WEBVTT 1 00:00:00.500 --> 00:00:03.300 Narrator: Welcome back aboard! Fishing for boat improvement? 2 00:00:03.300 --> 00:00:06.300 Well you caught it. Right here at Ship Shape TV. 3 00:00:07.000 --> 00:00:09.300 Wolf: John, these are virgin 4 00:00:09.300 --> 00:00:12.700 polycarbonate pellets which are used in the manufacture 5 00:00:12.700 --> 00:00:14.200 of the Perko Battery Switch. 6 00:00:14.200 --> 00:00:16.200 John: What are the physical characteristics 7 00:00:16.200 --> 00:00:18.400 of polycarbonate as a base material? 8 00:00:18.400 --> 00:00:21.800 Wolf: Polycarbonate has excellent impact resistance, 9 00:00:23.000 --> 00:00:26.600 extreme toughness and it also has good electrical properties 10 00:00:26.600 --> 00:00:28.600 which are necessary for the battery switches. 11 00:00:28.600 --> 00:00:30.600 John: Awesome. Hey I want to tell everybody 12 00:00:30.600 --> 00:00:32.800 who we have the privilege having back on the program 13 00:00:32.800 --> 00:00:34.800 This is Wolf Nennig. 14 00:00:34.800 --> 00:00:37.800 And Wolf is the director of engineering 15 00:00:37.800 --> 00:00:40.500 down here in Miami, Florida. 16 00:00:40.500 --> 00:00:42.900 This is Perko Incorporated. 17 00:00:42.900 --> 00:00:47.700 Which is a 430 thousand square foot manufacturing facility 18 00:00:47.700 --> 00:00:50.700 for marine hardware. And you guys are one of the leading 19 00:00:50.700 --> 00:00:54.200 industry experts in making battery switches. 20 00:00:54.200 --> 00:00:57.000 And how do we go from these pellets, 21 00:00:57.000 --> 00:01:00.100 to actually forming the housing for a battery switch? 22 00:01:00.100 --> 00:01:02.100 Let's talk about the machine that's behind us. 23 00:01:02.100 --> 00:01:04.100 Wolf: Okay. First of all we start off 24 00:01:04.100 --> 00:01:07.400 by drying the pellets in that large drying hopper behind us. 25 00:01:07.800 --> 00:01:10.400 And the pellets are dried for 3 to 4 hours 26 00:01:10.400 --> 00:01:12.400 before we can process them. 27 00:01:12.400 --> 00:01:15.700 John: Now is this a process of heat? 28 00:01:15.700 --> 00:01:18.500 Or is this a process of high pressure? 29 00:01:18.500 --> 00:01:20.000 Wolf: It's a process of both. 30 00:01:20.000 --> 00:01:23.400 The plastic is melted inside the barrel, 31 00:01:23.400 --> 00:01:26.600 and then it's injected under high pressure into the mold. 32 00:01:26.600 --> 00:01:29.600 John: So the auger becomes a plunger, 33 00:01:29.600 --> 00:01:32.600 and it moves the shot to the mold. 34 00:01:32.600 --> 00:01:34.600 Alright now how hot is the the material? 35 00:01:34.600 --> 00:01:37.300 Wolf: The material is heated up to around 600 degrees 36 00:01:37.300 --> 00:01:39.500 John: Okay, and can I touch this at this point? 37 00:01:39.500 --> 00:01:40.200 Wolf: Certainly. 38 00:01:40.200 --> 00:01:42.200 John: Alright cause I want to show everybody 39 00:01:42.200 --> 00:01:44.200 one of the housings. It's a little bit warm but 40 00:01:44.200 --> 00:01:45.700 it is manageable. 41 00:01:45.700 --> 00:01:48.200 And, this is the housing 42 00:01:49.100 --> 00:01:52.200 What do we do with this portion right here on the battery switch? 43 00:01:52.200 --> 00:01:54.000 Wolf: Okay this is the sprue and that's where the 44 00:01:54.000 --> 00:01:56.000 plastic is injected into the mold. 45 00:01:56.000 --> 00:01:59.000 And then it's drilled out as a secondary operation. 46 00:01:59.000 --> 00:02:01.000 John: Well let's talk about the internal components 47 00:02:01.000 --> 00:02:03.000 on the battery switch. Where is that made? 48 00:02:03.000 --> 00:02:07.100 Wolf: The copper segments are made in our stamping department. 49 00:02:07.100 --> 00:02:08.400 John: Could you take me over there? 50 00:02:08.400 --> 00:02:09.000 Wolf: Let's go! 51 00:02:09.000 --> 00:02:09.700 John: Very good! 52 00:02:10.700 --> 00:02:11.700 (*hammer clank*) 53 00:02:11.700 --> 00:02:13.700 Wolf: John I want to show you the material 54 00:02:13.700 --> 00:02:16.000 that we use in our battery selectors here. 55 00:02:16.500 --> 00:02:20.000 We use 4 inch wide by 3/32 thick copper. 56 00:02:20.600 --> 00:02:22.800 And Steve, a punch press operator, 57 00:02:22.800 --> 00:02:24.900 he's punching out four of the components 58 00:02:24.900 --> 00:02:26.900 that make up the inside of the battery switch. 59 00:02:26.900 --> 00:02:29.300 John: Is that what these parts are right here on this table? 60 00:02:29.300 --> 00:02:30.100 Wolf: That's correct. 61 00:02:30.100 --> 00:02:33.400 John: Now what exactly are these parts here Wolf? 62 00:02:33.400 --> 00:02:35.400 Wolf: Those three are the segments that actually 63 00:02:35.400 --> 00:02:37.400 connect to the battery terminals. 64 00:02:37.400 --> 00:02:39.400 John: I know that you make a lot of different battery 65 00:02:39.400 --> 00:02:41.400 switches here at Perko. 66 00:02:41.400 --> 00:02:44.100 Which one is he punching parts out for? 67 00:02:44.100 --> 00:02:46.700 Wolf: This is for our four position battery switch. 68 00:02:46.700 --> 00:02:48.600 John: Now I heard that you guys do something pretty 69 00:02:48.600 --> 00:02:51.100 unique in the testing of your battery switches. 70 00:02:51.100 --> 00:02:53.600 And where is that done? Over in final assembly? 71 00:02:53.600 --> 00:02:56.100 Wolf: It's in final assembly and I'll be glad to show it to you. 72 00:02:56.100 --> 00:02:57.100 John: Awesome let's take a look! 73 00:02:57.100 --> 00:02:58.100 Wolf: Okay! 74 00:02:59.300 --> 00:03:01.700 Wolf: John, this board represents all the various 75 00:03:01.700 --> 00:03:04.100 battery switches that we assemble here at Perko. 76 00:03:04.100 --> 00:03:06.100 John: You got to be kidding me! That's quite a few. 77 00:03:06.100 --> 00:03:08.100 Wolf: Yes we do! Now this young lady here 78 00:03:08.100 --> 00:03:10.100 she's riveting the copper 79 00:03:10.100 --> 00:03:12.100 segments to the back plate. 80 00:03:12.100 --> 00:03:14.900 John: I see that we have several working stations here. 81 00:03:14.900 --> 00:03:16.900 Wolf: We have a couple of assembly 82 00:03:16.900 --> 00:03:18.900 stations where the switches are assembled 83 00:03:18.900 --> 00:03:20.900 with all the various components. 84 00:03:20.900 --> 00:03:22.900 All these components 85 00:03:22.900 --> 00:03:24.100 are made here at Perko. 86 00:03:24.100 --> 00:03:26.900 John: Okay, now I've heard that you guys to a lot testing. 87 00:03:26.900 --> 00:03:28.900 In fact, every battery switch 88 00:03:28.900 --> 00:03:31.100 gets tested before it goes out to a boater. 89 00:03:31.100 --> 00:03:31.800 Is that true? 90 00:03:31.800 --> 00:03:33.700 Wolf: That's true. We test them once before 91 00:03:33.700 --> 00:03:35.700 they are ultrasonically assembled. 92 00:03:35.700 --> 00:03:37.400 And we test them again after they have been 93 00:03:37.400 --> 00:03:39.400 ultrasonically assembled. 94 00:03:39.400 --> 00:03:41.400 John: What percentage of return 95 00:03:41.400 --> 00:03:43.800 do you get with the battery switch? 96 00:03:43.800 --> 00:03:45.200 Are they pretty reliable? 97 00:03:45.200 --> 00:03:46.900 Wolf: These are very reliable. 98 00:03:46.900 --> 00:03:49.100 We get a fraction of a percent 99 00:03:49.100 --> 00:03:50.900 back a year. That's minuscule. 100 00:03:50.900 --> 00:03:52.900 John: Awesome. Wolf thank you so much 101 00:03:52.900 --> 00:03:54.900 for all the information. Hey right now we need to take 102 00:03:54.900 --> 00:03:56.900 another time out. But keep it right here 103 00:03:56.900 --> 00:03:58.900 because when we come back, we're gonna be back 104 00:03:58.900 --> 00:04:01.500 out on the water. And we're gonna be dealing with battery switches. 105 00:04:01.500 --> 00:04:03.500 This time at Ship Shape University, 106 00:04:03.500 --> 00:04:05.700 we're gonna show you how to maximize 107 00:04:05.700 --> 00:04:06.900 the battery switch. 108 00:04:06.900 --> 00:04:08.900 Especially starting the engines 109 00:04:08.900 --> 00:04:10.900 and running your 12 volt accessories. 110 00:04:10.900 --> 00:04:13.100 We'll cover it, right after this. 111 00:04:13.100 --> 00:04:15.800 Congratulations John and staff! 112 00:04:15.800 --> 00:04:17.700 Ship Shape TV is celebrating it's 113 00:04:17.700 --> 00:04:19.300 10th season on the air! 114 00:04:19.300 --> 00:04:21.300 Great job!