nation outside of the United States, with national, corporate, and professional teams. The Olympics boosts basketball internationally and has also spurred the women's game by recognizing it
 
A standard basketball court.
as an Olympic event in 1976. Again, television coverage of the Olympics has been exceptionally important in drawing attention to international teams.
The first professional men's basketball league in the United States was the National Basketball League (NBL), which debuted in 1898. Players were paid on a per-game basis, and this league and others were hurt by the poor quality of games and the ever-changing players on a team. After the Great Depression, a new NBL was organized in 1937, and the Basketball Association of America was organized in 1946. The two leagues came to agree that players had to be assigned to teams on a contract basis and that high standards had to govern the game; under these premises, the two joined to form the National Basketball Association (NBA) in 1949. A rival American Basketball Association (ABA) was inaugurated in 1967 and challenged the NBA for college talent and market share for almost ten years. In 1976, this league disbanded, but four of its teams remained as NBA teams. Unification came just in time for major television support. Several women's professional leagues were attempted and failed, including the Women's Professional Basketball League (WBL) and the Women's World Basketball Association, before the WNBA debuted in 1997 with the support of the NBA.

Raw Materials

The outside covering of a basketball is made of synthetic rubber, rubber, composition, or leather. The inside consists of a bladder (the balloon-like structure that holds air) and the carcass. The bladder is made of butyl rubber, and the carcass consists of treads of nylon or polyester. Preprinted decals are used to label the ball, or foil is used to imprint label information. Zinc and copper plates are used in a press to either affix the decals or imprint the foil.

Design

The actual configuration of most basket-balls is dictated by the rules or standards of the type of game in which the ball will be used. NBA, WNBA, and other professional leagues have specified dimensions for regulation balls, as described above, and even the imprinted information is specified. Amateur sports bodies have also developed rules and specifications, and there are specialized basketballs made for junior players (younger than high-school age), intermediate players (high-school age), and for indoor, outdoor, or combination play. Promotional basketballs that are much smaller in diameter are also made as souvenirs of many events such as the NCAA Championships.

Basketball designers are always trying to improve the product and build a better basketball. Inventor Marvin Palmquist created the "Hole-in-One" basketball to improve a player's grip; the ball has dimples, much like a golf ball, and can be easily palmed Michael Jordan-style by players with smaller-than-Jordan hands. Even the most skilled NBA star copes with sweaty palms, and this obstacle is addressed in another modification consisting of microscopic holes in the surface, which is made of absorbent polyurethane. This is the same material that forms the grip on a tennis racket, but it has been strengthened to withstand the abrasion of bouncing on a wooden basketball court. It absorbs moisture to keep the ball's hide less slippery.


 
Michael Jordan.
Michael Jordan was born February 17, 1963. Accepting a basketball scholarship to the University of North Carolina, he became the second Tarheel freshman to start every game. Jordan was named Atlantic Coast Conference (ACC) Rookie of the Year and won the National Collegiate Athletic Association (NCAA) championship in 1982. He led the ACC in scoring and was named college player of the year in 1983 and 1984. Jordan left North Carolina after his junior year and was drafted by the Chicago Bulls as the third overall pick of the 1984 draft.
 
A broken foot sidelined Jordan for 64 games during the 1985-1986 season. He returned, scoring 49 points against the Boston Celtics in the first game of the playoffs and 63 in the second—an NBA record. During the 1986-1987 season Jordan became the first player since Wilt Chamberlain to score 3,000 points in a season. The Bulls won the 1991-1993 NBA titles. In 1994 Jordan joined the Chicago White Sox minor league baseball team, returning to the Bulls for the remaining 1994-1995 season. In the 1995-1996 season, the team finished 72-10, another NBA record. The Bulls went on to win their fourth NBA title in 1996, fifth in 1997, and sixth in 1998 where Jordan claimed his sixth NBA finals MVP award,
 
Jordan participated in the 1984 and 1982 Summer Olympics, earning gold medals for the United States. He was named 1985s Rookie of the Year, 1988s Defensive Player of the Year, NBA MVP five times, has a career record for the highest scoring average of 28.5 ppg, played in 11 All-Star games (starting in 10, missing one due to injury), and named All-Star MVP three times. Jordan retired January 13, 1999.

Still other inventors feel the size of the ball is a disadvantage to proper handling and have suggested increasing the circumference from 30 to 36 in (76 to 91.4 cm), resulting in an increase in diameter from 9.6 to 11.5 in (24.4 to 29.2 cm). The so-called Bigball still fits through a regulation hoop and has been used in training sessions by both college and NBA teams. The Bigball must be shot with a higher arc to fall through the hoop, and, after practicing with the larger basketball, the regulation ball seems easier to handle.

The Manufacturing Process

Forming the bladder

  • 1 The making of a basketball begins with the interior bladder. Black butyl rubber in bulk form (and including recycled rubber) is melted in the hopper of a press that feeds it out in a continuous sheet that is 12 in (30.5 cm) wide and 0.5 in (1.3 cm) thick. A guillotine-like cutter cuts the long strip into sheets that are 18 in (45.7 cm) long, and they are stacked up. A hand-controlled machine selects the sheets one at a time and, using a punch press, punches a 1-in-diameter (2.54-cm-diameter) hole that will hold the air tube for inflating the bladder.
  • 2 The sheets are carried on a sheet elevator or conveyor to an assembly line where the air tube is inserted by hand. A heated melding device bonds it to the sheet, which is folded into quarters. Another punch press stamps out a rounded edge and, at the same time, binds the edges to make the seams of the bladder. This bladder is not perfectly shaped.
  • 3 The odd-shaped bladder is taken to a vulcanizing machine. Vulcanization is a process for heating rubber under pressure that improves its properties by making it more flexible, more durable, and stronger. In the vulcanizer, the bladder is inflated. Heating by vulcanization uniformly seals the rubber so it will hold air. Completed bladders are stored in a holding chamber for 24 hours. This quality control measure tests their ability to hold air; those that deflate are recycled.

Shaping the carcass

  • 4 The bladders that withstand the 24-hour inflation test are conveyed from the holding chamber to the twining or winding department. They make this joumey suspended from a conveyor system by their air tubes. Machines loaded with spools of either polyester or nylon thread or string wrap multiple strands at a time around each bladder; this is the same process used to make the inside of a golf ball. The irregularly shaped bladders now begin to take on a better, more rounded shape as the precisely controlled threads build and shape the balls. The quality of the thread and the number of strands determine the cost and quality of the ball. The typical street-quality basketball has a carcass made of multiple wraps of three strands of polyester thread. The balls used by professional teams have carcasses constructed of nylon thread that is wrapped using four strands of thread. The same over-head conveyors continue carrying the carcass-encased bladders by their air tubes to the next step in the process where the carcasses and covers will meet.

Crafting the covers of the balls

  • 5 Meanwhile, the exteriors or covers of the balls have been in production as the bladders and carcasses have taken shape. On 60-inch-long (152-cm-long) tables, colored rubber is unrolled from a continuous roll. The smooth rubber does not have pebbling (small bumps) that characterizes the surface of a finished basketball so that the outlines for the panels can be clearly marked on the rubber. A silk screen is moved along a series of metal markers that are guides marking the length of the rubber sheet needed for each ball. The silk screen operator moves the screen by hand and imprints the outlines of the six panels making up the ball. Only one color is used at a time, and, depending on the design, multiple silk screenings may be needed to color the six panels with all the colors on the ball.
  • 6 A hand-operated punch press—equipped with specially designed and tooled dies—punches the rubber outlines to create six separate panels per ball. The same die has a hole that is punched in one of the six panels to make an opening for the air tube. The excess rubber surrounding the panels is lifted off the line and deposited in a bin for recycling.
  • 7 The assembly worker picks up the six panels for a single ball in a specific order and carries them to the vulcanizer. The interior of the vulcanizer for this process is different from the one for the bladders. It is form-fitted to hold the six panels, to create the channels between the panels, and to add any embossed information. The assembler fits the panels individually into specified sections in the vulcanizer. A bladder/carcass is taken off the overhead conveyor, covered with a coating of glue, and placed inside the chamber of the vulcanizer that is lined with the cover panels. When the ball emerges from the vulcanizer, most of its surface is still smooth (there are no bumps, called pebbling), but the channels and any embossing are formed into the surface.
  • 8 Decals and foil decoration and information (if any) are applied by hand with small heat presses after the smooth ball is retrieved from the vulcanizer. Each ball is carefully inspected for gaps between the panels. These can occur, but each gap is filled during this inspection with a small piece of rubber that is hand-cut to fit the gap. The ball then is fitted into another vulcanizer that unifies the finished surface, blending in any gap fillers, and is specially molded to form the surface pebbling. The vulcanized balls are stored again for 24 hours in a second test to make sure they hold air.

Synthetic laminated covers and leather covers

  • 9 The covers for basketballs that are made of synthetic laminated rubber or leather are also made in panels that are die-cut like the rubber panels. The synthetic laminated panels are shaved or trimmed along the edges, fitted and glued together by hand, and laminated to the carcass to create channels. They are also embossed by a heating process and decals are added. Any glue traces around the edges are removed, and any imperfect panels are replaced in the final inspection of synthetic laminated covers. Leather covers are made of full-grain, genuine leather and are stitched with heavy-duty machines; instead of indented, formed channels, the stitching forms the channels in leather balls. They are printed by silk screening and foil stamping, and their inspection includes a review of the uniformity and color of the leather.

Final testing, inspecting, and packing

  • 10 Balls that pass the second 24-hour air pressure test are "bounce tested" to meet the regulation for inflation pressure that results in each ball bouncing a prescribed height. Balls that pass the bounce test are numbered to show the production run, and the decals and other artwork are inspected and touched up by hand as needed. Each completed ball is inspected again. The inspector removes the production run tag, and the ball is deflated so it can be easily packed and shipped. Each flattened ball is packed in a polyethylene bag, and the bagged balls are boxed for bulk shipment to the distributor. The distributor also inspects the balls when they are received and is responsible for reinflating them to the correct pressure and packaging them in display boxes for sale. The display boxes may also be packed in bulk for distribution to retailers.

Byproducts/Waste

No byproducts result from the manufacture of basketballs, but most makers have a variety of lines and may also make balls for other sports. Waste is limited. Dies for cutting panels of rubber, synthetic laminate, and leather are carefully designed to space the panels closely and limit the material used. This is especially critical for leather because of the cost; some leather waste is inevitable, though, because leather is a natural material and has irregularities in color, thickness, and surface. All rubber materials can be recycled, and they represent the bulk of material used in making a basketball.

Quality Control

Throughout the manufacturing process, inspections occur regularly to make sure the finished basketball will hold air and to correct any surface variations. Machines like punch presses, dies, vulcanizers, and printing tools are carefully designed initially to maximize use of materials and to create perfect pieces. The assembly process includes many steps that are performed by hand, and the assemblers are trained to watch for imperfections and reject unsuitable products. Inspections and tests also include weight-control testing of the completed carcasses and the panels, regardless of material. Whenever the completed products are stored for any length of time, they are randomly inspected for appearance, size, inflation, and any wobble.

Some distributors have special tests for products bearing their name. For example, Rawlings Sporting Goods Company tests the basketballs they produce for the NCAA Tournament with a unique "Slam Machine" that simulates the workout a ball will get in four games in just five minutes. The machine works by propelling the ball down a chute between two wooden wheels that launch it at about 30 mph (48 kph) toward a backboard that is angled to direct the ball back to the chute. Rawlings also uses this machine to test new designs, materials, glues, and other changes.

The Future

Basketball sales have escalated dramatically with the sport's popularity. Figures from 1998 show that 3.6 million balls were sold in the United States alone for a total of about $60 million. Given the record number of television viewers for the 1999-2000 NBA Championships, many parents and children are likely to purchase basketballs to test their own slam-dunking skills. Participation in the sport and sale of basketballs shows no sign of slowing down.

Another aspect of the worldwide popularity of basketball is that it has sharpened collectors' enthusiasm for souvenir balls, autographed balls, and those from key moments of the great players' games. An example with a high price tag is the basketball Wilt Chamberlain used to score 100 points in a game; it was sold in the 1990s for $551,844.

Where to Learn More

Books

The Diagram Group. The Rule Book: The Authoritative, Up-to-Date, Illustrated Guide to the Regulations, History, and Object of All Major Sports. New York: St. Martin's Press, 1983.
Jacobs, A. G., ed. Basketball Rules in Pictures. New York: Perigee Books, 1966.

Periodicals

Feldman, Jay. "A Hole New Ball Game." Sports Illustrated 18, no. 26 (December 26, 1994): 102.
Jaffe, Michael. "For Better Shooting, Think Big: A Team of Ohio Entrepreneurs Insists that Their Oversized Basketball Will Improve Your Touch." Sports Illustrated 74, no. 15 (April 22, 1991): 5.
Mooney, Loren. "Get a Grip." Sports Illustrated (November 30, 1998): 16.
Tooley, Jo Ann. "On a Roll." U.S. News & World Report 107, no. 8 (August 21, 1989): 66.

Other

Rawlings Sporting Goods Co., Inc. http://www.rawlings.com . (December 14, 2000).
Gillian S. Holmes

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Baby Carrier

Background

Family members have carried babies in a variety of carriers since the beginning of human civilization. Baby carriers keep the baby close and provide the infant with comfort and security while allowing the carrier some freedom to work and care for other members of the family. The most basic form of baby carrier is the sling. In South America, woven shawls are used to carry babies in front of their mothers. The shawl is anchored over one shoulder, wrapped under the other arm, and tied around the back. The baby is free to nurse and sleep, and is cooled or warmed by the weave and wool of the shawl. In Asia, the sling is tied over one arm but carried lower on the opposite side so the baby rests on the hip. African cultures use the sling in this fashion or with the sling tied in front around the chest with the baby balanced behind. The front-tied sling is also practical for older babies who need to nurse less often and are more settled in their routine.


Other Asian cultures tie a woven cloth around the infant in a complex series of wraps and ties that isolate the child's legs on the mother's sides and allow the baby to move its arms freely against the mother. In cold climates where mothers wear hooded coats or parkas, the hood doubles as a sling that gives the baby room to see around its mother's head or cuddle deep in the hood to nap. Hot climates feature baby carriers of loosely woven airy cloth and even net bags that can be hung from the shoulders or balanced on the head. The cradle boards used by many tribes of Native Americans are ancient forerunners of today's framed back-pack that provides rigid strength to carry the child and cloth wrapping for comfort.

Side-and hip-balanced carriers are used by fathers and brothers who hunt and harvest with the baby. Other relatives can baby-sit, thanks to the convenience of baby carriers. The closeness of the baby carrier is not only a convenience but a way of nurturing the whole family.

History

The invention of the cloth infant carrier grew out of one woman's service in the Peace Corps. Ann Moore, a pediatric nurse who worked in Togo, Africa, in the 1960s observed the native women carrying their babies in slings. After she returned to the United States, Moore and her mother, Lucy Aukerman, designed a fabric pouch to resemble these slings but also to be rugged and to have adjustable shoulder and waist supports for the parent. Moore and Aukerman patented the Snugli in 1969.

In 1978, a Nigerian child care professional named Toritse Onuwaje moved to the United States. She was dismayed at the amount of crying American babies did compared to their Nigerian counterparts. She patterned a carrier she called the Baby Wrap on the ukpoma, a cloth carrier worn by members of her native Itshekiri tribe. The women of her tribe work all day with their babies wrapped on their backs, and the babies seldom cry because the mothers' closeness is comforting.
The rigid, molded plastic carrier grew out of the invention of the child safety seat for use in automobiles (and, later, airplanes). The first child safety seats were patented in the late 1970s. In the period from 1982 through 1985, a number of designs of molded plastic carriers were patented with varying configurations
 
Different types of 6a6y carriers.
for carrying a reclining infant. The shape was contoured to support the child's back and seat and incorporated an adjustable handle that could be raised and locked into place while the child is being carried and lowered to lift the baby in and out. Various types of fabrics cushion the child; some carriers use fabric mesh that is suspended in the frame to support the infant, while others are fitted out with padded cloth inserts that fasten in the plastic carrier securely but can be removed for cleaning.

Raw Materials

Slings and cloth carriers are manufactured from fabrics and polyester fiber or foam for stuffing or padding. The fiber is purchased in 500-lb (227-kg) bales. Velcro fasteners, woven fabric webbing for straps, and metal buckles and fasteners for supports around the parent are used to hold cloth carriers in place. Backpack-type carriers can be made mostly of cloth, but a second type consists of an aluminum frame with a cloth support for the baby and padded cloth straps that adjust to the parent.
The rigid or molded infant carrier is made of polypropylene, a medium-impact plastic. It has the advantages of being lightweight, flexible, and durable. Manufacturers receive the plastic in pellets. Metal components are made of steel by specialized metal fabricators. These parts may include buckles, locking clips, and hardware for adjusting harnesses. Rivets and fabric fasteners may be made of other metals but are also supplied by specialty contractors.

Fabrics used to make infant cariers include durable fabric like denim and nylon mesh and webbing for hamesses. All fabrics have to be specially treated to meet standards for flammability, but they also have to be washable. Chemical cleaning methods and even strong detergents can break down the treatments used to make the material flame-resistant, so these fabrics must be cleaned with water and mild soap. The fabrics are also chosen for their appeal, so color and fashion trends are observed by designers in selecting these materials.

Foam padding and fiber fill are also required to be flame resistant. For manufacturers of molded plastic carriers, most of the cloth liners and pads are sewn by outside suppliers to the specifications of the carrier manufacturers.

All infant carriers bear manufacturers' labels, and printers make paper and adhesive-backed labels according to the manufacturers' requirements and Federal standards for consumer information.

Design

There are three basic designs of infant carriers. The first is the sling of which the Snugli and Baby Wrap are best known. The second is a modification of an aluminum-framed backpack in which the pack portion is fitted to carry a baby and padded straps are provided for the parents' comfort. The third type is the molded plastic carrier that resembles an automobile safety seat with a plastic back, seat, and handle and a padded interior but without the devices needed to secure the carrier in an automobile.

Factors influencing the design of infant carriers are many and relate to how the individual consumer is most comfortable carrying their child. Safety is, of course, the overriding concern. The infant must be comfortably held or restrained in the carrier, a soft carrier must have openings for the child's legs but not so large that the baby will fall out, and a rigid carrier designed to sit on solid surfaces must not tip over. Comfort for the baby is the second leading design factor. All forms of carriers have some type of cloth liner or insert to cushion the baby, and this must be comfortable as well as durable and easily cleaned. And, finally, the person carrying the child must also be comfortable. Cloth infant carriers and backpack-type carriers have to adapt to different body types so the baby can be carried with equal comfort. This is usually accomplished with a set of straps that cross the shoulders and fit around the waist or on the hips. Carriers made of molded plastic must strike the right balance between the weight and strength needed to support the child adequately and light weight for the parent to carry.

These combinations of characteristics have not been easy for manufacturers to produce successfully. Consumer protection groups like the Consumer Product Safety Commission list a number of carriers that have been recalled. The molded plastic carriers have had notable problems such as failure of the handle locks that can cause the carrier to release and tip the baby out. But the cloth carriers have also been made with leg openings that are too large and allow tiny babies to slip through. To the manufacturers' defense, many more problems have been cited related to misuse of the carriers by the adults caring for the infants. Sitting a rigid carrier on a soft surface like a couch permits the baby's movements to tip the carrier over. In 1997 alone, over 8,700 children were brought to the emergency room and treated for falls from carriers. Also, a number of medical reports show that infants are left in one position in the carriers for too long. In the supine or reclining position, the back of the baby's head flattens as it rests against the carrier. Babies held upright in cloth carriers or backpack-type carriers are subject to spinal stress that complicates the natural development of curves in the spine. Sling-type carriers have been found to hold the baby in the best position for its growth.

The Manufacturing Process

Cloth carriers

  1. Following initial design, prototypes are sewn by hand and checked for fit on both infants and parents of a range of sizes and weights. When the final design is approved, the pattern on blueprints or computerized drawings is transferred to paper patterns. The patterns are tacked to the fabric with pins and stacked together. A fabric cutter that looks much like a band saw is used to cut through all the layers at once so the pieces for many carriers are produced at the same time.
  2. The fabric pieces are stitched together by workers operating industrial-quality sewing machines. Typically, each worker is responsible for one section of the carrier such as the back or the straps. The pieces are stitched together inside out with the seams exposed then turned right side out. Sections that will be padded are left with small openings in the seams where the padding can be added.
  3. The sections to be padded are stuffed with polyester fiber or foam padding. The fiber is purchased by the manufacturer in tightly packed bales that are fluffed up with a machine called a picker. The fiber is selected for the packing by the quality of the fibers, and, when it is inserted into the camier section as padding, it will be stuffed to the proper density. At the stuffing machine, air pressure blows the fiber into the fabric section. The operator manipulates the section to disperse the fiber throughout the section and to the desired density. The openings through which the stuffing has been added are then stitched together.
  4. The sections of the carrier are assembled to create the finished product at another set of sewing machines. Any restraining straps and webbing are stitched securely in place. Hardware and fasteners (if any) are also stitched on or driven into place by special machines, and labels are sewn in place at joins between two fabric sections. A final inspection is performed to check all the seams and fasteners, and the carrier is packed in a plastic bag and boxed. Multiple boxes are packed in shipping cartons for storage or transport.

Backpack-type carriers

  1. The cloth sections of the backpack-type carriers are designed, cut, stitched, and padded like the cloth carriers described above.
  2. The aluminum frames used to support the carriers are made of tubing formed by aluminum fabricators to the sizes, shapes, and curves specified by the carrier manufacturer. They are received by the carrier manufacturer in bulk lots that are distributed to bins along the assembly line. Assembly line workers pair a cloth carrier to a metal frame and attach it; methods of attachment vary widely among makers but can include Velcro and metal buckles and fasteners. Some frames also have plastic feet or pads where they balance against the parent or so they can be stood on the ground or a solid surface while the infant is placed in the carrier. These feet are inserted into holes in the frame and fastened in place.
  3. The frame/carrier assembly is inspected and packaged like the cloth carrier.

Molded plastic carriers

  1. Molding of the carrier's plastic shell is the first step in manufacture of this type of carrier. Plastic pellets stored in bulk are melted and injected into specially machined dies or forms for the shell. The dies are the highly detailed product of the design process, and even the finished texture of the carrier has been designed in the interior of the mold. The shells are extracted from the dies, cooled, trimmed of flashing (excess bits of plastic), and cleaned.
  2. At the assembly line, the molded shells and all other parts are distributed to work stations. Each worker is responsible for fitting the carrier with one item or type of item and handing it to the next worker who adds another piece. The padded insert that forms the cushion for the baby is a completed item that has been sewn and stuffed. It is attached to the carrier by Velcro or other fasteners. Alternatively, the nylon mesh used to make a hammock-like support for the infant in some types of carriers is attached to sections of the plastic shell that were designed to trap the mesh and lock it in place. Straps, harnesses, buckles, and labels are added in turn.
  3. In the packing department, the infant camiers are individually packed in cartons. The cartons are significant sources of information for consumers and are preprinted with consumer data as well as company information and bright designs. The cartons are stacked and bulk-wrapped in plastic for storage and distribution.

Quality Control

Hands-on assembly is key to the construction of the three types of infant carriers described here. Workers are highly skilled in their own and related parts of manufacture of carriers, and they are rewarded for identifying errors and rejecting imperfect carriers. Molded plastic carriers are nominally the most complex to manufacture; the shell is carefully checked for uniform thickness and strength and compared to a master copy for correctness. Because manufacturers usually make several different lines or models of carriers, each product has a bill of materials listing the part numbers of all the parts making up that model. Assembly workers monitor these, and line managers periodically pull carriers from the assembly line to check the materials, review the overall quality, and test the products.

Byproducts/Waste

The making of infant carriers results in little waste because most of the materials used can be recycled. The molded plastic shells can be reground into pellets that are mixed with new plastic pellets for melting and injection molding. The percentage of reground plastic is kept to a minimum in any single batch of new plastic. Sewn linings of the plastic shells are returned to the supplier and can often be resewn; similarly, cloth carriers can be resewn, assuming the error is not picked up and corrected immediately by the sewing machine operator. Metal parts are also recycled by suppliers.

Safety concerns are important in several aspects of carrier manufacture. Sewing machines, fabric cutters, and power hand tools have automatic emergency shutoffs, safety guards, and other protections. Operation of the injection molding machinery is automated, and workers seldom have reason to approach these machines with their high operating temperatures. Mold operators wear protective gloves. Fabric cutters, sewing machine operators, and those who handle the polyester fiber and foam padding wear masks over their mouths and safety glasses.

The Future

The concept of the infant carrier may be as old as civilization, yet the "modern" baby carrier is less than half a century old. Despite this new or reborn acceptance, the carrier has become an essential part of every baby's layette. This is not surprising because every parent's first priorities are the safety and comfort of that new baby. The alarming aspect of infant carriers may be the number of product recalls. Perhaps this should not be surprising either, because the manufacture of carriers is an attempt for an industry to fit a standard to tiny babies and an even wider variety of sizes and shapes of parents and care givers.

Manufacturers are conscientious about doing their part to keep improving and varying products to prevent child injury and provide security. Responsibility for proper use of infant carriers is beyond the manufacturers' purview, yet they try to design out opportunities for consumer error. Doctors are also adding to the information base by studying physical changes to babies, particularly flat spots on their skulls and improper spinal development, that may be attributable to infant carriers. Recalls, errors, and skeletal stress sound like negative reasons for a product's future, but all these negatives are strong motivators toward the best possible products for the most babies.

Where to Learn More

Books

Bernhard, Emery. A Ride on Mother's Back: A Day of Baby Carrying Around the World. New York: Gulliver Books, Harcourt Brace & Company, 1996.

Periodicals

Karvonen, Karen. "Child Carriers." Women's Sports and Fitness 14, no. 5 (July-August 1992): 112.
Quindlen, Anna. "A Mother's Nominees For the Nobel Prize." New York Times (September 21, 1986).
Sommars, Jack. "Oh Baby!" Colorado Business Magazine 23, no. 3 (March 1996): 16.

Other

Consumer Product Safety Commission. http://www.cpsc.gov (September 18, 2000).
"43 Reasons to Carry Your Baby." Nuturing Magazine (1998). http://www.nurturing.ca/carrybaby.htm (January 2001).
The Lemelson-MIT Prize Program: Women's History Month. http://web.mit.edu/invent/www/inventorsR-Z/whm3.html (September 27, 2000).
Loving Attachment. Choosing a Carrier: Infant Carriers and Spinal Stress. http://www.lovingattachment.com (September 27, 2000).
The Mayo Clinic. Misshapen Infant Heads: Not an Epidemic (May 22, 1999). http://www.mayohealth.org/home?id=CC0OO10 (September 27, 2000).
Gillian S. Holmes

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Tuesday, November 6, 2018

Fire Engine

Background

The term "fire truck" is commonly used as a generic expression to describe a fire-fighting vehicle. Technically, a "fire truck" is a vehicle equipped with ladders and is used mainly to gain access to elevated portions of a structure or to provide a means of applying an elevated stream of water. "Fire engine" is a vehicle with a pump and is used primarily to pump water. A "fire wagon" carries large amounts of hose and is primarily used to lay hose as a complement to a pumper. "Fire apparatus" is the proper generic term for all of these vehicles. This entry will focus on the manufacture of a fire engine. From our first toys and books as toddlers to the everyday newscasts showing fire fighters in action, the fire apparatus remains one of the most familiar and impressive examples of technology in our lives. 


Uncontrolled fire was one of the greatest fears until quite recently. Early attempts to quell fires were merely bucket brigades, that is, lines of citizens handing water buckets to the fire, which was often ineffective against a fully involved building. Some attempts at increased water application were hand-operated piston pumps whose hoses pumped water from a holding tank or a pond. (These early hoses were made of leather with copper rivets; cotton hoses came into use in the 1800s.) Eventually wheels were added to the apparatus, but it was still pulled and operated by the firemen. Volunteer fire departments were established to man the equipment and fight the fire.

With the appearance of property insurance, insurance companies created fire departments and spent considerable time improving the fire apparatus. By the 1860s, the steam engine was used to operate the piston pump, and it was pulled to the fire by horses. Other attempts to pressurize the hoseline were chemical tanks, which used acid combined with soda dissolved in water to start a chemical reaction that would produce carbon dioxide. In this process, the carbon dioxide expanded, pressurizing the tank and propelling the entire mixture out of the hoseline and onto the fire. 

All of these designs were practically obsolete after the introduction of the centrifugal pump in early 1900. After the advance of the automobile, the internal combustion engine became the primary power source for the fire engine. Adaptation of the truck frame to accommodate the pump and tank completed the transition to the presentday fire truck apparatus.

Design

The basic design of the fire apparatus begins with a thorough review of the fire load and geographical terrain of the area the fire department will be responding to. The vehicle's ease of operation, adequate response speed, and equipment storage and deployment are all important factors to consider. The National Fire Protection Association (NFPA) has compiled guidelines for apparatus design based upon these and other variables. In addition, the fire fighters responsible for the apparatus also contribute to the design of the vehicle.

Most fire apparatuses are purchased by tax-supported governments, cities, towns, townships, and counties. In small departments, the design and approval process can take up to a year, mainly because of funding issues. When medium and large departments choose a new apparatus, funding is usually already established, and designs can be approved and purchased in less time. A fire engine can cost from $50,000 to over $750,000.



The basic fire apparatus has evolved into specialized units for particular types of fires and response. In the 1950s, pumpers, ladder trucks, and other miscellaneous designs such as small tankers and hose trucks were common, though airport crash trucks and large rural tanker trucks were also in use. Today, fire apparatuses are tailored to meet many kinds of specific hazards. Due to this wide variety, the rest of this article will discuss the manufacture of the basic combination pumper apparatus for small- and medium-size communities.

The Manufacturing 
Process


The manufacture of a fire engine remains a custom, almost one-of-a-kind operation. Typically, a group of workers is assigned to the fabrication of the body and assembly of the truck frame. A separate group performs body finishing, then the apparatus is wired, equipped, and tested by a third, or "equipment," group. Aside from the body, manufacture of the fire apparatus is typically an assembly process.

Fire was a plague in many early American cities. Americans responded with a variety of weapons: volunteer fire department's; inventions that prevented,, retarded., or fought fire; and insurance cooperatives ond plans that protected against losses caused by fire. Through the early and mid decades of the 1°fh century, a major fire was a calamity but also a social affair.

A city's volunteer fire companies often illustrated the city's social, ethnic, and demographic composition. Fire companies represented the ioyalty and corwaderies of special groups. Neighborhood pride, political rivalries, ethnic hostility, and class animosity were alt evident in the volunteer fire companies. Companies received public acclaim for their efforts and competed wiih one another for those public accolades. Af the first signal of a fire, companies would race to the scene pulling their hose carts and handpumped engines—not necessarily to catch the fire in its early stages. The commander of the first company to arrive would be in charge of the entire operation with absolute control over rival companies. Members fought with one another on the way and at the site, sometimes forgetting even to fight the fire! Once at the scene, more fighting could occur and volunteers were threatened as much by other firefighters as they were by the fire itself.

Members took great pride in their uniforms and equipment because these represented the group's social status as much as they did its fire-fighting competence. Equipment and uniforms were dtspfayed during public ceremonies and parades where competition for social status was particularly evident in pre-Civil War America. Hose carts and engine! were display pieces os well as functional equipment.


William S. Pretzer

Chassis

  • 1 The selection and purchase of the truck chassis is based upon the tactical application of the apparatus. The truck frame may be "bare," having only the engine, axles, springs, frame members, steering, and brake systems installed. The apparatus builder may choose, however, to use a "cab and chassis," where the frame has the engine, cab, seats, front sheet metal, and wiring already completed. In either case, the truck frame is usually ordered from a well-established truck builder such as General Motors, Ford, International, Freightliner, or Peterbilt. The apparatus builder advises the truck manufacturer of the intended design so special options concerning the performance of the frame can be made. It is critical that the proper selection of suspension be made to support the average 35,000-pound (15,890 kg) fire engine. In our example, we have chosen the cab and chassis frame design.

Body

  • 2 After the truck frame is received and inspected, the fabrication of the body (or "coach," as it is sometimes called) begins. Primarily sheet steel is used for body panels and supports, although aluminum and some stainless steel are also incorporated. Sheet steel is approximately 0.06 inch (1.5 mm) thick and comes in sheets 48 inches (1.2 m) and 96 inches (2.4 m) long. It can also be supplied in rolls of the same width and weighing 2,000 pounds (908 kg) or more. Each door panel, support, body panel, and equipment tray is cut and bent using shearing machines and press brakes. Holes for electrical equipment and piping are also punched at this time. The body is typically metal inert gas (Mig) welded together, with the doors and access panels bolted for ease of replacement. Many manufacturers protect the body from corrosion by dipping each panel into a rust inhibiting sealer. The interior and other hidden areas of the doors and cabinets are pre-painted before assembly. While the body construction is underway, the pump and tank are mounted to the frame.

Pump

  • 3 The pump is selected to perform specifically for the practices of the fire department. Essentially, the pump is the only reason for the fire engine. All of the other features are practically useless if the pump does not perform adequately. Most firepumps today are centrifugal pumps, and are manufactured by separate companies and purchased by the apparatus builder. A typical firepump can pump 1,000 gallons (3,785 1) of water per minute. This flow can safely provide enough water to fight a residential or small commercial building fire. Pump size can be restricted by the available water supply, particularly in rural areas where there are no fire hydrants. Pumps are usually cast iron, with bronze for the rotating impeller and steel gears in the drive unit. Our truck shall have the 1,000 gallon per minute pump bolted to the frame near the center, and driven by an auxiliary output shaft (or "power take off") from the truck transmission. This type of arrangement is referred to as a "midship" pump apparatus. The pump sits across the frame of the truck, and is bolted through the support castings to the upper frame flange. Alignment with the transmission is important to reduce vibration.

Tank

  • 4 The water tank for this example apparatus would typically be a polypropylene tank holding 500-1,000 gallons (1,892-3,785 1) of water. This is bolted to special 
    supports before being attached to the frame immediately behind the pump. Connective piping to the pump and filling openings is also installed, typically of galvanized steel construction. Tanks may be square, round, or oval, and many are "hot-welded" together out of sheet material. The hot-welding process uses a high temperature stream of air to melt the plastic pieces at their joint, where the material mixes and fuses together. Most tanks contain perforated plates or "baffles" to reduce the sloshing of the water while driving.
    Occasionally, a "quick dump" is installed in the tank of an apparatus designed for use in rural locations. This large valve "dumps" the water from the main tank into a folding portable tank, carried to the fire on a separate tanker truck. This allows the tanker trucks to shuttle water from long distances and empty into the portable tank, where large suction hoses feeding directly into the pump allow the flow to be increased to maximum capacity. These quick dump valves empty the 1,500 gallons (5,677 1) of water in 45 seconds.

Assembly

  • 5 When the body is completed, it is mounted to the frame over the pump and tank, and bolted using neoprene or rubber vibration strips. Along each side and above the tank are the equipment and hose compartments. They are formed into the body with doors and covers for protection. Related equipment, such as hose nozzles, as well as tactical equipment, such as forcible entry tools and self-contained breathing units, are stored in the side equipment compartments. They are sized and equipped to allow the fastest and easiest deployment of the equipment.
    The hose beds carry the fire hose. The top bed usually contains 50 foot (15 m) long 2.5 inch (76 cm) diameter sections of fire hose, connected together to form hoselines reaching up to 1,000 feet (305 m). This hose is folded in such a manner as to allow it to be pulled from its bed with ease and speed. Shorter sections of suction hoses are also carried on the apparatus. These suction hoses are made of a firm material so they do not collapse from the reduced pressure when coupled to the suction of the pump. They cannot be folded, so they are usually placed into hose troughs specially designed for suction hoses. All other types of fire hoses are collapsible and for use on the pressure side of the pump only.
    In front of the tank, and above the pump, are the attack hoseline beds. These beds contain 1.5 inch (3.8 cm) diameter firehoses preconnected to the output of the pump with the nozzles ready for action. Two or four beds of "preconnects" are common. These will be the first hoses used in the incident, therefore they are the most important. Behind the tank is the reel booster. Here, a one-inch (2.5 cm) diameter hose on a power roll-up reel is stored. This booster hose is used for cleaning the apparatus and equipment, and for cooling the outside of the apparatus when it is near a large fire. It is also occasionally used to put out small trash or grass fires. This reel is handy because the hose can be quickly rewound by simply pressing a button. All other hoses on the fire truck must be washed and packed back into their beds by hand after the fire incident.
    Ladders for the fire service are extra heavy duty. Though made out of aluminum, they are physically heavy, so they are typically carried in racks above the curb-side (right side) equipment compartments. Power racks have been developed to lower the ladder to waist height, but most commonly the fire fighters simply lift the ladder off of the rack and proceed to the fire. Ladders, like pumps, are also purchased from other suppliers and installed by the apparatus builder.

Painting

  • 6 Once the body has been assembled to the truck frame, the equipment mounting holes are located and drilled, and any additional holes or passages are cut into the panels. This allows the painting operation to seal the exposed edges of holes and other openings. The exterior of the apparatus is washed and sanded in preparation for painting. The interior of the doors and compartments have already been painted. The out-side can be painted in matching colors. The painting process includes a primer surfacer to fill small sanding marks and surface defects and a sealer to improve paint adhesion. Fire trucks used to be all red, but some experiments with yellow, blue, and white have been done to increase visual identification. Today, the NFPA recommends yellow or the standard Fire Engine Red. The type of paint is usually a tough enamel or synthetic to resist burning embers and wear from fire service. Hardening agents are added to the paint to improve the shine and durability. After painting, the ladders and accessories can be installed using stainless steel fasteners.

Installing wires

  • 7 The modern fire apparatus can be complicated. Radio systems, cellular phones, computers, and cellular fax machines are all finding their way into the fire service. Even our example apparatus will require several hundred feet of wiring to operate the warning lights, siren, radios, bay lights, generator, flood lights, pump electricals, and other systems. Most apparatuses have two independent battery systems, which must be wired into the apparatus after painting. The pump operator's control panel, containing the pressure gauges and valves used to control the pump, will also be installed.

Quality Control

After the last accessories are installed and individually tested, the apparatus builder submits the finished truck to an independent inspection agency. The agency takes delivery of the truck equipped just as it would be placed into service. It operates and inspects all of the apparatus systems. The pump is operated at maximum capacity for two hours to assure that this vital component performs properly. Upon successful completion, the apparatus and the builder are awarded a certificate of performance. In many areas, the apparatus cannot be legally delivered without this certificate.

The Future

Many new technologies are being applied to the modern fire apparatus. New tank materials are increasing in strength while reducing weight, allowing for more water capacity. Some large departments are using computers and cellular communications to handle information about hazardous materials, structure design, and geographics of the fire district. Perhaups the most exciting of the new technologies in the fire apparatus is the increased use of Class A foam solutions to attack structure and vegetation fires. This involves a separate on-board foam concentrate tank and a mixing proportioner to combine the foam concentrate with the water in the proper amount. Class A foam coats burning surfaces and absorbs heat significantly better than water. When used with compressed air from a separate air compressor on the vehicle, this technology is known as a Compressed Air Foam System, or CAFS. The compressed air pushes the water/foam stream to a much greater distance, and the resulting foam clings like shaving cream. In addition to these advances, firefighters are becoming better trained and are customizing their equipment to fit the types of fires they encounter.

Where To Learn More

Books

Buff, Sheila. Fire Engines: Motorized Apparatus Since 1900. Longmeadow Press, 1994.
Fire Protection Handbook, 17th Ed., 1991. National Fire Protection Association, Quincy, Mass.

Periodicals

Cottet, Jack L. "Enclosed Cabs for Fire Apparatus." Fire Engineering, October 1990, p. 50-52.
"Agile Fire Engine Borrows from Racing Car Design." Engineering, September 1990.
— Douglas E. Betts


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