这是波音747的最新型号 She's the latest model 747,
波音747-8 the -8,
它疾驰在跑道上正要起飞 hurtling down the runway for a take-off.
突然间，飞行员紧急制动 Suddenly, the pilot has to slam on the brakes.
飞机戛然而止 Screeching to a halt,
刹车片磨得炽热 they glow red hot.
救火车纷纷赶到 Fire fighters scramble,
却并不行动 but do nothing.
这并不是灾难降临 This isn't a disaster in the making,
而是最新型747 要面对的一系列测试之一 but one of the many tests the latest model 747 will face.
如果它燃起火焰就失败了 If she bursts into flames, she fails.
曾有近四十年 For almost 40 years,
珍宝客机都是毫无争议的天空之王 the Jumbo was the undisputed "Queen of the Skies".
最近，它的王位 被更大的空中客车A380夺走 Recently, she's lost that crown to the bigger Airbus A380
波音的团队想要夺回荣誉 and the team of Boeing wants it back.
他们对这标志性飞机的重新设计 They're going to completely redesign this iconic plane
就在这世界上最大的建筑里 in the world's largest building -
波音超级工厂 the Boeing Mega-Factory.
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紧张的五分钟过后 After 5 tense minutes,
消防员将747轮胎刹车片冷却 fire crews cool the brakes in the 747's wheels.
这证明了它能安全地中止起飞 It's proved she can abort a take-off safely
并让旅客逃离 and let passengers escape.
波音希望这是它唯一一次中止起飞 Boeing hopes this will be her only aborted take-off.
波音747-8 The 747-8
是这个公司旗舰的最新型号 is the latest and the most technologically advanced version
也是技术最先进的 of the company's flagship.
它将是世界上最长的客机 She'll be the world's longest airliner,
更重要的是 and more importantly,
它是同级别中最环保的 the greenest in her class.
跟所有飞上蓝天的珍宝客机一样 Like every Jumbo that braces the skies,
它也会诞生在华盛顿州埃弗雷特 she'll be born at Everett, Washington,
就在西雅图的北面 just north of Seattle.
波音超级工厂是地球上最大的建筑 Boeing's Mega-Factory is the largest building on the planet.
吉尼斯纪录最大的壁画就在它门上 Its doors hold the Guinness record for the largest mural.
有多大？ How big?
它能把整个迪斯尼乐园装在里面 You could fit all of Disney Land inside it
还能空出停车场空间 and still have room for parking.
这不仅是一座工厂 This is more than just a factory.
这是一个小城市 It's a small city
有自己的消防局 with its own fire department
和全美最繁忙的七个咖啡馆 and 7 of America's busiest coffee shops
都在这间厂房之内 right there on the Franchi floor.
好了，两块零七分 All right, it's gonna be 2.07, please.
这是工业强度的三轮车和自行车 There's our model of industrial-strength trikes and bikes
方便员工在厂内行动 to help the employees to get around.
多数人要几个月才能熟悉厂房布局 It takes most people months to learn the factory layout.
这的确大得让人吃不消 The size was definitely overwhelming.
开始时有点儿忙乱 It is a little hectic,
我都不知道我在干啥 didn't really know what I was doing
也不知道要去哪里 or really where I was going.
我在这里23年半了 23 and a half year
还会在厂里迷路，人们有时会这样 and I still get lost in this factory. People sometimes do.
这个巨穴般的建筑非常庞大 This cavernous building is so large
从前在11层楼高的屋顶 clouds have been known to form
会形成云雾缭绕的现象 near the 11-storey-high ceiling.
这里混杂着形状大小各异的 It's a bewildering jumble of aircraft parts
无数飞机部件 in all shapes and sizes.
不过表面的混乱背后自有规矩 But there is method beneath the madness.
每种型号的飞机都有指定的位置 Each jet that the company makes has its own assigned place.
这个区域留给了公司的掌上明珠 This area is reserved for the company's darling -
波音747 the 747.
这里建造的第一架飞机就是747 The first plane ever built here was a 747,
珍宝客机的原型机 the original Jumbo jet.
它迅速奠定了“天空之王”的地位 She quickly establishes herself
这一荣誉无可争议 as the undisputed "Queen of the Skies".
它的统治近40年没有受到挑战 The dominance goes unchallenged for 40 years
直到2007年 until in 2007,
空客A380从大小和容量上超过了它 the Airbus A380 eclipses her in size and capacity.
这是种双甲板飞机 It's a double-decker
载客量550人 seating 550 passengers.
空客A380是空中客车公司 对过去10年间 The A380 is Airbus's response to the upsurging air traffic
空中运输迅速增长的对策 over the past decade.
航空业的确在好转 There is really an upturn in the aerospace industry.
（麦克·华纳） 人们乘飞机出行更频繁了 With people fly more often,
（市场部） 飞机都是满载 airplanes are full.
确实需要更多新飞机 There's really a lot of demand for new airplanes.
不过可不是什么飞机都行 But not just any planes,
航空公司需要更高效的飞机 airlines are demanding more efficient planes.
A380符合要求 The A380 fits the bill.
然而在这样的环境下 But in this environment,
老式珍宝客机就不再适用了 the old Jumbo doesn't cut it any more.
燃油价格飞涨 With soaring fuel costs
人们对环境也越来越关心 and concern for the environment,
它已经变得昂贵而且肮脏 she's becoming expensive and dirty to fly.
不过波音公司可不会不分好坏 一概摈弃 But Boeing isn't throwing a baby out with bath water.
他们不会从零开始设计全新飞机 Instead of designing a new plane from the ground on,
这可得花上十年时间和几十亿美元 which can take a decade and billions of dollars,
他们准备对其从前的最爱 they are going to give a radical make-over
进行彻底改装 to their old favorite -
制造更好更环保的珍宝客机 a better and greener Jumbo.
747-8飞得更快 The -8 will fly faster,
不加油的情况下可以飞越 travel a third of the way around the world
地球的三分之一 without refueling
燃烧也比任何之前的747干净得多 and burn a lot cleaner than any 747 before it.
我们确实认为747-8 We really think the 747-8
是市场上大小合适的飞机 is the right-sized airplane for the market.
空中客车的确有更大的飞机A380 Airbus offers, or course, a bigger airplane A380.
可747-8每座位燃油消耗 The 747-8 will burn less fuel per seat
比A380低 than the A380,
所以对于航空公司来说 so an important decision for airline
选择哪一类大型飞机 when they are deciding on
可是个重要决定 what type of big airplane they need.
不过A380已经在飞了 But the A380 is already flying,
所以波音要赶上步伐才行 so Boeing has some catching-up to do.
好帮手就在隔壁机库里面 Good thing is in the hangar next door.
他们有现成的创新技术可以借用 They've got some innovative technology ready to go.
他们在这里制造革命性的 碳纤维“梦想客机” This is where they are making the revolutionary carbon-fiber Dreamliner -
波音787 the 787.
它会借给波音747创新的机翼设计 She'll lend the 747 her innovative wing design
和全新的节油引擎 and brand new fuel efficient engines.
新珍宝客机的名字都带着它的痕迹 The new Jumbo is even named after her little sister.
它叫波音747-8 She'll be the 747-8.
这是向未来借贷 She's borrowing from the future,
也是在继承它40年的宝贵财富 but also from her own 40-year heritage.
747的故事始于上世纪六十年代中期 The 747 story starts in the mid-1960s.
喷气式飞机的发明 The invention of jet aircraft
带来了空中运输的迅猛发展 has created an upsurge in air travel.
洲际飞行的需求与日俱增 Demand for intercontinental flights is taking off
一家航空公司独占鳌头 and one carrier leads the way.
泛美航空 Pan Am.
到了1965年 By 1965,
泛美迫切需求更大 航程更远的喷气机 Pan Am is desperate for bigger and longer ranged jets.
其总裁胡安·特里普 Its president Juan Trippe
会见了波音总裁威廉·艾伦 meets with Boeing's president William Allan.
问他能不能建造 He asks him to build an aircraft
航程五千公里 with a range of 5,000 kilometers
350个座位的飞机 that will seat 350 people
这是那时最大飞机座位数的两倍 twice as many people as any plane before.
这对首席工程师乔·萨特来说 是空前的任务 It's a unprecedented task for chief engineer Joe Sutter
他被称为波音747之父 known as the father of the 747.
我们开始要开发350座的客机 When we had to develop an airplane with...
（波音747之父） 而不是100座的客机 ..for 350 passengers instead of 100,
（乔·萨特） 怎么办呢？ how do you do it?
最初的想法是 The first thought was to
把一架飞机放到另一架上面 put one airplane on top of another.
在A380出现的40年前 40 years before the A380,
乔就想到过双甲板客机 Joe considers a double-decker.
我的工程师们这么做后 我们看了一下 My engineers got to work on it and we looked at it.
双甲板的问题在于 The troubles with the double-decker,
得用上一打才够 you got at least a dozen of them,
这时他们开始考虑宽体客机 and that's where they conceived idea of a wide
有两个过道 airplane with two aisles.
故事变成了传奇 Legend has it,
泛美的胡安·特里普告诉波音 Pan Am's Juan Trippe tells Boeing,
“只要你造我就买” "If you build it, I'll buy it."
他签下了25架珍宝客机 He signs up for 25 Jumbos,
价值相当于现在的27亿美元 worth a total of 2.7 billion dollars in today's money.
波音接受了挑战 Boeing accepts the challenge.
有个小问题 Small problem,
他们没有够大的厂房来建747 they don't have a factory large enough to make a 747.
于是在1966年 So in 1966,
波音开始建造 Boeing begins construction
世上有史以来最大的超级工厂 of the biggest Mega-Factory the world has ever seen.
工人们开始建造747原型机 Workers start building the original 747
厂房的墙壁就在他们周围竖起 even as the walls of the factory go up around them.
他们被称为“不可思议” They become known as the "Incredibles".
他们的标志是 They have emblem that was this...
（波音747） 扛着斧子的保罗·班扬 ..posture - Paul Bunyan who walks under with an axe raised on.
说实话，我的工程师们 Frankly, my engineers
可没这么大肆宣扬 didn't go for that hoopla.
他们有的是活儿 They had a job to do.
他们知道该干啥，而且都做到了 They knew what the job was doing and they just did it.
不过他们的确“不可思议” But "Incredible" they are.
他们在仅仅28个月里就从无到有 They build the first ever 747 from scratch
建出了第一架747 in just 28 months.
它在1968年9月30日 She rolls out of Boeing's mega-factory
从波音超级工厂出厂 on September 30th, 1968,
庆祝时刻有些没想到的小插曲 champagne moment that didn't go quite as planned.
现在拿好，别打开 Now take it, don't break it yet.
一会儿数一、二、三，明白吗？ It's gonna be one, two, three, got it?
哦，等等！ Okay, wait, wait!
等一下！ Wait!
好吧 All right.
再来一次，一 Go again. One,
二 two,
三 three.
我们有过一些问题 We did have a few problems, but...
（747原型机试飞员） 起飞那一刻悬着的心才落下 the moment of lifting off was a great moment of relief,
（布莱恩·威戈） 我想我们都是这样 I think, for all of us.
人们问我有没有担心 People've asked me if there were concerns,
就是说安全问题 you know, about our personal safety,
不过，其实，我们真没想过这些 but, you know, we weren't... That didn't enter into it.
我们非常忙 We were busy.
我们有活儿要干，有很多事要想 We had a job to do. There was a lot to think about.
我们都很兴奋 And we were very excited.
我们出舱后被人们团团围住 When we got out, we were mobbed by everybody
那一刻真好 and it was a great moment
那飞机真棒 and it was a great airplane.
不过747原本只是个临时过渡产品 But the 747 is only meant to be a stopgap.
在七十年代中期，全世界向往的是 In the mid-70s', the world wants supersonic flight -
能够比声音还快的超音速航班 planes that can travel faster than the speed of sound.
波音预计只能卖出去50架747客机 Boeing reckons it will only ever sell 50 passenger 747s.
他们认为喷气客机真的未来 It believes the real future for the jet set
是他们的超音速变后掠翼客机 is its supersonic swing-wing
能够跟欧洲的协和客机并驾齐驱 which will go head to head with European Concord.
不过超音速之梦在经济上 But the supersonic dream proves
进了死胡同 a economic dead end.
这是耗油魔鬼 It's a gas Godzilla.
波音的研发止步于这个全尺寸模型 Boeing never gets beyond this full-scale mock-up.
而引擎效率更高的波音747 Instead, it's the 747 with more fuel efficient engines
则从过渡产品变成了天空的主宰 that goes from stopgap to ruler of the skies.
从1978年至今 Since 1978,
波音生产过一千四百余架珍宝客机 Boeing's built over 1,400 Jumbos.
它们飞行的总里程 Together, they flown the equivalent
相当于来回月球十万一千次 of 101,000 trips to the moon and back.
它们都是在这个波音超级工厂 And they've all been hand crafted
被手工制造出来的 here at the Boeing Mega-Factory.
43年来 In 43 years,
这从未改变 that hasn't changed.
珍宝客机仍是手工制造 Making good Jumbo is still hands-on work.
这里一个机器人都没有 There is not a robot inside.
好了，我们进去了 All right, we are in the hole.
在我们的组装流程中 In our assembly line processes,
（747生产副总裁） 保持节奏非常重要 it's really important to get the cadence going,
（保罗·纽岩） 有时我们称之为“踩鼓点” or sometimes we call "the drum beat".
要全都运转起来 It's all about the cycling.
就是让我们的机械师 And that is getting our mechanics
能够完成一件任务后 be able to work on a job
来到下一架飞机上面继续工作 and then cycle back to the next airplane
保持这种节奏 and keep the rhythm going.
不过这里什么都不生产 But nothing is actually made here.
埃弗雷特只是组装枢纽 Everett is simply an assembly hub.
部件从全世界各地 Parts from all corners of the globe
汇集到埃弗雷特 converge on Everett -
飞机座椅来自德国 aircraft seats from Germany,
机翼部件来自中国 wing elements from China,
副翼来自澳大利亚 flaps from Australia.
仅新型的747-8 The new 747-8 alone
就需要超过六百万个零件 needs more than 6 million parts.
更重要的是，它们得按时到达 And critically, they all need to be here just in time.
即时生产这一方法 Just-in-time manufacturing
已经被证明能为波音节省资金 is a proven method that saves Boeing money
因为不需要提前很久 by not having to purchase
就购买并储存零件 and store parts too far in advance.
但这风险很大 But it's risky.
准时就是一切 Timing is everything.
（克里斯蒂·金） 对，我们有采购短缺 Yes, we do have purch shortages.
（服务厂长） 我们成功的关键 The key to our success
和保证厂房里建造正常进行的要点 and being able to keep manufacturing in building
就是要确保 is to make sure that
能让生产系统停转的关键零件 parts that will actually stop the production system
绝不短缺 never become short.
最不希望摆在场地附近的 One of the biggest components
最大零件之一就是 you don't wanna hanging around
价值两千万美元的引擎 is a 20-million-dollar engine.
引擎是昂贵商品 The engines are expensive commodity
所以我们管理资金的立场 and so we are managing our money
就是通过在产品存货控制成本 from a standpoint of WIP inventory costs.
所以我们所有型号飞机 So engines are usually put on in all of our models
通常都是在出厂前一、两天 about a day or two before they roll out of the factory
才装上刚到的引擎 and they come to us just in time.
要想装错747引擎并不容易 It's hard to misplace a 747 engine,
不过波音需要确定六百万零件去向 but Boeing needs to keep track of over 6 million parts,
它们可不都像七吨的引擎一样显眼 not all as obvious as a seven-ton engine.
- 你好 - 我们今天如何？ - Yes, sir. - How do we do today?
- 不错 - 我需要一个量油尺 - Good. - I'm gonna need a dipstick
还要一个那样的炮筒钻 and probably a gun barrel drill over there.
每个零件都有电子标签 Every part is electronically tagged,
让波音能随时了解每个零件的去向 giving Boeing an instant assessment of what's gone where.
- 给你 - 很好，很好，这就行了 - Here you go. - Excellent, excellent. That'll do.
- 好了 - 谢谢 - Good to go. - Thank you.
谢谢 Thank you.
波音747-8的建造 从其最重要的部分开始 Making a 747-8 starts with the most important part of all -
机翼 the wing.
机翼的组装区域 The wing assembly area
占据了珍宝厂房的四分之一 takes up a quarter of the Jumbo's factory space.
747的新型机翼 The new wings of the 747
是波音建造过的最大的 are the largest Boeing has ever built.
每个上面都能放下 Each one is big enough to fit
四个三居室房子 four 3-bedroom houses on top.
机翼的设计 The wing design
对新型747达到更高效率至关重要 is crucial to making the new 747 more efficient
这样才能更加环保 and therefore greener.
（迈克尔·提尔） 波音747的前四十年 The 747 for the first 40 years
（747首席工程师） 用的是六十年代的机翼设计 had the 1960s' technology airfoil.
在波音787上使用的 And the latest modern design airfoils
最现代机翼设计 that had been used on 787
所使用的形状有所不同 have a different shape of airfoil
这能提高升阻比 which improves the lift-drag ratio
提升飞机的燃油燃烧效率 which improves the fuel-burn on the airplane.
组装从机翼侧缘开始 The assembly starts with its wing on its edge
这样容易进入 to allow easy access.
机翼骨架是由三根 The wing skeleton is made of three spars
贯穿全翼的翼梁 which run along the length
和55跟翼肋构成 joined by 55 ribs.
这种形状能带来强大的结构强度 This shape provides great structural integrity
非常有用 which will be needed.
机翼飞行时支撑着整个飞机的重量 The wings support the full weight of plane in flight,
紊流的压力 the stresses of turbulence,
同时还最多携带着58吨燃油 whilst each wing will carry up to 58 tons of fuel.
机翼的铝质蒙皮 The aluminum skin of the wing
是用数千扣件固定在框架上的 is attached to the frames with thousands of fastener,
每一枚都至关重要 every one of them is vital.
这是攸关生死的环节 The stakes here could cost lives.
每一枚扣件都要经过反复检查 So each and every fastener is double checked.
这片面板用这些扣件连到金属杠 Fasteners on this panel to these bars,
我用这个螺母套筒拧紧 I'm torquing it with this nut-setter.
加固完成之后 And once we're done fastening it,
我们要再来一遍 we go through again.
确认扭矩达到要求 Make sure it's all torqued down.
当机翼快完成时 As the wing nears completion,
就能看出它的独特形状了 it starts to take on its unique shape.
正是机翼的形状 It's the shape of the wing
能将440吨的珍宝客机送到空中 that will lift a 440,000-kilo Jumbo into the air.
当机翼穿过空气时 As wings move through the air,
在上面产生一个低压区 they create a area of low pressure above
下面是高压区，这就产生了升力 and high pressure below which creates lift.
（马克·弗斯汀） 只要飞机在飞行 Whenever the airplane is in flight,
（747首席试飞员） 当然就有空气流过机翼 of course, there is air flowing around the wing.
这时机翼上的净压力 And the net pressure, if you will, on the wing
应该是向上的 is wanted an upward direction.
有一个问题 There's just one problem.
当这些气流汇集到翼尖时 When these air flows meet to the wing tips,
机翼下的气流绕道上面 air flow below the wing moves around to the top.
这种环形气流形成漩涡 This circular flow forms a vortex,
或叫乱流 or dirty air.
这种乱流在机翼上形成向下的压力 This dirty air adds downward pressure on the wing
减小了机翼产生的升力 and reduces the lift it can generate.
解决方法 The solution
是采用倾斜的翼尖 is slanted or raked wing tips.
新型翼尖迫使漩涡 These new wing tips force the vortex
在机翼的最末端形成 to form at the very end of the wings.
从而减少拉力 and help reduce drag.
这一新设计也带来了新挑战 The new design also creates new challenges.
试飞表明在机翼上有较小的振动 Test flights review a small vibration in the wings
被叫做颤振 known as flutter.
机翼振荡幅度 The wings have been oscillating
最多达5厘米 up to 5 centimeters.
在对飞机的试飞中 During the testing on the airplane,
我们把飞机置于所有极限之下 we put the airplanes through all corners of the envelope -
速度极限、高度极限 the speed envelope, the altitude envelope.
当我们在有一定载荷 When we are at high speed
携带一定燃油高速飞行时 with certain payload on the plane with certain fuel,
我们注意到机翼和引擎有小幅振动 we did notice a small vibration of the wing and engine combination.
在极端情况下 In extreme cases,
颤振能把整个机翼晃掉 flutter could bring a plane down
从而导致坠机 by literally shaking the wings off.
为了符合要求并减少延误 To meet regulations and prevent delays,
机翼的问题必须彻底解决 the problem with the wing needs to be eliminated,
否则可能会让747项目搁浅 or it could ground the 747 program
而这种情况不是首次出现 and not for the first time.
在六十年代末 In the late 60s',
747原型机曾有过不同的机翼问题 the original 747 had a different wing issue.
风洞测试表明机翼压力 Wind tunnel test show the pressure of the wing
分布不正确 was not distributed correctly
威胁到整个设计 threatening a complete redesign.
但是乔·萨特挺身而出 But Joe Sutter came to the rescue.
我们想到了个主意 We came up with the idea
把机翼外缘向上扭转几度 of just twisting outboard wing down a couple of degrees.
我们觉得这样可能有效 We thought maybe this would work
他们在风洞里进行测试 while they tried it in the wind tunnel
就是这么简单一弄，问题就解决了 and with just that simple fix, we solved the problems.
简单的调整很有效 The simple fix works.
珍宝客机机翼压力分布正确了 It distributes the stresses on the Jumbo's wings correctly
747也就绪了 and the 747 is good to go.
为了纪念此事 这被称作“乔·萨特扭转” In Joe's honor, it's dubbed the "Sutter twist".
这次扭转对于“不可思议”团队 The twist is key to the "Incredibles"
按时完成珍宝客机是个关键 completing the Jumbo on time for its launch.
但是747-8的故事 But the -8 story
有着不同的曲折 takes a different twist.
工程师们用了新世纪典型的方法 In a typically 21st century solution,
通过机上电脑系统 engineers use the plane's computer systems
来消除振动 to cancel out the vibrations.
这种电脑系统叫做“电传操纵” They call this computerized system "fly-by-wire",
是对过去用线缆操纵机翼 a huge improvement on the cables
进行的巨大改进 that used to control the wings.
飞行员的指令能使线缆移动 A pilot input would cause a cable to move
这样就能够 which would, in turn,
发出让表层移动的信号 signal to the surface to move.
电传操纵系统 A "fly-by-wire" system
就是在其中加入了电脑 is where you've got the computers in the loop.
飞行员移动操纵杆、转动方向盘 It's where a pilot will move the column, turn the wheel
这么做的同时 and when they do that,
会沿线路发出电子信号到促动器上 it sends a electronic signal by wire to the actuator
促动器会控制表层移动 that will control the surface.
现在能做的是 Now, what that allows you to do is
添加更多电脑 put more computer and more
和更多飞行控制软件 flight control software technology
来对飞机操纵属性进行调整 into the handling characteristics of the airplane.
他们用电脑系统 They can use the computer system
来对机翼控制进行微小调整 to make tiny changes to the wing controls
从而消除颤震 to cancel out the flutter.
这种简单的解决之道 It's a simple solution
正是乔·萨特的 “不可思议”团队精神的体现 in the spirit of Joe Sutter's "Incredibles".
我感到无比自豪 I have an immense amount of pride
这工作是在乔·萨特和他的团队 working on a product that Joe Sutter and his team
高效设计、建造和测试的基础上 effectively designed, built and tested
那时我还没进幼儿园呢 before I was in kindergarten.
1968年 In 1968,
乔·萨特和他的“不可思议”团队 Joe Sutter and his team of "Incredibles"
带来了世界商业航空史上 give the world the most iconic shape
最标志性的形状 in commercial aviation history -
著名的“鹅头” that famous "hump".
不过这最初可不是 为了头等舱而设计的 But they don't design it as a first class retreat for the jet set
因为波音当时认为超音速才是未来 because Boeing thinks the future is supersonic.
他们认为珍宝的未来是做运输机 They see the Jumbo's future as a freighter.
幸运的是乘坐350名乘客的需求 So, luckily, the passenger requirement for 350 passengers
和对大型货运容量的需求 and the big freight capacity requirements
融为一体 blended together,
所以我们可以建造较为理想的飞机 so we could build a fairly optimum airplane
同时满足客运和货运的需求 for both the passenger role and the freighter role.
让乘客登机不难 Getting passengers on is easy.
将货物装上飞机 Getting lodge cargo on,
就是挑战了 that's a challenge.
我看过很多方案 We looked at a lot of schemes
其中一个的概念是在机鼻处设舱门 and one concept was to put a nose door on the airplane
从机鼻位置装载货物 for some way of loading freight from the nose.
在这种特别的设计 In a radical design move,
让货物从机鼻处进入 cargo will enter through the nose.
这里上面是飞行甲板，也是出口 This place is the flight deck above and out of the way
于是著名的鹅头就诞生了 and so that famous hump is born.
泛美总裁胡安·特里普 Pan Am president Juan Trippe
马上就看到了它的潜力 immediately sees the potential.
胡安·特里普转过身，看着这里 Juan Trippe turned around, looked at this area
问道：“这是干什么的” and said, "What's this used for."
首席工程师说： And the chief engineer said,
“这可以做机组休息区” "Well, it could be a crew rest area."
胡安·特里普看着工程师说： And Juan Trippe looked at the engineer and said,
“这里应该留给乘客” "This would be reserved for passengers."
这就是我们现在 And that's how this upper deck
飞行的上层甲板的由来 that we now flying on came into be.
在新的747客机上 On the new passenger 747,
这标志性的鹅头 that iconic hump
延长到了波音737的整机长度 is expanded to the length of an entire 737.
回到工厂 Back at the factory,
工程进入到了机身部分 work is progressing on the fuselage.
它是分段构建的 It's built in several sections -
尾段 rear,
中段 middle,
和首段 and the front
那里有出名的鹅头 with that famous hump.
每一部分都是一块块面板组装的 Each section is assembled panel by panel.
整个机身面板都有 保护性绿色塑料薄膜覆盖 All the body panels are coated with a green protective vinyl
防止在建造过程中受损 to prevent damage during construction.
只有机鼻是一体制造的 Only the nose is made in one piece.
主机身的下部是翻过来建造的 The lower part of the main body is built up-side-down
这样工艺流程更简单 for easier work flow.
之后这会用特殊旋转装置 Then it's rotated 180 degrees
进行180度翻转 in a special turn fixture,
然后好放置顶部 so they can put on the roof.
组装完毕后 Once assembled,
它的重量惊人 it's so unwieldly,
只能靠巨大的34吨吊车才能吊起 only a mammoth 34-ton crane can lift it.
有这里50公里导轨 A total of 26 cranes
总共有26架吊车 on 50 kilometers of ceiling tracks
就在天棚上跨越厂房的巨大空间 fly the sections among the massive complex.
（吊车操作员多恩·麦特兰德） 我们跟所有飞行员们说： We get to tell all the airline pilots, say,
“在你们之前 我们就已经飞过第一次了” "We've flown it first for you before you just pick it up."
我们上班时就得忙活 While we're at work, it's gotta go.
我们撤下的时候 It starts to back down and
人们就要上去干活了 you can get to go to work on it.
有些人干这活儿时会恐高 There are a couple of people who have a fear of height in this job,
当然不怕更好 but it's best if you don't.
在机身分段被移到最终安装位置前 Before the fuselage pieces are moved to their final assembly position,
一定要确认没落下什么东西 it's critical to make sure that nothing is left behind.
要是落到不该到的地方 A loose bolt could cause a disaster
一颗松动的螺栓就能带来灾难 if it's rolled into the wrong place,
比如说掉进引擎或某个油箱里 such as an engine or even one of the few tanks.
（技师帕特里克·伊万哥） 放上去的每个铆钉、每个扣件 Every rivet, every fastener you put in,
都是至关重要的 it could be a critical item.
我记得多年前听到的一句话 I remember an old thing I heard years ago,
数量不分质量，是靠得住的 quantity is something you can't quality, is something you count on.
现在是凌晨两点 It's 2:00am,
不过波音从不入眠 but Boeing never sleeps.
在世界最大的建筑里 Inside the world's largest building,
人们正在进行一个极度复杂的操作 an extremely complicated maneuver is underway.
747-8已经完成了机翼和机身 So far, a -8 has built her wings and her fuselage.
现在是把它们组装到一起的时候了 Now it's time to bring it all together
747-8这样才能有珍宝客机的模样 to make this -8 look like a Jumbo.
把三段机身分段连在一起 Joining up the threes sections of the fuselage
是整个组装过程中要求最高的任务 is one of the most demanding jobs in the entire assembly process,
所以才选择在夜深人静的时候 which is why it's done in the dead of night.
这样更安全 It's safer.
场地上人更少些 Fewer people on the floor,
出问题的机会就更少些 less chance of something going wrong.
将价值数百万美元的部件拼到一起 With millions of dollars worth of aircraft parts coming together,
是极其精巧的工业舞蹈 this is a extremely delicate industrial dance.
主控组必须对所有最小的细节 The grand crew have to pay attention
都十分注意 to the smallest details.
组员把机身前段就位 The crew are positioning the forward section
好安装机翼 to receive the wings.
在放下分段时 When lowering the section,
团队必须精准 the team must be precise.
我们必须保证将它放进支架里 ...line up to make sure that we set it in the cradle
到正确位置之上 at the right position.
这要精确到不到一厘米 It's a matter of a quarter inches away.
机翼现在安装到机身中段上 The wings are now joined to the center fuselage.
翼展几乎是就是车间的整个宽度 They span almost the entire width of the factory floor.
两个牵引机以完全相同的速度拖曳 Two tractors both pull at exactly the same speed
防止机翼部分 to stop the wing section from falling off
掉落到车间的侧面 into the sides of the factory.
机翼和墙壁之间的间隙 The clearance between the walls and the wing tips
只有5厘米 is just 5 centimeters.
接下来 Next,
尾端要连到整架飞机上 the tail section joins up with the rest of the plane.
珍宝客机的外形特征 The characteristic Jumbo outline
已经成形了 is taking shape.
它长达76米 She's 76 meters long
宽达68米 and 68 meters across.
到了这一步已经过数千双手的劳动 Thousands of hands have got the aircraft to this stage.
管理和组织这么庞大的人群 The task at managing and organizing such a large crew
并非易事 isn't easy.
但是波音在这方面有40多年来 But it's something Boeing has had plenty of practice out
积累的丰富经验 over the last 40 years.
在早些年 During the early years,
波音曾经遭遇过经济危机 Boeing faced to financial meltdown.
它曾濒临破产边缘 It came close to bankruptcy.
进行过裁员 There were lay-offs
也有停止研发的压力 and pressure to hold development.
运作747项目 Running the 747 program
是真正的挑战 was a real challenge.
我们非常尽力地工作 We are working very hard to
（波音747之父） 好能及时画完所有的图纸 get all of the drawings out at that time,
（乔·萨特） 所以工程部 so the engineering department
当时人员最多，达四千五百人 that was peaking out by 4,500 people.
他们告诉我 I was asked to
要大规模裁员 take a big cut in that.
可我们还少800名工程师 We needed 800 more engineers.
我想也许我会丢掉工作 I think, Maybe I'm gonna lose my job today,
不过我得告诉他们我的想法 but I'm going to tell them the way I see it.
我认为那是我对波音 I figure that was when I did
做出过的最大贡献 the best job I could for Boeing.
要是我缩减工程部力量 If I had reduced the engineering force,
这个项目都可能会垮掉 the whole program could have tumbled.
最新的珍宝客机项目 The latest Jumbo jet program
也有潜在的崩溃危机 also has the potential to tumble.
（近两万七千波音工人罢工） （波音工人停止工作）
（波音工人在午夜开始罢工） 在2008年 In 2008,
波音的机械师进行了两个月的罢工 Boeing's machinists go on strike for two months
使已经很紧张的时间计划乱成一团 throwing an already tight schedule into disarray.
（罢工可能导致数十亿美元损失）
（波音因罢工损失30亿美元利润） 罢工每天 Each day lost
使波音损失一亿美元 costs Boeing 100,000,000 dollars.
加上机翼的工程问题 Added to the wing engineering issues,
波音被迫宣布延迟交货两年 Boeing is forced to delay delivery by two years.
有些买家取消了订单 Some buyers cancel their orders.
但是波音当务之急 But Boeing's immediate concern
是完成这架飞机 is to finish this one.
现在该给它提供动力了 It's time to give her some power.
该安装新型引擎了 Time for the new engines,
四具革命性的新引擎 four revolutionary ones.
老式747引擎 The old 747 engines
每小时燃油消耗一万两千升 consume over 12,000 liters of fuel per hour.
因为油价处于历史最高点 With oil prices at an all-time high,
航空公司在寻求减小油耗的办法 airlines are seeking any way to minimize fuel consumption.
找到更加高效的引擎 Finding a more efficient engine
是747-8成功的关键 is critical to the -8's success.
通用电气站在喷气引擎设计的前沿 General Electric is at the forefront of jet engine design.
这些崭新的引擎是他们制造过的 These brand new engines are most efficient
最高效的引擎 they have ever made.
波音要求通用电气 Boeing challenged GE
将其改装适合新型747飞机 to adapt them for the new 747.
不过价格自然不菲 But they don't come cheap.
最低价格也是每具引擎两千万美元 With a least price of 20 million dollars each,
这些引擎是新型珍宝客机上 最昂贵的零件 these engines are the new Jumbo's single most expensive component.
不过它们货真价实 but they are worth every cent.
涡扇和外壳采用了合成材料 Composite materials used in the fan blades and casing
使每具引擎减重180公斤 trim 180 kilograms from each engine.
这样再乘以四 Multiply that by four
就基本相当于多出10名乘客 and it equals almost 10 extra passengers.
涡扇叶片更少、转速更低 这使得它们成为 And with fewer fan blades and lower turning speeds,
通用电气制造的最安静的引擎 these are the quietest engines GE has ever made.
它们能够用更少消耗吹出更多空气 They can push through more air with less work
这意味着更低的油耗 and that means burning less fuel.
他们是怎样做到的呢？ So how do they do that?
空气只有百分之十与燃油混合 Only ten percent of the air is mixed with fuel
在燃烧室中燃烧 and burnt in the combustion chamber
驱动一系列涡轮旋转 driving a serials of turbines
带动前面的巨大涡扇 that power the big fan at the front.
这些涡扇将其余百分之九十空气 And that's the fan which pushes the other 90 percent of the air
从引擎后面喷出 out the back of the engine,
产生推力 creating thrust.
尽管消耗更少燃油 Despite burning less fuel,
四具引擎能带动满载的747-8 four of them can propel an fully laden 747-8
以一千多公里的时速飞行 at over 1,000 kilometers per hour.
仅一具引擎产生的推力 Just one of these engines
就相当于B-52所有八具引擎的总和 creates as much thrust as all 8 engines on a B-52.
回到工厂 Back at the factory,
现在该吊装引擎了 it's time to hang the engines.
机翼上引擎位置悬挂着重物 Massive torque blocks hang on the wings
提供巨大扭矩 where the engines will go.
要是没有它们，飞机就会倒向尾部 Without them, the airplane will tip back on its tail.
每具引擎重七吨 Each engine weighs 7 tons
他们要从车上卸下四具引擎 and there are 4 engines to get off their trolleys
装到机翼上去 and onto the wings.
这就好比把四头公象吊上去 That's like hanging 4 bull elephants.
这是需要慢而仔细的工作 It's a job to do slowly and carefully.
我来加一点力测试一下 Let me put a little tension on it to test it.
要是四个绞车排列稍有偏移 If the four winches are slightly misaligned,
就不会对正位置 it won't go in square
他们就有麻烦了 and they are in trouble.
四十五 Forty-five.
轮子位置刚好合适 Got you wheels where you want them.
我们团队很协调一致 Our team's pretty tight unit.
我们配合很不错 We work together fairly well.
我们在飞机上都有各自喜欢的位置 We all have our positions on the plane that we like.
零 Zero.
好了，提好裤子 All right, start pulling your pants.
我们用这种方法沟通 We communicate well together this way,
这样不会出现什么问题 keeps us from getting into any troubles.
系上好保证安全 Harness up for safety.
安全第一 For safety.
（艾克赛尔·维特沙姆） 我们还有近四十厘米 We're about 12 inches away.
（机械师） 我们要把前面重物的螺栓松开 We are gonna pull the bolts from the front fitting.
在前面上边有个销 There's a pin upfront
用来挂住前面的重物 that lines up the forward mount.
我们可以用C号扳手松开它 So we loop that up with any Cs.
我们再上来20厘米 We come up another 6 inches,
确定一切都没问题 make sure everything is clear,
再向上最后20厘米 then we come up the last 6 inches
之后把四个螺栓全部安上 and then put all four bolts in.
允许的误差很小 Very close tolerance.
只有几十微米 Within a thousandth of an inch.
上来吧 Come on up.
挂上巨大的引擎 It only takes 8 bolts
只用八颗螺栓 to hang these massive engines.
四颗都在拧 All four started.
都抓住了 All grabbing.
来吧，一半了 Here you go, 50 percent.
就这样，我还在往下卸，艾克赛尔 That's it. I'm still getting these down, Axle.
好的 Okay.
后部的螺栓扭矩是 The torque on the bolts are
461牛米 625 foot pounds on the rear,
前部的是277牛米 375 foot pounds on the front.
前部的是设计成可以剪切掉的 The fronts are designed to shear off.
这是按设计来的 That's per design
要是万一有了问题 and that's in case there is any problem
引擎可以切断前面 so the engine will shear the front,
倒向后面、然后脱离飞机 fall back and break away from the plane
而不会带走机翼或副翼什么的 without taking out wings or flaps or any of that.
一 One.
还有三具引擎要装 There are three engines to mount.
工作组 Once again,
要在午夜时分熬夜 the crew will need to burn the mid-night oil
来完成工作 to get the job done.
经过了数周辛苦的工作 After weeks of painstaking work,
快到打开基地开关的时候了 it's almost time to switch the base on.
不过还要先经过更痛苦的工作 But first, there's more painstaking work.
每条线路都要一个个进行检查 Every circuit needs to be checked, one by one.
飞机上要用很多电力 This plane uses a lot of electricity,
够50户人家使用的 enough to power over 50 households.
飞机上铺设的电线 214 kilometers of wiring
长度达214公里 runs through the aircraft.
它们都汇集到电子舱内 It all converges in the electronic bay.
这是飞机的神经系统 It's the plane's nerve system.
新的线传操纵技术 The new fly-by-wire technology
是通过机上电脑来控制的 is controlled by on-board computers.
但这不全是自动的 But it's not totally automated.
飞行员可以超驰控制进行手动操纵 The pilot can override the computer.
这里有多层后备 And there are multiple layers of backup
以防出现什么问题 if something should go wrong.
要是我想放下副翼 If I were to lower the flaps,
（柯克·万宁） 需要由液压系统来完成 it takes hydraulic systems to do that.
（747试飞员） 不过要是因为什么原因 But if for some reason
液压系统无法使用 the hydraulics were unavailable,
我们可以使用空气或气压 we could use the air or numeric air pressure
来放下副翼 to lower the flaps.
要是这也不行 If that was unavailable,
我们可以使用电力来放下副翼 we could use electricity to lower the flaps.
所以是有多层冗余 So, there's multiple layers of redundancy.
技术员用一台特殊电脑 Technicians use a special computer
给每个线路发送一个信号 to send a signal to every single circuit.
在10495上打开拖曳 Take a drag at 1-0-4-9-5
打开 On.
好，公里数2 Okay, kilo 2.
关闭 Off.
真相时刻 Moment of truth.
该到插入工厂电源的时候了 Time to plug in the factory power supply
这是它第一次启动 and fire her up for the first time.
通电是完成747-8的重要时刻 Power-on is a key moment in completing a -8.
引擎就位后 With engines in place,
这架珍宝客机已经可以飞上蓝天了 this Jumbo is almost ready to take to the skies.
不过它还需要内部装饰 But first, she needs a interior.
就像通用电气的NX引擎和机翼那样 Like the GE NX engines and wings,
它的内装也是从梦想客机 her new interior is borrowed from her little sister -
那里借来的 the Dreamliner.
有新的颜色、更大的空间 There's new colors, more space
和可调照明 and mood lighting.
波音客户对内部设计有自己的主意 Boeing customers have their own idea of interior design.
都希望珍宝客机涂上自己的颜色 Each wants their Jumbo painted in their colors,
无论里外 inside and out.
在超级工厂的巨型喷漆车间里 In the Mega-Factory's huge paint shop,
绿色保护膜被洗掉了 the green protective vinyl is washed off.
手工喷涂一层基底 A base layer is sprayed on by hand
再接着喷涂几层颜色 followed by several coats of color
这要看客户具体需求 depending on the customer's delivery.
他们需要注意 They need to be careful
喷漆的具体层数 with the number of layers they apply.
太多层漆 Too much paint
会掩盖住金属疲劳的明显迹象 could mask tell-tale signs of metal fatigue.
另外 Besides,
油漆的多余重量 the extra weight of more paint
将会增加燃油消耗 would only increase fuel consumption.
一次正常喷漆 A typical paint job
会用掉500公斤油漆 uses 500 kilos of paint.
这能用上四年 It will last four years.
这一架喷涂的是波音自己的颜色 This one is painted in Boeing's own colors
因为到对它进行测试的时候了 because it's time to put her through a basis.
它在被交付前必须通过一系列 She must undergo a serials of grueling test flights
艰难的试飞 before delivery.
试飞员将飞机用到极限 Test pilots push the plane to extremes
乘客绝不会承受这些 that will never be endured by its passengers
除非他们为波音工作 unless they work for Boeing.
仅仅把携带的行李放在一边 Just putting away the hand luggage
对这次飞行来说可不够 won't be enough for this flight.
这些波音工程师 These Boeing engineers
必须把所有东西都绑上 have to tie everything down,
无论是他们的午餐还是笔记本电脑 from their lunch to their lap-top.
要是不把它们固定下来 You don't have it clammed down,
它们就会飞到空中 things fly in the air.
这些真的会直接飞到空中 It will literally go straight up to the ceiling
落下来时可能会砸到头上 and can come down and hit you on the head.
飞行载荷检验 The flight load survey
是飞机要面对的最艰难的测试之一 is one of the most grueling tests for the plane
对机上乘客也是如此 and for those on board.
胃肠坚强很有必要 A strong stomach comes in handy.
着看了好像有趣 It might look like fun,
然而这可是正经事 but it's serious business.
飞行载荷检验 The flight load survey
测试飞机上的重量载荷 tests weight loads across the plane.
飞行员进行极限操作 The pilots perform extreme maneuvers,
拉起飞机然后下降 pitching the plane up, then down,
几秒内过载从零变到2G going from 0 gravity to 2Gs in seconds,
对机身和机翼产生巨大压力 stressing the fuselage and the wings.
（马克·弗斯汀） 对他们来说 It's great fun for them
（747首席试飞员） 前几分钟很有趣 for the first couple of minutes,
不过想象一下，我们一做就几小时 but imagine that we do this for several hours at a time.
或早或晚 Sooner of later,
也许这就没那么好玩了 maybe it's not such great fun any more.
在测试中 During these tests,
飞机上的重量分布 the weight distribution of the plane
是用水控制的 is controlled using water.
飞行员和工程师把水装进桶里 The pilots and engineers compound water through barrels,
来改变机身上承受的重量 to shift weight along the fuselage.
这样能模拟在实际使用中 This simulates various load configurations
飞机能遇到的各种 the plane might encounter
载荷分布情况 when it's in service.
重心靠前 At the forward center-of-gravity,
重心靠后 aft center-of-gravity,
载重大时 heavy weight,
载重小时 light weight,
我们要确保 we need to make sure
在飞机的各种操作范围内 that over the entire range of operating envelope of the airplane,
技术特点都达标 the characteristics are good.
接下来 Next,
还有严峻的最低速度起飞测试 The -8 faces the grueling velocity minimum unstick test.
试飞员要用尽量低的速度 Test pilots try to take off
进行起飞 as slowly as possible.
这会迫使机尾刮到跑道 This forces the tail to scrape the runway.
要通过测试 To pass the test,
飞机必须在此速度下安全起飞 the plane will safely lift off at this speed.
如果飞行员起飞时没把握好 If a pilot were to inadvertently abuse a take-off
导致机尾在起飞前碰到地上 and the tail were to strike the ground before take-off,
飞机必须能在这种姿态下安全起飞 the airplane can still lift off safely in that attitude.
所以我们测试时 So when we do that,
会在机尾上装上长木条 we attach a long wooden block on the tail
这样当机尾拖到地面上时 so that we'll drag the tail on the ground
我们就不会刮坏飞机蒙皮 and we don't damage the skin of the airplane that way.
再之后 Next,
他们要让新飞机经受颤震测试 they put this new jet through the flutter test.
颤震是表示振动的航空术语 Flutter is the aviation word for vibration.
这项测试把线传操纵控制推到极限 This test pushes fly-by-wire control to the limit.
全部在高速下完成 It's all high speed,
通常比我们正常允许 generally above the ordinary envelope
飞行员操作的速度要高 that we let airplane pilots operate the aircraft at.
我们会让飞机沿每个轴线振动 We vibrate each of the axis of the airplane
实际就是进行大幅度操作 by, quite literally, kicking the controls one at a time
看看控制的反应 to watch how the controls are reacting,
确定飞机能够 make sure that airplane, in fact,
排除振动 dams the vibration out
迅速地恢复到 to a quiet and smooth ending
安静平稳的状态 in a very quick fashion.
现在该进行空中制动了 Now, it's time to slam on the brakes in the midair
看看会如何 and see what happens.
航班飞行员通常受训 Airline pilots typically are trained how to recover
从进近变为失速 from an approach to a stall,
不过就算有也很少会真的看到 but rarely, if ever, actually see
有飞机进入失速状态 an aircraft in a stalled state.
我们经常这么做 We see it all the time.
我们在这一型飞机上进行过的失速 We've done hundreds and hundreds of stalls
有成百上千次 on just this model of airplane.
其实这些并没那么可怕 And they are really quite benign.
失速是指当机鼻抬起太高 A stall is when a plane's nose rises to high,
这样机翼就不再产生升力 the wings then stop generating lift
飞机开始从空中向下掉落 and the plane begins to fall from the sky.
我就是将操纵杆向后拉 I just release back pressure on the column
然后让它自己回到中间 and let it migrates towards the center.
有时候我会把手放到身侧 And sometimes I just drop my hands to my sides.
飞机自己就能恢复过来 Airplane recovers just fine all by itself.
数千工人 Thousands of workers
将六百万个零件 have put together 6 million parts
装成这架飞机 to form this one aircraft.
它承受住了试飞员给予的所有考验 She's conquered every thing that test pilots could throw at her.
它经受住了生产延期 She survived manufacturing delays
和最后期限 and deadlines.
只要三亿三千三百万美元 For just 333 million dollars,
就可以拥有属于自己的 you can have a brand new Boeing 747-8
全新波音747-8 all of your own.
新珍宝客机已经准备面对终极考验 The new Jumbo is ready to take on the ultimate test -
天空中的竞争 competition in the skies.
我要告诉747-8飞行员，应该兴奋 I would tell new pilots of the 747-8 to be excited.
这是很好的机器 This is a wonderful machine.
我认为这种747-8是该选的飞机 I think this 747-8 will be the airplane that takes to...
这会是未来20年里的最佳飞机 It will be the airplane for next 20 years.
世界上最大的建筑 The world's biggest building,
这座超级工厂 this Mega-Factory,
正要交付第3381架飞机 is delivering its 3,381st air craft.
它有点儿迟到 She's a little bit late
却值得等待 but worth the wait.
全新的波音747-8 The brand new 747-8
已经准备要夺回属于自己的称号 is ready to reclaim her title
“空中之王” as "Queen of the Skies".