Download "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary"
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FZ2DGhCk2aFo%252Fmaxresdefault.webp&w=1139&q=75)
Table of contents
Similar videos from our catalog
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252F7WFgxpWJXQo%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FBxOsahJPm5A%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FVR7r9bBRVi0%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FYTm3Wjs_XaQ%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FfUF3xbPxc58%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252FhNFnn-YAA1k%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252Fn70eobB2TgI%252Fmaxresdefault.webp&w=1139&q=75)
%3Aformat(webp)%2Fi.ytimg.com%252Fvi_webp%252Ft9vyx8hLa-k%252Fmaxresdefault.webp&w=1139&q=75)
Video tags
Subtitles
Russian
00:00:34
germany's only motorbike factory is00:00:37
located in the berlin suburb of spandau00:00:40
bmw has been mass producing motorcycles00:00:42
here since 1969.00:00:48
the plant covers an area of 30 soccer00:00:50
fields00:00:51
this is also where bmw's two-wheel00:00:54
flagship is built00:00:55
the s-1000rr00:00:59
nicknamed the double r the 19900:01:02
horsepower superbike00:01:04
consists of more than 4 500 separate00:01:07
parts00:01:08
[Music]00:01:09
it is fully assembled in just two hours00:01:14
[Music]00:01:17
this is champions league stuff00:01:20
the double r's high performance engine00:01:22
in particular is something very special00:01:25
its components are machined to an00:01:26
accuracy of one thousandth00:01:29
of a millimeter00:01:30
[Music]00:01:32
that's formula one precision production00:01:35
runs like clockwork00:01:37
every step is timed to the second00:01:41
working in close cooperation people and00:01:43
robots manufacture up to ten thousand00:01:46
superbikes a year00:01:47
as well as other two-wheelers made in00:01:50
germany00:01:52
despite 2 000 staff members here00:01:56
manufacture up to 800 motorbikes and00:01:58
scooters every day that's00:01:59
one every 65 seconds00:02:10
motorbike production in berlin centers00:02:12
on the u-shaped assembly line00:02:14
which has 62 fully automated carriages00:02:17
constantly traveling around it although00:02:20
it's similar to a conveyor belt00:02:22
this high-tech transport system is far00:02:24
more intelligent and customized00:02:28
laid in the workshop floor are induction00:02:31
loops which guide the driverless00:02:33
carriages00:02:34
along the way the system records every00:02:36
work step and every part that is00:02:38
installed00:02:40
[Music]00:02:44
each worker can also adjust the height00:02:46
of the driverless transport carriage00:02:57
the complete superbike is built on a00:02:59
carriage like this in two hours00:03:04
the heart of the double r is its engine00:03:07
later all parts will be assembled around00:03:09
it00:03:10
with its 199 horsepower the 999 cubic00:03:14
centimeter engine has a top speed00:03:16
of 299 kilometers an hour00:03:21
the four-cylinder inline engine is built00:03:24
entirely at the berlin plant00:03:27
the assembly team takes 120 minutes for00:03:29
the task00:03:31
first of all a fitter checks the conrod00:03:33
and bolts it to the piston00:03:37
in all four conrads are installed in the00:03:39
crank case00:03:41
everything has to fit perfectly00:03:46
[Music]00:03:50
with this motorbike the piston goes up00:03:52
and down 238 times a second00:03:55
so obviously the crankcase has to be00:03:57
manufactured with extreme precision00:04:00
the circulatory tolerance is one tenth00:04:02
of the width of a human hair00:04:04
you can well imagine what that involves00:04:07
the final piston is inserted in the00:04:09
cylinder the quartet is now complete in order to00:04:12
install the crankshaft00:04:14
the block has to be tilted00:04:18
the mechanic can only introduce the00:04:20
crankshaft into the housing in one00:04:22
specific position00:04:25
the small white rods help him to slip00:04:28
the shaft exactly onto the four little00:04:30
ends00:04:31
the conrod covers are then firmly bolted00:04:34
on00:04:36
[Music]00:04:38
the mechanic then fits the six-gear00:04:40
transmission with the drive sprocket00:04:42
[Music]00:04:44
there is very little room in the00:04:45
crankcase everything is extremely00:04:48
compact00:04:49
so even though he has performed this00:04:51
task thousands of times00:04:52
the fitter needs total concentration00:04:59
the engine block moves on to the next00:05:01
assembly point00:05:03
the other half of the housing has had a00:05:04
sealant applied and closes off the00:05:08
transmission an industrial robot00:05:11
tightens the 23 volts in a specific00:05:13
sequence00:05:14
and with a specific torque00:05:17
later the housing will be flooded with00:05:19
oil so it must be00:05:20
100 tight00:05:24
[Music]00:05:29
at the next assembly point the cylinder00:05:32
head is added00:05:33
it will contain the valves the camshafts00:05:35
and the spark plugs00:05:40
the cylinder head is the most complex00:05:42
and thus the most expensive part of the00:05:44
engine block00:05:45
the automatic bolting control tells the00:05:47
mechanic the sequence in which the ten00:05:49
bolts have to be tightened00:05:51
here two the correct torque has also00:05:53
been programmed in00:05:54
all the data are recorded00:05:57
the timing chain is mounted and the00:05:59
camshafts inserted and pressed in place00:06:03
up to 140 of these engines are00:06:05
manufactured each day00:06:06
[Music]00:06:09
every work step is timed to the second00:06:15
finally the cylinder head is closed with00:06:18
a sealed cover00:06:23
[Music]00:06:26
to save time many tasks in the motorbike00:06:28
factory are performed by automatic00:06:32
machines00:06:35
this machine coats the edge of the00:06:36
dynamo housing with a synthetic sealant00:06:42
the operation could never be performed00:06:44
as quickly00:06:45
cleanly and precisely by human hand00:06:51
[Music]00:06:58
at the next assembly point the super00:07:00
light magnesium cover is bolted to the00:07:02
block00:07:03
every operation concerning the engine is00:07:05
recorded in the central data bank00:07:12
now the clutch is fitted one of the last00:07:14
work steps in assembling the00:07:16
four-cylinder engine00:07:18
[Music]00:07:21
when the engine has been fully assembled00:07:23
and sealed it is put on a test rig00:07:28
every drive unit must leave the plant00:07:30
having passed this00:07:31
cold test the technician attaches eight00:07:35
lines to the engine00:07:36
they will measure the air volume in the00:07:38
cylinders00:07:43
only when the cabin door has been closed00:07:46
can the test begin00:07:55
the engine is powered up electrically to00:07:57
2000 revs a minute00:07:59
in its interior all the components are00:08:01
now moving as they would in the00:08:02
combustion process00:08:05
the yellow hoses measure the air being00:08:07
sucked into the engine and then expelled00:08:10
in this way the intake of fuel and the00:08:12
expulsion of exhaust fumes are simulated00:08:15
this engine is sealed and functions00:08:18
flawlessly00:08:19
it has passed the coal test00:08:24
after two hours assembly is completed00:08:26
every opening is closed off with a00:08:28
safety cap to rule out any contamination00:08:30
of the sensitive engine00:08:33
two bolts are attached to the sides to00:08:35
enable the 58 kilogram block to be00:08:37
lifted by a crane00:08:50
the four-cylinder online engine will now00:08:52
be suspended from a hook00:08:54
and taken for a ride00:08:58
[Music]00:09:00
the lift provides access to a huge00:09:03
transport system under the roof of the00:09:04
workshop00:09:07
every engine built in berlin first ends00:09:09
up in the loft00:09:11
installed up here is a complex overhead00:09:14
rail network00:09:16
the superbike engine travels fully00:09:18
automatically through the labyrinth00:09:19
to its waiting position hanging in this00:09:22
depot are more than 600 engines for00:09:24
different types of motorcycles00:09:26
they are waiting to be installed on one00:09:28
of the plant's assembly lines00:09:34
this engine block is on the way to its00:09:35
destination00:09:37
the double r assembly belt the chain00:09:40
hoist takes it back to the production00:09:42
shop00:09:43
this is the birth of a superbike 3400:09:47
assembly stations and two hours later00:09:49
the motorbike will be ready00:09:52
at station number one the engine is00:09:54
connected to the exhaust00:09:56
system00:09:59
the automatic transport system00:10:01
dispatches a carriage00:10:02
the engine block is placed on it and00:10:04
secured the base00:10:06
is ready next to be fitted is the frame00:10:10
made of aluminum it weighs only 1100:10:12
kilograms00:10:14
yet this lightweight is the motorbike00:10:16
supporting structure00:10:19
to cope with the huge forces occurring00:10:21
at nearly 300 kilometers an hour00:10:23
it has to be manufactured with extreme00:10:25
precision00:10:26
in the plant's own welding shop the four00:10:28
cast aluminum parts that make up the00:10:30
frame are positioned on the welding00:10:31
table00:10:34
the blank is turned and presented to the00:10:37
two welding robots00:10:42
the robots travel along the weld edges00:10:44
with millimeter precision00:10:46
at a temperature of 2000 degrees the00:10:48
electric arc00:10:49
melts the welding wire and fills the gap00:10:51
between the components00:10:53
each seam is welded twice00:10:57
here of course we see a beautiful theme00:11:00
located beneath it is the main world00:11:02
the root seam which is actually crucial00:11:04
for the stability of the frame00:11:06
the robots can weld 40 superbike frames00:11:09
a day yet despite their precision the machines00:11:12
are not infallible00:11:15
the main job is done by robots but since00:11:18
a robot always does the same thing the00:11:20
quality has to be checked by humans00:11:22
final inspection is always carried out00:11:23
by a person00:11:25
the robots are fast and extremely00:11:27
precise but because of their structure00:11:29
and size00:11:30
they cannot reach every corner of the00:11:31
construction00:11:33
these areas are then finished by00:11:35
experienced manual welders00:11:37
[Music]00:11:40
after being powder coated the frame is00:11:42
given a serial number00:11:43
and a tight plate the black aluminum00:11:46
skeleton then moves on further to00:11:48
pre-assembly00:11:49
[Music]00:11:54
here various lines and the wiring00:11:56
harness are installed00:11:57
the workers can't afford to lose any00:11:59
time the assembly line constantly needs00:12:02
replenishing00:12:03
the transport carriage with the double r00:12:05
engine is already waiting for the00:12:08
marriage00:12:11
this is where the frame and the engine00:12:13
are married as we say00:12:15
the aluminum bridge frame is slowly00:12:17
lowered onto the engine block00:12:19
the first fixing bolts are tightened00:12:21
married00:12:22
frame and engine enter the assembly line00:12:26
the carriage is continuously in motion00:12:28
many work steps are performed with the00:12:30
fitters walking alongside00:12:38
all the bolts that are tightened at this00:12:40
station have to meet high safety00:12:42
standards00:12:47
here we have a bolt connection that is00:12:48
clearly safety relevant00:12:50
the bolting is registered electronically00:12:52
so we can always refer back to the data00:12:54
bank to see if it was io00:12:56
or nio io and nio stand for00:12:59
in order and not an order io applies to00:13:02
a bolting whose measured torque meets00:13:04
the stipulated requirements00:13:06
if a bolt connection is registered as00:13:08
nio the bike will get special treatment00:13:12
located at the center of the u-shaped00:13:14
production line00:13:15
is the pre-assembly section it is here00:13:18
that certain units like the front00:13:20
fork are assembled and made available to00:13:22
workers on the conveyor belt for00:13:23
installation00:13:28
the fitter inserts the front wheel00:13:29
suspension in the aluminum frame00:13:32
here too every bolting is registered00:13:37
with a glance at the monitor the fitter00:13:39
checks that all the nuts have been00:13:41
tightened correctly00:13:48
in addition to the double r seven other00:13:51
motorbike models are manufactured on00:13:53
this assembly line00:13:56
during one shift the workers assemble00:13:58
various models00:13:59
completing up to 220 bikes each day00:14:06
if we laid out all the assembly points00:14:07
in a straight line00:14:09
it would be about 130 meters long that's00:14:12
34 basic assembly steps00:14:21
motorbikes have been built in spandau00:14:23
since 1969.00:14:25
but motorbike parts from the berlin00:14:27
aircraft engine factory were already00:14:29
being delivered to munich in the 1920s00:14:33
back then motorbikes were highly popular00:14:35
and a cheaper alternative to a motor car00:14:38
the sector boomed its technical00:14:41
innovations made bmw one of germany's00:14:43
leading motorcycle00:14:44
manufacturers00:14:47
today the concern is the country's only00:14:49
major producer of motorbikes00:14:51
and faces stiff competition from japan00:14:53
and the united states00:15:00
at the plant in berlin the next00:15:02
important components are being assembled00:15:05
the rear swing arm and the suspension00:15:07
strut ensure stability on the road00:15:10
at assembly station 7 the aluminum swing00:15:12
arm is mounted00:15:14
just like the frame it was welded00:15:16
together beforehand in the plant00:15:19
the height can be adjusted during00:15:20
driving operation with little effort00:15:24
with a suspension travel of 12000:15:26
millimeters00:15:27
the central strut is electronically00:15:29
adjustable and can thus be adapted to00:15:31
any road surface00:15:35
[Music]00:15:38
the hose for the air box is secured with00:15:41
a kind of surgical clamp00:15:43
the tools required for each operation00:15:45
are specifically stipulated00:15:48
the fitter mounts the air box on the00:15:50
engine it's the bike's lung00:15:52
filtering and regulating the intake air00:15:55
for combustion in the cylinders00:15:59
[Music]00:16:03
for the next work step the lifting00:16:05
column moves upwards00:16:08
the aluminum swing arm is still naked00:16:11
the rear wheel is still being prepared00:16:12
for installation in the swing arm00:16:18
wedge-shaped torque dampers made of hard00:16:20
rubber are inserted in the hub00:16:23
they dampen the force created when00:16:25
driving off00:16:27
[Music]00:16:30
the chain sprocket with its 44 teeth00:16:33
seals the hub00:16:34
and is pressed in place00:16:36
[Music]00:16:39
the hoist saves the workers back and00:16:41
guides the 12 kilogram rear wheel00:16:43
into the swing arm in a perfect fit00:16:47
at 200 kilometers an hour the wheel will00:16:50
rotate 28 times a second00:16:54
the drive chain consists of high grade00:16:56
steel that is super hard00:16:57
yet at the same time elastic it is00:17:00
riveted hydraulically00:17:03
a mass producer like bmw also improves00:17:06
certain components and electronic00:17:07
systems in ongoing series production00:17:10
so the double r is constantly undergoing00:17:12
further development00:17:14
to achieve this above all the firm's00:17:15
engineers need data and experience00:17:18
obtained from practice that is why bmw00:17:21
cooperates with selected race teams00:17:24
like nrt48 at the circuit in usherslavem00:17:27
and eight-hour races in progress00:17:30
nrt48 is competing in the stock sport00:17:32
world championship00:17:34
with two double r's the team has already00:17:37
practiced the pit stop hundreds of times00:17:41
the wheels are changed the tank filled00:17:44
and the bike roars off again00:17:46
in the stock sport class there is a00:17:48
ruling that is highly important for00:17:50
cooperation with bmw00:17:56
we compete with bikes that are virtually00:17:58
production models00:18:00
we are not allowed to modify the00:18:02
important components the frame00:18:04
the arm the fork the engine and the00:18:06
intake silencer00:18:08
so our bikes have the original harness00:18:10
and original00:18:13
in other lights 90 of the parts are00:18:15
original components from that00:18:17
perspective00:18:18
the customer rides the same motorbike we00:18:20
race with00:18:21
during the race the onboard computer00:18:23
records an enormous volume of data00:18:26
which in the pit is made visible on a00:18:27
laptop00:18:30
the cryptic diagrams and graphs provide00:18:32
information on the bike's weak spots00:18:40
we i'm looking at how the front wheel00:18:43
loses speed when it's in the air00:18:45
basically it's just to see whether the00:18:47
brake has operating clearance00:18:51
during the season teams like nrt48 drive00:18:54
hundreds of thousands of kilometers00:18:56
always pushing their superbikes to the00:18:57
limit00:19:01
their vast experience also influences00:19:03
production at the berlin motorcycle00:19:04
plant00:19:05
where software updates or new electronic00:19:08
and engine settings will be implemented00:19:17
developments from the cooperation flow00:19:20
back into the factory00:19:21
in this way we ensure that our00:19:23
developments in the motorsport sector00:19:25
are an open source every customer00:19:28
private or professional can benefit from00:19:31
our experience the s-1000rr has been on00:19:36
the market since 2009.00:19:39
but it took tremendous efforts before00:19:41
the model could enter series production00:19:43
the development process lasted several00:19:46
years00:19:50
it all began in 2005 with a few pencil00:19:53
sketches00:19:54
what could a new superbike look like00:19:57
performance and design have to harmonize00:20:00
sporty handling characteristics have to00:20:02
function not only on the circuit00:20:04
but also in everyday traffic on ordinary00:20:07
roads [Applause]00:20:10
from the finished draft a one-to-one00:20:12
clay model is produced00:20:14
which serves as a template for all later00:20:16
scans and installations00:20:24
then what is known as a fees model is00:20:26
milled00:20:28
weighing several tons this metal pattern00:20:30
will be the template00:20:32
for most of the components in subsequent00:20:34
series production00:20:36
at the same time the engine is00:20:38
mercilessly pushed to its limits00:20:40
on a dynamometer vibrations00:20:43
gear change behavior and temperatures00:20:45
are intensified to limits far beyond00:20:47
what a rider could cope with00:20:49
[Music]00:20:52
these tests provide important data for00:20:54
developers00:20:55
the double r reaches maximum performance00:20:58
of 199 horsepower00:21:00
at an engine speed of 14 300 rpm00:21:06
the prototypes also spend hundreds of00:21:08
hours in a wind tunnel00:21:10
at wind speeds of up to 300 kilometers00:21:12
an hour along with aerodynamic00:21:14
properties00:21:15
the temperature distribution on the00:21:17
machine is also optimized00:21:19
engine transmission and exhaust reach a00:21:21
temperature over 100 degrees00:21:23
these parts can only be cooled by the00:21:25
headwind00:21:28
[Music]00:21:29
paraffin trails make the flow lines00:21:31
visible the engineers test various00:21:34
fairings until they find the optimum balance00:21:36
between aerodynamics00:21:38
and cooling00:21:51
[Music]00:21:53
on the test circuit experienced test00:21:56
riders then analyze the handling00:21:57
characteristics of the new double r00:22:00
[Music]00:22:05
it is here that electronic assistance00:22:07
systems like abs and traction control00:22:10
are brought to series production00:22:11
readiness00:22:19
i'm trying to tune the traction control00:22:20
so that a rider who is not so00:22:22
experienced00:22:23
will be able to handle the enormous00:22:25
engine performance00:22:26
so that when he opens the throttle00:22:28
coming out of a turn and the rear starts00:22:30
to drift slightly he doesn't take a00:22:32
tumble00:22:38
the prototype is then subjected to00:22:40
long-distance tests on the circuit00:22:44
when they have determined the basic00:22:45
configuration of the double r00:22:47
the developers test camouflaged00:22:49
prototypes on public roads worldwide00:22:53
in their design and performance these00:22:55
bikes are the same as the future00:22:56
production models00:22:58
the special paintwork makes it hard to00:23:00
distinguish the shape of the bike00:23:02
on no account must the press catch wind00:23:05
of the new model and publish photographs00:23:07
prior to its market launch secrecy is00:23:10
still paramount00:23:13
over 60 test drivers put the bikes00:23:15
through their paces on all five00:23:16
continents00:23:17
and in all the world's climate zones00:23:20
since the superbike is to be sold00:23:22
worldwide00:23:23
it must function perfectly in all00:23:24
weathers and in all road conditions00:23:31
in the end the prototypes will have been00:23:33
driven more than a million test00:23:34
kilometers00:23:36
four years after the first pencil stroke00:23:39
the double r00:23:40
is officially launched up to 1800 new00:23:43
motorbikes are registered each year in00:23:45
germany alone00:23:46
basic cost 18 000 euros00:23:53
the oldest tract at the motorcycle plant00:23:56
houses mechanical production a department of00:23:59
great importance00:24:00
this is where the most complex engine00:24:02
components are customized for assembly00:24:05
[Music]00:24:10
each day around 4 300 parts leave here00:24:13
for engine assembly00:24:14
this is where we manufacture the main00:24:16
components cylinder head00:24:18
crankcase con rods and crankshaft00:24:22
this place is the highest demands on00:24:24
staff and00:24:25
on the high tech machines precision00:24:28
tolerances are within the micrometer00:24:30
range00:24:34
[Music]00:24:41
the human eye can still distinguish00:24:43
things between 30 and 40 micrometers00:24:45
but we have to work to precisely three00:24:47
micrometers00:24:48
that's the high performance precision00:24:50
you associate with formula one00:24:52
one of the precision parts is the conrod00:24:55
each engine has four conrods which00:24:57
convert the up and down motion of the00:24:59
piston00:25:00
into the rotational movement of the00:25:01
crankshaft00:25:03
so these cast parts have to withstand00:25:05
enormous forces00:25:07
the blank is subjected to a series of00:25:09
work steps grinding00:25:11
drilling milling and reaming up to 2 00000:25:14
conrods are manufactured here every day00:25:18
in the cracking machine the eye of the00:25:20
conrod is lasered to create a00:25:21
predetermined breaking point00:25:23
a wedge then breaks into two halves00:25:26
through this special procedure00:25:28
perfect form closure is obtained00:25:35
we do this because a broken surface fits00:25:37
together superbly one to one00:25:39
and that's what you need in top class00:25:41
motor racing00:25:44
every con rod passes through this fully00:25:46
automated measuring cell00:25:49
the robot weighs and measures the00:25:50
component with total precision00:25:53
just to remind you later the engine will00:25:55
have four conrods00:25:58
in shape and weight they must be almost00:26:00
identical00:26:01
otherwise powerful vibrations and00:26:03
imbalance could become manifest00:26:05
when the bike is on the road so here the00:26:08
conrods are categorized00:26:10
and sorted according to weight class00:26:15
[Music]00:26:18
the manufacturer of high performance00:26:20
components has a long tradition at bmw00:26:23
the first motorcycle was produced in00:26:25
192300:26:27
from then on motorbikes got faster and00:26:29
faster00:26:32
in 1929 on a bmw wr00:26:35
750 factory driver ants jakob henna00:26:38
set a world speed record of 216.7500:26:41
kilometers per hour00:26:43
[Music]00:26:50
in the years that followed henna set00:26:51
another six world records for the firm00:26:53
the last one in 1937 when he reached00:26:57
279.5 kilometers00:26:59
on a bmw 500 compressor00:27:02
but the young motorcycle manufacturing00:27:04
company also became involved in team00:27:06
sport00:27:08
and in doing so underlined the00:27:10
suitability of its products for00:27:12
everyday use00:27:21
[Music]00:27:26
the mechanical production department00:27:28
also manufactures the superbike's00:27:30
crankshaft00:27:31
again with micrometer accuracy the cast00:27:35
blank is first turned to shape on a00:27:36
lathe00:27:39
[Music]00:27:42
when the cheeks have been turned the00:27:44
shaft enters a vortex milling machine00:27:48
the bearing surfaces have to be00:27:49
perfectly round in order to absorb the00:27:51
enormous motive forces00:27:55
this is where the four cracked con rods00:27:57
will grip later00:27:58
and accelerate the shaft to a speed of00:28:00
1400:28:02
300 revs per minute00:28:04
[Music]00:28:07
when the gear wheels have all been00:28:09
milled and all the holes for the oil00:28:11
circulation system have been drilled in00:28:13
the crankshaft00:28:14
it is deburred and cleaned with high00:28:16
pressure jets00:28:18
[Music]00:28:23
a fully automatic washing robot then00:28:26
takes up the contaminated crankshaft00:28:29
inside the washing chamber the shaft is00:28:30
first given a hot full bath00:28:34
[Music]00:28:43
water at a pressure of 600 bar then00:28:45
deburrs00:28:46
every millimeter of the component00:28:48
[Music]00:28:51
after a minute the crankshaft is squeaky00:28:56
clean00:29:06
at a temperature of over 600 degrees00:29:08
nitrogen is introduced into the surface00:29:10
of the shaft00:29:11
in a hardening oven the crankshaft is00:29:14
now extremely00:29:15
solid but at the same time flexible00:29:19
when it is cooled the shaft is ground00:29:22
the automatic grinder too00:29:24
works to an accuracy of 1 000th of a00:29:26
millimeter00:29:30
at germany's only motorcycle factory 11000:29:34
crankshafts are manufactured per shift00:29:45
[Music]00:29:47
back to the conveyor belt after 4500:29:50
minutes the structure already looks like00:29:52
a motorbike00:29:53
it is now filled with coolant this task00:29:56
too is performed automatically00:30:01
the unit performs a vacuum test to00:30:04
ensure that the cooling circuit is00:30:05
leak-proof00:30:06
then the vehicle is filled with a00:30:08
coolant00:30:09
while the coolant is flowing the00:30:11
speedometer with its integrated00:30:13
on-board computer is installed in the00:30:15
handlebars00:30:18
together with the engine control unit00:30:20
they are the superbike's brain00:30:22
and monitor its functions00:30:28
the machine is now past the midpoint of00:30:30
the assembly line00:30:31
hundreds of individual parts have been00:30:33
installed by a dozen fitters00:30:36
quality control now ensures that no part00:30:38
has been forgotten00:30:39
or installed incorrectly inspection is00:30:42
still carried out by experienced staff00:30:45
but now they are supported by high-tech00:30:48
robots00:30:51
these two robot arms subject the bike to00:30:53
close scrutiny00:30:56
[Music]00:30:59
here we have a so-called mrk quality00:31:01
gate that's a human robot collaboration00:31:03
the robot also takes on individual00:31:06
control activities like checking that00:31:07
the correct rear wheel the correct00:31:09
kickstand and so on00:31:10
have been installed the robot compares00:31:13
the structure with photos from the huge00:31:15
data bank00:31:18
the sports bike is half completed00:31:21
induction coils laid in the workshop00:31:23
floor guide the driverless transport00:31:25
carriage00:31:26
at walking speed the double r heads for00:31:28
the second half of the assembly line00:31:32
filters on the last 65 meters of the00:31:34
conveyor belt are responsible for the00:31:36
fuel tank00:31:37
the fairing and the electronic system00:31:41
the air intake is fitted to the front00:31:42
section it's through this duct00:31:44
that the gas engine breathes it's now00:31:47
that the double r is also given its00:31:49
distinctive face00:31:51
the synthetic cockpit with its00:31:53
asymmetrical light system looks a bit00:31:55
scary00:31:57
the fitters work at high speed but also00:32:00
with great concentration00:32:02
nobody can afford to make a mistake00:32:04
especially when00:32:05
as in this case the abs system is00:32:08
attached00:32:11
the engine and the air box are the heart00:32:14
and lungs of the bike00:32:15
now it's the brain's turn via a data00:32:19
transfer unit00:32:20
the on-board computer receives its00:32:22
software00:32:23
that takes a while so the unit remains00:32:26
connected to the machine00:32:27
through the end of the assembly process00:32:29
[Music]00:32:33
next the exhaust system is bolted on the00:32:36
men have only a specific time window for00:32:38
each work step00:32:41
the motorcycle factory in berlin runs00:32:43
like a well-oiled machine00:32:46
and machines need fuel00:32:51
the double r has a 17.5 liter gas tank00:32:54
since it is made entirely of aluminum it00:32:57
weighs only two kilograms00:33:00
the welding robots have produced the00:33:02
tank from three separate parts00:33:04
the seams must not be bulky but they00:33:07
must be absolutely leak-proof00:33:11
like every component coming from the00:33:13
welding robots these tanks too00:33:15
are finished by human hand00:33:19
this lady handles 50 fuel tanks a day00:33:23
her rotatable welding table enables her00:33:25
to reach every spot with ease00:33:31
basically i do what the rubber doesn't00:33:33
manage to do00:33:35
like welding the small tubes and all the00:33:37
spots the robot can't get to00:33:40
her biggest challenge is the aluminum00:33:42
the tank is made of00:33:43
its wafer thin walls are only 1.500:33:46
millimeters thick00:33:48
so melt holes have to be avoided at all00:33:50
costs they would immediately turn the00:33:53
tank into scrap00:33:56
after 10 minutes this particular fuel00:33:58
tank is ready00:34:04
the manual welders need to be highly00:34:06
qualified and have a lot of feeling this00:34:08
is champions league stuff00:34:10
each tank then has to be checked for00:34:12
leaks the fuel tanks are filled with air00:34:15
in a special immersion basin containing00:34:16
distilled water00:34:18
since excess pressure is created inside00:34:20
each tank00:34:21
any hole in the aluminum shell will00:34:23
result in air escaping and creating tiny00:34:25
bubbles00:34:28
the 3d ultrasonic survey head searches00:34:31
for any such bubbles00:34:32
and approves or rejects the tank00:34:34
accordingly00:34:37
these two candidates are fine and can be00:34:39
released for assembly00:34:45
the cleaned and degreased tanks are00:34:47
placed on a frame00:34:50
from here on everything again takes00:34:52
place fully automatically00:34:54
the containers enter the paint booth to00:34:56
be given their first coating00:35:06
after two minutes the eight tanks are00:35:08
blue and end up on this colleague's00:35:11
table to be prepared for the next00:35:14
coating00:35:17
but now certain areas have to be00:35:18
protected from the white paint00:35:24
right here this area has to be taped00:35:28
and this area painted white so she will00:35:31
cover the places in the tank that have00:35:33
to remain blue00:35:36
the red template provides her with fixed00:35:38
points for sticking the protective film00:35:40
but first she sprays them with water so00:35:43
that their position00:35:44
can be corrected slightly after00:35:45
application00:35:52
i wet the tape a little then put it in00:35:55
place on the marking00:35:56
the tape the protective masking is00:35:59
slowly stuck on the tank00:36:01
it mustn't bubble or crease because00:36:03
later the red stripe will remain on the00:36:05
fuel tank00:36:06
as a decorative element00:36:17
during spring the red film protects the00:36:19
upper side and the tank opening from the00:36:21
white paint00:36:22
it takes only a few minutes to mask the00:36:24
tank00:36:27
the masking is now finished and the tank00:36:29
is prepared for the second color00:36:32
along with seven others the tank now00:36:34
heads back into the spraying booth00:36:36
where a robot sprays it white in less00:36:38
than 120 seconds00:36:41
when the paint is dried the tank is00:36:43
given a layer of clear varnish00:36:47
on the assembly belt the painted00:36:48
lightweight tank is attached to the bike00:36:51
storing fuel is not the tank's only roll00:36:54
because of its special shape it also00:36:56
gives the rider stability on difficult00:36:58
bends00:36:59
[Music]00:37:00
this can be crucial especially on a race00:37:04
[Music]00:37:06
track00:37:09
in osha's laban the qualifying race for00:37:12
the eight-hour event is underway00:37:15
the private team nrt48 is refueling00:37:19
here the fuel tank is not standard00:37:24
we can modify the tank we're allowed to00:37:26
have up to 24 liters00:37:28
so we have altered the basic original 1700:37:31
liter tank00:37:32
to take 24 liters the team consists of00:37:35
one male00:37:36
and one female rider who alternate every00:37:38
40 or 60 minutes00:37:40
but there seems to be something wrong00:37:41
with the bike00:37:45
at first there was nothing then just a00:37:47
little bit the input from the riders is00:37:50
tremendously important the brake isn't00:37:52
working properly00:37:53
it needs to be replaced the team00:37:56
dismantle the brake calipers on the00:37:57
front wheel00:37:58
and replace them with a new set00:38:07
shortly before the long distance race00:38:09
begins other parts on the double r00:38:11
need to be replaced this involves00:38:14
removing the underbody protection00:38:17
along with the front fairing and the00:38:19
tank container00:38:21
the men need access to the radiator00:38:31
we're is the radiator on this bike once00:38:34
again at the moment it has a used radiator on00:38:37
it that has already been through one00:38:38
24-hour race it's a routine operation00:38:41
for us00:38:43
we always have new material or material00:38:45
that's as good as new00:38:47
simply to rule out any source of error00:38:51
the coolant circuit of a racing bike is00:38:53
filled with water00:38:54
so in the event of damage no oily00:38:56
substances can contaminate the surface00:38:58
of the track00:38:59
and cause other riders to skid00:39:02
the old radiator is replaced with a new00:39:04
one00:39:06
[Applause]00:39:09
finally the nrt48 the two riders00:39:12
and the double r hit the track for eight00:39:15
hours they will lap the 3.7 kilometer00:39:17
long circuit00:39:18
in the battle for vital points towards00:39:20
the super stock world championship00:39:24
despite all the effort victory has00:39:26
eluded the team00:39:28
still the experience and the data gained00:39:30
over the weekend will benefit many00:39:32
riders on public roads00:39:38
germany's only motorcycle factory in00:39:41
berlin 200:39:42
they're on the finishing straight now00:39:44
the superbike's 13 fairing parts are00:39:46
being assembled00:39:48
they give the machine its unmistakable00:39:50
appearance00:39:51
some parts are not quite finished this00:39:56
side fairing comes with a special00:39:57
sticker00:39:59
it tells every road user here comes a00:40:02
double r00:40:08
when this if the tape is okay00:40:12
no bubbles or creases i usually rub it00:40:15
down ever so lightly00:40:17
when it's finished it is once again00:40:19
given a full coat of clear varnish in00:40:21
the paint booth00:40:23
the side element enters the fully00:40:25
automated spraying booth for a third00:40:27
time00:40:28
first blue then white and now clear00:40:31
varnish00:40:32
[Music]00:40:35
then the part is dried this takes about00:40:37
an hour00:40:39
at the bmw plant in spandau six thousand00:40:42
fairing components for all types of two00:40:44
wheelers are varnished every day00:40:50
every completed part then has a chip00:40:52
stuck to it00:40:54
together with the barcode on the00:40:55
transport tray the part can be clearly00:40:57
identified00:40:58
irrespective of its location00:41:03
before the two side fairings set off on00:41:05
a long trip00:41:06
they are scanned and registered within00:41:08
the system00:41:13
the tablet enters the plant's fully00:41:15
automated storage system00:41:17
the transport belt is several hundred00:41:19
meters long and runs over several floors00:41:23
like a road network it supplies specific00:41:25
workplaces with the necessary parts00:41:28
often the initial destination is the00:41:30
huge high bay store00:41:33
it is 37 meters high on 18 000 storage00:41:36
places00:41:37
90 000 components are waiting to be sent00:41:39
for further finishing00:41:42
down below the almost completed00:41:44
superbike now has the finishing line in00:41:46
sight00:41:47
it is already leaving the u-shaped00:41:49
assembly line the machine is now00:41:51
roadworthy but it still lacks00:41:53
important fluids here that changes00:41:57
at the media loading station the brand00:41:58
new motorbike is primed00:42:00
brake fluid is forced into the rear and00:42:02
front brakes00:42:04
the oil circulation system is filled and00:42:06
some fuel added to the tank00:42:10
after about four minutes the machine has00:42:12
been supplied with the basic fluids00:42:16
[Music]00:42:20
now the superbike heads for the finish00:42:22
belt where it is given its final00:42:24
appearance00:42:26
the side parts the windshield two00:42:28
mirrors and the mud guard00:42:30
are installed00:42:32
[Music]00:42:35
the double r is now complete00:42:41
[Music]00:42:43
the driverless carriage takes the00:42:44
motorbike to the roller test bench00:42:46
[Music]00:42:48
over the last two hours a superbike of00:42:50
outstanding quality has been built from00:42:52
thousands of individual parts00:42:56
it has an engine output of 19900:42:58
horsepower00:42:59
and an engine capacity of almost one00:43:01
liter00:43:03
the six-speed transmission gives the00:43:04
double r a top speed of 299 kilometers00:43:07
an hour00:43:08
maximum torque is 113 newton meters00:43:12
depending on how the bike is handled00:43:14
consumption is between 6 and 8 liters of00:43:16
gas per 100 kilometers00:43:18
with a tank full of fuel the double r00:43:20
weighs around 200 kilograms00:43:23
in its short life the bike has already00:43:25
experienced one marriage00:43:27
now it even faces separation separation00:43:30
from the transport carriage takes00:43:32
seconds00:43:33
from now on the double r will proceed on00:43:35
its own two wheels00:43:37
the driverless carriage goes straight00:43:38
back to the assembly line where a new00:43:40
engine block is00:43:41
already waiting00:43:50
on the roller test bench the bike is00:43:52
pushed to the limit00:43:58
[Music]00:44:08
the test rider accelerates to 14000:44:10
kilometers an hour00:44:11
and goes through all six gears00:44:14
all the bike's functions are checked in00:44:16
line with a strict test report00:44:18
brakes clutch indicators and lights all00:44:21
have to work perfectly00:44:23
otherwise the machine will not leave the00:44:25
plant00:44:28
in their own words the experienced00:44:29
testers can tell through the seat of00:44:31
their pants00:44:32
whether a bike is running smoothly00:44:36
the works has eight of these test cabins00:44:39
where up to 600 two-wheelers of all00:44:41
kinds are tested every day00:44:43
a driver might test as many as 4000:44:45
vehicles on one shift00:44:51
the data connection is cut the00:44:53
motorcycle has been technically approved00:44:58
the double r is a complex high00:45:00
performance vehicle with a powerful00:45:01
internal combustion engine00:45:03
in the foreseeable future other00:45:05
propulsion systems like electric motors00:45:07
will play a major role00:45:11
[Music]00:45:14
that is why bmw is already looking to00:45:16
the future with a concept vehicle00:45:18
and showing what a motorbike could one00:45:20
day look like00:45:22
emission-free drive units on an electric00:45:24
or fuel cell basis will be standard00:45:28
they might not have the same throaty00:45:30
roar as a combustion engine00:45:32
but a sound system could stimulate the00:45:34
sound of a racing machine00:45:37
where safety is concerned there will be00:45:39
many new developments00:45:40
this concept bike is equipped with a00:45:42
gyroscopic sensor00:45:44
designed to make a tumble impossible but00:45:47
the technical highlight will be the00:45:48
networking of driver motorcycle00:45:50
and environment00:45:55
i can imagine that motorcycling in the00:45:56
future will have a lot to do with00:45:58
connectivity00:45:59
the vision is that all vehicles and road00:46:02
traffic will permanently exchange00:46:03
information on their position and speed00:46:06
collisions would then be foreseeable and00:46:08
thus preventable00:46:13
if a car detects a rock on the road the00:46:15
motorcyclist will see that at once on00:46:18
his display so we're talking about communication00:46:20
between motorcycle and car00:46:22
with a car being braked automatically if00:46:24
the driver hasn't spotted the00:46:25
motorcyclist00:46:26
these things will undoubtedly come in00:46:28
the future00:46:30
assistance systems like these data00:46:32
glasses reflect00:46:33
all important information into the00:46:34
driver's field of vision00:46:36
so there's no need for a glance the00:46:38
speedometer or the rear view mirror00:46:42
another dream is that in future there00:46:43
will be no need for helmets either00:46:45
because special motorcycle clothing will00:46:47
contain airbags00:46:48
and neck stabilizers but with so many00:46:51
visions00:46:52
no doubt many bikers will already be00:46:54
wondering just where the kick is00:46:55
supposed to come from00:46:57
[Music]00:46:59
well maybe it's still possible to find a00:47:02
double r lying around in some garage or other00:47:06
this one is still hot from being tested00:47:08
on the roller test rig00:47:10
so it's put in a giant fridge00:47:14
the bike has to cool otherwise the00:47:16
packing film could melt on the hot00:47:18
engine or the exhaust and stick it takes the00:47:21
machine just00:47:22
30 seconds to pass through the cooling00:47:24
tunnel00:47:25
[Music]00:47:35
most of the bikes head off to the00:47:37
customer in recyclable packing00:47:39
the metal frame is reinforced with00:47:41
wooden lathes00:47:43
the order and delivery forms are stapled00:47:45
on and after a final control look00:47:48
the machine leaves00:47:54
in 95 seconds the wrapping machine00:47:56
envelops the transport frame00:47:58
in a tear resistant film a labeling00:48:01
machine then gives the final goodbye00:48:02
kiss00:48:04
[Music]00:48:05
three hours after the first work step on00:48:07
the assembly belt00:48:08
the bmw s-1000rr is loaded onto a truck00:48:14
it is taken by road to the nearest goods00:48:17
station container ship00:48:18
or airport depending on where in the00:48:21
world its new owners waiting for it00:48:31
in the meantime work continues on the00:48:33
130 meter long assembly line00:48:37
day after day 2 000 people and countless00:48:40
robots produce00:48:41
two wheelers made in germany 80000:48:44
motorcycles and scooters are00:48:46
manufactured here every day00:48:48
at germany's only motorcycle plant00:49:07
[Music]00:49:12
youDescription:
Exceptional Engineering: Motorbike Factory The BMW plant in Berlin-Spandau has been one of the most important international locations in motorcycle construction for 47 years. Two-wheelers made here are traded worldwide. The product range of the Bavarian automobile manufacturer includes a variety of models, including agile cross-bikes, sporty cruisers, and eco-friendly electric motorcycles. Special wishes? No problem. Bikes that go beyond the usual standard version can also be made to measure in Spandau. __________________________________________________________ Subscribe Free Documentary Channel for free: https://www.youtube.com/channel/UCijcd0GR0fkxCAZwkiuWqtQ?sub_confirmation=1 Facebook: https://bit.ly/2QfRxbG Twitter: https://bit.ly/2QlwRiI __________________________________________________________ __________________________________________________________ Free Documentary is dedicated to bring high-class documentaries to you on youtube for free. With the latest camera equipment used by well-known filmmakers working for famous production studios. You will see fascinating shots from the deep seas and up in the air, capturing great stories and pictures from everything our beautiful and interesting planet has to offer. Enjoy stories about nature, wildlife, culture, people, history and more to come.
Preparing download options
* — If the video is playing in a new tab, go to it, then right-click on the video and select "Save video as..."
** — Link intended for online playback in specialized players
Questions about downloading video
How can I download "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary" video?
http://unidownloader.com/ website is the best way to download a video or a separate audio track if you want to do without installing programs and extensions.
The UDL Helper extension is a convenient button that is seamlessly integrated into YouTube, Instagram and OK.ru sites for fast content download.
UDL Client program (for Windows) is the most powerful solution that supports more than 900 websites, social networks and video hosting sites, as well as any video quality that is available in the source.
UDL Lite is a really convenient way to access a website from your mobile device. With its help, you can easily download videos directly to your smartphone.
Which format of "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary" video should I choose?
The best quality formats are FullHD (1080p), 2K (1440p), 4K (2160p) and 8K (4320p). The higher the resolution of your screen, the higher the video quality should be. However, there are other factors to consider: download speed, amount of free space, and device performance during playback.
Why does my computer freeze when loading a "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary" video?
The browser/computer should not freeze completely! If this happens, please report it with a link to the video. Sometimes videos cannot be downloaded directly in a suitable format, so we have added the ability to convert the file to the desired format. In some cases, this process may actively use computer resources.
How can I download "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary" video to my phone?
You can download a video to your smartphone using the website or the PWA application UDL Lite. It is also possible to send a download link via QR code using the UDL Helper extension.
How can I download an audio track (music) to MP3 "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary"?
The most convenient way is to use the UDL Client program, which supports converting video to MP3 format. In some cases, MP3 can also be downloaded through the UDL Helper extension.
How can I save a frame from a video "Exceptional Motorbike Factory | Exceptional Engineering | Free Documentary"?
This feature is available in the UDL Helper extension. Make sure that "Show the video snapshot button" is checked in the settings. A camera icon should appear in the lower right corner of the player to the left of the "Settings" icon. When you click on it, the current frame from the video will be saved to your computer in JPEG format.
What's the price of all this stuff?
It costs nothing. Our services are absolutely free for all users. There are no PRO subscriptions, no restrictions on the number or maximum length of downloaded videos.