Sendung mit der Maus - Wie entsteht ein Airbus (A321-100 / D-AIRY) Teil 1/8

Uploaded by xxxXThunderstormXxxx on 02.08.2011

Morning, morning, morning, hello Mouse-Fans
Welcome the the longest "story to learn from" [Sachgeschichte] that has ever been made.
Today in the first part you will learn what's this
how such barrels are build
and what is put inside
how such a cigar is made
and what this cigar is good for
and the whole thing as always with the mouse, the elephant and the duck
Today it's about that.
That's how an airplane says goodbye, it rocks its wings
It's an Airbus A321, it bears the name of the city of "Flensburg"
its real name is delta, alpha, india, romeo, yankee
In between it was called D-AVZK, a temporary registration, something like a red number plate for cars
For us most of the time it just was the N901
We accompanied this airplane for nearly a year
and that's what everything began with.
Here is our airplane or at least a part of it, a crumpled sheet of metal
With such suckers it is taken
and our airplane is already flighting for the first time albeit not with its own power
This crumpled sheet of metal is taken and laid onto that huge machine.
There the suckers let go of the plate
There is gets aligned
And then such cheeks clamp the plate on one side
the same on the other side
again the cheeks
then the sucker's marks are wiped off thoroughly
then a touch of a button
and then the machine first straightens the plate
"stretch forming" this process is called
and afterwards it gets bend roundly
and for the curvature to be even such belts are laid above the plate
and when all are at the correct position a bell rings
and then those belts are tautened.
and these pulling belts cause the plate to be round evenly over the entire length, some hammer blows to correct small mistakes
then check with a hand if no dents are left, these guys have a feeling for this
when everything is fine the belts are taken off
again the suckers and our airplane again flies to the next position
Here a plastic foil is sprayed onto the bended plate
and scarcely the foil has dried a laser places small cuts in the foil
this is controlled by a computer for the cuts to be at the correct position
then some cuts are sealed again
when that has happened the plate is erected as it's easier to work that way
and then from the just sprayed foil a part is removed
only the sealed cuts are left
and all that's done only to make the airplane as light as possible
the plate is then lifted into a chemical liquid
and at those places where the foil has been removed the chemical liquid affects the plate
and makes it thinner, "chemisch abtragen" this process is called, you can't see more
After a few baths the plate is black
then those places that have been sealed till now are freed from the foil
and then again into a bath. That happens 18 times in total
And after the last bath the plate looks shiny again
Only when looking carefully you see that it's thinner in some places now
because every gram of weight that can be saved is important.
Then holes get drilled into the plate. The position of the holes is controlled by a computer again.
Next the edges are cut off cleanly, milled off
also controlled by the computer and the same computer using a different tool cuts out the places that shall become the windows
and after so much computers and high-tech the metal shavings are swept away with a broom
So it works best.
And when the plate is lifted you can see that it's still very floppy
And how the airplane builders get this floppy plate stiff
that we will show you after the next mouse.
First the plate is sprayed green
How do those airplane builders get is stable, how do they join parts at all?
For example to plates: lap and fix them
then pre-drill.
In doing so metal shavings come out, sweep them away and clean up
Then drill out the hole to the right size
and clean up again.
By drilling sharp edges that are called "burrs" were made, so you have to unburr
Clean up.
Not only from the top but from all sides,
Clean again and take the plates apart
and then putty is spread between the two parts
because humidity mustn't get there.
Humidity is an airplane builder's archenemy.
Then the two plates are put onto each other
and a rivet it put through the hole
and a rivet tool squeezes the rivet
and then the connection is going to last forever and three days.
And that is done with every hole
There are small, big, long, thin and thick rivets depending on where you search on the airplane
and they get tightened in different ways.
Either this way
or with pincers the rivets are squeezed
there are also rivets that get screwed these are called "Hi-Loks"
and finally some rivets are placed using automates.
And how all this riveting makes the plates stable we will show you after the next mouse.
That's the putty that is put onto these metal stripes which are called "stringer"
and they shall be riveted onto the floppy plates first.
To fixate them for now such staplers are used
and with those staplers the stringers are fixed thus nobody has to hold them
and when they have been fixed the metal stripes get riveted provisionally
That's how it's done.
When the metal stripes have been riveted the staplers are removed
And now the plate is firm in the direction the stringers lie
in the other direction you can still bend it.
Something is obviously missing
One plate with holes for windows and stringers and one plate that's gray on the bottom
These belong together and will continue the productions process together One plate with holes for windows and stringers and one plate that's gray on the bottom
These belong together and will continue the productions process together
Not such small plates which are called "clips" are attached
In the next step the window frames get inserted with some putty because of the humidity
and are fixed provisionally.
Here the two sheets with their provisional clips and stringers are joined
and here two small sheets become one big sheet
and everything that has been assembled provisionally up to now is riveted by an automate definitely
And when the automate is done all places look like this
But if you remember the parts that make our sheets stiff into the other direction are still missing
and that is made here out of this band of metal.
when it has gone through this machine and has come out on the other side it looks like this
It's round and has got such edges.
And now this thing is called "rib" [Spant].
It's cut off
and here you see what kind of edges it has got. Those are called "profiles" by technicians.
Of course it gets painted green too, that's obvious.
And then this rib is put together with this big piece
and now you can also see what those clips are made for. They have to hold the rib.
The first rivets are placed by hand
and because you don't want to do that several hundred thousand times
there's also an automate that basically does the same
Pre-drill, drill out, deburr, put a rivet into the hole, and the putty is already between.
Here you see it:
Drill, put a rivet in,
And now the sheet of metal will retain its form by means of ribs and stringers.
Now this piece is called "hull/shell" [Schale].
Everything we have seen until now happened in Nordenham.
The finished hull is loaded into a huge box
the box is loaded onto a truck and heads for Hamburg.
All hulls that get made for our airplane here are hauled to Hamburg this way
and what happens to those hulls in Hamburg we will show you in a moment after the next mouse.
When they have arrived in Hamburg the boxes are unloaded,
here a box arrives that contains a hull with two doors
and with a system of rails on the ceiling
with lots of points
all hulls that belong to our airplane get unloaded and moved to a store which is called "hull puffer"
Here they are.
But before we can continue with our hulls something different has to be made
that's our airplane's width
this will become the floor
First such bars are placed in a gauge and are fixed
and of course in all positions where something has to be joined putty is put
and these things are placed lengthwise of the airplane
the seats will be mounted in the holes.
four such strips with holes get placed, two on each side
and then some without holes, there.