NGC全民英檢超級工廠-法拉利0001

1、Megafactories: FerrariNGC全民英檢：超級工廠-法拉利播出時間 :07 月 05日 星期日 11:00-12:00Ferrari!For decades, one of the most legendary names in automobiles.Now a new model is hitting the streets.One and a half tonnesof high performance sports car.Engineered with the precisionof a spacecraft.The fastest, most powerful p

2、roduction carFerrari has ever designed.And this is where its being made!Inside Ferraris mega factory!Few cars have carried such an aura of legendand mystique through the decades.The Ferrari of the formula one track.The winningest name in the historyof the sport.The Ferrari of the open road.An iconic

3、 sportscar of the ages.Whether for the race track or for the road,every Ferrari is hand crafted.Northern Italy. the town of Maranello.This is the site of Ferraris mega factory.part hi-tech garage,part art studio.a place where raw metal is transformedinto raw power and where carsare created like scul

4、ptures.Its buildings are every bitas sleek and modern as the cars created here.Because Ferrari makes cars for the streetand for the racetrack,the factory boasts some unique features.A wind tunnel for research and development designed by Italys super-architect,Renzo Piano.An engine works flooded by n

5、atural light, with trees to provide exactly the right humidity for engine construction.Even a three kilometer private racetrack used to trial Ferraris latest racecars and road test its sportscars.These are the buildings through whichevery Ferrari makes its first journey.And for the three thousand wo

6、rkersalong the way, being here is an Italian dream.For us Italians, Ferrari has alwaysbeen a myth, always.I mean, the boys here grow up with Ferrari in them.Few outsiders and even fewer camerasare ever allowed into Ferraris factory.Security is intense.For Ferraris formula one team thats based at the

7、 factory,theres the ever-present threat of industrial espionage.And Ferraris formula one secretsgo straight into its street cars.This is the fastest and most powerful production car Ferrari has ever designed- the Fiorano 599.Its speed tops 330 kilometers per hour- and its price? Over 200,000 euro!Fe

8、rraris president- Luca Di Montezemolo.For me this kind of car means freedombraking acceleration, handling, engine using. all these ingredient make the Ferrari unique.Five years of research and development have gone into Ferraris newest model.So have sixty years of history.Ferraris legendary founder

9、Enzo Ferrari was a racing purist.To him, Ferraris street cars were just a way to help fund his formula one team.Early Ferrari sportscars may have been beautiful to look at, but they were notoriously hard to drive.Their racing characteristics werent suited to the open road.But over the decades, Ferra

10、ri has moved closer and closer to designing a sportscar that puts all the companys formula one experience into the ultimate street machine.The Fiorano 599 is that car.Ferraris designers and workers face a daunting challenge: build a car with the soul- and speed- of a formula one racer- but that hand

11、les smooth as silk on real-world streets.Make it beautifulbefitting the Ferrari legacy of art-in-motion.And dress it in luxuryworthy of its 200,000 euro price tag.Race car- street carwork of art- luxury item.A tall order- for the team at Ferraris Maranello factory. Its a vast complex. Forty-five bui

12、ldings- with enough space to fit fifty football fields.In all- eight separate sectionsof the factory will build the 599 from scratch.From the fires of the foundry.to the beauty of the body shop.From the robotic precision of the engine works and the paint shop. to the handcrafting of the 599s leather

13、 upholstery.and the final assembly line where it all comes together.The factorys first challenge?Giving the 599 its signature trait- speed.The 599 boasts a v-12 engine putting out 620 horsepower.And the foundry is where that key component begins its life.Here- Ferraris metalworkershave to cast the t

14、wo core elements of the engine, the cylinder head and the engine block.Most factories mass-produce these parts- but Ferrari turns them out one at a time.A separate mould is made for every single engine.Theyre made out of compacted sand and resin.Other car companies use sand casts.At high-end factori

15、es like Ferrari workers finish the sand moulds by hand.It takes around five hoursto hand finish the moulds for a single v12 engine.Theyre fitted together like an intricate three dimensional jigsaw.to minimize the chance of chips, cracks or flaws.This will be cast into the cylinder headof a 599.A fla

16、ming torch blackens the sand model with a thin layer of carbon.The carbon layer acts as a lubricant to let the molten metal flow smoothly into the spaces of the cast.Its time. the moulds are ready.The precision of the casting procedure is critical. Any flawcould cause the finished engineto under-per

17、form.The molten metal is preparedjust as carefully as the sand moulds.In the melting process, obviously,there cant be any mistakes.It has to be of the highest qualityto be able to sustain a carthat goes over 200 miles per hour.At temperatures of over 700 degrees Celsius, the heart of the 599 engine

18、begins its fiery birth.This is what theyre going to build.This is where it starts.In the Ferrari foundry,the main furnace is fired up.The metal that will be cast into the core of the 599s mighty engine is being melted.Some of the raw metal being fed into the furnace comes from previously cast compon

19、ents that have failed Ferraris quality checks.The metal melts almost instantly, as massive electrical charges are fired through it.Melting the two tons of metal in the furnace uses enough electricity in one day to light a house for a year!The raw molten metal pours into a giant crucible for further

20、purifying.At 1300 degrees,it looks like liquid silver.At 700 degrees, it looks like liquid silver.But this is a super strong-super secret aluminum alloy specifically created for Ferraris engines.Nitrogen pumps through the metalin the crucible, combining withany impurities- which float to the surface

21、.The pure alloy is transferredto smaller holding tanks,from which the engine components will be cast.This mould of compacted sandis about to become the cylinder headof one of the most powerfulproduction car engines ever made.The metal gushes into the mould.Theres a casting here every ten minutes.Inc

22、redibly, only one in every fifty componentsfails its quality testand is sent back to the scrap heap.Thats because of the carethats gone into preparingboth mould and metal.While the foundry casts the Ferraris v-12 heartin another building, workers fashion its body.Like many high-end sports car makers

23、,Ferraris body shop is part art studio.But while the 599 may be Ferraris latest artwork.Its also a masterpieceof aerodynamic engineering.Thousands of hours have gone into designing a sports car thats not only beautiful but can cheat the air almost as well as Ferraris formula one race cars.In essence

24、 the 599s body shape is the opposite of an aircraft wing.At high speed its streamlined body creates negative lift, using the airflow over and through it to press the car to the road.The downforce means more secure road handling and far better traction out of corners.The Ferraris streamlined bodyneed

25、s strong support.If you want to put a formula one race car on the street, you need a chassis that can take the stresses of high-speed and high performance.Made entirely of aluminum alloy,the 599s chassis must be strong enoughto do three things:Withstand high speed impacts.Anchor the 500 pound v-12 e

26、ngine, which produces a tremendous amount of torque and power.The chassis also has to provide a strong mount for the wheel assembly and suspension.At high speeds the wheels of a sportscar go up and down like a jackhammer- so Ferrari equipped the 599s chassis with super tough suspension mounts.High-s

27、trength adhesives and meticulous hand-welding make the joints in this chassis as strong as the original metal.Regular cars chassis are put together by machines, but high performance sports cars like the 599 are hand welded.It means the chassis can be more exactly shaped- and the body panels more pre

28、cisely fitted.With the 599s chassis now welded and the first of its body panels attached, its time for one of the factorys robots to take over.Its basically a gigantic stapler.The robot is programmed to precisely drive one hundred and eighty rivets at specific points over the entire chassis.The rive

29、ts give the car the muscle to hold itself together at 330 plus kilometers an hour.Each time these jaws snap, theyre punching a high-strength rivet through up to three layers of solid aluminum.But the chassis cant move on down the line before it passes a rigorous test.Another robot comes into play, e

30、quipped with needle-like probes.The probes test the chassis in 800 hundred different places.At each point they touch the metal.They are measuring the bodyagainst a computer model.Searching for tiny cracks in the metalor any flaw in the chassis overall shape.If a flaws detected,the chassis is sent ba

31、ck.but that only happens to one in every hundred.Theres a reason for this insistenceon perfection: the slightest flawin any component of a high-performance sportscar can create the ripple effect.The flaw magnifies throughall the other components dependent on it.At high speeds, the stresses on the ch

32、assis could turn cracks into fissures.and severely compromise the cars structural integrity.After an exhaustive examination, the robot arms raise for the last time. the 599s metal skeleton is now ready to receive the rest of its sculpted body panels.Back in the foundry, the engine casts are complete

33、.Seven minutes later, theyve cooled enough for the sand moulds to be removed.Theres nothing too high-techabout this process!The compressed sand is just shaken off the solidified metal.The high-performance specs of the 599 require engine parts that are perfect. Powerful x-rays scan the cast component

34、s- looking for microscopic cracks or flaws in the metal.The slightest vibration from a defect in the finished engine will be magnified at high speed.Worst case scenario-the engine itself could fail!Components that pass the x-ray testare hand finished.Then theyre checked again.Its no surprise that Fe

35、rrari foundry workers feel theyre making more than just an engine.We create the soul and then someone else adds the organs to make it live.In the body shop, metal is becoming artas the 599s sleek outer shellmeets its chassis.When anyone thinks of a Ferrari, you think of two things in particular: one

36、, the motor, immense power, the sound, the growl of it;and second the external beauty of the Ferrari.Like its chassis, the Ferraris body panels are aluminum.It may be the most powerful production car the companys ever made-but its fully-aluminum constructionmeans its also one of the lightest.The 599

37、 has more power propelling less car.Workers fix the doors, hood and trunk to their precision hinges and align them to a tenth of a millimeter.From this point on, its all about art.Creating a finished bodythat is as close to flawless as possible.The body shops specialistscheck for trouble spots.Dents

38、 or flaws, no matter how small.To Ferrari people, this is no longer a car.its a sculpture.In a sealed plexiglas room- where no speck of dust can interfere with its final inspection- the 599 is given the thumbs up to move out of the body shop.We have to guarantee the perfect shape, the unique finishi

39、ng, consequently the perfect paint-job.At Ferraris Maranello factoryin northern Italy, the unfinished Fiorano 599 takes its next step toward the finish line. This is Ferraris twenty-first century paint shop. one of the most advanced of its kind in any car factory.The environment is a high priority f

40、or this paintshop. Most materials are water-based, and nearly all waste is captured and recycled.Formula one racers dont have to worry about rust, but the 599 is built for the streets.Before they can be painted, every 599 car body receives an anti-corrosion treatment.Ferrari claims its the most adva

41、nced rust-proofing in the world- a claim thats hard to test because the chemical process going on here is a trade secret.The one-ton bodies are plunged.tipped. and shaken.Every one of these giant baths chemically alters the metal of the cars bodycreating a super-thin armour against the elements.Thes

42、e anti corrosion baths also give the 599s body a positive electrical charge.Thats vital for the next stageof the painting process.At the end of this tunnellies the real work of the paint shop-a glass-walled, hermetically-sealed place populated by graceful robots and their human controllers.The chamb

43、ers are sealed to avoid any air drafts that might cause the tiny particles of primer and paint to drift and create an uneven finish.This first coat is primera special compound that binds the actual paint to the body.the primer is a fine dust- as fine as talcum powder.It sticks to the body because of

44、 the electrical charge the metal was given earlier.The robots are programmed to spread the particles of primer into a layer about as thick as a human hair.The body glides into a giant oven,which bakes the primer.fusing it onto the metal.and providing the foundation layer for the Ferraris final paint

45、 finish.Every stage of a Ferraris construction is about beauty and power.The 599s v-12 engine is that power.Its created here, in Ferraris engine works.The engine blocks and cylinder heads cast in the foundry are now fine tuned to an almost microscopic degree.Other workers turn out the rest of the en

46、gines eight hundred parts.Ferraris engine works is a architectural triumph.Natural light floods in through a glass roof.Its environmentally efficientand provides better light for workers.And in the center of the engine works, a small forest of trees grows indoors!These trees help maintain the ideal

47、humidity and air quality levels for engine construction.Theyre also here to ensurethe workers comfort.This factory is rated as one of the best places to work in Italy.Ferrari workers dont see themselves as part of a production line but as craftspeople building a handmade product.My passion is to mak

48、e Ferraris.I think Ive made a part of the motorof every single vehicle that you seeon the road, and every time I see a Ferrari I feel pride in my heart,inside that motor theres a part of my heart.And at every step of a Ferraris creation, they sign off on their work.I am and we all are absolutely res

49、ponsible for what we build. We certify what we do so that it can be traced back to us.All through the engine worksFerraris metal workers are machining the most detailed components of the v 12 engine.Italians have a reputation of being some of the most skilled metal workers in the world.This tiny val

50、ve is only one of the 599 engines eight hundred components.it alone takes nearly an hour to make.But while the emphasis is on hand crafting, there are two very special robots in the engine works.The first is a robot they callRomeo and Juliet.These two arms are Romeo.Giving Juliet a ring.But this is

51、no ordinary ring.The ring is actually the valve seatin the engines cylinder.It forms a seal through which the valve movesand allows air into the chamber where it mixes with the fuel and explodes.With the valve moving in and out thousands of times a second, the valve seat must be tight. immovable in

52、fact. If it came loose, it could enter the engine and cause complete failure.Romeo dips each valve ring into a bath of liquid nitrogenfreezing it to minus 180 degrees and shrinking it by a tiny amount.Juliet holds the cylinder headwhile Romeo sets the valve ring in place.The first is a practice run-

53、to check the exact positionof the two components.Laser sensors make minute adjustments.Then Romeo sets the valve ring in place.In the following few seconds,the frozen ring warms and expands.Its now locked in place.The second of the engine works two robots has to fine-tune another critical component-

54、 the crankshaft.The power generated by the 599s engineis transferred through the crankshaft.to the transmission.to the drive shaft.to the wheels.and then to the open road.At the 599s top speedits crankshaft is spinning over a hundred times a second. if it fails the pistons attached to itwould shoot

55、through the engine block. destroying the engine.The crankshaft is the heart of the motor, therefore every tiny operation needs to as precise as possible and as perfect as possible.When its spinning at over 8,000 rpm, any imperfections will cause the crankshaft to become unbalanced. and create potent

56、ially destructive vibrations through the entire engine.The robot drills, shaves and grinds the crankshaft. making it perfectly balanced.Removing excess metal also improves the engines performance.The less the crankshaft weighs, the easier it is to make it spin.The faster it spins, the more power the

57、 engine generates.Eight hundred separate components.being made, fine-tunedand checked all through the engine works.From its birth from molten metalin the foundry. the 599s engineis about to be assembledinto its final form.While the engine works builds the power,the paintship adds the beautyFerrari is famous