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00:00:34
Germany's only motorbike Factory is
00:00:37
located in the Berlin suburb of Spandau
00:00:40
BMW has been mass producing motorcycles
00:00:42
here since 1969 the plant covers an area
00:00:49
of 30 soccer fields this is also where
00:00:52
BMWs two-wheel flagship is built the
00:00:56
s1000rr
00:00:59
nicknamed the double are the 199
00:01:02
horsepower Superbike consists of more
00:01:05
than 4,500 separate parts it is fully
00:01:10
assembled in just two hours
00:01:16
this is Champions League stuff the
00:01:20
double R's high performance engine in
00:01:22
particular is something very special its
00:01:25
components are machined to an accuracy
00:01:27
of one thousandth of a millimeter
00:01:30
[Music]
00:01:32
that's Formula One precision production
00:01:35
runs like clockwork every step is timed
00:01:38
to the second
00:01:40
working in close cooperation people and
00:01:43
robots manufacture up to 10,000
00:01:46
Superbikes a year as well as other
00:01:48
two-wheelers made in Germany
00:01:52
spiked towels and gigabytes a fattie
00:01:54
2,000 staff members here manufacture up
00:01:57
to 800 motor bikes and scooters every
00:01:59
day that's one every sixty five seconds
00:02:01
[Music]
00:02:10
motorbike production in Berlin centers
00:02:12
on the u-shaped assembly line which has
00:02:15
62 fully automated carriages constantly
00:02:18
travelling around it although it's
00:02:20
similar to a conveyor belt
00:02:22
this high-tech transport system is far
00:02:24
more intelligent and customized laid in
00:02:29
the workshop floor our induction loops
00:02:31
which guide the driverless carriages
00:02:33
along the way the system records every
00:02:36
work step and every part that is
00:02:38
installed worker can also adjust the
00:02:45
height of the driverless transport
00:02:47
carriage turn it and also call the
00:02:52
previous worker for example the complete
00:02:57
Superbike is built on a carriage like
00:02:59
this in two hours
00:03:03
the heart of the Double R is its engine
00:03:06
later all parts will be assembled around
00:03:09
it with its 199 horsepower the 999 cubic
00:03:14
centimeter engine has a top speed of 299
00:03:17
kilometers an hour
00:03:21
the four cylinder in-line engine is
00:03:23
built entirely at the berlin plant the
00:03:27
assembly team takes 120 minutes for the
00:03:29
task first of all a fitter checks the
00:03:32
con rod and bolts it to the piston
00:03:36
in all four Konrad's are installed in
00:03:39
the crank case everything has to fit
00:03:42
perfectly
00:03:47
the koi be heaped with this motorbike
00:03:50
the piston goes up and down 238 times a
00:03:54
second so obviously the crankcase has to be
00:03:57
manufactured with extreme precision the
00:04:00
circulatory tolerance is one tenth of
00:04:02
the width of a human hair you can well
00:04:05
imagine what that involves the final
00:04:07
piston is inserted in the cylinder the
00:04:10
quartet is now complete in order to
00:04:12
install the crankshaft the block has to
00:04:14
be tilted the mechanic can only
00:04:19
introduce the crankshaft into the
00:04:21
housing in one specific position the
00:04:25
small white rods help him to slip the
00:04:28
shaft exactly onto the four little ends
00:04:30
the Conrad covers are then firmly bolted
00:04:33
on
00:04:35
[Applause]
00:04:38
the mechanic then fits the six gear
00:04:40
transmission with the drive sprocket
00:04:43
there is very little room in the
00:04:45
crankcase everything is extremely
00:04:48
compact so even though we asked perform
00:04:50
this task thousands of times the fitter
00:04:53
needs total concentration
00:04:58
the engine block moves on to the next
00:05:01
assembly point the other half of the
00:05:04
housing has had a sealant applied and
00:05:06
closes off the transmission
00:05:09
an industrial robot tightens the 23
00:05:12
volts in a specific sequence and with a
00:05:14
specific torque later the housing will
00:05:18
be flooded with oil so it must be 100%
00:05:21
tight
00:05:24
[Music]
00:05:29
at the next assembly point the cylinder
00:05:32
head is added it will contain the valves
00:05:34
the camshafts and the spark plugs the
00:05:40
cylinder head is the most complex and
00:05:42
thus the most expensive part of the
00:05:44
engine block the automatic bolting
00:05:47
control tells the mechanic the sequence
00:05:48
in which the ten bolts have to be
00:05:50
tightened veer to the correct torque has
00:05:52
also been programmed in all the data are
00:05:55
recorded the timing chain is mounted and
00:05:59
the camshafts inserted and pressed in
00:06:01
place up to 140 of these engines are
00:06:05
manufactured each day every work step is
00:06:11
timed into the second finally the
00:06:16
cylinder head is closed with a sealed
00:06:18
cover
00:06:25
to save time many tasks in the motorbike
00:06:28
factory are performed by automatic
00:06:30
machines
00:06:34
this machine coats the edge of the
00:06:36
Dynamo housing with a synthetic sealant
00:06:42
the operation could never be performed
00:06:44
as quickly cleanly and precisely by
00:06:48
human hand
00:06:57
at the next assembly point the
00:07:00
superlight magnesium cover is bolted to
00:07:02
the block every operation concerning the
00:07:05
engine is recorded in the central data
00:07:07
bank
00:07:11
now the clutch is fitted one of the last
00:07:14
work steps in assembling the
00:07:16
four-cylinder engine
00:07:21
when the engine has been fully assembled
00:07:23
and sealed it is put on a test rig every
00:07:28
drive unit must leave the plant having
00:07:30
passed this cold test the technician
00:07:34
attaches eight lines to the engine they
00:07:37
will measure the air volume in the
00:07:38
cylinders
00:07:43
only when the cabin door has been closed
00:07:45
can the test begin
00:07:54
the engine is powered up electrically to
00:07:56
2,000 revs a minute in its interior all
00:08:00
the components are now moving as they
00:08:02
would in the combustion process the
00:08:05
yellow hoses measure the air being
00:08:07
sucked into the engine and then expelled
00:08:08
in this way the intake of fuel and the
00:08:12
expulsion of exhaust fumes are simulated
00:08:15
this engine is sealed and functions
00:08:18
flawlessly it has passed the cold test
00:08:23
after two hours assembly is completed
00:08:26
every opening is closed off with a
00:08:28
safety cap to rule out any contamination
00:08:30
of the sensitive engine two bolts are
00:08:34
attached to the sides to enable the 58
00:08:36
kilogram block to be lifted by a crane
00:08:49
the four-cylinder online engine will now
00:08:52
be suspended from a hook and taken for a
00:08:54
ride
00:09:00
the lift provides access to a huge
00:09:02
transport system under the roof of the
00:09:04
workshop every engine built in Berlin
00:09:08
first ends up in the loft installed up
00:09:12
here is a complex overhead rail network
00:09:15
the super bike engine travels fully
00:09:18
automatically through the labyrinth to
00:09:20
its weighting position hanging in this
00:09:22
Depot are more than 600 engines for
00:09:24
different types of motorcycles they are
00:09:27
waiting to be installed on one of the
00:09:29
plants assembly lines
00:09:33
this engine block is on the way to its
00:09:35
destination the double our assembly belt
00:09:38
the chain hoist takes it back to the
00:09:41
production shop this is the birth of a
00:09:45
super bike 34 assembly stations and two
00:09:48
hours later the motorbike will be ready
00:09:52
at station number one the engine is
00:09:54
connected to the exhaust system
00:09:59
the automatic transport system
00:10:01
dispatches a carriage the engine block
00:10:03
is placed on it and secured the base is
00:10:06
ready next to be fitted is the frame
00:10:10
made of aluminum it weighs only 11
00:10:13
kilograms yet this lightweight is the
00:10:16
motorbike supporting structure to cope
00:10:20
with the huge force is occurring at
00:10:21
nearly 300 kilometres an hour it has to
00:10:24
be manufactured with extreme precision
00:10:26
in the plant zone welding shop the
00:10:28
forecast aluminium parts that make up
00:10:30
the frame are positioned on the welding
00:10:32
table the blank is turned and presented
00:10:36
to the two welding robots the robots
00:10:42
travel along the weld edges with
00:10:44
millimeter precision at a temperature of
00:10:47
2,000 degrees the electric arc melts the
00:10:50
welding wire and fills the gap between
00:10:52
the components each seam is welded twice
00:10:56
here of course we see a beautiful seam
00:10:59
located beneath it is the main world the
00:11:02
root seam which is actually crucial for
00:11:04
the stability of the frame the robots
00:11:07
can weld 40 Superbike frames a day yet
00:11:10
despite their precision the machines are
00:11:12
not infallible
00:11:15
the main job is done by robots but since
00:11:18
a robot always does the same thing the
00:11:20
quality has to be checked by humans
00:11:22
final inspection is always carried out
00:11:23
by a person the robots are fast and
00:11:26
extremely precise but because of their
00:11:28
structure and size they cannot reach
00:11:30
every corner of the construction these
00:11:33
areas are then finished by experienced
00:11:35
manual welders
00:11:37
[Music]
00:11:39
after being powder-coated the frame is
00:11:42
given a serial number and a tight plate
00:11:44
the black aluminum skeleton then moves
00:11:47
on further to pre assembly
00:11:53
here various lines and the wiring
00:11:56
harness are installed the workers can't
00:11:58
afford to lose any time the assembly
00:12:01
line constantly needs replenishing the
00:12:03
transport carriage with the double our
00:12:05
engine is already waiting for the
00:12:08
marriage
00:12:11
this is where the frame and the engine
00:12:13
are married as we say the aluminum
00:12:16
bridge frame is slowly lowered on to the
00:12:18
engine block the first fixing bolts are
00:12:20
tightened married frame and engine enter
00:12:23
the assembly line the carriage is
00:12:26
continuously in motion many work steps
00:12:29
are performed with the fitters walking
00:12:31
alongside
00:12:38
all the bolts that are tightened at this
00:12:40
station have to meet high safety
00:12:42
standards
00:12:46
here we have a bolt connection that is
00:12:49
clearly safety relevant the bolting is
00:12:51
registered electronically so we can
00:12:53
always refer back to the data bank to
00:12:55
see if it was IO or n io io and ni o
00:12:59
stand for in order and not in order
00:13:01
io applies to a bolting whose measure
00:13:03
torque meets the stipulated requirements
00:13:06
if a bolt connection is registered as ni
00:13:09
o the bike will get special treatment
00:13:12
located at the center of the u-shaped
00:13:14
production line is the pre assembly
00:13:16
section it is here that certain units
00:13:19
like the front fork are assembled and
00:13:21
made available to workers on the
00:13:23
conveyor belt for installation
00:13:28
the fitter inserts the front wheel
00:13:29
suspension in the aluminum frame here -
00:13:33
every bolting is registered
00:13:37
with a glance at the monitor the fitter
00:13:39
checks that all the nuts have been
00:13:41
tightened correctly
00:13:48
in addition to the double are seven
00:13:51
other motorbike models are manufactured
00:13:53
on this assembly line during one shift
00:13:57
the workers assemble various models
00:13:59
completing up to 220 bikes each day if
00:14:06
we laid out all the assembly points in a
00:14:08
straight line it would be about 130
00:14:10
metres long that's 30 for basic assembly
00:14:13
steps
00:14:20
motorbikes have been built in spandau
00:14:23
since 1969 but motorbike parts from the
00:14:27
Berlin aircraft engine factory were
00:14:29
already being delivered to Munich in the
00:14:30
1920s back then motorbikes were highly
00:14:34
popular and a cheaper alternative to a
00:14:37
motor car the sector boomed its
00:14:40
technical innovations made BMW one of
00:14:42
Germany's leading motorcycle
00:14:44
manufacturers today the concern is the
00:14:48
country's only major producer of
00:14:50
motorbikes and faces stiff competition
00:14:52
from Japan and the United States at the
00:15:01
plant in Berlin the next important
00:15:02
components are being assembled the rear
00:15:05
swingarm and the suspension strut ensure
00:15:08
stability on the road at assembly
00:15:11
station 7 the aluminum swing arm is
00:15:13
mounted just like the frame it was
00:15:16
welded together beforehand in the plant
00:15:18
the height can be adjusted during
00:15:20
driving operation with little effort
00:15:23
with a suspension travel of 120
00:15:26
millimeters the central strut is
00:15:28
electronically adjustable and confussed
00:15:31
be adapted to any road surface
00:15:38
the hose for the air box is secured with
00:15:41
a kind of surgical clamp the tools
00:15:43
required for each operation are
00:15:45
specifically stipulated the fitter
00:15:48
amounts the air box and the engine
00:15:50
it's the bikes long filtering and
00:15:53
regulating the intake air for combustion
00:15:55
in the cylinders for the next work step
00:16:04
the lifting column moves upwards the
00:16:08
aluminum swing arm is still naked the
00:16:11
rear wheel is still being prepared for
00:16:13
installation in the swing arm
00:16:17
wedge-shaped torque dampers made of hard
00:16:20
rubber are inserted in the hub they
00:16:23
dampen the force created when driving
00:16:25
off
00:16:29
[Music]
00:16:30
the chain sprocket with its 44 teeth
00:16:33
seals the hub and is pressed in place
00:16:36
[Music]
00:16:38
the hoist saves the workers back and
00:16:41
guides the 12 kilogram rear wheel into
00:16:44
the swingarm in a perfect fit at 200
00:16:48
kilometres an hour the wheel will rotate
00:16:50
28 times a second the drive chain
00:16:54
consists of high-grade steel that is
00:16:57
super hard it at the same time elastic
00:16:59
it is riveted hydraulically a mass
00:17:04
producer like BMW also improves certain
00:17:06
components and electronic systems in
00:17:08
ongoing series production so the WR is
00:17:11
constantly undergoing further
00:17:13
development to achieve this above all
00:17:15
the firm's engineers need data and
00:17:17
experience obtained from practice that
00:17:20
is why BMW cooperates with selected race
00:17:23
teams like NRT 48 at the circuit in
00:17:27
Ash's Latham and 8 hour races in
00:17:29
progress NRT 48 is competing in the stock sport
00:17:32
world championship with two double ARS
00:17:36
the team has already practiced the
00:17:38
pitstop hundreds of times
00:17:40
the wheels are changed the tank filled
00:17:43
and the bike roars off again in the
00:17:47
stock sport class there is a ruling that
00:17:49
is highly important for cooperation with
00:17:51
BMW we compete with bikes that are
00:17:58
virtually production models we are not
00:18:01
allowed to modify the important
00:18:02
components the frame of the arm the fork
00:18:05
the engine and the intake silencer so
00:18:08
our bikes have the original harness and
00:18:10
original lights in other words 90% of
00:18:15
the parts are original components from
00:18:17
that perspective the customer rides the
00:18:19
same motor bike we race with during the
00:18:22
race the on-board computer records an
00:18:24
enormous volume of data which in the pit
00:18:26
is made visible on a laptop
00:18:29
the cryptic diagrams and graphs provide
00:18:32
information on the bikes weak spots
00:18:40
so it's I'm looking at how the front
00:18:43
wheel loses speed when it's in the air
00:18:45
basically it's just to see whether the
00:18:47
break has operating clearance during the
00:18:51
season teams like NRT 48 drive hundreds
00:18:54
of thousands of kilometers always
00:18:56
pushing their super bikes to the limit
00:19:00
their vast experience also influences
00:19:03
production at the Berlin motorcycle
00:19:04
plant where software updates or new
00:19:07
electronic and engine settings will be
00:19:09
implemented developments from the
00:19:18
cooperation flow back into the factory
00:19:21
in this way we ensure that our
00:19:23
developments in the motorsport sector
00:19:25
are an open source every customer
00:19:28
private or professional can benefit from
00:19:30
our experience the s1000 double r has
00:19:35
been on the market since 2009 but it
00:19:39
took tremendous efforts before the model
00:19:41
could enter series production the
00:19:44
development process lasted several years
00:19:50
it all began in 2005 with a few pencil
00:19:53
sketches
00:19:54
what could a new super bike look like
00:19:57
performance and design have to harmonize
00:20:00
sporty handling characteristics have to
00:20:02
function not only on the circuit but
00:20:04
also in everyday traffic on ordinary
00:20:07
roads from the finished draft a
00:20:11
one-to-one clay model is produced which
00:20:14
serves as a template for all later scans
00:20:16
and installations
00:20:22
[Music]
00:20:23
then what is known as a fees model is
00:20:26
milled weighing several tons this metal
00:20:30
pattern will be the template for most of
00:20:32
the components in subsequent series
00:20:34
production at the same time the engine
00:20:38
is mercilessly pushed to its limits on a
00:20:40
dynamometer vibrations gear change
00:20:44
behavior and temperatures are
00:20:46
intensified to limits far beyond what a
00:20:48
rider could cope with
00:20:51
these tests provide important data for
00:20:54
developers the double law reaches
00:20:57
maximum performance of 199 horsepower at
00:21:00
an engine speed of fourteen thousand
00:21:02
three hundred rpm
00:21:06
the prototypes also spend hundreds of
00:21:08
hours in a wind tunnel at wind speeds of
00:21:11
up to 300 kilometers an hour
00:21:13
along with aerodynamic properties the
00:21:15
temperature distribution on the machine
00:21:17
is also optimized engine transmission
00:21:20
and exhaust reach a temperature over a
00:21:22
hundred degrees these parts can only be
00:21:25
cooled by the headwind
00:21:29
parafin trails make the flow lines
00:21:31
visible the engineers test various
00:21:34
fairings until they find the optimum
00:21:36
balance between aerodynamics and cooling
00:21:51
[Music]
00:21:52
on the test circuit experience test
00:21:56
riders then analyze the handling
00:21:57
characteristics of the new double are
00:22:01
[Music]
00:22:05
it is here that electronic assistance
00:22:07
systems like ABS and traction control
00:22:09
are brought to series production
00:22:11
readiness
00:22:16
Aoife Sylvia epoch so let's go to a
00:22:18
lobster I'm trying to tune the traction
00:22:20
control so that a rider who is not so
00:22:22
experienced will be able to handle the
00:22:24
enormous engine performance so that when
00:22:27
he opens the throttle coming out of a
00:22:29
turn and the rear starts to drift
00:22:31
slightly he doesn't take a tumble
00:22:38
the prototype is then subjected to long
00:22:41
distance tests on the circuit when they
00:22:45
have determined the basic configuration
00:22:46
of the double are the developers test
00:22:48
camouflaged prototypes on public roads
00:22:51
worldwide in their design and
00:22:54
performance these bikes are the same as
00:22:56
the future production models the special
00:22:59
paintwork makes it hard to distinguish
00:23:00
the shape of the bike on no account once
00:23:04
the press catch wind of the new model
00:23:05
and publish photographs prior to its
00:23:07
market launch secrecy is still paramount
00:23:13
over 60 test drivers put the bikes
00:23:15
through their paces on all five
00:23:16
continents and in all the world's
00:23:19
climate zones since the super bike is to
00:23:21
be sold worldwide it must function
00:23:23
perfectly in all weathers and in all
00:23:26
Road conditions
00:23:31
in the end the prototypes will have been
00:23:33
driven more than a million test
00:23:34
kilometers four years after the first
00:23:38
pencil stroke the Double R is officially
00:23:40
launched up to 1800 new motorbikes are
00:23:44
registered each year in Germany alone
00:23:45
basic cost eighteen thousand euros
00:23:53
the oldest tract at the motorcycle plant
00:23:56
houses mechanical production a
00:23:58
department of great importance this is
00:24:01
where the most complex engine components
00:24:03
are customized for assembly
00:24:08
regardless of ethical philosophy each
00:24:10
day around 4300 parts leave here for
00:24:13
engine assembly this is where we
00:24:15
manufacture the main components cylinder
00:24:17
head crankcase con rods and crankshaft
00:24:21
this place is the highest demands on
00:24:24
staff and on the high-tech machines
00:24:27
precision tolerances are within the
00:24:29
micrometer range one thousandth of a
00:24:33
millimeter a human hair is about 70
00:24:39
micrometers in size the human eye can
00:24:42
still distinguish things between 30 and
00:24:44
40 micrometers but we have to work to
00:24:46
precisely 3 micrometers that's the high
00:24:49
performance precision you associate with
00:24:51
Formula 1 one of the precision parts is
00:24:54
the con rod each engine has four con
00:24:57
rods which convert the up-and-down
00:24:59
motion of the piston into the rotational
00:25:01
movement of the crankshaft so these cast
00:25:04
parts have to withstand enormous forces
00:25:07
the blank is subjected to a series of
00:25:09
work steps grinding drilling milling and
00:25:12
reaming up to 2,000 con rods are
00:25:15
manufactured here every day
00:25:18
in the cracking machine the eye of the
00:25:20
con rod is laser to create a
00:25:21
predetermined breaking point a wedge
00:25:24
then breaks into two halves through this
00:25:27
special procedure
00:25:28
perfect form closure is obtained
00:25:34
we do this because a broken surface fits
00:25:37
together superb ly one-to-one and that's
00:25:40
what you need in top-class motor-racing
00:25:44
every con rod passes through this fully
00:25:46
automated measuring cell the robot
00:25:49
weighs and measures the component with
00:25:51
total precision just to remind you later
00:25:54
the engine will have four con rods in
00:25:58
shape and weight they must be almost
00:26:00
identical otherwise powerful vibrations
00:26:03
and imbalance could become manifest when
00:26:05
the bike is on the road so here the con
00:26:08
rods are categorized and sorted
00:26:10
according to weight class
00:26:18
the manufacturer of high-performance
00:26:20
components has a long tradition at BMW
00:26:23
the first motorcycle is produced in 1923
00:26:26
from then on motorbikes got faster and
00:26:29
faster in 1929 on a BMW WR 750 factory
00:26:36
driver ants jakob henna set a world
00:26:39
speed record of 216 point 7 5 kilometers
00:26:42
per hour
00:26:43
[Music]
00:26:49
in the years that followed henna said
00:26:51
another six world records for the firm
00:26:53
the last one in 1937 when he reached two
00:26:56
hundred and seventy nine point five
00:26:58
kilometers on a BMW 500 compress aura
00:27:01
but the young motorcycle manufacturing
00:27:04
company also became involved in team
00:27:06
sport and in doing so underlined the
00:27:10
suitability of its products for everyday
00:27:12
use
00:27:13
[Music]
00:27:26
the mechanical production department
00:27:28
also manufactures the Superbikes
00:27:30
crankshaft again with micrometer
00:27:33
accuracy the cast blank is first turned
00:27:36
to shape on a lathe
00:27:42
when the cheeks have been turned the
00:27:44
shaft enters a vortex milling machine
00:27:47
the bearing surfaces have to be
00:27:49
perfectly round in order to absorb the
00:27:51
enormous motive forces this is where the
00:27:56
four cracked con rods will grip later
00:27:58
and accelerate the shaft to a speed of
00:28:00
fourteen thousand three hundred revs per
00:28:03
minutes when the gear wheels have all
00:28:09
been milled and all the holes for the
00:28:11
oil circulation system had been drilled
00:28:13
in the crankshaft it is d bird and
00:28:15
cleaned with high-pressure jets
00:28:20
[Music]
00:28:22
a fully automatic washing robot then
00:28:26
takes up the contaminated crankshaft
00:28:28
inside the washing chamber the shaft is
00:28:30
first given a hot full bath
00:28:33
[Music]
00:28:43
water at a pressure of 600 bar then
00:28:45
Devers every millimeter of the component
00:28:50
after a minute the crankshaft is squeaky
00:28:54
clean
00:28:55
[Music]
00:29:05
at a temperature of over 600 degrees
00:29:08
nitrogen is introduced into the surface
00:29:10
of the shaft in a hardening oven the
00:29:14
crankshaft is now extremely solid but at
00:29:17
the same time flexible when it is cooled
00:29:20
the shaft is ground the automatic
00:29:23
grinder too works to an accuracy of one
00:29:26
thousandth of a millimeter
00:29:30
at Germany's only motorcycle factory 110
00:29:34
crankshafts are manufactured per shift
00:29:45
[Music]
00:29:47
back to the conveyor belts after 45
00:29:50
minutes the structure already looks like
00:29:52
a motorbike it is now filled with
00:29:54
coolant this task too is performed
00:29:57
automatically the unit performs a vacuum
00:30:03
test to ensure that the cooling circuit
00:30:05
is leak proof then the vehicle is filled
00:30:07
with the coolant while the coolant is
00:30:10
flowing the speedometer with its
00:30:12
integrated onboard computer is installed
00:30:14
in the handlebars together with the
00:30:19
engine control unit they are the
00:30:21
Superbikes brain and monitor its
00:30:23
functions
00:30:27
the machine is now past the midpoint of
00:30:30
the assembly line hundreds of individual
00:30:32
parts have been installed by a dozen
00:30:34
fitters quality control now ensures that
00:30:38
no part has been forgotten or installed
00:30:40
incorrectly inspection is still carried
00:30:43
out by experienced staff but now they
00:30:46
are supported by high-tech robots these
00:30:51
two robot arms subject the bike to close
00:30:54
scrutiny here we have a so-called MRK
00:31:00
quality gate that's a human robot
00:31:02
collaboration the robot also takes on
00:31:05
individual control activities like
00:31:07
checking that the correct rear wheel the
00:31:09
correct kickstand and so on have been
00:31:11
installed the robot compares the
00:31:13
structure with photos from the huge data
00:31:15
bank the sports bike is half completed
00:31:20
induction coils laid in the workshop
00:31:23
floor guide the driverless transport
00:31:25
carriage at walking speed the double are
00:31:28
heads for the second half of the
00:31:29
assembly line filters on the last sixty
00:31:34
five meters of the conveyor belt are
00:31:35
responsible for the fuel tank the
00:31:37
fairing and the electronic system the
00:31:41
air intake is fitted to the front
00:31:42
section it's through this duct that the
00:31:45
gas engine breathes it's now that the
00:31:48
double R is also given its distinctive
00:31:50
face the synthetic cockpit with it's
00:31:53
asymmetrical light system looks a bit
00:31:54
scary
00:31:57
the fitters work in high speed but also
00:31:59
with great concentration nobody can
00:32:03
afford to make a mistake especially when
00:32:05
as in this case the ABS system is
00:32:08
attached the engine and the airbox are
00:32:13
the heart and lungs of the bike now it's
00:32:16
the brains turn via a data transfer unit
00:32:19
the on-board computer receives its
00:32:22
software that takes a while so the unit
00:32:25
remains connected to the machine through
00:32:27
the end of the assembly process
00:32:29
[Music]
00:32:33
next the exhaust system is bolted on the
00:32:36
men have only a specific time window for
00:32:38
each work step the motorcycle Factory in
00:32:42
Berlin runs like a well-oiled machine
00:32:44
and machines need fuel
00:32:50
the double R has a seventeen point five
00:32:53
liter gas tank since it is made entirely
00:32:56
of aluminum it weighs only two kilograms
00:32:59
the welding robots have produced the
00:33:02
tank from three separate parts the seams
00:33:05
must not be bulky but they must be
00:33:07
absolutely leak proof like every
00:33:12
component coming from the welding robots
00:33:14
these tanks too are finished by human
00:33:16
hand
00:33:19
this lady handles 50 fuel tanks a day
00:33:22
her rotatable welding table enables her
00:33:25
to reach every spot with ease basically
00:33:32
I do what the robber doesn't manage to
00:33:34
do like welding the small tubes and all
00:33:37
the spots the Robert can't get to her
00:33:40
biggest challenge is the aluminum the
00:33:42
tank is made of its wafer thin walls are
00:33:45
only 1.5 millimeters thick
00:33:47
so melt holes have to be avoided at all
00:33:50
costs they would immediately turn the
00:33:53
tank into scrap
00:33:55
after 10 minutes this particular fuel
00:33:58
tank is ready
00:34:04
the manual welders need to be highly
00:34:06
qualified and have a lot of feeling this
00:34:08
is Champions League stuff each tank then
00:34:11
has to be checked for leaks the fuel
00:34:13
tanks are filled with air in a special
00:34:15
immersion basin containing distilled
00:34:17
water since excess pressure is created
00:34:20
inside each tank any hole in the
00:34:22
aluminum shell will result in air
00:34:24
escaping and creating tiny bubbles the
00:34:28
3d ultrasonic survey head searches for
00:34:31
any such bubbles and approves or rejects
00:34:34
the tank accordingly these two
00:34:37
candidates are fine and can be released
00:34:40
for assembly the clean and degrease
00:34:46
tanks are placed on a frame from here on
00:34:50
everything again takes place fully
00:34:53
automatically the containers and to the
00:34:55
paint booth to be given their first
00:34:57
coating
00:35:06
after two minutes the eight tanks are
00:35:08
blue and end up on this colleagues table
00:35:11
to be prepared for the next coding but
00:35:17
now certain areas have to be protected
00:35:19
from the white paint this area has to be
00:35:26
taped and this area painted white so she
00:35:31
will cover the places in the tank that
00:35:33
have to remain blue the red template
00:35:37
provides her with fixed points for
00:35:38
sticking the protective film but first
00:35:41
she sprays them with water so that their
00:35:43
position can be corrected slightly after
00:35:45
our application I wet the tape a little
00:35:53
then put it in place on the marking the
00:35:57
tape the protective masking is slowly
00:35:59
stuck on the tank it mustn't bubble or
00:36:02
crease because later the red stripe will
00:36:04
remain on the fuel tank as a decorative
00:36:06
element
00:36:16
during spraying the red film protects
00:36:19
the upper side and the tank opening from
00:36:21
the white paint it takes only a few
00:36:23
minutes to mask the tank the masking is
00:36:28
now finished and the tank is prepared
00:36:30
for the second color along with seven
00:36:33
others the tank now heads back into the
00:36:35
spraying booth where a robot sprays it
00:36:38
white in less than 120 seconds when the
00:36:41
paint is dried the tank is given a layer
00:36:43
of clear varnish on the assembly belt
00:36:48
the painted lightweight tank is attached
00:36:50
to the bike storing fuel is not the
00:36:52
tanks only role because of its special
00:36:55
shape it also gives the rider stability
00:36:58
on difficult bends this can be crucial
00:37:01
especially on a racetrack
00:37:09
in OSHA's Laban the qualifying race for
00:37:12
the 8-hour event is underway the private
00:37:16
team nrt 48 is refueling here the fuel
00:37:19
tank is not standard we can modify the
00:37:25
tank we're allowed to have up to 24
00:37:27
litres so we have altered the basic
00:37:30
original 17 litre tank to take 24 litres
00:37:33
the team consists of one male and one
00:37:36
female rider who alternate every 40 or
00:37:38
60 minutes but there seems to be
00:37:41
something wrong with the bike at first
00:37:45
there was nothing then just a little bit
00:37:47
the input from the riders is
00:37:49
tremendously important the brake isn't
00:37:52
working properly it needs to be replaced
00:37:54
the team dismantled the brake calipers
00:37:57
on the front wheel and replaced them
00:37:59
with a new set
00:38:06
shortly before the long-distance race
00:38:09
begins other parts on the Double R need
00:38:11
to be replaced this involves removing
00:38:14
the underbody protection along with the
00:38:18
front fairing and the tank container the
00:38:22
men need access to the radiator
00:38:29
I will be vixen it's not mine we're
00:38:31
exchanging the radiator on this bike
00:38:33
once again at the moment it has a used
00:38:36
radiator on it
00:38:37
that has already been through one
00:38:38
24-hour race it's a routine operation
00:38:41
for us we always have new material or
00:38:45
material that's as good as new
00:38:47
simply to rule out any source of error
00:38:50
the coolant circuit of a racing bike is
00:38:53
filled with water so in the event of
00:38:55
damage no oily substances can
00:38:57
contaminate the surface of the track and
00:38:59
cause other riders to skid the old
00:39:03
radiator is replaced with a new one
00:39:06
[Applause]
00:39:09
finally the nrt 48 the two riders and
00:39:12
the double are hit the track for eight
00:39:15
hours they will lap the three point
00:39:17
seven kilometer long circuit in the
00:39:19
battle for vital points towards the
00:39:21
Superstock World Championship despite
00:39:25
all the effort victory has eluded the
00:39:27
team still the experience and the data
00:39:30
gained over the weekend will benefit
00:39:32
many riders on public roads Germany's
00:39:38
only motorcycle Factory in Berlin -
00:39:41
there on the finishing straight now the
00:39:44
super bikes 13 fairing parts are being
00:39:46
assembled they give the Machine its
00:39:49
unmistakable appearance some parts are
00:39:52
not quite finished
00:39:55
this side fairing comes with a special
00:39:57
sticker it tells every road user here
00:40:01
comes a double are
00:40:10
if the tape is okay no bubbles or
00:40:13
creases I usually rub it down ever so lightly
00:40:16
when it's finished it is once again
00:40:18
given a full coat of clear varnish in
00:40:21
the paint booth the side element enters
00:40:24
the fully automated spring booth for a
00:40:26
third time first blue then white and now
00:40:30
clear varnish
00:40:32
[Music]
00:40:34
then the part is dried this takes about
00:40:37
an hour at the BMW plant in Spandau 6000
00:40:42
fairing components for all types of 2
00:40:44
wheelers are varnished everyday
00:40:49
every completed part then has a chip
00:40:52
stuck to it together with the barcode on
00:40:55
the transport tray the part can be
00:40:57
clearly identified irrespective of its
00:41:00
location
00:41:03
before the two side fairing set off on a
00:41:05
long trip they are scanned and
00:41:07
registered within the system
00:41:13
the tablet enters the plants fully
00:41:15
automated storage system the transport
00:41:18
belt is several hundred meters long and
00:41:20
runs over several floors like a road
00:41:23
network it supplies specific workplaces
00:41:26
with the necessary parts often the
00:41:29
initial destination is the huge high
00:41:31
base door it is 37 meters high on 18,000
00:41:36
storage places 90,000 components are
00:41:38
waiting to be sent for further finishing
00:41:42
down below the almost completed
00:41:44
superbike now has the finishing line in
00:41:46
sight it is already leaving the u-shaped
00:41:49
assembly line the machine is now
00:41:51
roadworthy but it still lacks important
00:41:53
fluids here that changes at the media
00:41:57
loading station the brand new motorbike
00:41:59
is primed brake fluid is forced into the
00:42:02
rear and front brakes the oil
00:42:04
circulation system is filled and some
00:42:06
fuel added to the tank after about four
00:42:11
minutes the machine has been supplied
00:42:13
with the basic fluids
00:42:20
now the super bike heads for the finish
00:42:22
belt where it is given its final
00:42:24
appearance the side parts the windshield
00:42:28
two mirrors and the mudguard are
00:42:30
installed
00:42:32
[Music]
00:42:34
the Double R is now complete
00:42:43
the driverless carriage takes the motor
00:42:45
bike to the roller testbench over the
00:42:49
last two hours a super bike of
00:42:50
outstanding quality has been built from
00:42:52
thousands of individual parts it has an
00:42:57
engine output of 199 horsepower and an
00:43:00
engine capacity of almost 1 liter the
00:43:03
six-speed transmission gives the Double
00:43:05
R a top speed of 299 kilometers an hour
00:43:08
maximum torque is 113 Newton meters
00:43:12
depending on how the bike is handled
00:43:14
consumption is between 6 and 8 liters of
00:43:16
gas per 100 kilometers with a tank full
00:43:19
of fuel the double are weighs around 200
00:43:21
kilograms in its short life the bike has
00:43:25
already experienced one marriage now it
00:43:28
even faces separation separation from
00:43:30
the transport carriage takes seconds
00:43:32
from now on the double r will proceed on
00:43:35
its own two wheels the driverless
00:43:37
carriage goes straight back to the
00:43:39
assembly line where new engine block is
00:43:41
already waiting
00:43:49
on the roller test bench the bike is
00:43:52
pushed to the limit
00:44:07
the test rider accelerates to 140
00:44:10
kilometres an hour and goes through all
00:44:12
six gears
00:44:14
all the bikes functions are checked in
00:44:16
line with a strict test report brakes
00:44:19
clutch indicators and lights all have to
00:44:22
work perfectly otherwise the machine
00:44:24
will not leave the plant
00:44:27
in their own words the experienced
00:44:29
testers can tell through the seat of
00:44:31
their pants
00:44:32
whether a bike is running smoothly the
00:44:37
works has eight of these test cabins
00:44:39
where up to six hundred two wheelers of
00:44:41
all kinds are tested every day a driver
00:44:44
my tests as many as forty vehicles on
00:44:46
one shift the data connection is cut the
00:44:53
motorcycle has been technically approved
00:44:57
the double R is a complex
00:44:59
high-performance vehicle with a powerful
00:45:01
internal combustion engine in the
00:45:04
foreseeable future other propulsion
00:45:05
systems like electric motors will play a
00:45:07
major role
00:45:13
that is why BMW is already looking to
00:45:16
the future with a concept vehicle and
00:45:18
showing what a motorbike could one day
00:45:20
look like emission-free drive units on
00:45:23
an electric or fuel cell basis will be
00:45:26
standard they might not have the same
00:45:29
throaty roar as a combustion engine but
00:45:32
a sound system could stimulate the sound
00:45:34
of a racing machine where safety is
00:45:37
concerned there will be many new
00:45:39
developments this concept bike is
00:45:41
equipped with the gyroscopic sensor
00:45:43
designed to make a tumble impossible but
00:45:47
the technical highlight will be the
00:45:48
networking of driver motorcycle and
00:45:50
environment I can imagine that
00:45:56
motorcycling in the future will have a
00:45:57
lot to do with connectivity the vision
00:46:00
is that all vehicles and road traffic
00:46:02
will permanently exchange information on
00:46:04
their position and speed collisions
00:46:06
would then be foreseeable and thus
00:46:08
preventable
00:46:13
if a car detects a rock on the road the
00:46:16
motorcyclist will see that at once on
00:46:18
his display so we're talking about
00:46:20
communications between a motorcycle and
00:46:22
car with a car being braked
00:46:23
automatically if the driver hasn't
00:46:25
spotted the motorcyclist these things
00:46:27
will undoubtedly come in the future
00:46:29
assistant systems like these data
00:46:32
glasses reflect all important
00:46:33
information into the driver's field of
00:46:35
vision so there's no need for a glance
00:46:38
the speedometer or the rearview mirror
00:46:41
another dream is that in future there
00:46:43
will be no need for helmets either
00:46:45
because special motorcycle clothing will
00:46:47
contain airbags and next stabilizers but
00:46:51
with so many visions no doubt many
00:46:53
bikers will already be wondering just
00:46:54
where the kick is supposed to come from
00:46:57
[Music]
00:46:59
well maybe it's still possible to find a
00:47:02
double are lying around in some garage
00:47:04
or other this one is still hot from
00:47:07
being tested on the roller test rig so
00:47:10
it's put in a giant fridge the bike has
00:47:15
to cool otherwise the packing film could
00:47:17
melt on the hot engine or the exhaust
00:47:19
and stick it takes the machine just
00:47:22
thirty seconds to pass through the
00:47:24
cooling tunnel
00:47:26
[Music]
00:47:34
most of the bikes head off to the
00:47:37
customer and recyclable packing the
00:47:39
metal frame is reinforced with wooden
00:47:41
lathes the order and delivery forms are
00:47:44
stapled on and after a final control
00:47:47
look the machine leaves
00:47:54
in 95 seconds the rapping machine
00:47:56
envelops the transport frame in a tear
00:47:59
resistant film a labeling machine then
00:48:01
gives the final goodbye kiss three hours
00:48:06
after the first work step on the
00:48:07
assembly belt the BMW s1000 double R is
00:48:11
loaded onto a truck it is taken by road
00:48:16
to the nearest Goods station container
00:48:18
ship or airport depending on where in
00:48:21
the world its new owners waiting for it
00:48:31
in the meantime work continues on the
00:48:33
130 meter long assembly line
00:48:36
day after day two thousand people and
00:48:39
countless robots produced two wheelers
00:48:41
made in Germany eight hundred
00:48:44
motorcycles and scooters are
00:48:46
manufactured here every day at Germany's
00:48:49
only motorcycle plant
00:48:56
[Music]
00:49:08
[Music]

Description:

The BMW plant in Berlin has been one of the most important international locations in motorcycle construction for decades. Two-wheelers manufactured here are traded worldwide. The product range of the Bavarian automotive group includes a variety of models, including agile cross machines, sporty cruisers or environmentally friendly electric motorcycles. Special wishes? No problem. Bikes that go beyond the usual standard version can also be made to measure in Berlin. Among other things our BMW documentary shows the creation of a BMW S 1000 RR Superbike. 📺 Watch more documentaries https://www.youtube.com/playlist?list=PL-5sURDcN_Zl8hBqkvZ6uXFpP3t55HU9s 🔔 Subscribe our full documentary channel https://www.youtube.com/channel/UCBAeFXaLV1ZqKqc-Uf3pKaA?sub_confirmation=1

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question iconHow can I download an audio track (music) to MP3 "BMW Motorcycles - Worlds Biggest Motorbike Factory | Full Documentary"?arrow icon

    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.

question iconHow can I save a frame from a video "BMW Motorcycles - Worlds Biggest Motorbike Factory | Full Documentary"?arrow icon

    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.

question iconHow do I play and download streaming video?arrow icon

    For this purpose you need VLC-player, which can be downloaded for free from the official website https://www.videolan.org/vlc/.

    How to play streaming video through VLC player:

    • in video formats, hover your mouse over "Streaming Video**";
    • right-click on "Copy link";
    • open VLC-player;
    • select Media - Open Network Stream - Network in the menu;
    • paste the copied link into the input field;
    • click "Play".

    To download streaming video via VLC player, you need to convert it:

    • copy the video address (URL);
    • select "Open Network Stream" in the "Media" item of VLC player and paste the link to the video into the input field;
    • click on the arrow on the "Play" button and select "Convert" in the list;
    • select "Video - H.264 + MP3 (MP4)" in the "Profile" line;
    • click the "Browse" button to select a folder to save the converted video and click the "Start" button;
    • conversion speed depends on the resolution and duration of the video.

    Warning: this download method no longer works with most YouTube videos.

question iconWhat's the price of all this stuff?arrow icon

    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.