1
00:00:19,719 --> 00:00:21,822
制造的原理

2
00:00:22,476 --> 00:00:24,803
在本集“制造的原理”中

3
00:00:26,025 --> 00:00:27,427
高尔夫球金属球杆

4
00:00:32,432 --> 00:00:33,533
松饼

5
00:00:37,493 --> 00:00:39,329
客制化电线与电缆

6
00:00:43,214 --> 00:00:44,544
以及火车车轮

7
00:00:46,706 --> 00:00:52,051
================
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=====================
摘  订  : gblim

8
00:00:54,018 --> 00:00:57,816
高尔夫球选手
根据不同打法选用不同型式的球杆

9
00:00:58,313 --> 00:01:00,819
用木杆进行长距离开球

10
00:01:01,051 --> 00:01:03,322
用推杆把球推进洞里

11
00:01:03,622 --> 00:01:05,824
在这两者之间则选用铁杆

12
00:01:06,314 --> 00:01:09,527
因此选用正确的高尔夫球杆

13
00:01:09,642 --> 00:01:11,674
成为比赛策略的关键部分

14
00:01:20,855 --> 00:01:22,183
这些高尔夫球杆的杆头

15
00:01:22,331 --> 00:01:25,003
是用航太级的不锈钢制成的

16
00:01:26,807 --> 00:01:31,036
要生产杆头
工厂得先从杆头的蜡制复制品开始

17
00:01:32,036 --> 00:01:34,364
首先要制造蜡制模型

18
00:01:34,446 --> 00:01:36,692
工人把热蜡倒入铸模里

19
00:01:38,610 --> 00:01:43,086
工人取出模型,去除多余的热蜡

20
00:01:49,594 --> 00:01:51,570
利用热蜡作为黏着剂

21
00:01:51,771 --> 00:01:56,875
机械手臂以料头及浇道
把几个模型跟其他热蜡连结

22
00:01:57,316 --> 00:02:01,169
指的是导引融化金属
流入铸造模具的渠道

23
00:02:03,082 --> 00:02:04,884
接着机器手臂把这些模型

24
00:02:04,984 --> 00:02:08,087
浸入陶瓷材料溶液里共四次

25
00:02:08,301 --> 00:02:11,190
每次浸泡之间还要喷洒硅砂

26
00:02:11,743 --> 00:02:16,295
这些陶瓷跟硅砂会变硬
沿着蜡制模型形成一个外壳

27
00:02:16,996 --> 00:02:19,219
接着工厂要融掉热蜡

28
00:02:19,760 --> 00:02:23,201
外壳现在成为
即将铸造金属杆头的铸模

29
00:02:25,204 --> 00:02:26,505
在铸造室里

30
00:02:26,605 --> 00:02:30,646
熔炉把钢条加热到摄氏1635度

31
00:02:30,793 --> 00:02:32,826
远远超过熔点

32
00:02:33,612 --> 00:02:38,237
同时另一个熔炉
将铸模加热到摄氏980度

33
00:02:38,450 --> 00:02:40,920
这足以去除任何残留热蜡

34
00:02:41,794 --> 00:02:43,722
同时也可以强化陶瓷

35
00:02:43,822 --> 00:02:46,725
让它得以承受融化的金属

36
00:02:47,926 --> 00:02:50,041
倒入的技巧非常重要

37
00:02:50,254 --> 00:02:52,331
金属的流速必须一致

38
00:02:52,431 --> 00:02:54,533
避免气泡产生

39
00:02:56,959 --> 00:03:01,041
五小时后,用气动锤打破铸模

40
00:03:05,845 --> 00:03:09,795
工人切料头及浇道,把杆头分开

41
00:03:11,943 --> 00:03:15,154
再磨掉料头及浇道的最后残留物

42
00:03:21,616 --> 00:03:24,960
转盘将杆头带到喷砂机这里

43
00:03:25,239 --> 00:03:27,366
让金属接受特别抛光程序

44
00:03:32,043 --> 00:03:35,774
工人贴上金属标签,上面有球杆型号

45
00:03:37,387 --> 00:03:39,578
工人用汽车油漆涂在圆点上

46
00:03:40,403 --> 00:03:42,881
用颜色代表球杆的角度

47
00:03:43,075 --> 00:03:44,983
一共有12种不同的角度

48
00:03:47,887 --> 00:03:50,765
工人用环氧树脂黏住杆头

49
00:03:51,437 --> 00:03:54,993
然后把环氧树脂涂在轴末端
再穿入杆头里

50
00:03:57,420 --> 00:04:00,831
利用气动锤把轴推得愈深愈好

51
00:04:01,200 --> 00:04:05,142
轴可能是由挤型钢铁
或碳纤维做成的

52
00:04:09,208 --> 00:04:10,910
现在要对轴下功夫了

53
00:04:20,307 --> 00:04:22,340
然后把轴放在转轴上

54
00:04:22,721 --> 00:04:25,439
用双面胶带缠绕最前面25公分

55
00:04:25,521 --> 00:04:27,472
好固定球杆的握把

56
00:04:34,372 --> 00:04:37,275
工人润滑胶带跟握把内部

57
00:04:37,576 --> 00:04:39,678
再将握把穿入轴里

58
00:04:40,390 --> 00:04:43,742
雷射光可以帮忙校正握把到正确位置

59
00:04:43,942 --> 00:04:46,833
这点是非常重要的
因为握把是高尔夫球选手

60
00:04:46,899 --> 00:04:48,547
可以指引双手摆放的位置

61
00:04:48,647 --> 00:04:50,749
这对于击球非常重要

62
00:04:53,352 --> 00:04:55,555
接着电脑读取底角

63
00:04:55,637 --> 00:04:58,719
指的是杆头相对于地面的角度

64
00:04:59,158 --> 00:05:03,112
然后电脑再读取杆面角
指的是杆头表面的角度

65
00:05:03,965 --> 00:05:05,965
然后电脑会指示技师

66
00:05:06,112 --> 00:05:07,752
该如何调整

67
00:05:08,457 --> 00:05:10,069
一旦调整完毕

68
00:05:10,169 --> 00:05:14,982
电脑再度分析新的杆面角跟底角
确保一切完美无暇

69
00:05:19,478 --> 00:05:22,245
最后高尔夫球杆要秤重

70
00:05:23,682 --> 00:05:26,585
磅秤显示这根球杆还要加重18公克

71
00:05:26,685 --> 00:05:28,186
才能符合标准规格

72
00:05:28,753 --> 00:05:33,048
因此要贴上用热塑胶
跟金属制成的18公克重物件

73
00:05:33,492 --> 00:05:36,623
其实重量要稍低于18公克

74
00:05:36,918 --> 00:05:39,705
因为还要考虑环氧树脂的重量

75
00:05:41,885 --> 00:05:45,032
就是这种精准的态度
才能确保这些高尔夫球杆

76
00:05:45,147 --> 00:05:48,707
符合严格的标准规格

77
00:05:59,823 --> 00:06:03,853
松饼在中世纪时
其实是一种扁平的酥薄饼

78
00:06:03,870 --> 00:06:06,429
当时不是用面粉做的
而是用燕麦或大麦做成的

79
00:06:06,729 --> 00:06:09,149
随着松饼风行整个欧洲

80
00:06:09,312 --> 00:06:12,001
发展出许多不同的形状和配方

81
00:06:12,280 --> 00:06:14,444
直到引进酵母后

82
00:06:14,591 --> 00:06:18,412
才成为今天我们熟知
有蜂巢外观的松软糕饼早餐

83
00:06:23,346 --> 00:06:28,444
在1950年代引进冷冻松饼
可说是另一个新时代的开始

84
00:06:28,477 --> 00:06:30,379
对这种早餐松饼来说

85
00:06:30,543 --> 00:06:33,556
让制作早餐松饼变得轻而易举

86
00:06:37,861 --> 00:06:40,763
所有重要的准备工作都在工厂里进行

87
00:06:41,412 --> 00:06:45,368
工人把梅果口味的调味料
加入松饼面粉混料里

88
00:06:46,134 --> 00:06:48,471
再加入湿料

89
00:06:48,571 --> 00:06:51,708
像是水,芥菜籽油跟液态蔗糖

90
00:06:51,856 --> 00:06:55,019
先倒入大槽均匀混合

91
00:06:55,278 --> 00:07:00,183
然后加入松饼面粉预拌粉
搅成浓稠的面糊

92
00:07:00,938 --> 00:07:02,840
这里面还包括发粉

93
00:07:03,020 --> 00:07:07,168
它会跟水起反应会形成二氧化碳气孔

94
00:07:07,348 --> 00:07:10,414
而发酵的效果
也会在烘焙时继续进行

95
00:07:11,496 --> 00:07:14,797
再加入更多的梅果后,面糊已经完成

96
00:07:14,897 --> 00:07:19,001
这一缸面糊足以制作三千六百片松饼

97
00:07:20,644 --> 00:07:23,106
加热的松饼铁模通过一个喷嘴

98
00:07:23,206 --> 00:07:25,408
喷上不易沾黏的涂层

99
00:07:26,497 --> 00:07:29,011
生产线下方,全自动帮浦

100
00:07:29,111 --> 00:07:32,300
注入一定分量的面糊到每个方格板

101
00:07:34,517 --> 00:07:36,919
上方的方格板会包住面糊

102
00:07:39,465 --> 00:07:45,928
生产线是由电脑控制
确保迅速装填,不易渗漏

103
00:07:53,536 --> 00:07:57,138
松饼铁模在进入烤箱前会翻转

104
00:07:57,285 --> 00:08:00,482
让面糊充分渗透到每个角落

105
00:08:02,974 --> 00:08:05,748
松饼来到长型的瓦斯烤箱

106
00:08:05,948 --> 00:08:08,451
只要两分钟就可以烤熟

107
00:08:12,454 --> 00:08:14,757
从烤箱出来的松饼是热腾腾的

108
00:08:14,857 --> 00:08:18,827
再由采集滚筒机,从铁模上取出松饼

109
00:08:19,661 --> 00:08:21,614
随着采集滚筒机翻转

110
00:08:21,811 --> 00:08:25,598
刺针会插住松饼
从热腾腾的方格板取出

111
00:08:32,474 --> 00:08:35,878
采集滚筒机把松饼送到另一层

112
00:08:42,910 --> 00:08:46,698
刺针收缩
将松饼送上一连串的输送带

113
00:08:52,878 --> 00:08:56,999
在工厂的另一边
松饼接着送入强风冷冻机

114
00:08:59,813 --> 00:09:03,306
这里面的温度是摄氏零下七度

115
00:09:06,797 --> 00:09:09,311
风扇对着松饼吹冷冽寒风

116
00:09:09,411 --> 00:09:11,513
当松饼在冷冻机里旋转时

117
00:09:11,914 --> 00:09:14,076
只要20分钟就可以冷冻

118
00:09:14,175 --> 00:09:16,619
保存这些刚烤好的新鲜松饼

119
00:09:20,222 --> 00:09:24,326
冷冻松饼如今再次出发
送往各线道堆迭起来

120
00:09:28,630 --> 00:09:30,332
有个特殊设计的闸门系统

121
00:09:30,432 --> 00:09:34,737
一次运送三片到握爪
再送到输送带上

122
00:09:44,422 --> 00:09:46,127
输送带越变越窄

123
00:09:46,258 --> 00:09:49,151
迫使堆迭好的松饼成一列行进

124
00:09:49,914 --> 00:09:55,471
感测器启动的闸门会一次让
两份堆迭松饼通过到包装工作站

125
00:09:57,960 --> 00:09:59,462
只需要一瞬间

126
00:09:59,562 --> 00:10:04,566
就能让两叠冷冻松饼
用玻璃纸密封包装好

127
00:10:11,227 --> 00:10:13,375
然后送到金属探测器上

128
00:10:13,475 --> 00:10:15,077
为了要展示它的运作方式

129
00:10:15,374 --> 00:10:17,780
我们放了一个硬币在包装上

130
00:10:18,456 --> 00:10:20,308
系统立刻感测到

131
00:10:20,440 --> 00:10:23,586
送风机把包装吹离开输送带

132
00:10:26,244 --> 00:10:29,492
抽吸手臂会吸起外层纸盒

133
00:10:29,592 --> 00:10:32,294
打开纸盒并放在输送带上

134
00:10:35,097 --> 00:10:38,301
撞锤把包装好的松饼推入盒子里

135
00:10:40,903 --> 00:10:41,804
不可思议的是

136
00:10:41,904 --> 00:10:45,808
在这家工厂
一小时就可以生产八千六百盒松饼

137
00:10:46,108 --> 00:10:49,311
满足各种不同口味跟膳食需求

138
00:10:50,425 --> 00:10:52,704
值得为此庆祝一番

139
00:11:05,475 --> 00:11:09,951
大多数今日的高科技设备
需要特殊的电线和电缆

140
00:11:10,197 --> 00:11:13,770
从舞台照明,医疗装置到机器人

141
00:11:13,967 --> 00:11:16,704
电线和电缆必须经过客制化设计

142
00:11:16,804 --> 00:11:20,509
利用专业生产才能达成预定目标

143
00:11:20,708 --> 00:11:23,771
并承受各种多变的外在环境

144
00:11:27,935 --> 00:11:30,818
电缆可以设计用来承受高温

145
00:11:31,018 --> 00:11:33,083
或是执行特殊功能

146
00:11:33,220 --> 00:11:36,395
例如感测酸碱值
或与其他物体的距离

147
00:11:38,116 --> 00:11:42,132
电缆的中心是称为导线的电线

148
00:11:42,930 --> 00:11:45,833
制作导线先从裸铜线开始

149
00:11:47,234 --> 00:11:49,837
挤制机在导线外面裹上一层塑胶

150
00:11:52,479 --> 00:11:56,544
冷水可以强化
电线外围的塑胶绝缘体

151
00:11:56,844 --> 00:11:59,707
这可以隔绝周围的每一条电线

152
00:12:00,642 --> 00:12:04,314
每一根导线会通过火花试验机

153
00:12:04,672 --> 00:12:06,573
它会让电流流经导线

154
00:12:06,653 --> 00:12:09,056
确保绝缘效果无瑕疵

155
00:12:10,257 --> 00:12:13,060
如果绝缘效果稍微有点损坏

156
00:12:13,160 --> 00:12:16,479
机器会发出警铃找出破损的位置

157
00:12:21,268 --> 00:12:24,364
导线随后会进入并纱机

158
00:12:24,672 --> 00:12:27,151
它会释放绝缘导线

159
00:12:27,283 --> 00:12:31,430
并与其他零组件结合
一组成电缆的内部结构

160
00:12:32,380 --> 00:12:37,184
在这根特殊电缆中央的
是一对缠绕的绝缘导线

161
00:12:37,885 --> 00:12:40,988
在它们旁边的
是其他颜色的绝缘导线

162
00:12:41,889 --> 00:12:45,152
以及填充导线之间空隙的填料

163
00:12:45,413 --> 00:12:48,349
让电缆有平滑的圆柱型

164
00:12:49,576 --> 00:12:53,280
这里的填料是好几股的聚丙烯泡绵线

165
00:12:54,201 --> 00:12:58,305
定位板可以适当的位置对准零组件

166
00:12:58,406 --> 00:13:00,825
当电线进入电缆组装模具时

167
00:13:05,012 --> 00:13:07,614
零组件跟着填料离开模具

168
00:13:07,662 --> 00:13:12,235
缠绕在绝缘导线上
并包裹着中间的电线

169
00:13:13,842 --> 00:13:16,323
下一台机器被称为包带头

170
00:13:16,424 --> 00:13:18,809
沿着电缆包裹固定胶带

171
00:13:19,026 --> 00:13:21,859
这个胶带将所有物件紧紧固定

172
00:13:22,132 --> 00:13:25,052
因此组装好的元件就不会散开

173
00:13:29,925 --> 00:13:32,646
这是另一种不同的电缆组装机器

174
00:13:32,940 --> 00:13:37,073
跟先前一样
所有绝缘导线从卷盘释出

175
00:13:37,171 --> 00:13:40,247
行经定位板上面的洞

176
00:13:42,489 --> 00:13:46,712
模具把这条电缆的
六条导线分成两组各三条

177
00:13:46,954 --> 00:13:49,557
每一组缠绕在一起

178
00:13:51,828 --> 00:13:57,265
然后机器包裹每一组的电线
用镀铝的聚酯护套

179
00:13:57,844 --> 00:14:00,467
护套可以消除交扰的现象

180
00:14:00,728 --> 00:14:02,930
就是信号互相干扰的现象

181
00:14:03,470 --> 00:14:09,076
下一个模具把无需护套的电线
加到已装护套的电线里

182
00:14:09,176 --> 00:14:11,979
然后所有东西缠绕成为一条电缆

183
00:14:12,271 --> 00:14:15,664
最后的缠绕在这里用慢动作播出

184
00:14:15,883 --> 00:14:19,186
实际上的速度是每分钟一千转

185
00:14:21,589 --> 00:14:24,792
下一台机器在电缆外面缠上薄纸

186
00:14:26,878 --> 00:14:28,896
接着济制机再射出一层

187
00:14:28,996 --> 00:14:31,098
塑胶与橡胶化合物制作的护套

188
00:14:31,994 --> 00:14:37,704
薄纸就等于隔板
避免护套黏住里面的电缆

189
00:14:45,913 --> 00:14:48,289
有时不用薄纸

190
00:14:48,453 --> 00:14:50,667
电缆会行经一缸滑石

191
00:14:51,018 --> 00:14:53,142
滑石是一种吸热的矿物质

192
00:14:53,306 --> 00:14:57,124
因此就像薄纸可以避免护套黏住

193
00:15:02,454 --> 00:15:05,782
跟先前一样当电缆离开挤制机

194
00:15:05,930 --> 00:15:09,503
冷水会使融化材料凝固强化护套

195
00:15:10,324 --> 00:15:13,741
印有字母的滚轮会在护套上

196
00:15:13,841 --> 00:15:16,586
打印制造商的名字跟技术规格

197
00:15:18,445 --> 00:15:21,048
有些电缆需要编织的护套

198
00:15:21,148 --> 00:15:23,551
好消除电子干扰

199
00:15:24,160 --> 00:15:27,160
这台机器有48个承载线轴

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00:15:27,275 --> 00:15:30,958
每一个都有十条镀锡铜线做的电线

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00:15:31,458 --> 00:15:34,472
随着加装护套的电缆
沿着机器向上移动

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00:15:34,570 --> 00:15:36,914
线轴会以设定好的模式移动

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00:15:37,062 --> 00:15:39,407
沿着电缆编织护套

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00:15:46,173 --> 00:15:49,046
从那里，最后再穿过挤制机

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00:15:49,112 --> 00:15:51,379
包裹最后一道热塑胶护套

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00:15:53,670 --> 00:15:58,085
这条客制化电缆已准备接上电源
发挥效用了

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00:16:12,244 --> 00:16:15,540
火车车轮用在全世界的火车上

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00:16:16,048 --> 00:16:18,933
客车仰赖它们来运输人们

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00:16:19,252 --> 00:16:22,016
货车仰赖它们来载运货物

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00:16:22,114 --> 00:16:25,157
至于拉动这些火车货车的火车头

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00:16:25,258 --> 00:16:28,561
则仰赖它们
好让人斗跟货物行进顺利

212
00:16:34,668 --> 00:16:37,311
这家公司制作火车车轮跟轮轴的历史

213
00:16:37,393 --> 00:16:39,738
已经超过150年了

214
00:16:42,175 --> 00:16:45,678
一开始,电热熔炉在摄氏1600度

215
00:16:45,778 --> 00:16:48,381
融化回收的钢材

216
00:16:54,387 --> 00:16:57,230
巨型的大桶将液态金属

217
00:16:57,296 --> 00:16:59,066
输送到模具坑

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00:17:00,994 --> 00:17:04,837
在模具坑里
金属从下往上填满八个铸模

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00:17:05,034 --> 00:17:07,657
打造出六呎长的钢锭

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00:17:15,592 --> 00:17:19,920
带锯机切开冷却的钢锭,称为轮卷

221
00:17:20,413 --> 00:17:23,510
每一个轮卷重达450公斤

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00:17:27,319 --> 00:17:30,323
为了要让轮卷形成火车车轮

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00:17:30,423 --> 00:17:34,526
全自动机器
把它们送到这个回转的熔炉里

224
00:17:35,953 --> 00:17:40,068
达到摄氏1300度之后
才从另一边离开

225
00:17:46,577 --> 00:17:48,441
然后机器把轮卷放入

226
00:17:48,541 --> 00:17:50,921
一个高压水清除装置

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00:17:51,020 --> 00:17:53,546
它可以去除大多数外层金属

228
00:17:57,750 --> 00:18:03,234
压床把每一个轮卷像棉花糖
利用九千吨重的压力压制

229
00:18:03,430 --> 00:18:06,359
制成车轮的大略形状

230
00:18:12,665 --> 00:18:15,447
火车车轮直径是76公分

231
00:18:15,578 --> 00:18:17,529
当机器手臂从压床中取出

232
00:18:17,628 --> 00:18:19,872
送到辊轧矶

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00:18:24,300 --> 00:18:26,379
辊轧机用力挤压并替车轮塑形

234
00:18:26,479 --> 00:18:29,186
直到车轮直径扩充到91公分

235
00:18:29,268 --> 00:18:31,268
足足增加百分之20

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00:18:40,531 --> 00:18:43,396
火车车轮接着进入最后的成形压床

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00:18:43,496 --> 00:18:46,299
压床会打洞好让轮轴穿过

238
00:18:49,802 --> 00:18:53,706
所有剩余材料都会回到镕炉间再利用

239
00:18:57,581 --> 00:18:59,913
经过热处理之后

240
00:19:00,013 --> 00:19:02,014
机器在车轮外面喷上冷水

241
00:19:02,114 --> 00:19:03,816
这可以强化钢铁

242
00:19:06,419 --> 00:19:10,023
接着替车轮边跟轮轴做修整

243
00:19:13,426 --> 00:19:16,629
工人确保一切符合标准规格

244
00:19:21,534 --> 00:19:25,738
经过验证和贴上标签后
就可准备轮轴

245
00:19:32,044 --> 00:19:34,140
轮轴也先从钢锭开始

246
00:19:34,288 --> 00:19:37,402
机器手把纲锭送入转动的轧锻机

247
00:19:40,052 --> 00:19:42,550
机器不停转动并槌击钢锭

248
00:19:42,665 --> 00:19:45,615
慢慢把热金属塑造成轮轴

249
00:19:53,767 --> 00:19:57,070
机器手跟轧锻机合作无间

250
00:19:57,255 --> 00:20:01,174
最后终于达到轮轴需要的直径与长度

251
00:20:11,083 --> 00:20:14,086
轮轴之后进行热处理

252
00:20:17,470 --> 00:20:22,355
接着工人加工整个轮轴
去除多余的材料

253
00:20:22,388 --> 00:20:24,897
准备连接火车车轮

254
00:20:29,094 --> 00:20:33,306
车轮镶埋机,把车轮嵌在轮轴的两端

255
00:20:40,813 --> 00:20:44,016
工人润滑轮轴并装上轴承

256
00:20:49,122 --> 00:20:53,226
他利用扭矩扳手紧紧地拴好端帽螺栓

257
00:20:56,129 --> 00:20:58,831
利用压线钳把螺栓锁紧

258
00:21:00,632 --> 00:21:02,635
最后,组好的车轮组

259
00:21:02,735 --> 00:21:04,436
滚出生产线

260
00:21:04,603 --> 00:21:07,029
准备安装在火车车厢

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00:21:11,144 --> 00:21:15,348
翻译:sdi  media